SECTION 6A1-1 - ENGINE MECHANICAL - V6 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will

consist of either seat belt pre-tensio ners and a driver’s side air bag , or seat belt pre-

tensioners and a driver’s and front passenger’s side air bags. Refer to CAUTIONS,

Section 12M, before performing any service operation on or around SRS

components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS deplo yment, resulting in possible p ersonal injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of

safety, the LPG fuel system should be isolated by turning 'OFF' the manual service

valve and then draining the LPG serv ice lines, before any service w ork is carried out

on the vehicle. Refer to the LPG leaflet included with the Owner's Handbook for

details or LPG Section 2 for more specific servicing information.

1. GENERAL DESCRIPTI ON

The 1997 Model Year 3.8 litre, 3800 engine (production option LN3) for VT Series Models, is a 90 degree, V6,

overhead valve unit with a 96.52 mm bore and 86.36 mm stroke, displacing 3791 cc with a compression ratio of

9.35:1.

Engine features include, light weight, increased torque and horsepower, and a rigid valve train incorporating beehive

shaped valve springs for greater valve control. All combustion chambers and inlet/exhaust ports are symmetrical for

more even firing pressures, reduced emissions.

An EGR valve has also been introduced to improve emission control.

Fuel injection is sequential with an upper and lower inlet manifold, the upper manifold supporting a plenum chamber

with the throttle body mounted on the left hand side

A stiffened engine block and side bolted main bearing caps along with an insulated engine dress cover contribute to

engine quietness.

Techline

Figure 6A1-1-1

Figure 6A1-1-2

1. Generator brace bracket

2. Bolt

3. Bolt

4. Double ended stud

5. Cover bolt

6. Inlet manifold cover

7. Inlet manifold cover seal

8. Upper inlet manifold

9. Bolt

11. Throttle bracket mounting stud

12. Throttle body to inlet manifold seal

13. Throttle body

14. Nut

15. Heater outlet pipe

16. Drive belt tensioner assembly

17. Stud

18. Water inlet tube

19. Nut

20. Oil filler cap

21. Right hand rocker cover

22. Injector and fuel rail assembly

23. Seal

24. Crankcase vent valve spring

25. Crankcase vent valve

26. Crankcase vent valve seal

27. Oil separation baffle

28. Cylinder head upper outer bolt

29. Cylinder head upper inner bolt

30. Cylinder head lower bolt

31. Right hand exhaust manifold

32. Coolant outlet

33. Air vent valve

34. Bolt

35. Thermostat gasket

36. Thermostat

37. Lower inlet manifold

38. Inlet manifold gasket

39. Inlet manifold seal

40. Bolt

41. Left Hand Rocker cover

43. Rocker cover fastener

44. Rocker cover seal

45. Rocker arm pedestal bolt

46. Rocker arm assembly

47. Rocker arm retainer

48. Rocker arm pushrod

49. Lifter

50. Lifter guide

52. Valve collet

53. Valve spring cap

54. Valve spring

55. Valve stem seal

56. Valve

57. Left Hand exhaust manifold

58. Spark plug

59. Bolt lock plate

60. Cylinder head

61. Head gasket

62. D.I.S. ignition coil/module assembly.

63. Bolt

64. Dipstick tube assembly

65. Nut

66. Housing to cylinder head bolt

67. Engine harness retaining bracket

68. Pulley to housing bolt

69. Idler pulley cover

70. Idler pulley

175. Stud

176. Nut

177. Spark plug lead support bracket

178. EGR Valve

179. Screw

Figure 6A1-1-3

71. Bolts

72. Stud

74. Bolts

76. Studs

77. Bolt

78. Balance shaft driven gear

79. Balance shaft front ball bearing

80. Pin

81. Bolt

82. Balance shaft retainer

83. Balance shaft rear bearing

84. Balance shaft

85. Bolt

86. Timing chain

87. Camshaft sprocket

88. Balance shaft drive gear

89. Screw

90. Camshaft thrust plate

91. Camshaft

92. Camshaft bearings

93. Key

94. Camshaft position sensor magnet

95. Timing chain dampener

96. Cap bolt

97. Cap

98. Connecting rod bearings

99. Connecting rod

100. Piston and pin

101. Circlips

102. Piston rings

103. Bolt

104. Bolt

105. Flexplate

106. Crankshaft rear oil seal housing

107. Crankshaft rear oil seal housing gasket

108. Cylinder block

109. Cylinder head locater pin

110. Engine front cover locater pin

111. Engine front cover locater pin

112. Cup plug

113. Cup plug

114. Knock sensor

115. Knock sensor shield support bracket

116. Bolt

117. Cap bolt

118. Bolt

119. Bolt

120. Oil filter adaptor

121. Oil pressure switch

122. Oil filter adaptor seal

123. Pressure regulator valve

124. Spring

125. Special torque axis screw

126. Plug

127. O - ring

128. Oil suction pipe and screen

129. Bolt

130. Bolt short

131. Bolt long

132. Water pump

133. Water pump gasket

134. Camshaft position sensor

135. O - ring

136. Front cover gasket

137. Front cover

138. Crankshaft front seal

139. Bolt

140. Water pump pulley

141. Bolt

142. Bolt

143. Idler pulley cover

144. Bolt

145. Idler pulley

146. Bolt

148. Balancer

149. Shield

150. Oil pump gears

151. Oil pump cover

152. Crankshaft sprocket

153. Screw

154. Sprocket key

155. Main bearing upper shell

156. Main bearing lower shell

157. Main bearing cap

158. Crankshaft

159. Rear main oil seal

161. Main cap bolt

162. Flywheel

163. Clutch plate

164. Pressure plate and cover assembly

165. Bolt

166. Crankshaft position sensor bracket

167. Crankshaft position sensor stud

169. Bolt

170. Wiring harness support bracket

171. Oil pan

172. Oil pan seal

173. Bolt

174. Drain plug

180. O - ring

181. Starter motor

182. Oil filter

183. Oil filter connector

1.1 ENGINE SERIAL NUMBER

The engine serial number is s tamped on the engine

block front left hand face.

The engine number is pr ef ix ed by a two letter c ode:

VH.

Figure 6A1-1-4

1.2 ENGINE CONSTRUCTION

CYLINDER BLOCK

The cylinder block is made of cast iron. It has six

cylinders arranged in a 90 degree V - shape with

three cylinders in each bank.

The cylinder numbering is as shown in Fig. 6A1-1-

5. Firing order is 1-6-5-4-3-2.

Four m ain bearings support the crank shaft which is

retained by bearing caps that are machined with

the block for proper alignm ent and clearanc es. T he

three front main bearing caps are side bolted for

increased stiffness. Cylinders are completely

encircled by coolant jackets.

Figure 6A1-1-5

CYLINDER HEADS

Cylinder heads are cast iron and incorporate

integral valve guides and individual exhaust and

inlet ports for each cylinder. The cylinder head

features symmetrical ports and combustion

chambers

Right and left hand cylinder heads are identical and

interchangeable, although in service, it is good

practice to r einstall cylinder heads on the side from

which they are removed.

Figure 6A1-1-6

CRANKSHAFT

The crankshaft is cast nodular iron with rolled

fillets. It is supported by four main bearings, with

each bearing being specific (except No. 1 and No.

4 upper bearing shells having the same design),

with No. 2 main bearing taking crankshaft end

thrust.

The c rank shaf t is counter balanced by weights cast

integral with the crankshaft. Additional counter

balancing is obtained from the flywheel, crankshaft

balancer and a balance shaft which is located in the

cylinder block, above the camshaft. The balance

shaft is gear driven by the camshaft.

Figure 6A1-1-7

The 3800 V6 engine is even-firing, i.e. the cylinder

firing is at equal 120 degree intervals of crankshaft

rotation. The location of the crankpins are

displaced by an included angle of 30 degrees in

order to fire the cylinders at equal 120 degree

intervals of crankshaft rotation.

Figure 6A1-1-8

The crankshaft is common for both automatic and

manual transmissions. A spigot bearing and

flywheel locating dowel pins are installed into the

rear of the cr ankshaf t when manual trans miss ion is

used.

The flywheel/flexplate is held to the crankshaft by

eight bolts. One of the bolt holes in the crankshaft

and flywheel/flexplate is off set to allow ass embly to

the crankshaft in one position only.

These bolts are to be used only once, and if

removed, must be replaced.

Figure 6A1-1-9

PISTONS AND CONNECTING RODS

Pistons are of a lightweight, low friction short skirt

design with floating pins, dished crowns, and are

cast from aluminium alloy and machined.

Each piston has two com pression rings and one oil

control ring. Two transverse slots in the piston oil

ring grooves extend through the piston wall and

permit drain back of oil collected by the oil ring.

Piston pins are offset toward the major thrust side

of the piston (left hand side, as viewed from the

front of the engine) to provide a gradual change in

thrust pressure against the cylinder wall as the

piston travels its path.

Pistons pins are c as e-hardened and have a floating

fit in the pistons and connecting rod.

Connecting rods are cast malleable iron with a

bushed small end for the floating piston pin.

Bearing caps are held in place on the connecting

rods by attaching bolts. Figure 6A1-1-10

CAMSHAFT AND DRIVE

The camshaft is steel and supported by four steel

backed, babbitt-lined bearings.

It is driven by the crankshaft sprockets and chain

at the front of the engine. Both the crankshaft and

camshaft sprockets have timing marks to set the

correct valve timing.

A magnet, fitted to the camshaft sprocket, is used

by the camshaft sensor, located in the front cover,

to detect the position of the camshaft.

The PCM (Powertrain Control Module) uses this

information to control the fuel injectors. Refer to

Section 6C1 POWERTRAIN MANAGEMENT - V6

ENGINE.

Figure 6A1-1-11

BALANCE SHAFT

A counter rotating cast iron balance shaft is

installed in the cylinder block. It is located in the

lifter valley of the cylinder block above, and parallel

to, the camshaft. The balance shaft is gear driven

by the cam shaf t, at cranks haft speed, and resolves

primary rotational imbalance for improved engine

smoothness. The shaft has a ball bearing at the

front and plain rear bearing journal at the rear.

Figure 6A1-1-12

INLET MANIFOLD

The inlet manifold is a three piece aluminium

construc tion and is bolted to the inner f aces of both

cylinder heads so that it connects with all inlet

ports.

Provision is made for the mounting of the fuel

injectors and fuel rail assembly, throttle body,

thermostat and coolant outlet.

Figure 6A1-1-13

VALVE TRAIN

The valve rocker arms for each bank of cylinders,

pivot on roller bearings. The rocker arms are kept

in alignment by a single retainer on each cylinder

head.

Hydraulic, roller valve lifters and tubular push rods

are used to operate overhead rocker arms and

valves for both banks of cylinders from a single

cam shaft. T his system requires no lash adj ustment

at time of assembly or in service.

Inlet and exhaust valves feature "beehive" shaped

valve springs for greater valve control.

Figure 6A1-1-14

HYDRAULIC VALVE LIFTER OPERATION

In addition to its normal function of a cam follower,

each hydraulic valve lifter also serves as an

automatic adjuster which m aintains zero las h in the

valve train under all operating conditions. By

eliminating all lash in the valve train and also

providing a cushion of oil to absorb operating

shocks, the hydraulic valve lifter promotes quiet

valve operation. It also eliminates the need for

periodic valve adjustment to compensate for wear

of parts.

Oil is supplied to the lif ter through a hole in the s ide

of the lifter body which indexes with a groove and

hole in the lifter plunger. Oil is then metered past

the metering valve in the lifter, through the push

rods to the rocker arms.

Figure 6A1-1-15

W hen the lifter begins to ride up the cam lobe, the

check ball is held against its seat in the plunger by

the check ball sp ring. The c heck ball traps the oil in

the base of the lifter body below the plunger. The

plunger and the lifter body then rise as a unit,

pushing up the push rod to open the valve. The

force of the valve spring, which is exerted on the

plunger through the rocker arm and push rod,

causes a slight amount of leakage between the

plunger and lifter body. This 'leak down' allows a

slow escape of trapped oil in the base of the lifter

body. As the lifter rides down the other side of the

cam lobe and reaches the base circle, or 'valve

closed' position, the plunger spring quickly moves

the plunger back (up) to its original position. This

movement causes the check ball to open against

the ball spring, and oil from within the plunger is

drawn into the base of the lifter. This restores the

lifter to zero lash.

For hydraulic valve lifter diagnosis, refer to

4.5 HYDRAULIC VA LVE LIFTERS in this Section.

Figure 6A1-1-16

EXHAUST MANIFOLDS

Two nodular cast iron exhaust manifolds are used

to direct exhaust gases from the combustion

chambers to the exhaust system.

Figure 6A1-1-17

OIL PUMP

The oil pump assem bly is integrated with the front

cover assembly. The oil pump is a "gerotor" type

and is driven by the front end of the crankshaft

sprock et. For details of oil pum p operation, refer to

1.3 LUBRICATION in this Section.

Figure 6A1-1-18

ACCESSORY DRIVE

The 3800 V6 engine employs a single serpentine

belt which drives each of the engine mounted

accessories i.e. water pump, generator, power

steering pump and if fitted, air conditioning

compressor.

Each accessory drive pulley has six grooves which

mate with the contours of the belt inner surface.

The exception to this is the water pump pulley

which is driven of f the outer surf ace of the belt and,

consequently, does not require grooves.

Drive belt tension is provided by a tensioner

assem bly. The tensioner is an idler pulley mounted

on a spring-loaded arm that maintains the dr ive belt

at the proper tension, without imposing undue loads

on the various components.

Figure 6A1-1-19

Throughout its functional travel, the tensioner

mechanism will maintain correct belt tension while

compensating for increases in belt wear and

stretch.

When the indicator pointer on the tensioner has

reached m inimum tension range, the tensioner has

reached the f ull extent of its travel and r eplacem ent

of the belt is necessary.

Figure 6A1-1-20

POWERTRAIN MOUNTING

Engine front mounts are a hydraulic design which

incorporate a rubber body and two connected

cavities. These mounts provide engine vibration

damping by allowing oil transfer from one cavity to

another via controlled or ifices , similar in principle to

a hydraulic shock absorber.

Figure 6A1-1-21

MANUAL TRANSMISSION

For vehicles fitted with manual transmission,

powertrain rear mounting consists of a rubber

mounting attached to the transmission extension,

via an adaptor assembly and to the powerplant rear

support. The rubber mounting is connected to the

powerplant rear support by two attaching nuts.

Figure 6A1-1-22

AUTOMATIC TRANSMISSION

For vehicles fitted with automatic transmission, the

engine rear mounting consists of a rubber mounting

attached to the transmission rear extension. The

rubber mounting is connected to the rear

crossmember by two attaching nuts.

Figure 6A1-1-23

1.3 LUBRICATION

The engine lubrication system is of the force-feed

type in which oil is supplied under full pressure to

the crankshaft, connecting rods, camshaft

bearings, valve lifters and a controlled volume is

supplied to the rocker arms and push rods. The

engine has a pressure fed rear balance shaft

bearing. Oil is fed from the rear of the right oil

gallery through a rear seal housing . The housing

also includes the cross over passage for oil supply

to the left bank. All other moving parts are

lubricated by gravity flow or splash.

The supply of oil is carried in the oil pan which is

filled through a filler opening in the right hand

rocker cover (as viewed from the drivers seat). An

oil level indicator (d ip stic k), loc ated on the front lef t

hand side of the crankcase, (as viewed from the

drivers seat) is provided to check oil level.

The oil pump is located in the engine front cover

and is driven by the cranks haft. It is a 'gerotor' type

pump which is a combination of gear and rotor

pumps . It is c onnected by a passage in the cylinder

crankcase to an oil suction pipe and screen. The

screen is submerged in the oil supply.

Oil is drawn into the pump through the screen and

pipe assembly and the passage in the crankcase

which connects to passages in the front cover. All

oil is discharged from the pump to the oil filter

adaptor assembly which consists of a full flow oil

filter and by-pass valve.

The spring loaded oil pressure regulator valve,

located in the front cover, limits the oil pressure to

approximately 414 kPa. The oil filter by-pass valve

opens when the filter has become clogged. When

approximately 69 kPa pressure difference exits

between the filter inlet and disc harge, oil by-passes

the oil filter and channels unfiltered directly into the

main galleries of the engine.

The main oil galleries run the full length of the

crankcase and connect into the valve lifter guide

holes to supply oil at full pressure to the lifters.

Holes drilled from the crankshaft main bearings to

the main gallery, intersect the camshaft bearing

bores which supply oil to the camshaft bearings.

Holes drilled in the crankshaft, carry oil from the

crankshaft main bearings to the connecting rod

bearings. Pistons and cylinder walls are lubricated

by oil thrown off the crankshaft and by connecting

rod splash. Piston pins are lubricated by splash.

Each rocker arm and valve is supplied with oil

through the tubular push rod. This oil comes from

the inside of the lif ter, passing around the meter ing

valve, up the inside of the push rod and through a

hole in the rocker arm push rod seat.

Figure 6A1-1-24

1.4 SERVICE NOTES

CLEANLINESS AND CARE

A motor vehicle engine is a combination of many machined, honed, polished and lapped surfaces with tolerances

that are measured in thousandths of a millimetre. When any internal engine parts are serviced, care and cleanliness

are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and

lubricate the surfaces on initial operation. Throughout this Section, it should be understood that proper cleaning and

protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard

workshop practice even if not specifically stated.

Whenever valve train components are removed for service, they should be kept in order. They should be installed in

the same locations, and with the same mating surfaces, as when removed.

Battery terminals should be disconnected before any major work is performed on the engine. Failure to disconnect

terminals may result in damage to wiring harnesses or other electrical components.

THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS

IMPORTANT IN PREVENTING DAMAGE AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE.

When raising or supporting the engine for any reason, do not use a jack under the oil pan. The oil pan is of cast

aluminium construction and could be damaged.

Refer to Section 0A GENERAL INFORMATION for location of jacking points, also refer to Section 3 FRONT

SUSPENSION for jacking precautions.

Any time the air flow ducting is removed or disconnected, the intake opening should be covered. This will protect

against accidental entrance of foreign material which could follow the intake passage into a cylinder and cause

extensive damage when the engine is started.

CAUTION:

Do not start engine with engine inlet manifold top cover or throttle body removed, as engine will run at

wide open throttle.

2. MI NOR SERVICE OPERATIONS

2.1 COMPRE SSION CHECK

1. When conducting this check, ensure:

a. Engine is at operating temperature.

b. Battery is at or near full charge.

c. All spark plugs removed.

d. Remove fuse F14 which is located in

passenger compartment fuse panel.

Removal of this fuse prevents the fuel

pump and injector s f r om operating dur ing

engine cranking.

2. Install a suitable compression tester.

3. Crank engine. Record compression gauge

indication.

NOTE:

It is important to open the throttle when conducting

a compression test to ensure cylinder filling.

4. Check remaining cylinders.

NOTE:

The lowest reading of any cylinder should not be

less than 70 % of the highest and no cylinder

reading should be less than 689 kPa.

5. If cylinder compression in one or more

cylinders is low, pour a small amount of engine

oil into the cylinders through the spark plug

holes and retest compression.

Figure 6A1-1-25

INTERPRETATION OF COMPRESSION READINGS

NORMAL - Compression builds up quickly and

evenly on each cylinder.

PISTON RINGS - Compression low on first stroke

tending to build up on following strokes, but does

not reach normal. Improves considerably with

addition of oil.

VALVES - Low on firs t strok e and does not tend to

build up on following strokes. Does not improve

much with addition of oil.

HEAD GASKET - If cylinder compression in any

two adjacent cylinders is low, and if adding oil does

not help compression, cylinder head gasket has

blown.

2.2 CHECKING ENGINE OIL P RE S SURE

1. Check engine oil level and add oil as

required.

2. Ensure that engine is at operating

temperature.

3. Pull out retaining tang on engine harness

connector at oil pressure sender unit and

pull connector from sender unit.

4. Place an oil drain tray beneath engine.

5. Loosen and remove oil pressure sender

unit from oil filter adaptor.

6. Install a suitable oil pressure gauge

assem bly into oil filter adaptor oil pressure

sender unit hole.

7. Start engine and check oil pressure

reading with engine running under no load.

Figure 6A1-1-26

OIL PRESSURE SPECIFICATION

ENGINE RPM OIL PRESSURE READING

1850 and above 375 kPa minimum

8. After completion of test, apply Loctite 242

sealant or equivalent (Holden Specification HN

1256 Class 2, Type 2), to sender unit threads .

Install sender unit and tighten to the correct

torque specification.

OIL PRESSURE SENDER UNIT

TORQUE SPECIFICATION 12 - 14

9. Reinstall wiring harness connector to sender

unit, start engine and check for oil leaks and

warning lamp operation.

2.3 OIL FILTER

NOTE:

The oil filter should be replaced at the time or

distance intervals specified in the VT Owner's

Handbook or whenever the engine oil is

contaminated by foreign material.

REPLACE

1. Place an oil drain tray beneath engine.

2. Using a suitable oil filter wrench, unscrew oil

filter, remove and discard.

3. Ensure seal is installed correctly in recess of

new filter.

4. Pour som e c lean engine oil into filter until level

remains at approximately 2 cm below top of

filter.

5. Smear some engine oil over filter seal. Screw

filter into place until seal contacts mating

surface of adaptor. Tighten filter through a

further 2/3 of a turn.

6. Clean any excess oil from filter and adaptor.

7. Check oil level. Start engine and check for oil

leaks. Repair as necessary.

NOTE:

The oil level must be rechecked and oil added as

necessar y, after running the engine, to c ompensate

for oil used to refill the oil filter. Figure 6A1-1-27

2.4 OIL LEVEL CHECK

1. Engine must be at normal operating temperature (idle for 10 minutes or equivalent).

2 Park vehicle on level surface (as this will affect the accuracy indicated on dipstick, this is a critical

requirement).

3. Do not check oil level for at least 10 minutes after shut down to allow oil to drain back into the oil pan.

4. Remove dipstick and wipe clean.

5. Reinstall dipstic k with FULL/ADD mar ks f ac ing towards c entr e line of engine. T his as pec t is very im por tant due

to the angle that the dipstick enters the oil in the oil pan.

6. Ensure dipstick is fully seated and slowly r em ove to avoid sm ear ing. Hold horizontally or with lower end slightly

down to avoid oil running along dipstick.

7. Observe the oil level where it passes over the centre line of the dipstick.

8. When topping up the engine oil, allow approximately 10 minutes for the oil added to fully drain into the oil pan.

Alternatively, add 50 ml of oil for each millimetre below the “FULL” mark on the dipstick.

Techline

2.5 OIL FILTER ADAPTOR

REMOVE

1. Place an oil drain tray beneath engine.

2. Disconnect battery earth lead.

3. Remove oil filter, refer to 2.3 OIL FILTER in

this Section.

4. Pull out retaining tang on engine harness

connector at oil pressure sender unit and pull

connector from sender unit.

If necessary, loosen and remove oil pressure

sender unit.

Figure 6A1-1-28

5. Remove oil filter adaptor to front cover

attaching bolts, remove adaptor.

6. Remove oil filter adaptor gasket and discard.

7. Remove oil pressure regulator valve and

spring.

Figure 6A1-1-29

REINSTALL

1. Using a suitable size thread tap, clean adaptor

'long' attaching bolt threads in front cover.

Clean attaching bolt threads.

2. Ensure that oil filter adaptor and front cover

mating surfaces are clean and free of foreign

matter.

3. Inspect oil pressure regulator valve bore in

front cover for scoring or burrs.

Inspect regulator valve spring for tension loss

(compare with new spring) or bending. If in

any doubt, replace spring.

Refer to Fig. 6A1-1-30 for spring identification

details.

4. Install regulator valve spring and valve.

5. Install adaptor and new gasket to front cover.

Install attaching bolts and tighten to the cor rec t

torque specification.

NOTE:

Before installing 'long' adaptor attaching bolt, apply

Loctite 242 sealant or equivalent (Holden

Specification HN 1256, Class 2 Type 2) to bolt

threads.

OIL FILTER ADAPTOR TO FRONT

COVER ATTACHING BOLT 23 - 35 Nm

TORQUE SPECIFICATION

Figure 6A1-1-30

6. If reinstalling oil pressure sender unit, clean

sender unit threads and apply Loctite 242

sealant or equivalent (Holden Specification HN

1256, Class 2, Type 2). Install sender unit and

tighten to the correct torque specification.

OIL PRESSURE SENDER UNIT

TORQUE SPECIFICATION 12 - 14

7. Install new oil filter, refer to 2.3 OIL FILTER

in this Section.

8. Start engine and check f or oil leak s. Repair as

necessary.

2.6 DRIVE BELT

TENSION CHECK

NOTE:

A belt squeak when the engine is started or

stopped is normal and has no effect on drive belt

durability.

1. Inspect tensioner markings to see if belt is

within operating limits. Replace belt if

excessively worn or outside tensioner

operating range.

Figure 6A1-1-31

2. Run engine with air conditioning (if fitted)

switched off, until engine is warmed up. Switch

engine off and read belt tension with Tool

BT3373-F placed halfway between generator

and air-conditioning compressor. For vehicles

without air-conditioning, read tension between

power steering pump and crankshaft pulley.

Remove tension gauge.

NOTE:

Tool No. BT3373-F must be accurately calibrated

before carrying out drive belt tension check.

3. Start engine with air conditioning (if fitted)

switched off and allow drive belt to stabilis e f or

15 seconds. Turn engine off. Using a 15 mm

ring spanner, apply clockwise for ce (tighten) to

tensioner pulley bolt. Remove ring spanner

and immediately take a tension reading with

Tool No. BT3373-F without disturbing belt

tensioner assembly.

4. Using a 15 mm ring spanner, apply an anti-

clockwise force to tensioner pulley bolt and

raise pulley to 'belt install' position. Slowly

lower pulley to 'at rest' position and take a

tension reading without disturbing belt

tensioner position. Record reading and

remove tool.

5. Average the three readings. If the average of

the three readings is lower than 250 N and the

belt is within tensioner operating range,

replace belt tensioner.

Figure 6A1-1-32

INSPECT

Fig. 6A1-1-33 illustrates the various stages of belt

wear to aid in belt replacement decisions.

Condition of the belt ribs is best judged where the

belt is bent over the water pump pulley.

Techline

Figure 6A1-1-33

REMOVE

1. Disconnect battery earth lead.

2. Using a 15 mm ring spanner on drive belt

tensioner pulley pivot bolt, rotate tensioner

pulley assembly anti-clockwise and remove

drive belt from water pump pulley. Release

tensioner pulley assembly and remove drive

belt from remaining drive pulleys.

Figure 6A1-1-34

REINSTALL

1. Inspect drive belt condition, refer to Fig. 6A1-1-33.

2. Install drive belt onto accessory drive pulleys refer to Fig. 6A1-1-35.

NOTE:

Ensure that drive belt ribs are aligned into all accessory pulleys and crankshaft balancer drive belt grooves.

3. Using a 15 mm ring spanner, rotate tensioner pulley anti-clockwise and feed drive belt over water pump pulley.

Return tensioner to its normal position.

4. Reconnect battery earth lead, start engine and check drive belt operation.

Figure 6A1-1-35

2.7 DRIVE BELT TENSIONER ASSEMBLY

REMOVE

1. Disconnect battery earth lead.

2. Remove four nuts securing engine dress

cover.

3. Using a 15 mm ring spanner on drive belt

tensioner pulley pivot bolt, rotate tensioner

pulley assembly anti-clockwise and remove

drive belt from water pump pulley. Release

tensioner pulley assembly and remove drive

belt from remaining drive pulleys.

Figure 6A1-1-36

4. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot.

Sudden release of cooling system pressure is

very dangerous and could cause personal

injury.

5. Remove generator assembly, refer to

Section 6D1-1 CHARGING SYSTEM - V6

ENGINE.

Techline

6. Remove nuts and powertrain wiring harness

earth lead from tensioner bracket lower

attaching studs.

7. Loosen hose clamp and remove heater outlet

hose from heater outlet pipe connection.

Figure 6A1-1-37

Figure 6A1-1-38

8. Remove water inlet tube assembly.

9. Remove studs securing heater outlet pipe and

drive belt tensioner assembly, pull heater

outlet pipe out from inlet manifold connection

and remove drive belt tensioner assembly.

Figure 6A1-1-39

REINSTALL

Installation of the drive belt tensioner assembly is

the reverse of removal procedures, noting the

following points:

1. Ensure that all fasteners are tightened to the

correct torque specification.

2. Check and inspect O - rings on end of heater

outlet pipe and water inlet tube, replace if

necessary. Lubricate O - rings with petroleum

jelly.

3. Refill cooling system with the correct

concentration of coolant and check for leaks,

refer to Section 6B1 ENGINE COOLING -

V6 ENGINE.

4. Start engine and check drive belt operation

and for power steering fluid or cooling system

leaks.

2.8 UPPER INLET MANIFOLD

REMOVE

1. Disconnect battery earth lead.

2. Depressurise fuel system, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE.

3. Remove four nuts securing engine dress

cover.

4. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Figure 6A1-1-40

5. Using quick connect release tool No. 7370

open tool and install over fuel line.

6. Close 7370 and pull into fuel line quick

connect to release it from fuel inlet line, pull

back on quick connect, disconnect fuel feed,

return and fuel evaporative canister hoses at

quick connects. Plug all openings to prevent

foreign matter entry.

NOTE:

Do not attempt to remove hoses from fuel rail

connections. Once removed from fuel rail

connection, hoses require replacement.

Figure 6A1-1-41

7. Disconnect emission control purge hose from

throttle body connections.

Figure 6A1-1-42

8. Disconnect EGR outlet pipe from upper inlet

manifold.

Figure 6A1-1-43

9. Disconnect brake booster, heater vacuum

control and f uel pressure r egulator hoses f rom

upper manifold connections.

Figure 6A1-1-44

10. Remove generator assembly, refer to

Section 6D1-1 CHARGING SYSTEM - V6

ENGINE.

11. Disconnect throttle inner cable from throttle

body linkage. Loosen throttle outer cable lock

nuts at mounting bracket and lay cable away

from engine.

12. If vehicle is fitted with cruise control,

disconnect cruise control outer cable from

mounting bracket and push inner cable

forward off throttle body linkage.

Figure 6A1-1-45

13. Disconnect powertrain wiring harness

connectors from:

a. Throttle Position Switch (TPS)

b. Idle Air Control (IAC) Valve

c. Injectors

d. EGR valve

Figure 6A1-1-46

14. Remove the eight inlet manifold cover

attaching bolts and remove cover.

15. Using a suitable c loth or plug temporar ily block

off lower inlet manifold passages.

16. Completely loosen the five bolts securing

upper inlet manifold assembly to lower inlet

manifold assembly removing upper inlet

manifold injector and fuel rail assembly.

NOTE:

Upper inlet manifold assembly to lower inlet

manif old bolts are c aptive on a secondary thread in

the upper inlet manifold. Do not screw bolt past

captive feature.

17. Remove and discard upper inlet manifold to

lower inlet manifold seals.

NOTE:

Providing seal has not been removed from seal

groove, seal may be reused. Seal is designed to

swell approx. 20% in use and will be overlong once

removed.

Figure 6A1-1-47

NOTE:

The following operations need only be perform ed if

necessary.

18. Rem ove fuel rail and injector assem bly to inlet

manifold attaching bolts, separate assembly

from inlet manifold.

19. Disconnect crankcase ventilation hose from

inlet manifold connection. Remove throttle

body to manifold attaching nuts, remove

throttle body. Discard all gaskets.

20. Remove vacuum connectors from manifold.

Figure 6A1-1-48

REINSTALL

Installation of the upper inlet manifold is the

reverse of r emoval pr ocedur es , noting the f ollowing

points:

NOTE:

Steps 1-2 are applicable only if the relevant items

were removed from the manifold.

1. Install P.C.V. valve with O - ring and spring,

refer to 2.9 LOWER INLET MANIFOLD -

REINSTALL in this Section.

2. Reinstall fuel rail with injectors and throttle

body assembly. Refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE.

3. Lubricate injector O - rings with Petroleum

Jelly to Holden Specification HN 1974 or

equivalent and install upper inlet manifold to

lower inlet manifold.

2.9 LOWER INLET MANIFOLD

REMOVE

1. Disconnect battery earth lead.

2. Depressurise fuel system, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE.

3. Remove four nuts securing engine dress

cover.

Figure 6A1-1-49

4. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Figure 6A1-1-50

5. Using quick connect release tool No. 7370

open tool and install over fuel line.

6. Close 7370 and pull into fuel line quick

connect to release it from fuel inlet line, pull

back on quick connect, disconnect fuel feed,

return and fuel evaporative canister hoses at

quick connects. Plug all openings to prevent

foreign matter entry.

NOTE:

Do not attempt to remove hoses from fuel rail

connections. Once removed from fuel rail

connection, hoses require replacement.

Figure 6A1-1-51

7. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot.

Sudden release of cooling system pressure is

very dangerous and could cause personal

injury.

8. Drain engine coolant into a suitable drain tray

by disconnecting radiator lower hose from

front cover connection.

Figure 6A1-1-52

9. Disconnect em ission control purge/ hose from

throttle body connections.

Figure 6A1-1-53

10. Disconnect EGR outlet pipe from upper inlet

manifold.

Figure 6A1-1-54

11. Pull right hand side spark plug leads from

spark plug terminals and from retainer

supports at side of cylinder head. Lay spark

plug lead conduit away from the inlet manifold.

NOTE:

All spark plug leads and coil terminals are

numbered to correspond to cylinder numbering.

If cylinder numbering does not appear on top of

any coil assembly, refer to cylinder numbering on

the module (refer to Section 6D1-3 IGNITION

SYSTEM - V6 ENGINE).

Figure 6A1-1-55

12. Disconnect brake booster, heater vacuum

control and f uel pressure r egulator hoses from

upper manifold connections.

Figure 6A1-1-56

13. Remove generator assembly, refer to

Section 6D1-1 CHARGING SYSTEM - V6

ENGINE.

14. Disconnect radiator upper hose from coolant

outlet, lay hose away from engine.

Figure 6A1-1-57

15. Remove nuts and powertrain wiring harness

earth lead from tensioner bracket lower

attaching studs.

Figure 6A1-1-58

16. Remove water inlet tube assembly.

17. Remove s tuds securing heater outlet pipe and

drive belt tensioner assembly, pull heater

outlet pipe out from inlet manifold

Figure 6A1-1-59

18. Remove coolant outlet to manifold attaching

bolts. Pull outlet from manifold, remove and

discard gasket. Remove thermostat from

manifold.

Figure 6A1-1-60

19. Disconnect throttle inner cable from throttle

body linkage. Loosen throttle outer cable lock

nuts at mounting bracket and lay cable away

from engine.

20. If vehicle is fitted with cruise control,

disconnect cruise control outer cable from

mounting bracket and push inner cable

forward off throttle body linkage.

Figure 6A1-1-61

21. Disconnect powertrain wiring harness

connectors from:

a. Throttle Position Switch (TPS)

b. Idle Air Control (IAC) Valve

c. Injectors

d. EGR valve

e. Coolant Temperature Sensor

Figure 6A1-1-62

Figure 6A1-1-63

22. Pull out wiring harness retainers from inlet

manifold posts near injector mountings and

from boss at rear of manifold. Position

harness away from inlet manifold.

23. Remove 12 lower inlet manifold to cylinder

head attaching bolts and remove manifold

assembly.

Remove and discard inlet manifold gaskets

and seals.

Figure 6A1-1-64

NOTE:

The following operations need only be perform ed if

necessary.

24. Remove the eight inlet manifold cover

attaching bolts removing cover.

25. Completely loosen the five bolts securing

upper inlet manifold assembly to lower inlet

manifold assembly removing upper manifold

assembly and fuel rail.

26. Loosen fuel feed hose at fuel rail inlet and

rem ove fuel f eed hose from fuel rail inlet. Plug

all openings to prevent foreign matter entry.

Rem ove fuel rail and injector assem bly to inlet

manifold attaching bolts, separate assembly

from inlet manifold.

Figure 6A1-1-65

27. Disconnect crankcase ventilation hose from

inlet manifold connection. Remove throttle

body to manifold attaching nuts, remove

throttle body. Discard all gaskets.

Figure 6A1-1-66

28. Unscrew and remove coolant temperature

sensor.

Figure 6A1-1-67

29. Remove P.C.V. valve, spring seal and baffle

from lower inlet manifold.

NOTE:

For P.C.V. valve testing procedures refer to

Section 6E1 EMISSION CONTROL - V6 ENGINE.

30. Remove coolant outlet and thermostat.

Figure 6A1-1-68

REINSTALL

Installation of the inlet manifold is the reverse of

removal procedures, noting the following points:

NOTE:

Steps 1-4 are applicable only if the relevant items

were removed .

1. Install P.C.V. valve with seal baffle and spring.

Figure 6A1-1-69

2. Inspect sealing O - rings on water inlet tube

and heater inlet pipe connectors, replace if

necessary.

Smear O - rings with petroleum jelly, reinstall

water inlet tube and heater inlet pipe

assemblies to the correct torque specification.

3. Reinstall fuel rail with injectors and throttle

body assembly. Refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE.

4. Apply Loctite 242 sealant or equivalent

(Holden Specification HN 1256 Class 2, Type

2) to coolant temperature sensor threads.

Reinstall coolant sensor and tighten to the

correct torque specification.

COOLANT TEMPERATURE

SENSOR 8 - 12

5. Clean gasket and seal surfaces on cylinder

block, cylinder heads and inlet m anifold. Take

care not to scratch or gouge machined

surfaces.

Ensure that all gasket sealing surfaces are

clean and dry.

Ensure that manifold attaching bolts and

cylinder head threads are clean and free of

sealant. Use a suitable size thread tap to

clean out threads in cylinder head.

6. Install gaskets in the following manner.

a. Apply RTV 732 sealant or equivalent

(Holden Specification HN 1373) in a 2-3

mm bead to cylinder head to block joints

across edge of head gaskets (four

places).

b. Lay new front and rear manifold seals in

place pushing sealant out towards the

cylinder heads at seal and manifold

gasket join.

NOTE:

Ensure seals are installed with cut out sections

facing to outside of the cylinder block.

c. Slide manifold gaskets into place

ensuring that dowels on each gasket fit

into corresponding holes in cylinder head

ventilation system hole in each cylinder

head.

NOTE:

Both gaskets are identical.

d. Apply a further 2-3 mm diameter bead at

joints of inlet manifold gaskets to seals.

Figure 6A1-1-70

Figure 6A1-1-71

7. Apply Loctite 242 sealant or equivalent

(Holden Specif ication HN 1256, Class 2, Type

2) to lower inlet manifold attaching bolt

threads.

8. Install m anifold and attaching bolts. Seat bolts

to 3 - 6 Nm in the sequence shown. Retorque

bolts to specification again to sequence

shown.

LOWER INLET MANIFOLD 12- 18 Nm

ATTACHING BOLT Refer torque

TORQUE SPECIFICATION sequence

Figure 6A1-1-72

9. Install upper inlet manifold seals.

10. Lubricate injector O - rings with Petroleum

Jelly to Holden Specification HN 1974 or

equivalent and install upper inlet manifold to

lower inlet manifold.

11. Tighten upper inlet manifold to lower inlet

manifold attaching bolts to the correct torque

specification.

UPPER INLET MANIFOLD

ATTACHING BOLT

TORQUE SPECIFICATION 10 - 14 Nm

12. Install components in reverse order of removal

procedures. Ensure that all fasteners are

tightened to the correct torque specification.

13. Adjust throttle cable, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE, Service Operations. For cruise

control cable, refer to Section 12E CRUISE

CONTROL.

14. Reinstall air f low duct, rec onnec t mass air f low

sensor electrical connector.

15. Refill cooling system with specified coolant,

refer to Section 6B1 ENGINE COOLING -

V6 ENGINE.

16. Reconnect battery earth lead, star t engine and

check for air, fuel, oil and coolant leaks.

Repair as necessary.

2.10 EXHAUST MANIFOLDS

REMOVE

1. Disconnect battery earth lead.

2. Disconnect spar k plug leads f rom spark plugs,

pull lead retainers from support brackets and

lay leads on top of engine.

Figure 6A1-1-73

3. For left hand side exhaust manifold:

a. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner, remove air flow

duct. Carefully place air flow duct and mas s air

flow sensor assembly to one side.

Figure 6A1-1-74

4. Disconnect EGR outlet pipe from exhaust

manifold refer to Fig. 6A1-1-75.

5. Raise front of vehicle and support on safety

stands. Refer to Section 0A GENERAL

INFORMATION for location of jacking points.

6. Remove engine pipe to manifold stud

attaching nuts.

7. Fold up/down locking tabs to release nuts.

Figure 6A1-1-75

8. Remove the nut securing the dipstick tube to

the exhaust m anifold s tud. Disconnect dipstick

tube from stud and pull assembly from oil pan.

Disconnect EGR tube.

Remove lock nuts and lock plates.

Remove manifold to cylinder head attaching

studs and remove manifold.

Figure 6A1-1-76

REINSTALL

Installation of the exhaust m anifold/s is the r everse

of removal procedures, noting the following points:

1. Ensure that manifold, cylinder head and

engine pipe surfaces are clean.

2. Apply anti-seize compound such as AMPOL

Jet-Lube Kopr-Kote (Holden Specification HN

1325) to exhaust manifold to cylinder head

and engine pipe to manifold attaching studs.

3. Install manifold into position and install

attaching studs.

Connect manifold and engine pipe together

and install attaching nuts.

4. Tighten manifold to cylinder head attaching

studs to the correct torque specification.

EXHAUST MANIFOLD TO

CYLINDER HEAD STUD

TORQUE SPECIFICATION 25 - 35 Nm

5. Tighten engine pipe to manif old stud attaching

nuts to the correct torque specification.

ENGINE PIPE TO MANIFOLD

STUD ATTACHING NUT

TORQUE SPECIFICATION 18 - 35 Nm

NOTE:

Install dipstick tube bracket behind lock plate.

6. Reinstall lock plates, dip stick tube, s park plug

lead bracket and lock nuts. Tighten lock nuts

to the correct torque specifications. Fold tabs

to retain nuts.

EXHAUST MANIFOLD

STUD LOCK NUT

TORQUE SPECIFICATION 20 - 27 Nm

7. Reconnect spark plug lead retainers to

support brackets and leads to spark plugs.

Reinstall air f low duct, rec onnec t mass air f low

sensor electrical connector.

8. Reconnect battery earth lead, star t engine and

check for exhaust leaks. Repair as necessary.

2.11 ROCKER COV ERS AND/OR SEALS

REMOVE

1. Disconnect battery earth lead.

2. For left hand side rocker cover, disconnect

spark plug leads from coil terminals.

Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Fold up/down locking tabs and rem ove the nut

securing the dipstick tube to the exhaust

manifold stud. Disconnect dipstick tube from

stud and pull assembly from oil pan.

3. Disconnect spark plug lead retainers from

spark plug lead support.

NOTE:

All spark plug leads and coil terminals are

numbered to correspond to the cylinder numbering.

If cylinder numbering does not appear on top of

any coil assembly, refer to cylinder numbering on

the module (refer to Section 6D1-3 IGNITION

SYSTEM - V6 ENGINE).

Figure 6A1-1-77

4. Unscrew rocker cover to cylinder head

fasteners and remove rocker cover from

cylinder head.

5. If replacing rocker cover seal, remove seal

from cylinder head flange recess in rocker

cover.

6. If necessary, push out fastener and seal

assemblies from rocker cover.

Figure 6A1-1-78

REINSTALL

1. If necessary, install seal in rocker cover

recess. Install rocker cover fastener and seal

assemblies.

NOTE:

Ensure that seal is correctly installed in rocker

cover.

Figure 6A1-1-79

2. Inspect fastener seals and replace any

assembly if damaged.

3. Install rocker cover to cylinder head and

tighten fasteners to the correct torque

specification.

ROCKER COVER FASTENER

TORQUE SPECIFICATION 7 - 11

4. Refit spark plug lead retainers to support and

leads to spark plugs.

If removed, reinstall spark plug leads to coil

terminals, ensuring correct lead orientation

with coil terminal numbering.

Reinstall dip stick tube and air flow duct,

reconnect mass air flow sensor electrical

connector.

5. Reconnect battery earth lead, star t engine and

check for oil leaks. Repair as necessary.

2.12 ROCKER ARMS AND PUSHRODS

REMOVE

1. Disconnect battery earth lead.

2. Remove rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

3. Remove rocker arm bolts, rocker arms and

retainers.

NOTE 1:

Once removed, discard rocker arm pedestal bolts.

New bolts must be used on reassembly.

NOTE 2:

It is important that the original location of all

pedestals and rocker arms is retained during

reassem bly. For this reason, place components on

a suitable rack.

4. Remove pushrods.

Figure 6A1-1-80

CLEAN AND INSPECT

Clean all components in a s uitable cleaning solvent

and blow dry with clean dry compressed air.

Inspect all com ponents for wear, chec k rock er arm

pedestal bearings for freedom of movement;

replace as necessary.

If there is excessive wear on spherical surfaces of

pushrod, refer to 4. ENGINE MECHANICAL

DIAGNOSIS - Valve Train Noise in this Section.

REINSTALL

1. Lubricate pushrod contact surfaces with

Lubrizol 6612 or equivalent (Holden

Specification HN 1961) and install pushrods.

2. Install pedestal retainers onto cylinder heads.

3. Lubricate rocker arm pedestal bearings with

clean engine oil.

4. Assemble new rocker arm bolts and rocker

arms in their original positions on each

cylinder head.

5. Tighten pedestal bolts to the correct torque

specification and, at the same time, ensure

that each pedestal base engages into the

retainer squares and that pushrods remain in

contact with each lifter and rocker arm.

ROCKER ARM

PEDESTAL BOLT

TORQUE SPECIFICATION

11 - 19 Nm

+ 87 - 93 deg.

turn angle

6. Reinstall rocker covers, refer to

2.11 ROCKER COVERS AND OR/SEALS in

this Section.

7. Reconnect battery earth lead, star t engine and

check for oil leaks or valve train noise. Repair

as necessary.

2.13 VALVE STEM OIL SEALS

REPLACE

1. Disconnect battery earth lead.

2. Remove rocker cover/s, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

3. Remove r ocker arm s, ref er to 2.12 RO CKER

ARMS AND PUSHRODS in this Section.

4. Rem ove spark plug from relevant cylinder and

screw air adaptor, Tool No. 6A40A into spark

plug hole. Apply air pressure to hold valves in

closed position.

CAUTION:

Take care, as when air pressure is applied to

cylinder, it may cause the crankshaft to rot ate if

the piston in the cylinder is not at T.D.C or

B.D.C.

5. Using Tool No. KD2078 or equivalent,

compress valve spring. Remove valve collets.

NOTE:

It is important that only spring compressor tool no.

KD2078 be used as other tools may cause damage

to valve stem collet ‘contact’ area. It may be

necessary to tap top of valve cap with a soft faced

hammer after the spring compressor has been

applied to overcom e the binding of the valve collets

in the valve spring cap.

6. Remove spring, cap and spring compressor

tool as an assembly from cylinder head.

Figure 6A1-1-81

7. Using a screwdriver, lever valve stem oil seal

from valve guide. Remove and discard seal.

Figure 6A1-1-82

8. Thoroughly clean and dry all components.

9. Lubricate valve stems and valve guides

thoroughly with clean engine oil.

10. Lubricate new seal with engine oil and install

over valve with a twisting motion and pus h the

seal down until the rubber jacket touches the

top of guide.

11. Place the valve stem installation tool over the

valve stem seal (flat surfaced end toward the

seal).

12. Lightly tap the top (tapered end of the tool)

lightly with a plastic mallet until the valve stem

seal is resting flush with the top of the valve

guide.

NOTE:

Install seals using valve stem installation tool

No. J41512.

Figure 6A1-1-83

a. There are specific valve stem seals for

inlet and exhaust valves.

b. The colour of the replacement seal may

not be the same colour as the original

seal.

Ensure the correct type of seal is fitted to

the appropriate valve, based on part

number and package description.

Figure 6A1-1-84

13. Install spring with the larger diameter coils

towards the cylinder head spring seat. Install

cap and compressor as an assembly on to

valve stem.

14. Install valve collets, ensuring that they locate

correctly in groove in top end of valve stem.

Slowly release valve spring compressor,

checking that collets seat correctly. A sharp

tap on cap with a soft faced hammer will

ensure correct seating of collets.

Grease may be used to hold collets in place.

15. Disconnect air line to Tool No. 6A40A.

16. Repeat procedure f or rem aining seals that are

to be replaced.

17. Reinstall rocker arms, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

18. Reinstall rocker cover/s, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

19. Rem ove Tool No. 6A40A, r einstall spark plugs

and tighten to the correct torque specification.

SPARK PLUG

TORQUE SPECIFICATION 15 - 25

20. Reinstall spark plug leads and battery earth

lead.

21. Start engine and check for oil leaks and valve

train noise. Repair as necessary.

2.14 VALVE LIFTERS

REMOVE

1. Depressurise fuel lines, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE - Service Operations.

2. Disconnect battery earth lead.

3. Remove rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

4. Remove rocker arms and pushrods, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

5. Remove lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

6. From valley in cylinder block, remove two

valve lifter guide attac hing bolts . Remove lif ter

guides.

7. Remove lifters from cylinder block bores and

place in order on rack.

NOTE:

Ensure that all valve train components are kept in

order so they may be reinstalled, if r equired, in their

original locations.

Figure 6A1-1-85

DISASSEMBLE

1. Using a small, fine bladed screwdriver,

remove push rod seat retainer ring.

2. Remove push rod seat, oil metering valve,

plunger assembly and plunger spring from

lifter body.

NOTE:

If the plunger is stuck in the lifter body, turn lifter

body upside down and tap lifter body on a block of

wood.

If plunger cannot be moved, s oak lifter as sembly in

a suitable cleaning fluid.

Figure 6A1-1-86

3. Remove check valve retainer, ball check

spring and ball from plunger assembly with a

small, fine bladed screwdriver.

Figure 6A1-1-87

CLEAN AND INSPECT

1. Thoroughly clean all parts in a suitable

cleaning fluid. Blow dry with clean dry

compressed air.

2. Inspect lifter body for;

a. Wear

b. Scuffing. Also inspect lifter bore in

cylinder block.

3. Inspect roller for;

a. Freedom of movement. Replace lifter if

roller binds or roughness can be felt.

b. Excessive looseness in the roller bearing.

c. Flat spots. Replace lifter if roller is worn.

d. Pitting. Replace lifter if roller is pitted.

4. Inspect pushrod seat. If seat is worn, inspect

pushrod. Replace pushrod if worn.

5. If any lifter component is damaged or

excessively worn, replace entire lifter

assembly.

REASSEMBLE

NOTE 1:

Do not attempt to recondition lifter assemblies by

taking parts from other unserviceable lifters.

NOTE 2:

Cleanliness is very important when reassembling

lifters. Lint or dirt can cause the lifters to fail.

1. Place check ball on small hole in plunger.

Figure 6A1-1-88

2. Carefully place check ball spring and retainer

over ball and press retainer into position in

plunger with a small, fine bladed screwdriver.

3. Half fill valve lifter body with test fluid No.

E1151 (previously 361-1-93).

4. Reinstall plunger spring into lifter body.

5. Install plunger assembly in body, taking care to

align oil feed holes.

6. Fill lifter assembly with test fluid.

Figure 6A1-1-89

7. Use a 1 m m diameter pin to unseat check ball

in the plunger. Push plunger down to the full

extent of its travel.

8. Use Tool No. 6A24 to align oil feed holes in

body and plunger.

9. Fill lifter assembly with test fluid.

10. Reinstall oil metering valve, push rod seat (cup

side uppermost) and retaining ring.

NOTE:

The hydraulic lifter is now ready for checking as

outlined in the next operation.

Figure 6A1-1-90

TESTING LIFTER LEAK DOWN RATE

After a hydraulic lifter has been cleaned, inspected

and assembled, it must be tested before it is

reinstalled in the engine. T he lifter test f ixture, Tool

No. 6A23, has been designed to test the leak down

rate of the lifter to determine whether it is within the

limits which assure satisfactory lifter operation.

1. Thoroughly clean cup of tes t f ix tur e. Inst all cup

on fixture and place lifter into cup.

NOTE:

On som e versions of 6A23, it m ay be necessary to

make a small cup/support fixture to hold the base

of the lifter assembly inside the tester cup.

2. Add sufficient test fluid No. E1151 (previously

361-1-93) to completely cover lifter.

3. Place ball bearing supplied with test fixture in

push rod seat of lifter.

4. Lower test fixture ram to rest on ball bearing.

5. Operate lifter plunger through its maximum

travel to force all air out of lifter by using a

vigorous pumping action on test fixture weight

arm. Continue pumping action until

considerable resistance is built up in lifter and

lifter becomes solid.

6. Raise weight arm to allow lifter plunger to

come up to its retainer, then lower arm to rest

on ram.

7. Use a stop watch to check the time required

for the indicator to move from the 'START' to

0.125 in. position on the scale.

8. The leak down rate (time between start and

0.125 in. position) must be between 10 to 30

seconds to assure satisfactory lifter operation.

Figure 6A1-1-91

NOTE:

A doubtful lifter should be tested three or four

times. Any lifter which does not test within the

specified limits should be replaced.

9. After all lifters have been thoroughly tested,

place a cover over the test fixture to keep dirt

out of the cup.

10. Stand tested lifters upright so that fluid does

not drain from oil holes.

REINSTALL

1. Ensure that lifter bodies, rollers and lifter

bores are clean.

2. Lubricate lifter bodies and bores with Lubrizol

6612 or equivalent (Holden Specification HN

1961) and install lifters.

3. Install lifter guides, aligning flats on lifter body

with flats in guide.

4. Install valve lifter guide retainer and attaching

bolts. Tighten bolts to the correct torque

specification.

VALVE LIFTER GUIDE

RETAINER BOLT

TORQUE SPECIFICATION 26 - 34 Nm

5. Install rocker arms and pushrods, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

6. Install rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

7. Reinstall lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

8. Reconnect battery earth lead, star t engine and

check for oil or fuel leaks and valve train

noise. Repair as necessary.

2.15 CYLINDER HEADS

REMOVE

1. Depressurise fuel lines, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE.

2. Disconnect battery earth lead.

3. Disconnect spar k plug leads f rom spark plugs.

Remove spark plug leads from retainers.

NOTE:

All spark plug leads and coil terminals are

numbered to correspond to the cylinder numbering.

Figure 6A1-1-92

4. Remove drive belt, refer to

2.6 DRIVE BELT - REMOVE in this Section.

5. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot.

Sudden release of cooling system pressure is

very dangerous and could cause personal

injury.

6. Remove lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

7. Remove exhaust manifolds, refer to

2.10 EXHAUST MANIFOLDS in this Section.

8. Remove rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

9. Remove rocker arms and pushrods, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

10. For left hand side cylinder head:

a. Disconnect wiring harness connector to

ignition coil module assembly, remove bolts

securing ignition coil and module assembly to

left hand cylinder head.

Figure 6A1-1-93

b. Remove powertrain harness earth connector

at rear of cylinder head and connector from

EGR valve.

Figure 6A1-1-94

c. Remove screw securing starter motor heat

shield to rear of cylinder head, refer to

Fig. 6A1-1-95.

Figure 6A1-1-95

d. Remove bolts securing idler pulley assembly,

refer to 2.25 IDLER ASSEMBLY in this

Section.

Figure 6A1-1-95

e. Disconnect canister purge solenoid vacuum

lines and electrical connector at rear of

cylinder head.

Figure 6A1-1-96

11. For right hand side cylinder head:

a. Remove the drive belt tensioner

assembly refer to 2.7 DRIVE BELT

TENSIONER ASSEMBLY in this Section.

b. Remove generator brac e to cylinder head

bracket bolt and generator brace bracket

to cylinder head bolts.

c. Remove br ace to generator bolt rem oving

brace and bracket assembly.

Figure 6A1-1-97

12. Gradually and progressively slacken cylinder

head bolts in the sequence shown. Remove

rocker covers.

Figure 6A1-1-98

13. Remove cylinder head bolts, remove cylinder

heads and gaskets.

Figure 6A1-1-99

INSPECT

1. Clean mating surfaces of cylinder head and

cylinder block, taking care not to scratch

machined surfaces.

NOTE:

Do not use a motorised wire brush on any gasket

sealing surface.

2. Check cylinder head deck, inlet and exhaust

manifold mating surfaces for distortion. These

surfaces may be refaced by parallel grinding. If

more than 0.25 mm must be removed from

any surface, replace cylinder head.

Figure 6A1-1-100

NOTE 1:

To determine if cylinder head has sufficient deck

surface thickness for resurfacing, measure head

height from deck surface to cast pads, refer to

Fig. 6A1-1-101.

NOTE 2:

New cylinder heads measure f rom 1.37 m m to 1.67

mm. The minimum dimension allowed after

resurfacing is 1.12 mm

NOTE 3:

If the cylinder head does not meet the minimum

thickness after resurfacing, the cylinder head must

be replaced.

NOTE 4:

Do not reduce com bustion cham ber volum e below

minimum specified in 5. SPECIFICATIONS in this

Section. Machining 0.15 mm off deck face will

reduce combustion chamber volume 1.00 cm3.

Figure 6A1-1-101

3. Inspect all threaded holes for damage, repair

as required.

4. Inspect coolant jack et welsh plugs for signs of

corrosion, replace plugs as necessary.

If replacing welsh plugs, apply a coating of

Loctite 242 or equivalent (H olden Specification

HN 1256, Class 2 Type 2) around plug sealing

surface.

5. Inspect cylinder head for cracks, especially

between valve seats or exhaust ports.

6. Inspect cylinder head deck surface for

corrosion, casting sand inclusions or blow

holes.

7. Inspect cylinder block deck surface for

distortion, refer to 3.15 CYLINDER BLOCK

in this Section.

8. Clean cylinder head bolt hole threads in

cylinder block using an appr opr iate size thread

tap. Threads may be reconditioned if

necessary with suitable thread inserts. Clean

out bolt holes with an air hose.

NOTE:

Thread size is 7/16 UNC.

9. Clean cylinder head bolts, replace any bolt

that has suspect threads, stretched or

damaged heads caused by improper use of

tools.

REINSTALL

Installation of the cylinder heads is the reverse of

removal procedures, noting the following points:

1. Place head gaskets in position over dowel pins

on cylinder block.

NOTE 1:

ENSURE THAT 'ARROW' MARKING ON

GASKETS IS FACING TOWARDS FRONT OF

ENGINE.

NOTE 2:

Head gaskets have a s pecial coating on both sides

and care must be taken when installing head

gaskets so as not to damage this coating.

NOTE 3:

The left hand c ylinder head gasket is identified by a

'L' shaped cut out and the right by a 5.0mm hole.

Both are visible on final engine assembly.

Figure 6A1-1-102

2. Carefully guide cylinder head into place over

dowel pins and onto gasket.

3. Coat threads of cylinder head bolts with Loctite

242 sealant or equivalent (Holden

Specification HN 1256 Class 2, Type 2) and

install finger tight.

NOTE:

Different length head bolts are used, refer to

Fig. 6A1-1-103.

Figure 6A1-1-103

4. Tighten head bolts to the following sequence

and in the order shown in Fig. 6A1-1-104.

NOTE:

It is important to follow the given procedur e to avoid

head gasket failure and possible engine damage.

5. Tighten all cylinder head bolts to 34 Nm.

The next step requires the use of Tool No.

E7115 with the torque wrench.

NOTE:

If a torque of 90 Nm at any time in step 6 is

reached, STOP tightening that particular head bolt.

6. Tighten each bolt 90 degrees in the order

shown.

7. Further tighten all bolts in the specified order

to 90 Nm.

8. The remaining reinstallation of components is

the reverse of removal procedures.

9. Start engine, check for oil, coolant, fuel and

exhaust leaks. Repair as necessary.

Figure 6A1-1-104

2.16 CYLINDE R HEAD RECONDITIONING

NOTE:

Ensure that all valve train components are kept

together and identified so that they can be

reinstalled in their original locations.

DISASSEMBLE

1. Using spring compressor tool No. KD2078,

compress each valve spring in turn and

remove valve collets.

NOTE:

It is important that only spring compressor tool no.

KD2078 be used as other tools may cause damage

to valve stem collet ‘contact’ area. It may be

necessar y to tap top of valve caps with a s oft fac ed

hammer after spring compressor has been installed

to overcome the binding of the valve collets in the

valve spring caps.

2. Remove valve spring caps, springs and valve

stem oil seals.

3. Remove valves from cylinder head.

CAUTION:

Do not force valves out of guides, as

mushroomed valve ends due to rocker arm

wear, or burred valve collet groove, or dirt in

the guides, will damage the guides. Remove

burrs by chamfering aff ected area of v alv e st em

with an oil stone only. During the stoning

process, protect the valve stem/g uide area w ith

rags or grease to prevent any possible ingress

of foreign material.

Figure 6A1-1-105

CLEAN

1. Clean all carbon from combustion chambers,

valve ports etc., using a rotary type carbon

removing wire brush.

NOTE:

Do not wire brush on any gasket sealing surface.

2. Clean cylinder head gasket sur face of cylinder

head.

3. Thoroughly clean valve guides with a suitable

cleaning solvent or a wire brush.

4. Clean valve heads with a buffing wheel.

NOTE:

Do not scratch the valve stem with the buffing

wheel.

Figure 6A1-1-106

5. Thoroughly wash all components in a suitable

cleaning solvent and blow dry with dry

compressed air.

CYLINDER HEAD INSPECTION

1. Inspect cylinder heads for cracks in valve

seats and combustion chambers, and for

external cracks to water jackets.

2. Check cylinder head deck surface for

corrosion.

3. Using a straight edge and f eeler gauge. Chec k

cylinder head deck inlet and exhaust manifold

surfaces for distortion.

Check cylinder head deck surface diagonally,

longitudinally and transversely.

These surfaces may be refaced by parallel

grinding. If more than 0.25 mm must be

removed from any surface, replace cylinder

head.

Figure 6A1-1-107

NOTE 1:

To determine if cylinder head has sufficient deck

surface thickness for resurfacing, measure head

height from deck surface to cast pads, refer to

Fig. 6A1-1-108.

NOTE 2:

New cylinder heads measure from 1.372 mm to

1.676 mm. The minimum dimension allowed after

resurfacing is 1.12 mm

NOTE 3:

If the cylinder head does not meet the minimum

thickness after resurfacing, the cylinder head must

be replaced.

NOTE 4:

Do not reduce com bustion cham ber volum e below

minimum specified in 5. SPECIFICATIONS in this

Section. Machining 0.15 mm off deck face will

reduce combustion chamber volume 1.00 cm3.

Figure 6A1-1-108

4. Inspect all threaded holes for damage, repair

as required.

5. Inspect coolant jack et welsh plugs for signs of

corrosion, replace plugs as necessary.

If replacing welsh plugs, apply a coating of

Loctite 242 or equivalent (H olden Specification

HN 1256, Class 2, Type 2) around plug

sealing surface.

VALVE GUIDES

Clearance Checking

Excessive valve stem to guide bore clearance will

cause lack of power, rough idling and noisy valve

operation. Insufficient clearance will result in noisy

and sticking func tioning of the valve and will dist urb

engine smoothness of operation.

Measure clearance as outlined in the following

steps.

1. Insert valve into its guide.

2. Clamp a dial indicator on one side of cylinder

head rocker cover seating rail, locating the

indicator so that movement of the valve stem

from side to side (crosswise to the head) will

cause a direct movement to the indicator

stem.

The indicator stem must contact the side of

the valve stem, 8 - 12 mm above top of valve

guide.

3. With the valve head dropped approximately 2

mm off its seat, move the stem of the valve

side to side using light force to obtain a

clearance reading. Figure 6A1-1-109

NOTE:

It is important to check the clearance with a new

standard valve bef ore attem pting to ream the valve

guide.

INLET AND EXHAUST

VALVE STEM TO VALVE GUIDE

CLEARANCE SPECIFICATION

0.043 - 0.25

Total Indicated

Reading

The following chart is for valve stem to guide

clearance if checking clearance by measuring

valve stem diameter and subtracting from valve

guide internal diameter measurement.

NEW PARTS SPECIFICATION

INLET VALVE STEM

EXHAUST VALVE STEM

0.033 - 0.066

0.036 - 0.074

MAXIMUM SPECIFICATION ON

WORN PARTS 0.18

If valve stem to valve guide clearance is within

specification when using a new valve, check

original valve stem diameter (refer to VALVES in

this Section) and replace any worn valves as

necessary.

Valve guides m ay be reamed to acc ept an oversize

of 0.254 mm.

Valves with oversize stems are identified as shown

in Fig. 6A1-1-110.

Figure 6A1-1-110

NOTE:

Avoid breaking reamer flutes or jamming the

ream er into the valve guide due to pack ing of chips

or carbon. Clean the valve guides before reaming.

Do not push down on the reamer, and clean and

lubricate the reamer often during use.

VALVE SEATS

Reconditioning the valve seats is very important

because the seating of the valves must be precise

for the engine to deliver the power and

performance built into it.

Another important factor is the cooling of the valve

head. Good contact between each valve and its

seat in the head is imperative to ensure that the

heat in the valve head will be properly carried

away.

Several different types of equipment are available

for reconditioning valve seats with an oscillating

type valve seat grinder being preferred. The

recommendations of the manufacturer of the

equipment being used should be carefully followed

to attain proper results.

Check valve seats for any evidence of pitting or

damage at valve contact surface. If pitting is

evident, the valve seats will need to be

reconditioned.

NOTE:

Since the valve guide serves to support and c entre

the valve seat grinder, it is essential that the valve

guide is serviced before reconditioning the valve

seats.

Refer to Fig. 6A1-1-111 for valve seat angles. If,

after grinding, the seat is too wide, it may be

narrowed by using a 25 degree or 60 degree

grinding stone. The 25 degree stone will lower the

seat and the 60 degree stone will raise the seat.

Figure 6A1-1-111

If the valve seats are reconditioned, the valves

must also be reconditioned (refer to VALVES in

this Section) or replace valves as necessary.

VALVE SPRINGS

1. Inspect valve sp ring surf aces on cylinder head

and valve cap for wear or gouging. Replace

components as necessary.

2. Check spring ends, if they are not parallel, the

spring is bent, refer to Fig. 6A1-1-112.

Replace valve springs that do not meet

specification.

MAXIMUM ALLOWABLE VARIANCE 1.60

IN SPRING END LENGTH mm

Figure 6A1-1-112

3. Check valve spring load with a spring tester.

Springs should be compressed to the

specified height and checked against

specifications.

Replace any valve spring if not to

specification.

VALVE SPRING COMPRESSED LOAD/HEIGHT

SPECIFICATION N/mm

VALVE OPENED HEIGHT 970 - 1059/32.4

ASSEMBLED HEIGHT 316 - 351/43.7

Figure 6A1-1-113

VALVES

1. Inspect valve stem for burrs and scratches.

Burrs and minor scratching may be removed

with an oil stone.

Valves with excessive stem wear or that are

warped should be replaced.

Inspect valve stem tip for wear. The valve tip

may be reconditioned by grinding.

Follow the grinder manufacturer's instructions.

Ensure that new tip surface is at right angles

to the valve stem.

2. Inspect valve stem collet groove for damage.

3. Check valve face for burning or cracking.

If pieces have broken off, inspect

corresponding piston and cylinder head area

for damage.

Figure 6A1-1-114

4. Inspect valve stem for straightness and valve

head for bending or distortion. Use V - blocks.

Bent or distorted valves must be replaced.

Figure 6A1-1-115

5. Valves with pitted or grooved faces can be

reconditioned with a valve refacing machine,

ensuring correct relationship between head

and stem.

VALVE FACE

ANGLE 45 degrees

NOTE:

If pitting or grooving is so deep that refacing would

result in a 'knife' edge at the valve head, the valve

must be replaced. Measure valve margin after

refacing valves. If margin is less than minimum

specified, the valve must be replaced.

VALVE HEAD MARGIN 0.63

THICKNESS (MINIMUM) mm

Lightly lap reconditioned valves into valve seat.

NOTE:

New valves must not be lapped. Lapping destroys

the protective coating on the valve face.

Figure 6A1-1-116

After refacing an existing valve or installing a new

valve, check for correct seating as follows:

a. Lightly coat valve face with bearing blue.

b. Insert valve and rotate about 1/6th of a

revolution.

c. Remove valve and check its contact with the

seat

d. If full contact is indicated, valve and seat are

acceptable.

If partial contact is indicated, reinsert valve

and turn through a full revolution. If blue on

seat indicates f ull contact, ref ace valve. If blue

on the seat indicates partial contact, regrind

cylinder head valve seat.

e. Clean all traces of bearing blue from valves

and seats.

MEASURING VALVE STEM HEIGHT

After rec onditioning valves or valve s eats or when a

new valve is installed, the valve stem height must

be checked to ensure correct hydraulic valve lifter

operation.

1. Place valve in its guide and hold it in the

closed position.

2. Using a vernier calliper, measure from

machined valve spring seat to valve stem end.

Figure 6A1-1-117

3. Measurement should be as specified.

VALVE STEM HEIGHT 49.22 - 50.49

(INSTALLED) SPECIFICATION mm

If measurement is greater than specified,

remove valve and grind end of valve stem to

achieve specified dimension.

NOTE:

Do not grind off any more than is necessary.

Figure 6A1-1-118

4. Using a vernier calliper, measure from

machined valve spring seat to spring side of

cap.

Valve spring installed height should be as

specified.

If any measurement is not as specified, shim valve

spring seat as required.

Figure 6A1-1-119

VALVE SPRING INSTALLED HEIGHT

Excessive valve spring installed height, caused by

valve seat wear or valve and seat reconditioning,

must be compensated for by adding shims under

the valve springs.

1. Place valve in its guide.

2. Install valve spring cap and collets.

3. Pull up on valve spring cap to seat collet and

valve.

Figure 6A1-1-120

VALVE SPRING INSTALLED

HEIGHT 43.7 ± 0.5

REASSEMBLE

1. Thoroughly clean and dry all components.

2. Lubricate valve stems and valve guides

thoroughly with clean engine oil. Install valves

in corresponding guides.

3. Lubricate new seal with engine oil and install

over valve with a twisting motion and pus h the

seal down until the rubber jacket touches the

top of guide.

4. Place the valve stem installation tool over the

valve stem seal (flat surfaced end toward the

seal).

5. Lightly tap the top (tapered end of the tool)

lightly with a plastic mallet until the valve stem

seal is resting flush with the top of the valve

guide.

NOTE:

Install seals using valve stem installation tool

No. J41512. Figure 6A1-1-121

NOTE 1:

There are specific valve stem seals for inlet and

exhaust valves. Ensure the correct type is fitted to

the appropriate valve based on part number and

package description.

NOTE 2:

The colour of the replacement s eals may not be the

same colour as the original seals.

Figure 6A1-1-122

6. Place valve spring and cap over valve stem.

7. Compress valve spring with tool No. KD2078.

NOTE:

Compress valve spring only enough to install valve

collets. Excess compression can cause valve

spring cap to damage valve stem oil seal.

8. Install valve collets, ensuring that they locate

correctly in groove in top end of valve stem.

Slowly release valve spring compressor,

checking that collets seat correctly. A sharp

tap on cap with a soft faced hammer will

ensure correct seating of collets.

Grease may be used to hold collets in place.

9. Repeat procedure to install all valve springs,

caps and collets.

2.17 CRANKSHAFT BALANCER

REMOVE

1. Disconnect battery earth lead.

2. Remove drive belt, refer to 2.6 DRIVE BELT

in this Section.

3. Disconnect the wiring harness connector from

the oil pressure switch.

4. Lock crankshaft against rotation by inserting

the lugs of the cranks haf t balanc er holding tool

No. AU448 into two of the slots in the face of

the crankshaft balancer. Rotate balancer and

lock ing tool by hand resting the arm of the tool

on the R/H side rail.

Figure 6A1-1-123

5. Using a suitable size socket and 'breaker' bar

loosen and remove balancer retaining bolt.

6. Remove crankshaft balancer holding tool from

crankshaft balancer.

7. Install puller, Tool No. AU424, to front of

balancer and remove balancer from

crankshaft.

NOTE 1:

Before ins talling the puller to the balancer, lubric ate

threads and end of puller forcing screw with

grease.

NOTE 2:

When installing the puller to the balancer, ensure

that the locating pin in the front face of the puller

aligns with the indentation between two of the slots

in the front face of the balancer. This is to ensure

correct alignment of the bolt holes in the balancer

and puller.

NOTE 3:

With the introduction of ECOTEC engines the puller

attaching bolts need to be 10 mm longer than thos e

originally supplied with Tool No. AU 424.

NOTE 4:

A series of holes are drilled in the perimeter of the

puller plate to enable the installation of a bar to hold

the puller from rotating while tightening the forcing

screw.

Figure 6A1-1-124

REINSTALL

Installation is the reverse of removal procedures,

noting the following points:

NOTE:

The balancer is serviced only as an assembly.

1. Visually inspect interrupter rings, on rear of

balancer, for any damage or distortion.

2. Lubricate front seal and seal contact surface

of balancer with engine oil. Install balancer,

engaging key on crankshaft with slot in

balancer.

3. Pull crankshaft balancer into position by

tightening retaining bolt. Once balancer has

seated onto front end of crankshaft, lock

crank shaft against rotation by inserting lugs of

crankshaft balancer locking tool No. AU448

into two of the slots on the face of crankshaft

balancer. Rotate balancer and locking tool by

hand so that the arm of the tool rests against

the L/H side rail. Continue to tighten balancer

retaining bolt to the correct torque

specification.

CRANKSHAFT BALANCER

ATTACHING BOLT

TORQUE SPECIFICATION 270 - 325

4. Rotate Crankshaft and ensure that interrupter

rings do not make contact with crank sensor.

If any part of the interrupter rings touch the

crank sensor then the crank shaft balancer

must be replaced, refer to

2.17 CRANKSHAFT BALANCER.

5. Check drive belt operation.

2.18 CRANKSHAFT FRONT SEAL

REPLACE

1. Remove crankshaft balancer, refer to

2.17 CRANKSHAFT BALANCER in this

Section.

2. Using Tool No. E308, remove seal.

Figure 6A1-1-125

3. Using Tool No. J28540-A install new seal.

Figure 6A1-1-126

4. Inspect seal s urface on c ranks haft balancer, if

grooved or damaged, replace balancer.

5. Reinstall crankshaft balancer, refer to

2.17 CRANKSHAFT BALANCER in this

Section.

2.19 FRONT COVER AND GASKET

REMOVE

1. Disconnect battery earth lead.

2. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot.

Sudden release of cooling system pressure is

very dangerous and could cause personal

injury.

3. Remove crankshaft balancer, refer to

2.17 CRANKSHAFT BALANCER in this

Section.

4. Remove water pump pulley to hub attaching

bolts, remove pulley.

Figure 6A1-1-127

5. Place an oil drain tray beneath engine.

6. Loosen radiator lower hose clamp at front

cover connection, disconnect and remove

hose.

Figure 6A1-1-128

7. Remove two nuts from belt tensioner lower

mounting studs and remove water inlet tube

from front cover.

Figure 6A1-1-129

Techline

8. Remove power steering pump drive pulley

bolts and remove pulley.

NOTE:

It may be necessary to use a suitable Allen key

inserted in front of power steering pump shaft to

prevent shaft from turning.

Figure 6A1-1-130

9. Rem ove spark plug leads from their sock ets in

coil pack and disconnect electrical connector

from Direct Ignition System Module on coil

pack.

Figure 6A1-1-131

10. Remove bolts securing idler pulley and coil

pack assembly to cylinder head.

Figure 6A1-1-132

11. Remove screws securing battery harness and

transmission cooler pipes refer to Fig. 6A1-1-

133 and move to one side.

12. Bend back tabs securing power train harness.

Figure 6A1-1-133

13. Using a fine bladed screwdriver, lever back

power train harness connector retaining tang

from crankshaft position sensor and camshaft

position sensor, pull connector from sensors

and move harness to one side.

Figure 6A1-1-134

14. Using a screwdriver behind c r ank s haf t pos ition

sensor shield, lever each corner of shield fr om

front cover studs, remove shield.

Figure 6A1-1-135

15. Remove crank angle sensor bracket to front

cover attaching studs and remove sensor

assembly.

Figure 6A1-1-136

16. Pull out tang on oil pressure s ender unit wiring

harness connector and pull connector from

sender unit.

Figure 6A1-1-137

17. Raise front of vehicle and support on safety

stands. For location of jacking points refer to

Section 0A GENERAL INFORMATION.

18. Remove beaming brace, refer to

2.24 BEAMING BRACE in this Section.

19. Remove oil pan to front cover attaching bolts.

Loosen oil pan to cylinder block bolts.

Figure 6A1-1-138

20. Rem ove front cover to cylinder block attac hing

bolts/studs and remove cover. Remove and

discard front cover gasket.

Figure 6A1-1-139

21. If necessary, remove water pump to front

cover attaching bolts and separate pump from

front cover. Remove and discard water pump

gasket.

Figure 6A1-1-140

22. If neces s ary, remove c amshaft position s ensor

to front cover attaching bolt and remove

sensor from front cover.

Figure 6A1-1-141

23. If necessary, remove oil pressure sender unit,

oil filter adaptor and pressure regulator valve

and spring. Refer to 2.5 OIL FILTER

ADAPTOR in this Section.

Remove and discard oil filter adaptor gasket.

REINSTALL

Installation is the reverse of removal procedures,

noting the following points:

1. Clean threads on all front cover to cylinder

block attaching bolts/studs.

Using a suitable size thread tap, clean front

cover attaching bolt/stud threaded holes in

cylinder block.

Ensure that front cover and cylinder block

surfaces are clean and free of foreign matter.

Ensure oil pan seal is not swollen. If the seal is

excessively swollen, the oil pan must be

removed and the seal replaced, refer to

3.2 OIL PAN AND SEAL in this Section.

If water pump was removed during

disassembly, ensure that water pump to front

cover mating surfaces are clean and free of

foreign matter.

If removed on disassembly, reinstall oil

pressure regulator valve spring and valve, oil

filter adaptor, refer to 2.5 OIL FILTER

ADAPTOR in this Section.

2. Check timing chain for overall 'in and out'

movement and inspect condition of timing

chain sproc kets, ref er to 2.21 TIM ING CHAIN,

TENSIONER, SPROCKETS AND BALANCE

SHAFT GEARS in this Section.

Figure 6A1-1-142

3. If necessary, install water pump with new

gasket to front cover. Install and tighten water

pump attaching bolts to the correct torque

specification.

WATER PUMP TO FRONT

COVER ATTACHING BOLT

TORQUE SPECIFICATION

12 - 18 Nm

plus 76 - 84

degrees angle

turn

4. If necessary, install camshaft position sensor

with new O - ring to front cover. Lubricate O -

ring with petroleum jelly. Install and tighten

camshaft position sensor attaching bolt to the

correct torque specification.

CAMSHAFT POSITION SENSOR

TO FR ONT COVER

ATTACHING BOLT

TORQUE SPECIFICATION

8 - 12

Techline

5. Using a dum my stud made f r om a 90 mm long

bolt with a thread of 5/16-18 UNC-2A thread,

and with the head cut off, install into bolt hole

shown in Fig. 6A1-1-143.

NOTE:

This step is im portant to ensure that when the f ront

cover gasket is installed, the oil feed hole in the

cylinder block aligns with the appropriate gasket

hole and is not partially blocked.

6. Install new front cover gasket onto cylinder

block to front cover dowel pins.

NOTE:

Ensure ends of gasket are level to 0.15 m m proud

of the cylinder block oil pan face.

Oil pan face of front c over m ust be aligned with the

block oil pan rail within ±0.2 mm.

7. Install front cover, aligning spline on nose of

crankshaft sprocket gear with spline on oil

pump inner gear. Figure 6A1-1-143

NOTE:

Ensure that oil pan seal is located correctly

between front cover and oil pan surfaces.

8. Coat threads of front cover to cylinder block

attaching bolts with Loctite 242 sealant or

equivalent (Holden Specification HN 1256

Class 2, Type 2). With front cover firmly in

place, rem ove dumm y stud installed at step 5.

Install bolts and tighten to the correct torque

specification.

Figure 6A1-1-144

FRONT COVER ATTACHING

BOLT/STUD

TORQUE SPECIFICATION 20 - 30

9. Ensure that interrupter rings on crankshaft

balancer do not contact crankshaft position

sensor at any point during crankshaft rotation,

refer to Section 6D1-3 IGNIT ION SYSTEM -

V6 ENGINE.

10. Smear approx . 6.0 mm wide and 0.2 mm thic k

film of Loctite 514 or equivalent (Holden

Specification HN 1823) centrally across the oil

pan rail at front cover to cylinder block joint

both sides, refer to 3.2 OIL PAN AND SEAL

in this Section. Install oil pan to front cover

attaching bolts and tighten all oil pan bolts to

the correct torque specification.

NOTE:

Front cover and oil pan/cylinder block faces must

be aligned to within 0.20 mm

OIL PAN ATTACHING BOLT

TORQUE SPECIFICATION 8 - 12

11. Reinstall beaming brace, refer to

2.24 BEAMING BRACE in this Section.

12. Check and inspect O - ring on end of water

inlet tube and replace if necessary. Lubricate

O - ring with petroleum jelly.

13. Install tube into front cover, engaging tube

onto belt tensioner bracket attaching studs.

Install nuts to studs and tighten to the correct

torque specification.

WATER INLET TUBE TO BEL T

TENSIONER STUD NUT

TORQUE SPECIFICATION 18 - 25 Nm

14. Ensure that all remaining component

fasteners are tightened to the correct torque

specifications as nominated at the end of this

Section.

15. Fill cooling system with the correct

concentration of coolant, refer to

Section 6B1 ENGINE COOLING - V6

ENGINE.

16. Start engine and check f or oil or c oolant leaks.

Repair as necessary.

2.20 OIL PUMP

REMOVE

The oil pump is integrated with the front cover

assembly. To gain access to the oil pump, it is

necessary to remove the front cover, refer to

2.19 FRONT COVER AND GASKET in this

Section.

DISASSEMBLE

1. Using a suitable oil filter wrench, remove oil

filter and drain oil from pump.

2. Remove oil filter adaptor to front cover

attaching bolts, remove adaptor.

3. Remove oil pressure regulator valve and

spring from front cover bore.

Figure 6A1-1-145

4. Remove oil pump cover screws, using Tool

No. J25359-4 (Torx bit T30) and a suitable

adaptor.

Remove cover and gears.

Figure 6A1-1-146

5. Using Tool No. E308, remove crankshaft front

seal from front cover.

6. Clean all mating surfaces.

Figure 6A1-1-147

INSPECT

1. Clean all components in a suitable cleaning

solvent and blow dry with clean dry

compressed air.

2. Using a suitable size thread tap, c lean adaptor

'long' attaching bolt threads in front cover.

Clean bolt attaching threads.

3. Inspect front cover and oil pump cover for

cracks, scoring, porous or damaged casting,

damaged threads or excessive wear or

scoring.

4. Check pressure regulator valve for scoring,

stick ing in valve bore or burrs in bore. Inspect

regulator valve spring for tension loss

(compare with new spring) or bending. If in

any doubt, replace spring.

5. Inspect oil pum p gears f or c hipping, scor ing or

excessive wear.

6. Install gears into front cover and check the

following clearances.

a. Inner gear tip to outer gear clearance.

INNER GEAR TIP TO OUTER 0.22 mm

GEAR CLEARANCE SPECIFICATION MAX.

OUTER GEAR TO

HOUSING GEAR 0.05 - 0.089

CLEARANCE SPECIFICATION mm

Figure 6A1-1-148

b. Outer gear to housing clearance.

INNER AND OUTER GEAR END TO

HOUSING CLEARANCE 0.025 - 0.089

SPECIFICATION mm

If any component is excessively worn or

damaged, replace front cover and oil

pump as an assembly.

Figure 6A1-1-149

c. Inner and outer gear end to housing

clearance.

Figure 6A1-1-150

7. Check pressure regulator valve to bore

clearance by measuring valve and bore

diameter s and then subtracting the valve fr om

bore diameters.

PRESSURE REGULATOR VALVE

TO BORE CLEARANCE 0.038 - 0.076

If any clearance specification is not as specified,

replace front cover and oil pump assembly.

REASSEMBLE AND REINSTALL

1. Using Tool No. J 28540-A, install new seal into

front cover.

Figure 6A1-1-151

2. Lubricate oil pump gears with petroleum jelly.

Install gears into housing.

NOTE 1:

Ensure that the inner gear is installed with the

chamfered inner edge facing away from the

housing.

NOTE 2:

The outer gear can be installed into the housing

either way.

Figure 6A1-1-152

3. Completely fill oil pump gear cavity with

petroleum jelly.

NOTE:

This is an important step, as the oil pump may not

begin to pump oil as soon as the engine is started.

Figure 6A1-1-153

4. Install oil pump cover screws. Tighten screws

to the correct torque specification.

OIL PUMP COVER SCREW

TORQUE SPECIFICATION 8 - 14

5. Install pressure regulator valve spring and

valve.

6. Install oil filter adaptor and new gasket to f ront

cover. Install adaptor attaching bolts and

tighten to the correct torque specification.

NOTE:

Before installing 'long' adaptor attaching bolt, apply

Loctite 242 sealant or equivalent (Holden

Specification HN 1256, Class 2 Type 2) to bolt

threads, refer to Fig 6A1-1-30 in this Section.

OIL FILTER ADAPTOR TO FRONT

COVER ATTACHING BOLT

TORQUE SPECIFICATION 23 - 35 Nm

7. Install front cover, refer to 2.19 FRONT

COVER AND GASKET in this Section.

8. Install new oil filter, refer to 2.3 OIL FILTER

in this Section.

9. Reconnect battery earth lead. Check engine

oil level and add as required. Star t engine and

check for oil or coolant leaks. Repair as

necessary.

NOTE:

The oil level must be checked and oil added as

necessary, after running the engine, to compensate

for oil used to refill the oil filter.

2.21 TIMING CHAIN, TENSIONER, SPROCKETS AND BALANCE SHAFT GEARS

REMOVE

1. Disconnect battery earth lead.

2. Remove front cover, refer to

2.19 FRONT COVER AND GASKET in this

Section.

3. Inspect timing chain for overall 'in and out'

movement between camshaft and crankshaft

sprockets, opposite side from damper

assembly.

Movement should not exceed the following

specif ic ation. If c learanc e is ex ce ss ive, ins pec t

sprockets at disassembly and replace timing

chain.

TIMING CHAIN 'IN AND OUT' 25.4

MOVEMENT SPECIFICATION mm

Figure 6A1-1-154

4. Loosen camshaft sprocket bolt.

NOTE 1:

On vehicles with automatic transmission, prevent

camshaft and crankshaft from rotating while

loosening bolt by replacing crankshaf t balanc er and

retaining bolt. Tighten bolt until balancer is fully

seated against crankshaft sprocket then install

crank s haf t balanc er holding tool No. AU448. Rotate

crankshaft and tool by hand so the arm of the tool

rests on the R/H side rail.

After loosening the camshaft sprocket bolt,

remove crankshaft balancer with crankshaft

balancer puller tool No. AU424. Refer to

2.17 CRANKSHAFT BALANCER in this Section.

On vehicles with manual transmission, to prevent

camshaft and crankshaft from rotating, pull park

brake fully 'ON', transmission in gear and chock

rear wheels. Figure 6A1-1-155

NOTE 2:

Grinding chamfer from top of socket will help in

ensuring f ull engagement over bolt head and assist

in removal and retightening of camshaft sprocket

bolt.

Figure 6A1-1-156

NOTE 3:

If carrying out this operation with the engine

removed from the vehicle, remove oil pan and

prevent camshaft and crankshaft from rotating by

positioning a suitable piec e of wood ( ideally a piece

of wood 50 mm x 75 mm, 150 mm long) between

the right hand inside of the cylinder block and the

crankshaft front counterweights.

Figure 6A1-1-157

5. Rotate crankshaft so that timing marks on

crankshaft and camshaft sprockets are

adjacent to each other (No. 1 T.D.C. position).

Remove camshaft sprocket retaining bolt.

6. Pull dampener away from timing chain and

remove camshaft sprocket and timing chain

taking care not to lose camshaft sensor

magnet due to its loose fit in the camshaft

sprocket.

7. Remove crankshaft sprocket from crankshaft.

8. If necessary, remove dampener attaching bolt

and dampener assembly.

Figure 6A1-1-158

If removing balance shaft gears, proceed as

follows:

9. Remove balance shaft drive gear and sprocket

key from camshaft.

Figure 6A1-1-159

10. Remove balance shaft refer to

3.9 BALANCE SHAFT AND BEARINGS in

this Section.

11. Hold balance shaft in a vice using soft jaws,

take care to ensure that balance shaft front

bearing and rear bearing journal surface are

not damaged

12. Remove balance shaft driven gear retaining

bolt and driven gear.

Figure 6A1-1-160

INSPECT

1. Clean all components in a suitable cleaning

solvent and blow dry with clean dry

compressed air.

2. Using a suitable size thread tap, clean

sprocket retaining bolt threads in front end of

camshaft. Clean retaining bolt threads.

3. If removed, clean balance shaft driven gear

retaining bolt threads in front end of balance

shaft. Clean retaining bolt threads.

4. Inspect all components for wear or damage.

Check chain for excessive wear or stretch at

roller links.

REINSTALL

1. If rem oved, reinstall driven gear, aligning slot on

the inside of gear with pin at front of balance

shaft.

2. Coat threads of balance shaft driven gear

retaining bolt with Loctite 242 sealant or

equivalent (Holden Specif ication HN 1256 Class

2, Type 2). Install driven gear retaining bolt to

balance shaft.

3. Tighten balance shaft driven gear retaining bolt

to the correct torque specification.

NOTE:

Use Tool No. E7115, angle wrench, to achieve

correct turn angle.

BALANCE SHAFT DRIVEN 18 - 26 Nm

GEAR RETAINING BOLT plus 67 - 73 deg.

TORQUE SPECIFICATION turn angle

Figure 6A1-1-161

4. Reinstall sprocket key to front end of camshaft.

Reinstall balance shaft drive gear to camshaft,

aligning sprocket key with gear slot and ensuring

that timing marks on each of the balance shaft

gears face together.

It may be necessary to rotate balance shaft

slightly to ensure that balance shaft timing

marks align.

Figure 6A1-1-162

5. Install crankshaft sprocket onto crankshaft,

aligning key slot in sprocket with sprocket key.

With sprocket installed on crankshaft, timing

mark should be facing upward. If not facing

upward, remove piece of wood between

crankshaft and cylinder block, rotate

crankshaft until correct position is reached

(No. 1 piston is at T.D.C.).

6. Temporarily install camshaft sprocket to

camshaft. Turn camshaft so that sprocket

timing mark is facing crankshaft sprocket

timing mark. Remove camshaft sprocket.

7. Install timing chain dampener locating spring

end into cylinder block hole. Inst all and tighten

dampener attaching bolt to the correct torque

specification.

TIMING CHAIN DAMPENER

ATTACHING BOLT 16 - 28 Nm

TORQUE SPECIFICATION

Figure 6A1-1-163

8. Lubricate timing chain and sprockets with

engine oil.

9. Ensure that front cover and cylinder block

mating surfaces are clean and free of foreign

matter. Install front cover, refer to

2.19 FRONT COVER AND GASKET in this

Section.

10. Install timing chain and camshaft sprocket

together ensuring that, if fitted, the camshaft

position sensor magnet is in position in the

camshaft sprocket. Pull back timing chain

dampener and install chain around

crankshaft sprocket and fit camshaft

sprocket to camshaft, aligning key slot in

sprocket with sprocket key. Release

dampener and ensure that timing marks on

sprockets are aligned.

11. Apply Loctite 242 sealant or equivalent

(Holden Specif ic ation HN 1256 Clas s 2, Type

2) to camshaft sprocket retaining bolt. Install

and tighten bolt to the correct torque

specification.

CAMSHAFT SPROCKET 90 - 110 Nm

RETAINING BOLT plus 86 - 94

TORQUE SPECIFICATION deg. turn angle Figure 6A1-1-164

12. Reconnect battery earth lead. Start engine

and check for oil or coolant leaks. Repair as

necessary.

2.22 CAMSHAFT

MEASURING CAMSHAFT LOBE LIFT

1. Remove rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section. Remove rocker arms, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

2. Remove spark plugs.

3. Mount a dial indicator so that its stylus is

resting on top end of a pushrod.

4. Rotate crankshaft and measure cam shaft lobe

lift.

CAMSHAFT LOBE LIFT

INLET 6.56 mm

EXHAUST 6.48 mm

Figure 6A1-1-165

5. Repeat steps 3 and 4, above, on the

remaining eleven pushrods.

If any lobe lift is not to specification, remove

and replace camshaft, refer to

2.22 CAMSHAFT in this Section.

6. If cam s haft lobe lif t is s atisf actory, reass em ble

rocker arms, refer to 2.12 ROCKER ARMS

AND PUSHRODS in this Section. Reinstall

rocker covers, refer to 2.11 ROCKER

COVERS AND/OR SEALS in this Section.

7. Reinstall spark plugs and tighten to the c orr ec t

torque specification.

SPARK PLUG

TORQUE SPECIFICATION 15 - 25

REMOVE

1. Disconnect battery earth lead.

2. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot.

Sudden release of cooling system pressure is

very dangerous and could cause personal

injury.

3. Remove cooling fan shroud, cooling fan and

radiator, refer to Section 6B1 ENGINE

COOLING - V6 ENGINE.

4. Remove crankshaft balancer, refer to

2.17 CRANKSHAFT BALANCER in this

Section.

5. Remove front cover, refer to 2.19 FRONT

COVER AND GASKET in this Section.

6. Remove timing chain, camshaft sprocket and

balance shaft drive gear, refer to

2.21 TIMING CHAIN, TENSIONER,

SPROCKETS AND BALANCE SHAFT

GEARS in this Section.

7. Remove rocker covers, refer to

2.11 ROCKER COVERS AND/OR SEALS in

this Section.

8. Remove lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

9. Remove rocker arms and pushrods, refer to

2.12 ROCKER ARMS AND PUSHRODS in

this Section.

10. Remove valve lifters, refer to 2.14 VALVE

LIFTERS0 in this Section.

11. Using a T30 Torx bit, Tool No. J25359-4,

remove cam shaft thrust plate to cylinder block

attaching screws, remove thrust plate.

Remove sprocket key from front end of

camshaft.

Figure 6A1-1-166

12. Carefully withdraw camshaft from front of

engine.

NOTE:

W hen rem oving camshaf t, avoid damaging bearing

surfaces.

Figure 6A1-1-167

INSPECT

1. Inspect camshaft bearing journals and lobes

for wear, damage or overheating

(discolouration).

2. Check camshaft journal diameter and run-out

with suitable measuring equipment.

If journals are not to specification, replace

camshaft.

CAMSHAFT JOURNAL 46.858 - 46.893

DIAMETER mm

Figure 6A1-1-168

3. Position camshaft on V - blocks and check

each camshaft lobe lift.

If any lobe is not to specification, replace

camshaft.

CAMSHAFT LOBE LIFT

INLET 6.56 mm

EXHAUST 6.48 mm

Figure 6A1-1-169

CAMSHAFT BEARING SERVICE

Slightly scored camshaft bearings will be

satisf actory if the surf aces of cam s haft journals ar e

polished and bearings are cleaned up to remove

burrs, and the fit of the c am shaf t in bearings is f ree

and within specification.

Should the bearings be badly damaged or worn,

the engine assembly must be removed from the

vehicle and the bearings replaced, refer to

3.8 CAMSHAFT BEARINGS in this Section.

REINSTALL

Installation of the camshaft is the reverse of

removal procedures, noting the following points:

1. Clean threads of camshaft thrust plate

attaching screws and mating threads in

cylinder block.

2. Lubricate cams haf t bearing j our nals with clean

engine oil and all lobes with Lubrizol 6612 or

equivalent (Holden Specification HN 1961)

and install camshaft.

3. When installing camshaft, take care not to

disturb lubricant film on camshaft lobes.

4. Apply engine oil to camshaft and thrust plate

contact surfaces.

5. Apply Loctite 242 or equivalent (Holden

Specification HN 1256 Class 2, Type 2) to

thrust plate attaching screws. Install screws

and tighten to the correct torque specification.

CAMSHAFT THRUST PLATE

TO CYLINDER BLOCK

ATTACHING BOLT

TORQUE SPECIFICATION

12 - 18

6. Lubricate all lifters and lifter bores with

Lubrizol 6612 or equivalent (Holden

Specification HN 1961) before installing.

7. Start engine, check for oil or coolant leaks.

Check for valve train noise. Repair as

necessary.

2.23 ENGINE MOUNTS

FRONT MOUNTS

CHECK

1. Check in the area of the mounts for signs of

oil leakage. If oil leakage from a mount is

present, mount is defective and must be

replaced.

2. Using a suitable engine lifting crane, raise

engine to remove weight from mounts and to

place rubber in slight tension.

Check that mounting rubber has not

deteriorated, split or separated from metal

plates.

Replace mount if defective.

REMOVE

1. Disconnect battery earth lead.

2. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Figure 6A1-1-170

3. Remove engine front mount to front

crossmember attaching nuts.

4. Remove right hand mount as follows:

a. Remove mount to mounting bracket

attaching nuts.

b. Raise engine slightly with a suitable

engine lifting crane to remove weight from

mounts.

c. Remove mounting bracket to cylinder

block attaching bolts, rem ove brac k et and

mount.

Figure 6A1-1-171

5. Remove left hand mount as follows:

a. Raise engine slightly with a suitable

engine lifting crane to remove weight

from mounts and gain access to air

conditioning compressor (if fitted)

attaching bolts.

b. If fitted, remove air conditioning

compressor to left hand engine mounting

bracket attaching bolts. Tie back

compressor from engine block.

Figure 6A1-1-172

c. Remove mount to mounting bracket

attaching nuts.

d. Remove mount bracket to cylinder block

attaching bolts, remove bracket, knock

sensor heatshield and mount.

Figure 6A1-1-173

REINSTALL

Installation of the engine front mounts is the

reverse of removal procedures, ensuring that all

fasteners are tightened to the specified torque.

ENGINE MOUNT TO MOUNTING

BRACKET AND FRONT

CROSSMEMBER ATTACHING

NUT TORQUE SPECIFICATION

35 - 65

MOUNTING BRACKET TO

CYLINDER BLOCK ATTACHING

BOLT TORQUE SPECIFICATION 35 - 65 Nm

AIR CONDITIONING

COMPRESSOR TO MOUNTING

BRACKET ATTACHING BOLT

TORQUE SPECIFICATION

35 - 65

REAR MOUNT

REMOVE

1. Raise vehicle front and rear and place on

safety stands. For location of jacking points,

refer to Section 0A GENERAL

INFORMATION.

2. Support rear of transmission with a garage

jack.

NOTE:

Use a block of wood between transmission and

jack.

3. Remove nuts and washers attaching rear

mount to crossmember.

4. Remove crossmember to frame bolts and

washers, remove crossmember.

5. Remove rear mount to transmission rear

extension attaching bolts/nuts and remove

rear mount.

Figure 6A1-1-174

REINSTALL

1. Reinstall rear mount and attaching bolts to

transmission rear extension. Tighten bolts to

correct torque specification.

AUTOMATIC TRANSMISSION:

REAR MOUNT TO REAR

EXTENSION ATTACHING BOLT

TORQUE SPECIFICATION

35 - 65

MANUAL TRANSMISSION:

REAR MOUNT TO REAR

ADAPTOR ATTACHING NUT

TORQUE SPECIFICATION

35 - 65

2. Install crossmember to side frame bolts and

washers. Tighten bolts to correct torque

specification.

CROSSMEMBER TO SIDE

FRAME BOLT

TORQUE SPECIFICATION 35 - 65 Nm

3. Lower garage jack supporting transmission

and tighten crossmember to rear mount

attaching nuts to correct torque specification.

4. Remove safety stands and lower vehicle to

ground.

2.24 BE AMING BRACE

REMOVE

1. Disconnect battery earth lead.

2. Remove beaming brace to torque converter/clutch housing to beaming brace bolts.

3. Remove beaming brace to oil pan bolts and remove beaming brace.

Figure 6A1-1-175

REINSTALL

Installation of the beaming brace is the reverse of

removal procedures, noting the following points:

1. Inspect the threads of the four beaming brace

to oil pan attaching bolts and replace any that

are damaged.

2. On vehicles with automatic transmission install

the bolts securing the beaming brace to the

converter housing prior to the beaming brace

to oil pan bolts

CLUTCH HOUSING TO BEAMING

BRACE BOLT

TORQUE SPECIFICATION 50 - 85 Nm

BEAMING BRACE TO TORQUE

CONVERTER HOUSING BOLT

TORQUE SPECIFICATION 50 - 85 Nm

BEAMING BRACE TO OIL PAN

BOLT ATTACHING

TORQUE SPECIFICATION 20 - 35 Nm

TRANSMISSION LOWER COVER

SCREW 3.0 - 5.0

2.25 IDLER ASSEMBLY

REMOVE

1. Disconnect battery earth lead.

2. Loosen the idler pulley attaching bolt.

3. Remove drive belt, refer to 2.6 DRIVE BELT in

this Section.

4. Remove ignition coil module assembly and

idler assembly housing mounting bolts,

remove idler and coil module assembly.

5. Remove the bolt securing the idler pulley

removing the pulley.

Figure 6A1-1-176

REINSTALL

1. Installation is the reverse of removal

operations noting the following points.

2. Tighten all fasteners to the correct torque

specification.

IDLER ASSEMBLY MOUNTING

BOLT TORQUE SPECIFICATION 40 - 50

IDLER ASSEMBLY PULLEY

ATTACHING BOLT TORQUE

SPECIFICATION 40 - 50 Nm

3. Start engine and check drive belt operation.

3. MAJOR SERVICE OPERATIONS

3.1 ENGINE ASSEMBLY

REMOVE

1. Depressurise fuel lines, refer to

Section 6C1 POWERTRAIN MANAGEMENT

- V6 ENGINE, Service Operations.

2. Disconnect battery leads from battery

terminals.

3. Remove radiator cap to release any cooling

system pressure.

WARNING:

To avoid serious personal injury, never remove

the radiator cap when the engine is hot. Sudden

release of cooling system pressure is very

dangerous and could cause personal injury.

4. Place an oil drain tray beneath engine.

5. Loosen radiator lower hose clamp at radiator,

disconnect hose and allow coolant to drain.

Loosen hose clamps and disconnect upper

and lower radiator hoses from engine.

Figure 6A1-1-177

6. Remove cooling fan and radiator assembly,

refer to Section 6B1 ENGINE COOLING -

V6 ENGINE.

7. Remove engine oil pan drain plug and allow

engine oil to drain.

Refit drain plug once oil has drained.

8. Disconnect windshield washer hose at the

inline connector located at the rear LH side of

hood.

Figure 6A1-1-178

Techline

9. With engine hood adequately supported,

remove clips securing upper end of struts to

hood pivots. Disengage struts from hood

pivots and lay strut down on fender inner

panel.

With the aid of an assistant hold hood

assembly, remove engine hood bracket to

hinge attaching bolt removing hood.

Figure 6A1-1-179

10. Loosen heater outlet pipe and water inlet tube

hose clamps, disconnect hoses from heater

outlet pipe and water inlet tube.

Figure 6A1-1-180

11. Disconnect main wiring harness to powertrain

and battery harness connectors at dash panel.

Figure 6A1-1-181

12. Remove nut securing battery harness earth

terminal from ABS/CRUISE CONTROL

bracket stud.

Figure 6A1-1-182

13. Loosen and remove high pressure pipe from

rear of power steering pump. Loosen low

pressure hose clamp at pump reservoir

connection and disconnect hose from

reservoir.

Plug all openings to prevent foreign matter

entry.

Figure 6A1-1-183

14. Remove the four nuts securing engine dress

cover.

Figure 6A1-1-184

15. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Figure 6A1-1-185

16. Disconnect throttle inner cable from throttle

body linkage. Loosen throttle outer cable lock

nuts at mounting bracket and lay cable away

from engine.

17. If vehicle is fitted with cruise control,

disconnect cruise control outer cable from

mounting bracket and push inner cable

forward off throttle body linkage.

Figure 6A1-1-186

18. Using quick connect release tool No. 7370

open tool and install over fuel line.

19. Close 7370 and pull into fuel line quick

connect to release it from fuel inlet line, pull

back on quick connect, disconnect fuel feed,

return and fuel evaporative canister hoses at

quick connects. Plug all openings to prevent

foreign matter entry.

NOTE:

Do not attempt to remove hoses from fuel rail

connections. Once removed from fuel rail

connection hoses require replacement.

Figure 6A1-1-187

20. From inside vehicle, remove left hand shroud

panel trim, glove box assembly and taking

care to remove the screw beneath the rocker

panel cover the lower left hand side trim

assembly, refer to Section 1A1 BODY.

21. Disconnect engine wiring harness connectors

from PCM. Compress lugs on engine harness

plug at dash panel and push engine harness

and connectors out into engine compartment.

Figure 6A1-1-188

22. From engine compartment release powertrain

harness to dash panel retaining clips,

disconnect intak e air tem peratur e sensor at air

cleaner and air conditioning pressure

transducer connector at air conditioning

condenser, lay wiring harness on top of

engine.

Figure 6A1-1-189

23. Disconnect brake booster, heater control and

fuel pressure regulator hoses from upper

manifold connections.

NOTE:

Do not attempt to remove hoses from fuel rail

connections. Once removed from fuel rail

connection hoses require replacement.

Figure 6A1-1-190

24. Raise vehicle front and rear and place on

safety stands. For location of jacking points,

refer to Section 0A GENERAL

INFORMATION.

25. Remove propeller shaft, refer to

Section 4C PROPELLER SHAFTS AND

UNIVERSAL JOINTS. Install a suitable plug in

end of transmission.

26. Disconnect oxygen sensors from powertrain

harness and left and right hand engine

exhaust pipes from manifold assemblies.

Figure 6A1-1-191

27. Disconnect gear shift control from

transmission. Refer to Section 7B1

MANUAL TRANSMISSION - V6 ENGINE, or

to Section 7C4 AUTOMATIC

TRANSMISSION - ON-VEHICLE

SERVICING. For those vehicles fitted with

column gearshift refer to

Section 9A STEERING.

28. On vehicles with manual transmission,

disconnect the hydraulic line to the clutch

actuating cylinder, refer to

Section 7A CLUTCH.

29. Attach suitable lifting brackets (position at

driver's side front and passenger side rear of

engine), lifting hook and chain to engine, raise

engine slightly to take weight off mounts.

Figure 6A1-1-192

30. Remove engine front mounting to front

suspension crossmember attaching nuts.

Figure 6A1-1-193

VEHICLES FITTED WITH MANUAL

TRANSMISSION:

31. Remove engine rear power plant support to

frame bolts and washers. Remove support to

mount attaching nuts and remove support.

Figure 6A1-1-194

VEHICLES FITTED WITH AUTOMATIC

TRANSMISSION:

32. Remove engine rear crossmember to frame

bolts and washers. Remove crossmember to

rear mounting attaching nuts and remove

crossmember.

Figure 6A1-1-195

33. On vehicles with air conditioning, disconnect

wiring harness connector from compressor

clutch connector.

Raise engine slightly and remove compressor

to left hand engine mount bracket mounting

bolts. Tie compressor back away from the

engine.

Figure 6A1-1-196

34. Raise engine with front tilted upwards and a

floor jack supporting rear of transmission

assembly, ensure that engine exhaust

manifolds, beaming brace, transmission or

starter motor do not rest on steering gear.

NOTE:

On vehicles with air conditioning, do not allow

engine to swing forward and damage air

conditioning condenser.

35. If necessary, separate engine and

transmission assemblies. Refer to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE or to Section 7C4 AUTOMATIC

TRANSMISSION.

DISASSEMBLE

1. Mount engine assembly in a suitable engine

stand.

2. Remove the following items as described:

a. Generator and brackets, refer to Section

6D1-1 CHARGING SYSTEM - V6 ENGINE.

b. Starter motor, refer to Section 6D1-2

STARTING SYSTEM - V6 ENGINE.

c. Ignition coil and mounting bracket, high

tension leads and spark plugs, refer to

Section 6D1-3 IGNITION SYSTEM - V6

ENGINE ..

d. EGR Valve assembly, refer to

Section 6E1 EMISSION CONTROL - V6

ENGINE .

3. Remove the following components as

described in this Section:

a. Oil filter and adaptor, refer to

2.3 OIL FILTER and 2.5 OIL FILTER

ADAPTOR.

b. Drive belt, refer to 2.6 DRIVE BELT.

c. Drive belt tensioner, refer to

2.7 DRIVE BELT TENSIONER.

d. Exhaust manifolds, refer to

2.10 EXHAUST MANIFOLDS.

e. Inlet manifold, refer to

2.9 INLET MANIFOLD.

f. Rocker covers, rocker arms and

pushrods, refer to 2.11 ROCKER

COVERS and 2.12 ROCKER ARMS

AND PUSHRODS.

g. Valve lifters, refer to 2.14 VALVE

LIFTERS.

h. Crankshaft balancer, refer to 2.17

CRANKSHAFT BALANCER.

i. Flywheel/flexplate, refer to

3.4 FLYWHEEL/FLEXPLATE.

j. Front cover, refer to 2.19 FRONT

COVER.

k. Timing chain, tensioner, sprockets and

balance shaft gears, refer to 2.21.

l. Camshaft, refer to 2.22 CAMSHAFT.

m. Balance shaft, refer to 3.9 BALANCE

SHAFT.

n. Cylinder heads, ref er to 2.15 CYLINDER

HEADS.

o. Oil pan, refer to 3.2 OIL PAN AND

SEAL.

p. Oil pump suction pipe and screen, refer

to 3.3 OIL PUMP.

q. Piston and connecting rod assemblies,

refer to 3.10 PISTON/CONNECTING

ROD.

r. Crankshaft, refer to

3.12 CRANKSHAFT.

4. Discard all gaskets and seals.

5. For inspection procedures for each

component, refer to the relevant component

description as listed under step 3.

REASSEMBLE

Reassembly is the reverse of disassembly

procedure for each component as outlined in this

Section. The relevant reassembly instructions for

each component is listed under step 3 of

DISASSEMBLE procedure.

REINSTALL

Installation is the reverse of removal procedures,

noting the following points:

1. Ensure that all fasteners are tightened to the

specified torque provided at the end of this

Section.

2. Use specified engine lubricant and coolant

when refilling lubrication and cooling systems.

3. Check transmission fluid level, add lubricant

as required.

4. Check for oil, fuel, coolant and exhaust leaks.

Repair as necessary.

5. Check engine hood alignment.

3.2 OIL PAN AND SEAL

REMOVE

1. Disconnect battery earth lead.

2. Remove engine mounting nuts refer to 2.23

ENGINE MOUNTS in this Section.

3. Raise engine 40 mm.

4. Fit 40 mm spacers under engine mounts to

support engine.

Figure 6A1-1-197

NOTE:

Vehicles with supercharged engine it is necessary

to. a. Remove front suspension crossmember,

refer to Section 3 FRONT

SUSPENSION.

b. Use safety stands, located under front

engine mounts, to steady engine

assembly.

5. Drain oil from oil pan.

6. Remove beaming brace, refer to

2.24 BEAMING BRACE in this Section.

7. Remove battery harness and automatic

transmission (if fitted) oil cooler line retainer

attaching screws from front of oil pan.

Figure 6A1-1-198

8. Rem ove oil pan attaching bolts and rem ove oil

pan and seal, discard oil seal.

Techline

INSPECT

1. Remove oil pan seal and check for porosity in

oil pan or foreign material in oil pan seal

groove. Clean or replace oil pan as required.

2. Check f or cor r ect dimension of the oil pan s eal

groove in several places around the oil pan.

Replace oil pan if oil pan seal groove is not to

specification.

OIL PAN SEAL GROOVE SPECIFICATION

GROOVE DEPTH 3.95-4.10 mm

GROOVE WIDTH 3.45-3.60 mm

Figure 6A1-1-199

REINSTALL

1. Thoroughly clean mating surfaces of oil pan,

front cover, rear oil seal housing and cylinder

block.

IMPORTANT:

Ensure old sealant etc. is removed from oil pan

seal groove.

2. Install new seal onto oil pan rail ensuring the

seal is seated in oil pan groove.

3. Apply Permatex “the Right Stuff” as a bead 6

mm wide and 0.4 - 0.2 mm thick to cylinder

block in the area of the rear oil seal housing

and front cover joints (refer to Fig. 6A1-1-200).

NOTE:

Do not apply excessive sealer, this may prevent

free movement of seal within oil pan groove.

Thickness of sealer can be controlled by first

applying 0.25 mm thick adhesive tape onto block,

using a scraper fill to thickness of tape then

remove tape.

Techline

Figure 6A1-1-200

4. Install oil pan and seal to cylinder block using

temporary guide pins to prevent smearing

sealer.

5. Install oil pan bolts and tighten to the correct

torque specification.

NOTE:

Oil pan must be torqued down within 5 minutes of

sealant application.

6. Ensure oil pan drain plug is tightened to the

correct torque specification.

OIL PAN ATTACHING BOLT 8 - 12

TORQUE SPECIFICATION Nm

OIL PAN DRAIN PLUG 30 - 60

TORQUE SPECIFICATION Nm Figure 6A1-1-201

7. Install battery harness and automatic

transmission (if fitted) oil cooler line retainer

attaching screws and tighten to the correct

torque specification.

BATTERY HARNESS AND OIL

COOLER LINE RETAINER TO OIL

PAN ATTACHING SCREW

TORQUE SPECIFICATION

3 - 5

8. Reinstall beaming brace, refer to

2.24 BEAMING BRACE.

9. If removed, reinstall front suspension

crossmember, refer to Section 3 FRONT

SUSPENSION.

10. Refill oil pan with the cor r ect amount of engine

oil, refer to Section 0B LUBRICATION AND

SERVICE.

11. Start engine and check f or oil leak s. Repair as

necessary.

3.3 OIL PUMP SUCTION PIPE AND SCREEN

REMOVE

1. Disconnect battery earth lead.

2. Remove oil pan drain plug and drain oil from

oil pan.

Refit drain plug once oil has drained.

3. Remove oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

4. Remove two bolts securing s uction pipe flange

to cylinder block and remove pipe and screen

assembly.

5. Rem ove suction pipe to c ylinder bloc k O - ring

and discard.

Figure 6A1-1-202

REINSTALL

Installation is the reverse of removal procedures,

noting the following points:

1. Ensure that screen is cleaned of any foreign

matter.

2. Clean suction pipe flange and cylinder block

mating surfaces.

3. Clean threads of suction pipe securing bolts

and mating threads in cylinder block with a

suitable size thread tap.

Apply Loctite 242 or equivalent (Holden

Specific ation HN 1256 Class 2, T ype 2) to bolt

threads.

4. Use a new O - ring between suction pipe

flange and cylinder block. Install and tighten

bolts to the correct torque specification.

OIL PUMP SUCTION PIPE FLANGE

TO CYLINDER BLOCK BOLT

TORQUE SPECIFICATION 8 - 12 Nm

5. Ensure oil pan drain plug is tightened to the

correct torque specification.

OIL PAN DRAIN PLUG

TORQUE SPECIFICATION 30 - 60

3.4 FLYWHEEL/FLEXPLATE

REMOVE

1. Disconnect battery earth lead.

2. Remove transmission, refer to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE, or Section 7C4 AUTOMATIC

TRANSMISSION - ON-VEHICLE

SERVICING.

3. For vehicles with manual transmission,

remove clutch pressure plate and driven plate,

refer to Section 7A CLUTCH.

NOTE:

Before removing the flexplate and torque converter,

note the position of paint aligning marks. If 0not

visible, scribe aligning marks on both components.

Figure 6A1-1-203

4. Using a screwdriver or suitable locking tool,

block flywheel/flexplate from rotating. Remove

flywheel/flexplate to crankshaft attaching bolts,

remove flywheel/flexplate.

Figure 6A1-1-204

NOTE:

Once removed, discard flywheel/flexplate attaching

bolts. New bolts must be used on reassembly.

There are specific bolts for flywheel and flexplate

attachment to the crankshaft.

Figure 6A1-1-205

INSPECT

1. Inspect flywheel/flexplate ring gear for

cracked, badly worn or damaged teeth.

If ring gear is damaged it will be necessary to

replace flywheel assembly or flexplate. For

flexplate replacement refer to

3.4 FLYWHEEL/FLEXPLATE in this Section.

For flywheel Service Operations refer to

Section 7A CLUTCH.

If ring gear teeth are dam aged, inspect starter

motor pinion gear for damage. Refer to

Section 6D1-2 STARTING SYSTEM - V6

ENGINE.

Check flexplate retainer plate for any damage.

2. Check crankshaft and flywheel/flexplate

mating surfaces for burrs. Remove burrs, if

present, with a fine mill file.

NOTE:

No attempt should be made to rebalance the

flywheel or flexplate these are non serviceable

units.

3. Using a 5/16 UNC thread tap, clean

flywheel/flex plate attaching bolt threads in rear

of crankshaft.

REINSTALL

Installation is the reverse of removal procedures,

noting the following points:

1. Vehicles with manual transmission align

flywheel dowel pin holes with crankshaft

flange dowel pins and install flywheel onto

crankshaft flange, tighten new attaching bolts

to the correct torque specification.

2. Vehicles with automatic transmission install

flexplate to crankshaft flange and tighten new

attaching bolts to the correct torque

specification.

NOTE:

Bolt holes are unevenly spaced so all

flywheel/flexplate bolts can only be installed with

the flywheel/flexplate in the correct position.

FLYWHEEL/FLEXPLATE BOLT TIGHTENING

SEQUENCE

STEP No. 1 TORQUE ALL

BOLTS TO 18 - 22 Nm

STEP No. 2

MANUAL

TRANSMISSION

TIGHTEN ALL BOLTS A

FURTHER 80 - 90 DEGREES

TURN ANGLE

STEP No. 2

AUTOMATIC

TRANSMISSION

TIGHTEN ALL BOLTS A

FURTHER 47 - 53 DEGREES

TURN ANGLE

3. On vehicles with automatic transmission,

mount a dial indicator on the rear of cylinder

block. Check flexplate run-out at the three

torque converter mounting bolt holes. Run-out

should not exceed the following specification.

FLEXPLATE RUN-OUT 0.38 mm

SPECIFICATION Max.

Figure 6A1-1-206

4. If runout exceeds specifications, attempt to

correct by tapping high side with a mallet. If

this condition cannot be corrected, replace

flexplate.

Figure 6A1-1-207

5. Check starter motor operation.

3.5 RING GEAR

REPLACE

On vehicles with automatic transmission, the ring gear is welded to the flexplate and is serviced only as an

assembly.

On vehicles with manual transmission, the ring gear is welded to the flywheel and if damaged will require

replacement of the flywheel assembly.

3.6 SPIGOT BEARING

REPLACE

1. Disconnect battery earth lead.

2. Remove transmission, refer to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE.

3. Remove clutch pressure plate and driven

plate, refer to Section 7A CLUTCH.

4. Using suitable spigot bearing removal tools,

such as Tool No. 6A22-2 with slide hammer

7A28 (AU354 or J6125-1) or Tool No. E6668,

remove spigot bearing.

Figure 6A1-1-208

5. In replacing spigot bearing, use a piloted

driver. Place new bearing on pilot of tool with

radius in bore of bearing next to shoulder on

tool. Drive bearing into crank shaf t until bearing

shoulder contacts crankshaft boss.

Figure 6A1-1-209

6. Lubricate bearing with several drops of SAE

90 Gear Oil.

7. Reinstall clutch assembly and transmission,

refer to Section 7A CLUTCH and to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE.

8. Reconnect battery earth lead, star t engine and

check clutch operation.

Techline

3.7 MAIN AND CONNECTING ROD BEARINGS

Each crankshaft main bearing journal has two bearing halves or shells which are not alike and not interchangeable

in the bearing cap or cylinder block, (except No. 1 and No. 4 upper bearing shells). The upper (cylinder block) shell

has two oil feed holes and is grooved to supply oil to the connecting rod bearing, with the lower bearing shells

having a continuation of this groove in each end of the shell. The two bearing shells on each journal must not be

interchanged. The No. 2 bearing shells are flanged to take end thrust.

Each connecting rod bearing consists of two bearing halves or shells which are interchangeable in the rod and cap.

Bearing shells are of the precision insert ty pe and do not require reaming to size or utilise shims for adjustment.

When shells are placed in the cylinder block or connecting rod and bearing cap, the ends extend slightly beyond the

parting surfaces so that when the cap bolts are tightened, the shells clamp tightly in place to ensure positive seating

and to prevent turning.

The ends of the bearing shells must never be filed flush with parting surfaces of the cylinder block, connecting rod

or bearing cap.

Service replacement main bearings are available in standard and 0.0254 mm undersize.

Figure 6A1-1-210

MAIN BEARINGS - INSPECT

1. With engine removed from vehicle refer to

3.1 ENGINE ASSEMBLY in this Section,

mount in a suitable stand and invert engine

assembly.

2. Remove oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

3. Remove oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

4. Remove main bearing cap bolts and main

bearing cap side bolts.

NOTE 1:

New main bearing cap side bolts must be used to

ensure bolts remain oil tight to cylinder block.

NOTE 2:

Main bearing caps are press fit and special care is

required when removing the caps. J41348 has

been designed to work in conjunction with J6125-B

in order to prevent damage to bearing and/or cap.

J41348 m ust be ins talled cor rectly into bolt holes of

caps and J6125-B attached in order to properly

remove main bearing cap without damage to the

cap and/or bearing. Deviation from this procedure

may cause damage to the cap and/or bearing

resulting in engine damage.

5. Install J41348 into main bearing cap bolt

holes.

6. Tighten bolts to 11 Nm.

7. Install J6125-B to J41348.

8. Using the slide hammer motion of J6125-B

remove main bearing cap.

Figure 6A1-1-211

9. Inspect lower bearing shells and crankshaft

journals. If journal sur face is heavily scored or

ridged, replace crankshaft, refer to

3.12 CRANKSHAFT in this Section.

To ensure satisfactory engine operation, new

bearing shells must be installed, refer to

MAIN BEARINGS and if necessary,

CONNECTING ROD BEARINGS in this

Section.

Check inner surface of bearing shells for

wear, gouges or imbedded foreign material. If

foreign material is found, determine its nature

and source. Inspect outer surface of bearing

shells for surface wear (indicates movement

of shell or high spot in surrounding material),

overheating (discolouration) or looseness or

rotation (flattened tangs and wear grooves).

Inspect thrust surfaces of thrust bearing shell

for wear or grooving. Grooves are caused by

irregularities in the crankshaft thrust surfaces

or dirt refer to 3.12 CRANKSHAFT in this

Section.

If condition of lower bearing shells and

crankshaft journals is satisfactory, check

bearing clearance as follows:

10. W ipe oil fr om c ranks haft journal and inner and

outer surfaces of lower bearing shell.

Reinstall bearing shell in original position in

bearing cap.

11. Place a piece of Plas tigage acros s f ull width of

crankshaft journal, parallel to crankshaft

centreline.

NOTE:

Ensure Plastigage will not seat across oil hole in

journal.

Figure 6A1-1-212

12. Install bearing cap and bolts into cylinder

block.

NOTE 1:

Ensure that the bearing cap is installed into the

crankcase correctly.

13. Before final installation of cap bolts, determ ine

if bolts have stretched by comparing with a

new bolt. Replace bolt/s as necessary.

Reinstall main bearing caps, hand start main

bearing cap bolts, on each bearing c ap in turn,

tighten cap bolts half a turn at a time to

carefully seat cap.

NOTE 2:

Do not tighten one cap completely at a time,

progressively tighten all four caps to one step of

procedure before moving to next stage of torque.

Torque m ain bearing cap bolts to 70 Nm to fully

seat cap.

Loosen cap bolts 360° then torque all cap bolts

to 20 Nm and then 40 Nm.

Tighten cap bolts in steps of 35° + 35° + 35° to

a total of 105°.

Torque m ain bearing cap side bolts 12 - 18 Nm

+42 - 48°.

Figure 6A1-1-213

NOTE 1:

In order to prevent the possibility of cylinder block

or bearing cap damage, do not install bearing cap

using a soft faced hammer. Use cap bolts to pull

bearing cap into position. Failure to observe this

procedure may damage cylinder block or bearing

cap.

NOTE 2:

Ensure that crankshaft does not turn with

Plastigage installed.

MAIN BEARING CAP BOLT

TORQUE SPECIFICATION Refer above

procedure

NOTE 3:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

14. Remove bearing cap bolts, remove cap. Look

for flattened Plastigage adhering to either

crankshaft or bearing shell in bearing cap.

15. Determine bearing clearance by comparing

width of flattened Plastigage at widest point

with graduation on Plastigage envelope. The

number within the graduation on the envelope

indicates the clearance.

Clearance between each main bearing and

crankshaft journal should not exceed

specification.

MAIN BEARING CLEARANCE 0.023 - 0.053 mm

Figure 6A1-1-214

NOTE:

This method of checking main bearing clearance

does not give any indication of crankshaft journal

taper or out-of-round.

To measure taper, undersize or out-of-round, the

crankshaft must be removed from the cylinder

block, refer to 3.12 CRANKSHAFT in this Section.

16. If bearing clearance exceeds specification, it is

advisable to install new bearing shells and

recheck clearance as previously described.

NOTE:

If lower bearing shell is a standard size, install a

0.0254 mm undersize shell and recheck clearance.

If clearance is still not to specification, remove

crankshaft, and measure crankshaft journals, refer

to 3.12 CRANKSHAFT in this Section.

17. Ensure that main bearing cap bolt threads and

cylinder block threads are clean and dry. Apply

some engine oil to the cap bolt threads.

NOTE:

Before final installation of cap bolts, determine if

bolts have stretched by com paring with a new bolt.

Replace bolt/s as necessary.

18. W ith m ain bearing caps installed ( refer to s tep

13), install and tighten cap bolts to the correct

torque specification.

19. If the thrust bearing shell is disturbed or

replaced, apply engine oil to thrust surfaces.

Also, it is necessary to line up the thrust

surfaces of the bearing shells before the cap

bolts are tightened. To do this, move the

crankshaft fore and aft the length of its travel

several times (last movement forward) with the

thrust bearing cap bolts finger tight.

Figure 6A1-1-215

20. Push crankshaft forward and measure

crankshaft end float between front of No. 2

main bearing and crankshaft thrust faces with

a feeler gauge.

If clearance is excessive, replace No. 2 main

bearing shells, refer to the following

replacement procedures.

CRANKSHAFT END FLOAT 0.08 - 0.28

SPECIFICATION mm

Figure 6A1-1-216

MAIN BEARINGS - REPLACE

The main bearing shells can be replaced with or

without the crankshaft installed.

WITH CRANKSHAFT INSTALLED

1. With engine removed from vehicle refer to

3.1 ENGINE ASSEMBLY in this Section,

mount in a suitable engine stand and invert

engine assembly.

2. Remove oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

3. Remove oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

4. Remove spark plugs.

5. Remove main bearing cap bolts and main

bearing cap side bolts.

NOTE 1:

New main bearing cap side bolts must be used to

ensure bolts remain oil tight to cylinder block.

NOTE 2:

Main bearing caps are press fit and special care is

required when removing the caps. J41348 has

been designed to work in conjunction with J6125-B

in order to prevent damage to bearing and/or cap.

J41348 m ust be ins talled cor rectly into bolt holes of

caps and J6125-B attached in order to properly

remove main bearing cap without damage to the

cap and/or bearing. Deviation from this procedure

may cause damage to the cap and/or bearing

resulting in engine damage.

6. Install J41348 into main bearing cap bolt

holes.

7. Tighten bolts to 11 Nm.

8. Install J6125-B to J41348.

9. Using the slide hammer motion of J6125-B

remove main bearing cap.

Remove bearing shell from bearing cap.

Figure 6A1-1-217

10. Remove upper bearing shell as follows:

a. Install Tool No. J8080 in the oil hole of the

crankshaft journal.

NOTE:

As an alternative to J8080, use a cotter pin.

b. Rotate crankshaft anti-clockwise as

viewed from front of engine. This will roll

upper shell out of cylinder block.

Remove Tool No. J8080 (or cotter pin).

11. Thoroughly clean crankshaft journal, cylinder

block bearing seat and bearing cap.

12. Lubricate new selected upper bearing.

Figure 6A1-1-218

13. Insert unnotched end of shell between

crank s haf t j ournal and notc hed s ide of c ylinder

block.

NOTE:

Ensure that the correct bearing shell is fitted

between the crankshaft journal and cylinder block

(refer to Fig. 6A1-1-220 for bearing shell

identification details).

Figure 6A1-1-219

14. Rotate bearing shell into place using

crankshaft and J8080 (or cotter pin).

15. Remove J8080 (or cotter pin) from crankshaft.

16. Check bearing to crankshaft clearance with

Plastigage as outlined in MAIN BEARING in

this Section.

17. Lubricate journal and bearing shells with

engine oil.

NOTE:

If replacing No. 2 main bearing shells, lubricate

thrust surfaces with engine oil.

18. Ensure that main bearing cap bolt threads and

cylinder block threads are clean and dry. Apply

some engine oil to the cap bolt threads.

19. Reinstall bearing cap and tighten all bearing

cap bolts to the correct torque specification.

NOTE:

Ensure that the bearing cap is installed into the

crankcase correctly and is parallel to bottom of

channel.

20. Before final ins tallation of cap bolts, determ ine

if bolts have stretched by comparing with a

new bolt. Replace bolt/s as necessary.

Reinstall main bearing caps, hand start main

bearing cap bolts, on eac h bearing cap in tur n,

tighten cap bolts half a turn at a time to

carefully seat cap.

Hand start main bearing cap side bolts.

Due to the thrust bearing shells being

disturbed, it is necessary to line up the thrust

surfaces of the bearing shells before the cap

bolts are tightened. To do this, move the

crankshaft fore and aft the length of its travel

several times (last movement forward).

NOTE 1:

Do not tighten one cap completely at a time,

progressively tighten all four caps to one step of

procedure before moving to next stage of torque.

Torque main bearing cap bolts to 70 Nm to

fully seat cap.

Loosen cap bolts 360° then torque all cap

bolts to 20 Nm and then 40 Nm.

Tighten cap bolts in steps of 35° + 35° + 35° to

a total of 105°.

Torque main bearing cap side bolts 12 - 18

Nm +42 - 48°.

NOTE 2:

New main bearing cap side bolts must be used to

ensure bolts remain oil tight to cylinder block.

Figure 6A1-1-220

NOTE 3:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

MAIN BEARING CAP BOLT

TORQUE SPECIFICATION

Refer procedure

following

NOTE 1:

21. If the thrust bearing shell is disturbed or

replaced, it is necessary to line up the thrust

surfaces of the bearing shells before the cap

bolts are tightened. To do this, move the

crankshaft fore and aft the length of its travel

several times (last movement forward) with the

thrust bearing cap bolts finger tight.

Figure 6A1-1-221

WITH CRANKSHAFT REMOVED

1. Remove crankshaft, refer to

3.12 CRANKSHAFT in this Section.

2. Remove bearing shells from cylinder block

and bearing caps.

3. Thoroughly clean crankshaft journals, bearing

caps and cylinder block bearing shell seats.

4. Install new bearing upper shells in cylinder

block, ensuring notches in bearing shells align

with recesses in cylinder block.

Figure 6A1-1-222

NOTE:

Ensure the correct bearing shells are fitted into the

appropriate cylinder block bearing seat (refer to

Fig. 6A1-1-210 in this Section for bearing shell

identification details).

5. Lubricate No. 2 main bearing shell thrust

surfaces with engine oil.

6. Lay crankshaft in upper bearing shells, taking

care not to damage crankshaft thrust flange

and No. 2 main bear ing thrus t f ac es . Als o tak e

care not to contact connecting rod journals

with connecting rods.

7. Install lower bearing shells in bearing caps,

ensuring the notches in the shells align with

the recesses in the caps and the correct

bearing shell is installed in the appropriate

cap.

8. Measure bearing to crankshaft clearances as

outlined in MAIN BEARINGS in this Section.

NOTE:

Ensure that bearing c ap is ins talled into the c ylinder

block correctly.

Figure 6A1-1-223

9. If clearances are satisfactory, continue

reassembly of crankshaft, refer to

3.12 CRANKSHAFT in this Section.

CONNECTING ROD BEARINGS - INSPECT AND REPLACE

Connecting rod bearings can be replaced without

removing the rod and piston assembly from the

engine.

1. With engine removed from vehicle refer to

3.1 ENGINE ASSEMBLY in this Section,

mount in a suitable engine stand and invert

engine assembly.

2. Remove oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

3. Remove oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

4. Remove spark plugs.

5. Mark connecting rods and caps with an

etching marker or felt tipped pen to indicate

cylinder number and orientation of cap.

Figure 6A1-1-224

6. Remove connecting rod cap securing bolts

and remove cap and lower bearing shell.

7. Push piston and connecting rod up cylinder

bore, so that connecting rod is free from

crank shaft jour nal. Remove bearing s hell from

connecting rod.

Figure 6A1-1-225

8. Clean crank shaft journal and measure for out-

of-round or taper with a micrometer.

If not to spec ification, replac e crank shaft, ref er

to 3.12 CRANKSHAFT in this Section.

CRANKSHAFT CONNECTING

ROD BEARING 57.117 - 57.147

JOURNAL DIAMETER mm

Figure 6A1-1-226

9. W ipe oil f rom both inner and outer s urfaces of

bearing shells.

10. Check inner surface of bearing shells for

wear, gouges or imbedded foreign material.

If foreign material is found, determine its

nature and source.

Inspect outer surface of bearing shell for

surface wear (indicates movement of shell or

high spot in surrounding m ater ial), over heating

(discolouration) or looseness or rotation

(flattened tangs and wear grooves).

If uneven side to side wear is found, the

crankshaft may be bent or have tapered

bearing journals. If necessary, remove

crankshaft, refer to 3.12 CRANKSHAFT -

REMOVE in this Section and check crankshaft

for bend or journal taper.

IMPORTANT:

Bearing failure, other than normal wear, must be

investigated carefully. With crankshaft removed,

inspect all connecting rod and crankshaft bearing

bores.

To inspect the bearing bores:

a. Install bearing caps without bearing shells

installed. Tighten cap bolts to the

specified torque.

CONNECTING ROD CAP BOLT

TORQUE SPECIFICATION

24 - 30 Nm

plus 47 - 53

degree turn

angle

b. Measure bearing bores for taper and out -

of-round.

Replace any component if not to

specification, refer to the relevant

component description in this Section.

CONNECTING ROD BEARING

BORE DIAMETER 60.295 -

60.312 mm

MAXIMUM OUT-OF-ROUND 0.008 mm

MAXIMUM TAPER 0.008 mm

11. If inspection reveals that crankshaft is OK,

reinstall bearing shells in original positions in

connecting rod and cap.

12. Pull connecting rod onto crankshaft so that

upper bearing is seated against crankshaft

journal.

13. Place a piece of Plastigage across width of

bearing journal, parallel to crankshaft

centreline.

NOTE:

Ensure Plastigage is not placed across oil hole in

journal.

Figure 6A1-1-227

14. Reinstall connecting rod cap in original position

as noted in step 5. T ighten bolts to the correct

torque specification.

NOTE:

Ensure that crankshaft does not turn with

Plastigage installed.

CONNECTING ROD 24 - 30 Nm

CAP BOLT plus 47 - 53

TORQUE SPECIFICATION degree turn angle

NOTE:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

Figure 6A1-1-228

15. Remove connecting rod cap bolts, remove

cap. Look for flattened Plastigage adhering to

either crankshaft or bearing shell in cap.

16. Determine bearing clearance by comparing

width of flattened Plastigage at widest point

with graduation on Plastigage envelope. The

number within the graduation on the envelope

indicates the clearance.

Clearance between connecting rod bearings

and crankshaft should not exceed

specification.

NOTE:

If a bearing is being fitted to an out-of-round

journal, be sure to fit Plastigage to the maximum

diameter of the j ournal. If the bearing is f itted to the

minimum diameter, and the journal is out-of-round

0.008 mm, interference between the bearing and

journal will result in rapid bearing failure.

CONNECTING ROD BEARING 0 .023 - 0.053

CLEARANCE mm

Figure 6A1-1-229

17. Ensure that connecting rod cap bolt threads

and connecting rod thr eads are clean and dry.

Apply some engine oil to the cap bolt threads.

NOTE:

Before final installation of cap bolts, determine if

bolts have stretched by com paring with a new bolt.

Replace bolt/s as necessary.

18. Install bearing shells in connecting rod and

cap, ensuring notches in shells match up with

recesses in connecting rod and cap.

Check clearance of new bearing with

Plastigage as previously described.

19. Remove all traces of Plastigage after

measuring.

20. Lubricate bearing s hells and jour nal with clean

engine oil. Reinstall connecting rod cap in

original position as noted in step 5. Tighten

bolts and then loosen one full turn. Finally

tighten cap bolts to the correct torque

specification.

CONNECTING ROD 24 - 30 Nm

CAP BOLT plus 47-53

TORQUE SPECIFICATION degree turn angle

NOTE:

Use an angle wrench such as E7115 to ensure

accurate turn angle. Figure 6A1-1-230

21. With bearing shells installed and cap bolts

tightened, it should be possible to move

connecting rod back and forth on crankshaft

journal as allowed by end clearance. Als o, the

crankshaft should rotate without binding.

If connecting rod binds on crankshaft journal,

loosen and re-tighten bearing cap bolts.

If rod still cannot be moved or crankshaft

binds, check bearing cap to rod orientation,

bearing clearance or connecting rod

alignment.

22. Measure clearance between connecting rods

and crankshaft journal flanges with a feeler

gauge.

CONNECTING ROD 0.10 - 0.50

SIDE CLEARANCE mm

Figure 6A1-1-231

23. Reinstall oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

24. Reinstall oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

25. Reinstall rear main oil seal, refer to

3.13 REAR MAIN OIL SEAL in this Section.

26. Reinstall spark plugs and tighten to the c orr ec t

torque specification.

SPARK PLUG

TORQUE SPECIFICATION 15 - 25

27. Refill oil pan with the cor r ect amount of engine

oil, refer to Section 0B LUBRICATION.

28. Reinstall engine assembly. Start engine and

check for oil leaks. Repair as necessary.

29. Check engine oil pressure, refer to

2.2 CHECKING ENGINE OIL PRESSURE in

this Section.

3.8 CAMSHAFT BEARINGS

REPLACE

Care must be exercised during bearing removal

and installation, not to damage bearings that are

not being replaced.

The following operations involve the use of Tool

No. AU384-B and finished sized camshaft

bearings. If installing unfinished sized bearings,

installation must be carried out by a specialist

machine shop and then line bored to correct final

size.

1. With engine removed from vehicle, refer to

3.1 ENGINE ASSEMBLY in this Section and

mounted in a suitable stand, remove

camshaft, refer to 2.22 CAMSHAFT in this

Section.

Inspect camshaft and lifters for contact

damage.

2. Remove crankshaft, refer to

3.12 CRANKSHAFT in this Section.

3. Install Tool No. AU384-7 into camshaft

bearing and assemble puller screw, Tool No.

AU384-1, into AU384-7. Install receiving

sleeve AU384-6A, washer and puller screw

nut onto puller screw.

Figure 6A1-1-232

4. Tighten nut and pull bearing from bore.

Figure 6A1-1-233

5. With bearing released from its bore,

disassemble remover tool and remove

bearing.

6. Remove all bearings in the same manner.

7. Install new bearing onto AU384-7 and install

into cylinder block, aligning oil hole/s in

bearing with holes in cylinder block.

NOTE 1:

The new bearing is a loose fit on Tool No. AU384-

7. As the bearing is installed into its bore, the

bearing will 'collapse' to the correct installed size.

The bearing must be installed with the notches in

the horizontal position as shown in Fig. 6A1-1-234

to ensure correct oil gallery alignment.

NOTE 2:

The camshaft bearings for journals 1 and 4 are

common, with 2 and 3 being common.

NOTE 3:

The bearings for journals 1 and 4 are identified by

having an oil feed slot on the outer surface.

NOTE 4:

Ensure that when installing No. 1 cams haf t bear ing,

the oil feed slot faces in the direction indicated in

Fig. 6A1-1-234.

Figure 6A1-1-234

8. Install puller screw, receiving sleeve, Tool No.

AU384-2, washer and puller nut.

Figure 6A1-1-235

9. Tighten nut until bearing is installed into the

correct position.

10. Install all bearings in the same manner.

Figure 6A1-1-236

11. With a piece of 2.4 mm diameter brass rod

with a 90 degree bend at the end, probe the

camshaft bearing oil holes to verify that they

are properly aligned with oil feed holes in

cylinder block.

NOTE:

Proper alignment of the oil holes is critical.

Restriction of the oil flow will cause severe engine

damage.

Figure 6A1-1-237

12. Lubricate camshaft bearings and journals with

clean engine oil. Temporarily install camshaft.

Ensure camshaft rotates without binding.

If camshaft binds, remove camshaft, inspect

bearings for high spots or incorrect

installation. Remove any burrs if present.

Check camshaft journal to bearing clearance.

If camshaft bearing journals are not within

specification, replace camshaft.

CAMSHAFT JOURNAL

DIAMETER 46.858 -

46.893 mm

CAMSHAFT BEARING

DIAMETER (INSTALLED) Refer to

SPECIFICATIONS

CAMSHAFT BEARING TO

JOURNAL CLEARANCE Refer to

SPECIFICATIONS

13. Reinstall camshaft and valve train

com ponents , refer to 2.22 CAMSHAFT in this

Section.

3.9 BALANCE SHAFT AND BE ARINGS

REMOVE

NOTE:

The balance shaft and both bearings are serviced

as a complete package.

1. With the engine removed from the vehicle,

refer to 3.1 ENGINE ASSEMBLY in this

Section, mount it in a suitable engine stand.

2. Remove lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

3. Remove front cover, refer to

2.19 FRONT COVER AND GASKET in this

Section.

4. Remove rear main oil seal and housing, refer

to 3.13 REAR MAIN OIL SEAL in this

Section.

5. Remove tim ing chain, sproc kets and cam s haft

gear, refer to 2.21 TIMING CHAIN,

TENSIONER, SPROCKETS AND BALANCE

SHAFT GEARS in this Section.

6. Remove balance s haft retainer attaching bolts,

remove retainer.

Figure 6A1-1-238

7. Using two screwdrivers, positioned behind

balance shaft driven gear, lever balance shaft

until front bearing area is free from its bore.

NOTE 1:

Ensure that screwdrivers lever behind the step on

the gear, behind the gear teeth. Do not lever

against the gear teeth.

NOTE 2:

If the balance shaft cannot be removed from

cylinder block in this method, remove driven gear

retaining bolt and gear. Install slide hammer, Tool

No. AU354, into balance shaft gear bolt hole and

remove balance shaft. Figure 6A1-1-239

8. Remove balance shaft from cylinder block.

9. Remove balance shaft driven gear, refer to

2.21TIMING CHAIN, TENSIONER,

SPROCKETS AND BALANCE SHAFT

GEARS in this Section.

10. Install Tool No. AU384-4 onto puller screw

AU384-1 and assemble into balanc e s haf t rear

bearing.

Figure 6A1-1-240

11. Install receiving Tool No. AU384-2 into rear of

bearing bore. Install washer and puller nut to

puller screw.

12. Tighten nut to remove rear bearing.

Figure 6A1-1-241

13. With bearing released from its bore,

disassemble remover tools and remove

bearing and discard.

REINSTALL

1. Dip new rear bearing in clean engine oil.

2. Install new rear bearing onto AU384-3 and

install into bearing bore.

3. Install puller screw into AU384-3.

Figure 6A1-1-242

4. Assem ble receiving sleeve AU384-6A, washer

and nut to puller screw.

5. Tighten nut to draw bearing into bore, at the

same time ensure that the flats on Tool No.

AU384-3 are at right angles to the bosses on

rear of cylinder block refer Fig 6A1-1-243.

Continue to tighten nut until the curved rear

section of AU384-3 just contacts the

transmission to cylinder block boss.

Figure 6A1-1-243

6. Remove bearing installation tools and check

that bearing is installed to the correct

dimension .

Figure 6A1-1-244

7. Check balance shaft rear bush clearance

specification.

REAR BUSH CLEARANCE 0.025 - 0.130

SPECIFICATION mm

Figure 6A1-1-245

8. Lubricate balance shaft front and rear

bearings and rear bearing journal with clean

engine oil.

9. Reinstall balance shaft driven gear (refer to

2.21 TIMING CHAIN, TENSIONER,

SPROCKETS AND BALANCE SHAFT

GEARS in this Section).

10. Install balance shaft into bearing bores. Using

a brass drift and a soft faced hammer, lightly

tap on balance shaft front bearing outer race

until front bearing is fully installed in bore

(bearing outer snap ring seated against

cylinder block). Figure 6A1-1-246

11. Install balance shaft retainer and attaching

bolts.

Tighten retainer attaching bolts to the correct

torque specification.

BALANCE SHAFT RETAINER

ATTACHING BOLT

TORQUE SPECIFICATION 26 - 34 Nm

12. Rotate balance shaft by hand and ensure that

it spins freely.

13. Reinstall sprocket key to front end of

camshaft.

Reinstall balance shaf t drive gear to cam shaf t,

aligning sprocket key with gear slot and

ensuring that timing marks on each of the

balance shaft gears face together.

It may be necessary to rotate balance shaft

slightly to ensure that balance shaft timing

marks align.

Figure 6A1-1-247

14. With balance shaft installed, carry out the

following balance shaft checks.

a. Measure balance shaft end play

BALANCE SHAFT END PLAY 0 - 0.203

SPECIFICATION mm

Figure 6A1-1-248

b. Measure balance shaft front and rear

radial play.

FRONT RADIAL PLAY 0 - 0.028

SPECIFICATION mm

Figure 6A1-1-249

15. Carry out the following procedure to measure

balance shaft drive gear lash:

a. Measure balance shaft gear lash at four

locations (every 1/4 turn).

BALANCE SHAFT GEAR LASH 0.050 - 0.127

SPECIFICATION mm

b. If gear lash exceeds specifications,

replace drive gears.

Figure 6A1-1-250

16. Reinstall balance shaft drive gear, timing

chain and camshaft sprocket, refer to

2.21 TIMING CHAIN, TENSIONER,

SPROCKETS AND BALANCE SHAFT

GEARS in this Section.

17. Reinstall lower inlet manifold, refer to

2.9 LOWER INLET MANIFOLD in this

Section.

18. Reinstall front cover, refer to 2.19 FRONT

COVER AND GASKET in this Section.

19. Reinstall rear main oil seal and housing, refer

to 3.13 REAR MAIN OIL SEAL in this

Section.

20. Start engine and check for oil, fuel or coolant

leaks. Repair as necessary.

3.10 PISTON AND CONNECTING ROD ASSEMBLY

The piston and connecting rod assemblies can be

removed without the engine being removed.

If the cylinder bore requires mac hining, rem ove the

engine assembly, refer to

3.1 ENGINE ASSEMBLY in this Section, and

remove piston and connecting rod assemblies.

Piston and pin assemblies/piston ring sets are

available in std. and 0.508 mm oversizes.

When fitting pistons, both piston and cylinder bore

condition must be considered together. Production

and service pistons have the same nominal weight

and can be intermixed without affecting engine

balance. If necessary, used pistons may be fitted

selectively to any cylinder of the engine, providing

they are in good condition.

NOTE:

Do not machine oversize pistons down or engine

balance will be affected.

REMOVE

1. Disconnect battery earth lead.

2. Remove cylinder heads, refer to

2.15 CYLINDER HEADS in this Section.

3. Remove oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

4. Remove oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

5. Examine cylinder bores above piston ring

travel. If bores are worn so that a shoulder or

ridge exists, remove using a ridge remover.

For each cylinder, rotate crankshaft so that

piston is at bottom of stroke and cover piston

with a cloth to collect cuttings.

6. Mark all pistons, connecting rods and caps

with an etching marker or felt tipped pen to

indicate cylinder identification.

Figure 6A1-1-251

Techline

7. Remove piston and rod assemblies as follows:

a. With connecting rod crankshaft journal at

bottom of its tr avel (Bottom Dead Centre) ,

remove connecting rod cap bolts and

remove cap with bearing shell.

Figure 6A1-1-252

b. Install the 'short' connecting rod guide tool

AU388-2, into connecting rod inner bolt

hole.

c. Install 'long' connecting r od guide AU388-

1, into opposite bolt hole.

Turn guides down fully to hold upper

bearing shell in place.

d. Using a hammer handle, push on long

guide to remove piston and connecting

rod from cylinder. Remove guides and

reinstall cap and bolts to connecting rod.

Figure 6A1-1-253

8. Remove all other piston and connecting rod

assemblies in the same manner.

DISASSEMBLE

1. Remove piston rings by expanding them and

sliding them off pistons, and then discarding.

NOTE:

Take care when removing piston rings as worn

rings may have sharp edges.

Figure 6A1-1-254

2. Remove two piston pin retainers.

NOTE:

Piston pin retainers may be reused if not damaged.

Figure 6A1-1-255

INSPECT

1. Inspect cylinder walls for scoring, roughness,

or ridges which indicate excessive wear.

Check cylinder bores for taper and out-of-

round with an accurate cylinder gauge at top,

middle and bottom of bore, both parallel and

at right angles to centreline of engine. Refer to

3.15 CYLINDER BLOCK in this Section.

2. Clean carbon from piston heads. Clean carbon

from ring grooves with suitable tool or a piece

of piston ring and remove any gum or varnish

from piston skirts with suitable cleaning

solvent.

Figure 6A1-1-256

3. Carefully examine piston skirt for rough or

scored surfaces, cracks in skirt or crown,

broken ring lands, chipping or uneven wear

which would cause rings to seat improperly or

have excessive clearance in ring grooves.

Damaged or faulty pistons should be replaced.

The pistons are cam ground, which means

that the diameter at right angles to the piston

pin is greater than the diameter parallel to the

piston pin. When a piston is checked for size,

it must be done at a point 90° to the piston pin

bore, 41 mm from top of piston.

Figure 6A1-1-257

PISTON SIZE SPECIFICATIONS

STANDARD 96.482 - 96.497 mm

AVAILABLE OVERSIZE 0.508 mm

4. Inspect piston pin bores and piston

pins/bushes for wear. Piston pin bores and

piston pins must be free of varnish or scuffing

when being measured. The piston pin should

be measured with a micrometer and piston pin

bore should be measured with a dial bore

gauge or an inside micrometer. If clearance is

not to specification, piston and pin should be

replaced.

If piston pin bush requires replacement

remove and install using suitable press and

plates. Honing of the bush prior to pin

installation may be necessary.

Figure 6A1-1-258

PISTON PIN DIAMETER 21.995 - 22.000 mm

PISTON PIN CLEARANCE

IN PISTON 0.002 - 0.013 mm

IN CONNECTING ROD 0.007 - 0.022 mm

Figure 6A1-1-259

5. Remove bearing shells from connecting rod,

install cap and bolts. Tighten bolts to the

correct torque specification.

CONNECTING ROD

CAP BOLT

TORQUE SPECIFICATION

24 - 30 Nm

plus 47 - 53

degree turn

angle

6. Place connecting rod assembly on a checking

fixture and check rod for bend or twist.

Do not attempt to straighten rod if bent or

twisted, replace it.

Check new connecting rods in the same

manner before using them.

CONNECTING ROD ALIGNMENT SPECIFICATION

BEND: 0.020mm/25.4 mm

TWIST: 0.038mm/25.4 mm

Figure 6A1-1-260

7. Inspect outside of connecting rod bearing

shells and internal diameter of connecting rod

big end for wear indicating high spots in rod

big end.

8. Remove cap bolts and check bolts for

stretching by comparing them with a new bolt.

Replace bolt/s if stretched.

REASSEMBLE AND REINSTALL

NOTE:

The connecting r od can be ass em bled to the piston

either way.

In production, the connecting rods are assembled

with the small raised dimple on the cap and rod on

the same side, and facing forward.

Figure 6A1-1-261

1. Lubricate piston pin bore and piston pin with

engine oil.

2. Install one piston pin retainer by starting one

side of r etainer in r etaining groove and r otating

retainer until fully seated in groove.

3. Assem ble connecting rod and piston pin, push

piston pin until it bottoms on installed retainer.

4. Install remaining retainer using procedure

outlined in step 2.

Figure 6A1-1-262

5. Install piston rings, refer to

3.11 PISTON RINGS in this Section.

6. Ensure cylinder bores, pistons, connecting r od

bearing shells and crankshaft journals are

absolutely clean, then coat cylinder bores and

all bearing surfaces with clean engine oil.

7. Before installation of a piston and rod

assembly in its bore, position the crankpin

straight down.

8. Remove cap, and with bearing upper shell

seated in connecting rod, install the 'short'

guide tool into inner bolt hole. Install 'long'

guide tool in the other bolt hole.

These guides hold upper bearing shell in

place and protect crankshaft journal from

damage during installation of connecting rod

and piston assembly.

9. Ensure piston ring gaps are separated as

detailed in 3.11 PISTON RINGS in this

Section.

10. Lubricate piston and rings with clean engine

oil. Using a suitable ring compressor to

compress rings, install each piston and

connecting rod assembly into its cylinder bore.

NOTE:

Ensure arrow on piston crown is facing forward.

Figure 6A1-1-263

11. Using a hammer handle, lightly tap piston into

its bore while holding ring compressor firmly

against cylinder block until all pistons rings

have entered bore.

12. Push piston down bore until connecting rod

seats against crankshaft journal.

Figure 6A1-1-264

13. Rem ove connecting rod guides. Install bear ing

cap and lower bearing shell assembly. Install

cap bolts and tighten and then loosen one full

turn. Finally tighten the cap bolts to the corr ect

specification.

NOTE:

Ensure correct orientation of cap with connecting

rod.

CONNECTING ROD 24 - 30 Nm

CAP BOLT plus 47 - 53

TORQUE SPECIFICATION degree turn angle

NOTE:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

Figure 6A1-1-265

14. Rotate cranks haft to ensure f ree m ovement of

crankshaft and connecting rod. If crankshaft

binds, recheck bearing cap to rod orientation,

bearing clearance or connecting rod

alignment.

15. Measure side clearance between connecting

rod and crankshaft journal.

If clearance is insufficient check bearing

clearance, refer to 3.7 MAIN AND

CONNECTING ROD BEARINGS in this

Section, or connecting rod alignment.

CONNECTING ROD SIDE 0.10 - 0.50

CLEARANCE mm

Figure 6A1-1-266

16. Install remaining piston and connecting rod

assemblies in the same manner.

17. Reinstall cylinder heads, refer to

2.15 CYLINDER HEADS in this Section.

18. Reinstall oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

19. Reinstall oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

20. Start engine and check f or oil leak s. Repair as

necessary.

3.11 PISTON RINGS

INSTALL

NOTE:

The pistons have three rings (two compression

rings and one oil ring). The top ring is a steel,

molybdenum filled, balanced section, barrel lapped

type. The second ring is a inverted torsional taper

faced type. The oil ring is of three piece design,

comprising two segments and a spacer.

1. Select a set of rings com parable in size to the

piston being used.

2. Install compression ring in relevant cylinder

bore, then using the head of a piston, press

ring down into bore approximately 50 mm.

NOTE 1:

Using a piston in this way will place ring square with

cylinder wall.

NOTE 2:

Be careful not to distort the ring during this

operation, or it may bind in the piston ring groove.

Fit each ring separ ately to the cylinder in which it is

going to be installed.

Figure 6A1-1-267

3. Measure gap between ends of ring with a

feeler gauge.

If the gap between the ends of a c ompress ion

ring is below specif ication, r em ove ring and try

another for size.

COMPRESSION RING END GAP SPECIFICATION

TOP RING 0.305 - 0.559 mm

SECOND RING 0.762 - 1.016 mm

4. Check gap between ends of each oil control

ring rail.

OIL RING RAIL END GAP

SPECIFICATION 0.254 - 0.762

5. W hen fitting rings to a piston that has been in

service, carefully remove all traces of carbon

from ring grooves in piston and inspect

grooves for any burrs or chips that might

cause ring to bind.

6. Slip outer surface of each com pression ring in

respective piston ring groove and roll ring

entirely around groove to check that ring is

free.

Also measure ring to piston groove side

clearance.

If the ring is too tight, try another ring.

NOTE:

Do not attempt to cut the piston ring groove,

although high spots in the ring groove may be

cleaned up by careful use of a fine file.

Figure 6A1-1-268

PISTON RING TO GROOVE CLEARANCE

TOP RING 0.039 - 0.079 mm

SECOND RING 0.039 - 0.079 mm

OIL CONTROL RING 0.023 - 0.201 mm

7. Install oil ring spacer in bottom piston ring

groove.

NOTE:

The ends of the spacer butt against each other.

Figure 6A1-1-269

8. Install one steel rail from top of piston

downward into oil ring groove.

9. Install remaining steel rail from bottom of

piston skirt upwards into the oil ring groove.

10. Install compression rings in second and first

grooves of each piston.

NOTE 1:

Ensure the correct compression rings are installed

in the first and second grooves, with the second

compression ring fitted and the correct way up.

NOTE 2:

The upper compression ring can be installed into

the first groove either way.

Figure 6A1-1-270

11. Make a final test of ring fit in piston grooves.

Separate ends as shown.

NOTE:

Never install piston with ring gaps in line, as this will

allow compression leakage at this point.

Figure 6A1-1-271

3.12 CRANKSHAFT

REMOVE

NOTE 1:

It is recommended that bearing clearance be

checked before removing crankshaft from cylinder

block, refer to 3.7 MAIN AND CONNECTING

ROD BEARINGS in this Section.

NOTE 2:

The crankshaft in this engine has rolled fillets and

the journals can be repolished up to 0.025 mm

undersize. If any more is required for refinishing,

the crankshaft must be replaced.

1. With engine removed from vehicle and

mounted in a suitable stand, remove oil pan,

refer to 3.2 OIL PAN AND SEAL in this

Section.

2. Remove oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

3. Remove rear main oil seal housing refer to

3.13 REAR MAIN OIL SEAL HOUSING in this

Section.

4. Remove crankshaft balancer, refer

2.17 CRANKSHAFT BALANCER in this

Section.

5. Remove spark plugs.

6. Remove tim ing c hain and c rankshaf t s pr ocket,

refer to 2.21 TIMING CHAIN, TENSIONER,

SPROCKETS AND BALANCE SHAFT

GEARS in this Section.

7. Mark connecting rod caps with an etching

marker or felt tipped pen to indicate cylinder

number and orientation of cap.

Figure 6A1-1-272

8. Remo ve connecting rod cap bolts and rem ove

caps. Push connecting rods away from

crankshaft.

Figure 6A1-1-273

9. Remove main bearing cap bolts and main

bearing cap side bolts.

NOTE 1:

New main bearing cap side bolts must be used to

ensure bolts remain oil tight to cylinder block.

NOTE 2:

Main bearing caps are press fit and special care is

required when removing the caps. J41348 has

been designed to work in conjunction with J6125-B

in order to prevent damage to bearing and/or cap.

J41348 m ust be ins talled corr ectly into bolt holes of

caps and J6125-B attached in order to properly

remove main bearing cap without damage to the

cap and/or bearing. Deviation from this procedure

may cause damage to the cap and/or bearing

resulting in engine damage.

10. Install J41348 into main bearing cap bolt

holes.

11. Tighten bolts to 11 Nm.

12. Install J6125-B to J41348.

13. Using the slide hammer motion of J6125-B

remove main bearing cap.

Figure 6A1-1-274

14. Lift crankshaft from cylinder block.

15. Remove flywheel/flexplate to crankshaft

attaching bolts, remove flywheel/flexplate and

discard bolts.

16. If necessary, remove sprocket key from front

end of crankshaft using a suitable punch and

hammer.

17. If necessary, remove crankshaft to flywheel

dowel pins from c ranks haft rear f lange using a

suitable removal tool.

Figure 6A1-1-275

INSPECT

1. Wash crankshaft in suitable cleaning solvent

and dry with compressed air.

2. Inspect crankshaft oil passages for

obstructions.

3. Inspect all bearing journals, thrust surfaces

and rear main oil seal contact surfaces for;

a. Cracks

b. Chips

c. Gouges

d. Roughness

e. Grooving

f. Overheating (Discolouration)

If crankshaft has any cracks, severe gouging

or burned spots, the crankshaft must be

replaced. Slight roughness may be removed

with fine polishing cloth soaked in clean

engine oil. Burrs may be removed with a fine

oil stone.

4. Inspect connecting rod and main bearing

shells for imbedded foreign material and

determine its source.

5. Measure bearing journals with a micrometer

for taper, out-of-round or excessive wear.

MAIN BEARING JOURNAL DIAMETER

STANDARD 63.470 - 63.495 mm

TAPER 0.008 mm MAX.

OUT-OF-ROUND 0.008 mm MAX.

CONNECTING ROD JOURNAL DIAMETER

STANDARD 57.117 - 57.147 mm

TAPER 0.008 mm MAX.

OUT-OF-ROUND 0.008 mm MAX.

Figure 6A1-1-276

6. Check crankshaft for run-out by supporting

front and rear main bearing journals in V -

blocks and checking No. 2 and No. 3 journals

with a dial gauge.

CRANKSHAFT RUN-OUT 0.008

SPECIFICATION mm

Figure 6A1-1-277

7. Position a dial gauge at crank shaft rear flange

and check rear flange run-out. During this

check , ensure that crank shaft is thrust for ward

on V - blocks so that there is no possibility of

crankshaft end float affecting dial gauge

reading.

CRANKSHAFT REAR FLANGE 0.05 mm

RUN-OUT MAX

Figure 6A1-1-278

8. Replace crankshaft if not within specifications.

9. Using a 5/16" thread tap, clean

flywheel/flex plate attaching bolt thread holes in

rear of crankshaft.

10. Clean all traces of sealant from cylinder block.

REINSTALL

1. If necessary, install sprocket key to front end

of crankshaft.

2. Lubricate all crankshaft journals and main

bearing upper shells in cylinder block with

clean engine oil.

3. Lay crankshaft in place in main bearing upper

shells in cylinder block. Take care not to

damage crankshaft thrust flange and No. 2

main bearing thrust faces. Also take care not

to contact connecting rod journals with

connecting rods.

4. If necessary, check main bearing clearance,

refer to 3.7 MAIN AND CONNECTING ROD

BEARINGS in this Section.

5. Ensure that main bearing cap bolt threads and

cylinder block threads are clean and dry. Apply

some engine oil to the cap bolt threads.

NOTE:

Ensure that the bearing cap is installed into the

crankcase correctly.

6. Before final installation of cap bolts, determ ine

if bolts have stretched by comparing with a

new bolt. Replace bolt/s as necessary.

Reinstall main bearing caps, hand start main

bearing cap bolts, on each bearing c ap in turn,

tighten cap bolts half a turn at a time to

carefully seat cap.

Hand start main bearing cap side bolts.

Due to the thrust bearing shells being

disturbed, it is necessary to line up the thrust

surfaces of the bearing shells before the cap

bolts are tightened. To do this, move the

crankshaft fore and aft the length of its travel

several times (last movement forward).

NOTE 1:

Do not tighten one cap completely at a time,

progressively tighten all four caps to one step of

procedure before moving to next stage of torque.

Torque main bearing cap bolts to 70 Nm to

fully seat cap.

Loosen cap bolts 360° then torque all cap

bolts to 20 Nm and then 40 Nm.

Tighten cap bolts in steps of 35° + 35° + 35° to

a total of 105°.

Torque main bearing cap side bolts 12 - 18

Nm + 42 - 48°.

NOTE 2:

New main bearing cap side bolts must be used to

ensure bolts remain oil tight to cylinder block.

Figure 6A1-1-279

MAIN BEARING CAP BOLT Refer procedure

TORQUE SPECIFICATION following

NOTE: 1

Figure 6A1-1-280

NOTE 3:

In order to prevent the possibility of cylinder block

or bearing cap damage, do not install bearing cap

using a soft faced hammer. Use cap bolts to pull

bearing cap into position. Failure to observe this

procedure may damage cylinder block or bearing

cap.

NOTE 4:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

7. Force crankshaft forward and measure

crankshaft end float between front of No. 2

main bearing s hell and crankshaf t thrust fac es

with a feeler gauge.

If clearance is excessive, replace No. 2 main

bearing shells.

CRANKSHAFT END FLOAT 0.08 - 0.28

SPECIFICATION mm

Figure 6A1-1-281

8. Install new rear main oil seal, refer to

3.13 REAR MAIN OIL SEAL in this Section.

9. Install flywheel/flexplate to crankshaft, install

and tighten new attaching bolts to the correct

torque specification refer to

3.4 FLYWHEEL/FLEXPLATE in this Section.

NOTE:

Bolt holes are unevenly spaced so

flywheel/flexplate bolts can only be installed with

the flywheel/flexplate and retainer plate in the

correct position.

Figure 6A1-1-282

NOTE:

There are specific bolts for flywheel and flexplate

attachment to the crankshaft.

FLYWHEEL/FLEXPLATE BOLT TIGHTENING

SEQUENCE

STEP NO. 1 TORQUE ALL BOLTS

TO 18 - 22 NM

STEP NO. 2

MANUAL TIGHTEN ALL BOLTS

TRANSMISSION A FURTHER 80 - 90

DEGREES TURN ANGLE

STEP NO. 2

AUTOMATIC TIGHTEN ALL BOLTS

TRANSMISSION A FURTHER 47 - 53

DEGREES TURN ANGLE

Figure 6A1-1-283

10. For vehicles with manual transmission,

reinstall clutch pres su re plate and dr iven plate,

refer to Section 7A CLUTCH.

11. Using guide pin tools, (AU388) pull connecting

rods up to crankshaft journals.

Figure 6A1-1-284

12. If necessary, check connecting rod bearing

clearances, refer to 3.7 MAIN AND

CONNECTING ROD BEARINGS in this

Section.

13. Lubricate crankshaft connecting rod journals

and bearings, install connecting rod caps and

bolts.

14. Tighten connecting rod cap bolts and then

loosen one full turn. Tighten bolts to the

correct torque specification.

NOTE:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

CONNECTING ROD CAP BOLT 24-30 Nm

TORQUE SPECIFICATION plus47-53

degree turn angle Figure 6A1-1-285

15. Measure clearance between connecting rods

and crankshaft journal flanges with a feeler

gauge.

CONNECTING ROD SIDE 0.10 - 0.50

CLEARANCE mm

Figure 6A1-1-286

16. Rotate cranks haft to ensure f ree m ovement of

crankshaft and connecting rods.

If crankshaft binds, check orientation of

bearing caps, correct fitting of bearing caps

(mains and connecting rods) or fitting of

bearing shells or bearing clearance.

17. Reinstall crankshaft sprocket, timing chain,

and front c over, r ef er to 2.21 T IM ING CHAIN,

TENSIONER, SPROCKETS AND BALANCE

SHAFT GEARS in this Section.

18. Reinstall crankshaft balancer, refer to

2.17 CRANKSHAFT BALANCER in this

Section.

19. Reinstall spark plugs and tighten to the c orr ec t

torque specification.

SPARK PLUG TORQUE

SPECIFICATION 15 - 25

20. Reinstall oil pump suction pipe and screen,

refer to 3.3 OIL PUMP SUCTION PIPE AND

SCREEN in this Section.

21. Reinstall oil pan, refer to 3.2 OIL PAN AND

SEAL in this Section.

3.13 REAR MAIN OIL SEAL

REPLACE

1. Disconnect battery earth lead.

2. Remove transmission, refer to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE, or Section 7C4 AUTOMATIC

TRANSMISSION.

3. Remove flywheel/flexplate, refer to

3.4 FLYWHEEL/FLEXPLATE in this Section.

4. On vehicles with manual transmission,

remove spigot bearing, refer to

3.6 SPIGOT BEARING in this Section.

5. Position a piece of shim brass between seal

lips and crankshaft. This is necessary to

protect the crankshaft seal surface.

6. Using a suitable lever, pry out seal, levering

against shim brass strip and remove seal.

7. Check seal bore in rear main oil seal housing

for nicks or burrs, correct as required.

Figure 6A1-1-287

8. Wipe the crank sealing surface carefully and

inspect for signs of dam age. In addition check

the area at the rear of the crankshaft that the

seal will slide past during ins tallation to ensur e

that there are no defects that will damage the

seal during installation. Repair or replace the

crankshaft as necessary.

9. Lubricate rear main oil seal housing and

crankshaft flange plus I.D. and O.D. of

J41349. Install r ear m ain s eal hous ing aligning

tool J41349 tapered end first to crankshaft

flange and rotate tool. Tool should turn evenly

without binding or tight spots if housing is

correctly aligned.

Figure 6A1-1-288

10. Apply engine oil to new seal inner and outer

diameter.

Apply a thin film of clean engine oil to the

surface of the crankshaft over which the seal

will slide during installation.

NOTE:

Do not apply petroleum jelly or grease to seal lip.

These substances can prevent correct seal

operation.

NOTE:

Seal installation using Tool No. J38196

Ensure that T-handle of Tool No. J38196 is

loosened right off. Slide seal over mandrel of

Tool No. J38196 until it bottoms squarely

against outer collar of tool.

CAUTION:

Inspect tool J38196 for damage to the seal lip

area. If damage is evident, the tool should be

replaced. Figure 6A1-1-289

11. Attach tool to rear of crankshaft by tightening

the two knurled attaching screws until tight.

It is important when using the seal installation

tool that the correc t holes in the c rankshaf t ar e

used.

One of the holes in the crankshaft is offset, if

this hole is one of the pair used then it can

result in the seal being installed incorrectly.

12. Turn T-handle of tool so that outer collar

pushes seal into its bore and continue to turn

handle until additional resistance is felt. Do not

over tighten T- handle other wise dam age to the

tool may result.

Figure 6A1-1-290

NOTE:

Seal installation using Tool No. J38196AUS

Separate tool by removing nut, and place

mandrel collar to one side.

CAUTION:

Inspect seal retaining mandrel for damage to

the seal lip area. If damage is evident, the tool

should be replaced.

13. Attach seal retaining mandrel to rear of

crankshaft by fitting two attaching screws until

tight.

It is important when using the seal installation

tool that the correc t holes in the c rankshaf t ar e

used.

Clearance holes are provided to avoid

interference with crankshaft dowel pins if

fitted.

One of the holes in the crankshaft is offset, if

this hole is one of the pair used then it can

result in the seal being installed incorrectly.

Figure 6A1-1-291

14. Install seal onto seal retaining m andrel, noting

that seal lips are facing out.

Figure 6A1-1-292

15. Install mandrel collar over seal retaining

mandrel.

16. Install nut onto seal retaining mandrill and

tighten nut until seal is seated into rear main

oil seal housing.

Figure 6A1-1-293

The seal must be installed parallel to the

crankshaft rear flange.

The crankshaft rear flange to seal dimension

should not vary more than 0.25 mm when

measured at different points around the

circumference of the crankshaft rear flange.

NOTE:

Dimension is shown with crankshaft in fully

rearward position.

Figure 6A1-1-294

IMPORTANT:

If the above dimension varies more than 0.25 mm

reattach tool J38196 / J38196AUS to rear of

crankshaft and turn t-handle until resistance is felt.

With tool in this position, remove spark plugs and

rotate engine slowly for two full revolutions.

Remove tool and recheck seal is parallel to

crankshaft flange.

If the crankshaft rear flange to seal dimension still

varies more than 0.25 mm, replace tool J38196 /

J38196AUS.

17. Remove seal installing tool from crankshaft.

18. If necessary, reinstall spigot bearing, refer to

3.6 SPIGOT BEARING in this Section.

Figure 6A1-1-295

19. Clean flywheel/flexplate attaching bolt threads

in rear of crankshaft using a 5/16 UNC thread

tap.

Reinstall flywheel/flexplate using new bolts

refer to 3.4 FLYWHEEL/FLEXPLATE in this

Section.

Figure 6A1-1-296

20. Reinstall transmission, check engine and

transmission lubricant levels.

FLYWHEEL/FLEXPLATE BOLT TIGHTENING

SEQUENCE

STEP No. 1 TORQUE ALL BOLTS TO 18

- 22 Nm

STEP No. 2

MANUAL

TRANSMISSION

TIGHTEN ALL BOLTS A

FURTHER 80 - 90

DEGREES TURN ANGLE

STEP No. 2

AUTOMATIC

TRANSMISSION

TIGHTEN ALL BOLTS A

FURTHER 47 - 53

DEGREES TURN ANGLE

21. Road test vehicle and check for lubricant

leaks.

3.14 REAR MAIN OIL SEAL HOUSING

REMOVE

1. Disconnect battery earth lead.

NOTE:

If performing this operation with engine installed

drain cooling system refer to

Section 6B1-1 ENGINE COOLING - V6 ENGINE.

2. Remove the four nuts securing engine dress

cover.

Figure 6A1-1-297

3. Remove bolts securing generator brace.

Figure 6A1-1-298

4. Disconnect mass air flow sensor wiring,

loosen air flow duct rubber boot clamps at

throttle body and air cleaner and remove air

flow duct. Carefully place air flow duct and

mass air flow sensor assembly to one side.

Figure 6A1-1-299

Techline

5. Remove lower radiator hose and drain coolant.

Figure 6A1-1-300

6. Remove the engine hood assembly, refer to

Section 1B SHEET METAL.

7. Install engine lifting brack ets and engine lifting

frame to engine.

NOTE:

Ensure adequate clearance between lifting

equipment and engine components.

Figure 6A1-1-301

8. Remove transmission, refer to

Section 7B1 MANUAL TRANSMISSION - V6

ENGINE, or to Section 7C4 AUTOMATIC

TRANSMISSION.

9. Remove flywheel/flexplate, refer to

3.4 FLYWHEEL/FLEXPLATE in this Section.

10. Remove steering rack mounting bolts, lower

steering rack to improve access.

Figure 6A1-1-302

11. Remove engine mounting to front

crossmember attaching nuts.

12. Raise engine 40 mm.

13. Fit 40 mm spacers between engine mounts

and crossmember to support engine.

Figure 6A1-1-303

14. Drain engine oil.

15. Remove the engine oil pan.

16. Disconnect wiring harness to knock sensors.

17. Drain remaining coolant by removing both

knock sensors from engine block.

18. Remove rear main oil seal housing to cylinder

block bolts, remove housing.

Figure 6A1-1-304

19. Thoroughly clean all mating surfaces using a

scraper and solvent.

REINSTALL

Installation is the reverse of removal procedures

noting the following points.

NOTE:

Ensure block face is clean of oil and water before

reinstalling housing. Approximately 15 minutes is

required for oil to drain suff iciently to achieve an oil

free surface.

1. Prior to reinstallation of rear main oil seal

housing, check thic k ness of housing as shown

in Fig. 6A1-1-305. If dimension is not within

specification of 7.24 - 7.29 mm, replace rear

main oil seal housing.

Figure 6A1-1-305

2. Fit rear main seal housing aligning tool

E1409/12 to oil pan rail.

3. Loosely reinstall rear main oil seal housing

and gasket to rear of cylinder block.

NOTE:

Rear main oil seal housing to block bolts are

torque-to-yield bolts and must not be reused.

4. Lubricate rear main oil seal housing and

crankshaft flange plus I.D. and O.D. of

J41349. Install r ear m ain s eal hous ing aligning

tool J41349 tapered end first to crankshaft

flange and rotate tool. Tool should turn evenly

without binding or tight spots if housing is

correctly aligned.

NOTE:

If correct location of housing cannot be achieved,

nylon inserts in housing may be removed.

Figure 6A1-1-306

5. Torque all bolts to 12-18 Nm + 47-53° in

sequence.

CRANKSHAFT REAR MAIN OIL SEAL HOUSING

TORQUE SPECIFICATION

STEP 1. 12 - 18 Nm

STEP 2.. 47 - 53 Degrees

Figure 6A1-1-307

6. Recheck location of housing by rotating tool

J41349 on crank shaft. Tool s hould turn evenly

without binding or tight spots.

Figure 6A1-1-308

7. Using feeler gauge and E1409/12, check

height of rear main oil seal housing to oil pan

rail. Housing must be even to - 0.10 mm to oil

pan rail. If not, replace rear main oil seal

housing assembly and install as from step 1.

Above.

8. Remove tools J41349 and E1409/12.

Figure 6A1-1-309

9. Reinstall rear main oil seal refer to

3.13 REAR MAIN OIL SEAL in this Section.

10. Reinstall flywheel/flexplate using new bolts

refer to 3.4 FLYWHEEL/FLEXPLATE in this

Section. For flywheel Service Operations ref er

to Section 7A CLUTCH.

11. Fill and bleed cooling system refer to

Section 6B1-1 ENGINE COOLING - V6

ENGINE.

12. Refill engine with oil.

13. Road test vehicle and check for oil leaks.

3.15 CYLINDER BLOCK

INSPECT

1. With engine removed from vehicle refer to

3.1 ENGINE ASSEMBLY in this Section and

mounted in a suitable engine stand, remove

all components as outlined under the

appropriate component heading in this

Section.

2. Clean all cylinder block gasket surfaces.

3. If necessary, remove all coolant jacket welsh

plugs, oil gallery screw plugs, knock sensors,

refer to Fig. 6A1-1-310 and camshaft

bearings, refer to 3.8 CAMSHAFT

BEARINGS in this Section.

4. Thoroughly clean cylinder block in a suitable

cleaning solution. Flush with clean water or

steam. Spray or wipe cylinder bores and

machined surfaces with engine oil.

NOTE:

Caustic cleaning solutions destroy all bearing and

alloy materials. All bearing and alloy components if

not removed before cleaning, must be replaced. Do

not clean bearing material or alloy parts with

caustic solutions.

5. Inspect all oil passages for restriction.

6. Check cylinder block deck surface for f latness

using a straight edge and feeler gauge.

Cylinder block deck s urface m ay be m achined

if any irregularity or distortion is less than

specified.

If irregularity or distortion exceeds

specifications, replace cylinder block.

CYLINDER BLOCK 0.013 mm PER

DECK SURFACE 25.4 mm OR

FLATNESS SPECIFICATION 0.08 mm MAX.

OVERALL

Figure 6A1-1-310

7. Inspect oil pan and front cover attaching area

for damage or burrs.

Minor irregularities may be cleaned up with a

fine mill file.

8. Inspect all threaded holes. If necessary clean

with a suitable threaded tap or drill out and

install thread insert.

The f ollowing cylinder block ins pections r equire the

main bearing caps to be installed and bolts

tightened to the correct torque specification. Refer

to 3.12 CRANKSHAFT in this section.

NOTE 1:

Use an angle wrench such as E7115 to ensure

accurate turn angle.

NOTE 2:

Ensure that the m ain bearing caps are installed into

the crankcase correctly.

NOTE 3:

In order to prevent the possibility of cylinder block

or bearing cap damage, do not install bearing cap

using a soft faced hammer. Use cap bolts to pull

bearing cap into position. Failure to observe this

procedure may damage cylinder block or bearing

cap.

Figure 6A1-1-311

9. Measure crankshaft and camshaft bearing

bores, check for concentricity and alignment.

If outside specification, replace cylinder block.

If examination of the outside of the bearing

shells indicates m inor high spots, rem ove high

spots from bearing seats with a fine mill file.

CRANKSHAFT BEARING BORE 0.008

MAXIMUM OUT-OF-ROUND mm

CAMSHAFT BEARING BORE 0.013

MAXIMUM OUT-OF-ROUND mm Figure 6A1-1-312

10. Measure cylinder bore walls for taper, out-of-

round, oversize and excessive ridging.

If bore is worn beyond limits, it may be

rebored, honed and fitted with oversize

pistons.

The smallest available oversize piston should

be selected, refer to

CYLINDER RECONDITIONING AND PISTON

FITTING in this Section.

STANDARD BORE DIAMETER 96.507-96.533 mm

MAX TAPER 0.013 mm

MAX OUT-OF-ROUND 0.010 mm

Figure 6A1-1-313

CYLINDER RECONDITIONING AND PISTON FITTING

If one or m ore cylinder bores are rough, scor ed, or

worn beyond limits, it will be necessary to smooth

or true up such bores to fit new pistons.

If relatively few bores require correction it will not

be necessary to rebore all cylinders to the same

oversize in order to m aintain engine balance, since

all oversize service pistons are held to the same

weight as standard size pistons.

No attempt should be made to machine oversize

pistons to fit cylinder bores, as this will destroy the

surface treatment and affect the weight. The

smallest possible oversize service pistons should

be used and the cylinder bores should be honed to

size for proper clearances.

Before the honing or reboring operation is started,

measure all new pistons at right angles to the

piston pin bore, 39 mm from top of piston.

Figure 6A1-1-314

If cylinder bore wear does not exc eed specif ication,

honing is recomm ended for truing the bore. If wear

or out-of-round exceeds specification, the bore

should be trued up by boring and then hone

finished.

When reboring cylinder bores, all crankshaft

bearing caps must be in place and tightened to

specified torque to prevent distortion of bores in

final assembly.

When taking the final cut with boring bar, leave

0.025 mm on the diameter for final honing to give

the specified clearance.

When cylinders are to be honed, follow the Hone

Manufactur er' s r ecommendations f or the us e of the

hone, cleaning and lubrication during honing.

When finish honing, pass the hone through the

entire length of cylinder bore at the rate of

approximately 60 cycles per minute. This should

produce the desired 45 degrees cross hatch

pattern on cylinder walls which will ensure

maximum ring life and minimum oil consumption.

During the final honing, each piston must be fitted

individually to the bore in which it will be installed

and marked to ensure correct assembly. After the

final honing and before the piston is c heck ed f or fit,

each cylinder bore must be washed and dried

thoroughly to remove all traces of abrasive and

then allowed to cool. Apply clean engine oil to

cylinder bores. The pis tons and c ylinder block mus t

be at a common temperature before checking.

When new piston rings are installed without

reboring cylinders, the glazed cylinder walls should

be slightly dulled, but without increasing the bore

diameter, by means of the finest grade of stone in

a cylinder hone.

To check piston to cylinder bore clearance,

proceed as follows:

1. Wipe cylinder walls and pistons with a clean

cloth. Apply clean engine oil to cylinder bores.

2. Accurately measure the bore with an inside

micrometer.

3. Measure piston diameter.

4. Subtract piston diameter from cylinder bore

diameter to determine piston-to-bore

clearance.

PISTON TO BORE

CLEARANCE 0.010 - 0.051

5. Mark each piston with cylinder number to

which it will be fitted and proceed to hone

cylinders and fit pistons.

CAUTION:

Handle the pistons with care and do not

attempt to force them through the cylinder until

cylinder has been honed to correct size, as

pistons can be distorted through careless

handling.

Reassemble components as outlined under the

appropriate component heading in this Section.

If coolant and oil gallery plugs were removed on

disassembly, coat new plugs with sealant (or its

equivalent) as specified in Fig. 6A1-1-315 and

install.

Figure 6A1-1-315

4. ENGINE MECHANICAL DIAGNOSIS

The following diagnostic information covers common problems and possible causes. When the proper diagnosis is

made, the problem should be corrected by adjustment, repair or part replacement as required. Refer to the

appropriate section for these procedures.

In the mechanical procedures described in this section, generally no references will be made to the removal of

optional equipment such as power steering pump, air conditioning compressor, etc.

Should it become necessary to remove any such item to perform other service, refer to the appropriate section for

specific information.

4.1 EXCESSIVE OIL LOSS

Excessive oil consumption (not due to leaks) is the use of 2 litres or more of engine oil within 10,000 km after the

engine has completed at least 10,000 km.

Excessive oil loss may result from one or more of the following conditions:

1. External oil leaks. Tighten bolts and/or replace gaskets and seals as necessary.

2. Improper reading of oil indicator (dipstick). Check oil with car on a level surface and allow adequate drain-down

time.

3. Continuous high speed driving, and/or severe usage such as towing, will normally cause increased oil

consumption.

4. P.C.V. system malfunctioning.

5. Improper oil viscosity. Use recommended S.A.E. viscosity for prevailing temperatures. Refer to

Section 0B LUBRICATION.

6. Valve guides and/or valve stem seals worn, or seals omitted. Ream guides and install oversize service valves

and/or new valve stem seals.

7. Piston rings improperly installed, broken, worn, or not seated. Allow adequate time for rings to seat. Replace

broken or worn rings as necessary.

8. Piston improperly installed or misfitted.

OIL LEAK DIAGNOSIS

Most oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary

parts. On some occasions, an oil leak may be difficult to locate or repair. The following procedure may help in

locating and repairing most leaks.

FINDING THE LEAK

1. Identify the fluid, determine whether it is engine oil, transmission lubricant, power steering fluid, etc.

2. To determine where the fluid is leaking, run the car at normal operating temperature, park the car over a large

sheet of paper. After a few minutes, the approximate location of the leak should be able to be found by

observing the oil spots on the paper.

3. Visually check around the suspected component. Check all gasket mating surfaces. A mirror may be used to

find leaks in hard to reach areas.

4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or

spray solvent. Operate the car for several kilometres at normal operating temperature and varying speed. After

operating the car, visually check the suspected component. If the location of the leak still cannot be found, try

using the following powder or black light and dye method.

POWDER METHOD

1. Clean the suspected area.

2. Apply an aerosol-type powder (such as foot powder) to the suspected area.

3. Operate the car under normal conditions.

4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.

BLACK LIGHT AND DYE METHOD

Various dye and light kits are available for finding leaks. Refer to the kit manufacturer's directions when using the

kit.

1. Pour specified amount of dye into leaking component.

2. Operate the car under normal operating conditions as directed in the kit.

3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

Techline

REPAIRING THE LEAK

Once the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order

for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the

leak. The bent flange must be repaired also. Before attempting to repair a leak, check to be sure that the following

conditions are correct as they may cause a leak.

GASKETS-INSPECT

1. Fluid level/pressure is too high.

2. Plugged ventilation filter or valve.

3. Improperly tightened fasteners or dirty/damaged threads.

4. Scratches, burrs or other damage to the sealing surface.

5. Warped flanges or sealing surfaces.

6. Damaged or worn gasket.

7. Cracking or porosity of the component.

8. Improper sealant used (where applicable).

SEALS-INSPECT

1. Fluid level/pressure is too high.

2. Plugged ventilation filters, or valve.

3. Damaged seal bore (scratched, burred or nicked).

4. Damaged or worn seal.

5. Improper installation.

6. Cracks in component.

7. Shaft surface scratched, nicked or damaged.

8. Loose or worn bearing causing excess seal wear.

4.2 LOW OIL PRESSURE

Oil pressure that is below 375 kPa at engine speeds above 1850 rpm is considered low and may result from one or

more of the following conditions:

1. Low oil level. Fill to mark on oil level indicator.

2. Incorrect or malfunctioning oil pressure sender or gauge.

3. Improper oil viscosity for expected temperature, or oil diluted with moisture or unburned fuel mixtures.

4. Oil pump worn or dirty.

5. Blocked oil filter.

6. Oil pump suction pipe screen blocked.

7. Hole in oil pump suction pipe.

8. Excessive bearing clearance.

9. Cracked, porous or blocked oil galleries. Repair or replace block.

10. Gallery plugs missing or misinstalled. Install plugs or repair as necessary.

11. Sticking pressure regulator (idle).

4.3 ENGINE NOISE DIAGNOSIS

There are four steps to diagnosing engine noise.

The following should be determined:

1. Type of noise.

2. Under which operating conditions the noise exists.

3. At what rate, and at what location in the engine.

4. Is the noise due to normal operation. Compare the sounds to that in other engines to make sure you are not

trying to correct a normal condition.

Identify the type of noise, for example, a light rattle or low rumble. Determine the exact operating conditions under

which the noise appears.

Engine noises are generally synchronised to either engine speed (caused by the crankshaft, connecting rods or

pistons) or one half the engine speed (valve train noises). Try to determine the rate at which the noise is occurring.

MAIN BEARING NOISE

Damaged or worn main bearing noise is revealed by dull thuds or knocks which happen on every engine revolution,

and this noise is loudest when the engine is under heavy load.

Excessive crankshaft end play is indicated by an intermittent rap or knock sharper than a worn main bearing. Cause

of main bearing noises include:

1. Low oil pump pressure.

2. Thin diluted or dirty oil and/or oil filter.

3. Excessive main bearing clearance.

4. Excessive crankshaft end play.

5. Out-of-round crankshaft journals.

6. Excessive belt tension.

7. Loose crankshaft pulley.

8. Loose flywheel or torque converter.

9. Loose main bearing cap.

CONNECTING ROD BEARING NOISE

A damaged or worn connecting rod bearing will produce a knock under all speeds. During the early stages of wear,

connecting rod noise may be confused with piston slap or loose piston pins. Connecting rod knock noise increase in

volume with engine speed and is at its loudest on deceleration. Cause of connecting rod bearing noise include:

1. Excessive bearing clearance.

2. Worn crankshaft connecting rod journal.

3. Thin, diluted or dirty oil and/or oil filter.

4. Low oil pressure.

5. Crankshaft connecting rod journals out of round.

6. Misaligned connecting rod.

7. Connecting rod bolts not correctly torqued.

8. Wrong bearing inserts or misaligned bearing half.

TIMING CHAIN AND SPROCKETS

Engines equipped with timing chain and sprockets can produce different noises. The most common noise is a high

frequency, light knocking sound. This sound will generally be the same in intensity whether the engine is idling,

operating at high speeds, or under load.

Causes of timing chain and sprocket noises include:

1. Worn timing chain and/or sprockets.

2. Misaligned sprockets.

3. Stretched or damaged timing chain.

4. Worn or faulty timing chain damper.

5. Sprocket loose or improperly seated on shaft.

6. Damaged sprocket.

7. Too much end play in camshaft or crankshaft.

PISTON NOISES

Piston pin, piston and connecting rod noises are difficult to separate. A loose piston pin, for example, causes a

sharp double knock usually heard when the engine is idling, or during sudden acceleration then deceleration of the

engine. A piston pin that has been improperly fitted will emit a light ticking noise that is more noticeable with no load

on the engine.

Excessive piston to cylinder bore clearance will cause piston slap noise. The noise is similar to a metallic knock, as

if the piston were "slapping" the cylinder wall during its stroke. As with most engine noises, understanding the cause

of the noise will help you imagine what the noise sounds like. An indication of piston slap is a decrease in noise as

the engine warms up. When the engine is cold, the piston to bore clearance is greater and piston slap will be louder.

Causes of piston noises include:

1. Worn or loose piston pin or bushing.

2. Improper fit of pin.

3. Excessive piston to cylinder bore clearance.

4. Lack of lubrication.

5. Carbon deposits on top of piston striking cylinder head.

6. Worn or broken piston ring land.

7. Broken or cracked piston.

8. Misaligned connecting rods.

9. Worn or damaged rings.

10. Worn or out-of-round cylinder walls.

11. Excessive ring land clearance.

12. Insufficient ring end gap clearance.

13. Piston 180 degrees out of position.

14. Incorrect piston cam grind.

VALVE TRAIN

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

noises increase with engine speed.

Before attempting to judge valve train noises, thoroughly warm up engine. By doing this you will bring all engine

components to a normal state of expansion. Also run the engine at various speeds and listen for engine noise with

the hood closed while sitting in the drivers seat.

If the valve mechanism is abnormally noisy, remove rocker arm covers and use a stethoscope to determine which

valves or valve train parts are causing the noise.

Valve train noises may be caused by one or more of the following:

1. Broken or weak valve springs.

2. Sticking or warped valves.

3. Bent push rods.

4. Dirty, stuck or worn valve lifters.

5. Damaged or improperly machined camshaft lobes.

6. Insufficient or poor oil supply to valve train (low oil pressure).

7. Excessive valve stem to guide clearance.

8. Worn valve guides.

9. Worn push rods.

10. Worn rocker arms.

11. Broken rocker arm stud.

12. Loose or worn rocker arm attachments.

13. Missing or mis-positioned lifter guides.

4.4 ENGINE KNOCK DIAGNOSIS

KNOCKS WHEN ENGINE COLD AND CONTINUES FOR TWO OR THREE MINUTES

Increases with torque

1. Loose or broken balancer or drive pulleys. Tighten or replace as necessary.

2. Excessive piston to bore clearance. Replace piston.

Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock which

disappears in 1.5 minutes should be considered acceptable.

3. Bent connecting rod.

4. Rod bearing; oil supply at start-up.

HEAVY KNOCK HOT WITH TORQUE APPLIED

This condition may be caused by one or more of the following:

1. Broken balancer or pulley hub. Replace parts as necessary.

2. Loose torque converter to flexplate attaching bolts.

3. Exhaust system contacting underbody. Reposition as necessary.

4. Flywheel/flexplate cracked.

5. Excessive main bearing clearance.

6. Excessive connecting rod bearing clearance.

7. Low fuel quality.

LIGHT KNOCK HOT

This condition may be caused by one or more of the following:

1. Detonation or spark knock. Check fuel quality.

2. Loose torque converter to flexplate attaching bolts.

3. Exhaust leak at manifold.

4. Excessive connecting rod bearing clearance.

KNOCKS ON INITIAL START-UP BUT ONLY LASTS A FEW SECONDS

This condition may be caused by one or more of the following:

1. Improper oil viscosity . Use proper oil viscosity for expected temperatures. Refer to

Section 0B LUBRICATION.

2. Hydraulic lifter bleed down.

When the engine is stopped, some valves will be open. Spring force against lifters will tend to bleed lifter down.

Attempts to repair should be made only if the problem is consistent.

3. Excessive crankshaft end float. Replace crankshaft thrust bearing shells.

4. Excessive front main bearing clearance. Replace worn parts.

5. Excessive piston or rod clearance. Replace worn parts.

6. Timing chain tensioner malfunction. Clean, inspect and replace if required.

KNOCKS AT IDLE, ENGINE HOT

This condition may be caused by one or more of the following:

1. Loose or worn drive belt. Check tension and/or replace as necessary .

2. Air conditioning compressor or generator bearing noisy. Replace as necessary.

3. Worn valve train components. Replace parts as necessary.

4. Improper oil viscosity . Use proper viscosity oil for expected temperature. Refer to Section 0B LUBRICATION.

5. Excessive piston pin clearance. Replace piston and pin.

6. Connecting rod alignment. Check and replace rods as necessary.

7. Insufficient piston to bore clearance. Hone bore and fit new piston.

8. Loose crankshaft balancer. Torque retaining bolt and/or replace worn balancer.

9. Piston pin offset to wrong side. Install piston correctly.

VALVE TRAIN NOISE

This condition may be caused by one or more of the following:

1. Low oil pressure. Repair as necessary (refer to diagnosis for low oil pressure).

2. Loose rocker arm attachments. Inspect and repair as necessary.

3. Worn rocker arm, pivot, and/or pushrod.

4. Broken valve spring.

5. Sticking valves.

6. Lifters worn, dirty, or defective.

7. Camshaft worn, or faulty machining. Replace camshaft.

8. Worn valve guides.

4.5 HYDRAULIC VALV E LIFTERS

Hydraulic valve lifters seldom require attention. The lifters are extremely simple in design, readjustments are not

necessary and servicing of the lifters requires only that care and cleanliness be exercised in the handling of parts.

The easiest method for locating a noisy valve lifter is by use of a piece of garden hose near the end of each inlet

and exhaust valve with the other end of the hose to the ear.

In this manner, the sound is localised, making it easy to determine which lifter is at fault.

Another method is to place a finger on the face of the valve spring retainer. If the lifter is not functioning properly, a

distinct shock will be felt when the valve returns to its seat.

The general types of valve lifter noise are as follows:

1. Momentary noise when car is started:

This condition is normal. Oil drains from the lifters which are holding the valves open when the engine is not

running. It will take a few seconds for the lifter to fill after the engine has started.

2. Intermittently noisy on idle only, disappearing when engine speed is increased:

Intermittent clicking may be an indication of a flat or pitted ball, or it may be caused by dirt.

Correction: Clean the lifter and inspect. If ball is defective, replace lifter.

3. Noisy at slow idle or with hot oil, quiet with cold oil or as engine speed is increased:

Insert a 0.375 mm feeler gauge between the rocker arm and valve stem. If noise momentarily disappears and

then re-appears after a few seconds, the lifter leak-down rate is too fast.

Correction: The lifter must be replaced.

4. Noisy at high car speeds and quiet at low speeds.

a. High oil level. Oil level above the FULL mark allows crankshaft counterweights to churn the oil into foam.

When foam is pumped into the lifters, they will become noisy since a solid column of oil is required for

proper operation.

Correction: Drain oil until proper level is obtained.

b. Low oil level. Oil level below the ADD mark allows the pump to pump air at high speeds which results in

noisy lifters.

Correction: Fill until proper oil level is obtained.

c. Oil pan bent on bottom or oil suction screen and pipe loose, repair or replace as necessary.

5. Noisy at idle becoming louder as engine speed is increased to 1500 rpm.

a. This noise is not connected with lifter malfunction and is caused by one or more of the following:

- Badly worn or scuffed valve tip and rocker arm pad.

- Excessive valve stem to guide clearance.

- Excessive valve seat run-out.

- Off square valve spring.

- Off square rocker arm pad.

- Excessive valve face run-out.

- Valves noisy regardless of engine speed.

This condition can be caused by foreign particles or valve lash.

Check for lash by turning engine so the piston in that cylinder is on top dead centre of firing stroke. If valve lash

is present, the pushrod can be freely moved up and down a certain amount with rocker arm held against valve.

If this occurs, replace suspected valve lifters

Valve lash indicates one of the following:

a. Worn pushrod.

b. Worn rocker arm.

c. Lifter plunger stuck in down position due to dirt or carbon.

d. Faulty lifter.

When checking the above items

1. Look at the upper end of pushrod. Excessive wear of the spherical surface indicates one of the following

conditions:

a. Improper hardness of pushrod ball. The pushrod and rocker arm must be replaced.

b. Improper lubrication of pushrod and rocker arm. The oiling system to the pushrod should be checked.

2. If pushrod appears in good condition and has been properly lubricated, replace rocker arm and recheck for

valve lash.

3. If valve lash exists and pushrod and rocker arm are OK, trouble is in the lifter. Lifter should be replaced.

5. SPECIFICATIONS

GENERAL

Engine Model Year 1997

Type 90 degree V6, OHV

Displacement 3791 cc

Compression ratio 9.35:1

Number of cylinders 6

Firing order 1-6-5-4-3-2

Cylinder numbering-front to rear

Left bank 1-3-5

Right bank 2-4-6

Taxable horsepower (RAC or SAE) 34.6

Power - kilowatts 147 @ 5200 rpm

Torque - Newton meters 304 @ 3600 rpm

Bore and stroke (nominal) 96.52 x 86.36 mm

Fuel research octane rating 91

Fuel requirement Unleaded

CYLINDER BLOCK

Bore diameter 96.507 - 96.533 mm

Bore out-of-round 0.010 mm max.

Bore taper 0.013 mm max.

Cylinder block to cylinder head surface

flatness 0.08 mm max. overall or

0.13 mm per 25.4 mm

Crankshaft bearing bore maximum out-of-

round 0.08 mm

Camshaft bearing bore maximum out-of-

round 0.013 mm

CRANKSHAFT

Material Cast Nodular Iron

Main bearing journals

Diameter 63.470 - 63.495 mm

Out-of-round 0.08 mm max.

Taper 0.08 mm max.

Cylinder block bore 68.250 - 68.270 mm

Crankshaft end clearance 0.08 - 0.28 mm

Bearing clearance 0.023 - 0.053 mm

End thrust Against main bearing No. 2

Connecting rod journals

Diameter 57.117 - 57.147 mm

Out-of-round 0.08 mm max.

Taper 0.08 mm max.

Connecting rod bore 60.295 - 60.312 mm

Bearing clearance 0.023 - 0.053 mm

Side clearance 0.10 - 0.50 mm

Crankshaft rear flange run-out 0.05 mm max.

CONNECTING RODS

Type Malleable Cast Iron 'I' Section

Length (centre to centre) 145.90 - 145.80 mm

Alignment Bend 0.020/25.4 mm,

Twist 0.038/25.4 mm

PISTONS

Material Cast Aluminium Alloy

Piston diameter (45.7 mm from top of

piston) 96.482 - 96.497 mm

Piston to bore clearance 0.010 - 0.051 mm

Piston pin bore offset and direction 0.25 - 0.55 mm, Major thrust side

Piston and pin assemblies serviced Std and 0.508 Oversize

Ring groove widths

Compression ring upper 1.230 - 1.255 mm

Compression ring lower 1.530 - 1.555 mm

Oil control ring 2.030 - 2.055 mm

PISTON PINS

Material Steel - Case Hardened

and Tempered

Length 65.0 - 65.5 mm

Diameter 21.995 - 22.000 mm

Pin to piston clearance 0.002 - 0.013 mm

Pin to rod clearance 0.007 - 0.022 mm

PISTON RINGS

Compression ring upper

Type Steel, Balanced Section

Molybdenum Filled, Barrel Lapped.

Width 1.176 - 1.191 mm

Gap 0.305 - 0.559 mm

Piston ring to groove clearance 0.039 - 0.079 mm

Compression ring lower

Type Inverted Torsional Taper Faced Type

Width 1.476 - 1.491 mm

Gap 0.762 - 1.016 mm

Piston ring to groove clearance 0.039 - 0.079 mm

Oil control ring type Segmented with Circumferential -

Expander Type Spacer

Width (ring assembly) 1.854 - 2.007 mm

Ring assembly to groove clearance 0.023 - 0.201 mm

Rail gap 0.254 - 0.762 mm

CAMSHAFT

Material 5150 Steel

Bearing journal

Diameter 46.858 - 46.893 mm

Number 4

Bearing diameter (installed)

Numbers 1 and 4 46.934 - 46.970 mm

Numbers 2 and 3 46.942 - 46.977 mm

Clearance in bearings

Numbers 1 and 4 0.041 - 0.112 mm

Numbers 2 and 3 0.049 - 0.119 mm

Camshaft end float (gear and bolt installed) 0.04 - 0.26 mm

Camshaft lobe lift

Inlet 6.56 mm

Exhaust 6.48 mm

Valve timing

Inlet

Opens - BTC 29.5 degrees

Closes - ABC 115 degrees

Duration 324.5 degrees

Exhaust

Opens - BBC 76.5 degrees

Closes - ATC 78.5 degrees

Duration 335 degrees

CYLINDER HEAD

Thickness (refer Fig 6A1-1-101 in this

Section) 1.12 mm minimum

Minimum combustion chamber volume

(with valves and spark plugs installed) 60 cc

VALVE - INLET

Material High Manganese Medium

Carbon Steel

Diameter head 45.59 - 45.85 mm

Diameter stem 7.955 - 7.968 mm

Angle valve face 45 degrees

Angle valve seat (in head) 45 degrees

Width valve seat (in head) 1.78 mm

Valve seat run-out 0.05 mm

Clearance in guide 0.04 - 0.25 mm

Valve installed height 49.22 - 50.49 mm

(from valve tip to spring seat)

Valve head margin thickness 0.63 mm minimum

Valve oversize available 0.25 mm

VALVE - EXHAUST

Material High Alloy Exhaust Valve Steel

Diameter head 38.48 - 38.74 mm

Diameter stem 7.948 - 7.965 mm

Angle valve face 45 degrees

Angle valve seat (in head) 45 degrees

Width valve seat (in head) 2.16 mm

Valve seat run-out 0.05 mm

Clearance in guide 0.04 - 0.25 mm

Valve installed height 49.22 - 50.49 mm

(from valve tip to spring seat)

Valve head margin thickness 0.63 mm minimum

Valve oversize available 0.25 mm

VALVE SPRINGS

Valve spring force

At assembled height 316 - 351 N @ 43.7 mm

At valve opened height 970 - 1059 N @ 32.4 mm

Valve spring at installed height 43.7 ± .5 mm

Valve spring allowable variance in

spring end length 1.6 mm

BALANCE SHAFT

End play 0 - 0.203 mm

Front radial play 0 - 0.028 mm

Rear bush clearance 0.025 - 0.130 mm

Drive gear lash 0.050 - 0.127 mm

Front bearing bore diameter 51.973 - 51.999 mm

Rear bearing inside diameter 38.12 - 38.19 mm

Installation depth of rear bearing from

rear seal cover mounting face 0.99 - 1.49 mm

FLEXPLATE

Flexplate Run out 0.38 mm

TIMING CHAIN

Timing chain movement 25.4 mm max.

LUBRICATION SYSTEM

Type of lubrication

Main bearings Pressure

Connecting rod bearings Pressure

Piston pins Splash

Camshaft bearings Pressure

Timing chain Splash

Balance shaft front bearing Splash

Balance shaft rear bearing Pressure

Cylinder walls Splash

OIL PUMP

Oil pump type Gerotor

Oil pressure regulator Approx 414 kPa

Oil pressure hot 375 kPa minimum @ 1850 RPM and

above

Oil filter by-pass valve Unseats at approx. 69 kPa pressure

differential

Oil pump gears

Inner gear tip to outer gear clearance 0.22 mm max.

Outer gear to housing clearance 0.05 - 0.13 mm max.

Inner and outer gear end to housing

clearance 0.025 - 0.089 mm

Gear Pocket

Depth 9.89 - 9.92 mm

Diameter 88.70 - 88.75 mm

Pressure regulator valve to bore clearance 0.038 - 0.076 mm

Oil pressure warning

Switch setting contacts open (light off) Less than 41.4 kPa (pressure

increasing)

Switch setting contacts close (light on) More than 13.8 kPa (pressure

decreasing)

Oil pan capacity (less filter) 4.5 litres

Oil filter

Type Full flow disposable canister

Capacity 0.3 litres

SEALANTS

Inlet manifold front and rear seal corners RTV 732 Holden Specification

HN 1373

Cylinder block coolant welsh plugs Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Right and left hand knock sensors to

cylinder block Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Oil gallery plug at lower front right hand

side of cylinder block Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Two oil gallery welsh plugs at frontface of

cylinder block Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Three idler pulley mounting studs into front

left hand side of cylinder block Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Oil pressure switch into oil filter adaptor Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Coolant temperature sender units to lower

inlet manifold Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Brake booster vacuum fitting to upper inlet

manifold Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Front cover to cylinder block attaching bolt

threads Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Cylinder head bolt threads Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Alternator brace bracket front bolt into right

hand cylinder head Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Plug into left hand cylinder head on inlet

manifold mounting face Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Inlet manifold to cylinder head bolts Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Oil suction pipe attaching bolt threads Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Oil filter adaptor long bolt threads Loctite 242 Holden Specification

HN 1256 Class 2, Type 2

Main bearing cap side bolts Recommend replacement with new

bolts, to ensure bolt under head

sealing to cylinder block

Four corners of oil pan to cylinder block Permatex “the Right Stuff”

LUBRICANTS

Engine internal components during

overhaul (unless specified) SG or SH Quality Engine Oil

Camshaft lobes Lubrizol 6612 Holden Specification

HN 1961

Hydraulic valve lifters and bores Lubrizol 6612 Holden Specification

HN 1961

Pushrod contact surfaces Lubrizol 6612 Holden Specification

HN 1961

Oil pump gears and pump cavity Petroleum Jelly

Techline

6. TORQUE WRENCH SPECIFI CATIONS

Engine Dress cover 4 - 6

Coil Securing Screws 4 - 5

Idler pulley housing/coil mounting bolts to

cylinder head 40 - 50

Idler pulley bolt 40 - 50

Crank Angle Sensor to Front Cover

Attaching Studs 20 - 30

Crankshaft Balancer Attaching Bolt 270 - 325

Camshaft Sprocket Bolt 90 - 110 Nm plus

86 - 94 degree turn angle

Camshaft Thrust Plate to Cylinder Block

Attaching Bolt 12 - 18

Camshaft Position Sensor to Front Cover

Attaching Bolt 8 - 12

Balance Shaft Retainer Bolts 26 - 34

Balance Shaft Driven Gear Retaining Bolt 18 - 26 Nm plus

67 - 73 degree turn angle

Connecting Rod Cap Bolts 24 - 30 Nm plus

47 - 53 degree turn angle

Coolant Temperature Sender 8 - 12

Coolant Temperature Sensor 18 - 12

Brake booster vacuum fitting to upper inlet

manifold 11 - 14

Main Bearing Cap Bolts Refer to 3.12

CRANKSHAFT in this

Section

Main Bearing Cap Side Bolts 12 - 18 Nm plus

42 - 48 degrees turn angle

Rear Main Oil Seal Housing bolts 12 - 18 Nm plus

47 - 53 degrees torque turn.

Refer torquing sequence.

Knock Sensors to Cylinder Block 16 - 22

Knock Sensor Shield to cylinder block bolt

Right Hand Side 40 - 45

Knock Sensor Shield Bracket to cylinder

block Left Hand Side 20 - 27

Knock Sensor Shield to Bracket Left Hand

Side 8 -10

Cylinder Head Bolts Refer to 2.15 CYLINDER

HEADS in this Section

Exhaust Manifold to Cylinder Head Studs

and one bolt 25 - 35

Exhaust Manifold Stud Lock Nuts 20 - 27

Engine Pipe to Manifold Nuts 18 - 35

Flywheel/Flexplate Attaching Bolts Refer to 3.4 FLYWHEEL /

FLEXPLATE in this Section

Front Cover Attaching Bolts/Studs 20 - 30

Fuel Rail to Inlet Manifold Bolts 8 - 11

Lower Inlet Manifold Attaching Bolts 12 - 18 refer 2.9 LOWER

INLET MANIFOLD torquing

sequence

Upper to Lower Inlet Manifold Bolts 10 - 14

Inlet Manifold Cover Bolts 8 - 11

Oil Filter Adaptor to Front Cover Attaching

Bolts 23 - 35

Oil Pressure Sender Unit 12 - 14

Rocker Cover Fasteners 7 - 11

Rocker Arm Pedestal Bolts 11 - 19 Nm plus 87 - 93

degree turn angle.

Valve Lifter Guide Retaining Bolts 26-34

Water Pump to Front Cover Attaching Bolts 12 - 18 Nm plus

76 - 84 degrees angle turn

Water Inlet Tube to Belt Tensioner Stud

Nut 18 - 25

Oil Pump Cover Screws 8 - 14

Timing Chain Dampener Attaching Bolt 16 - 28

Starter Motor Attaching Bolts 36 - 50

Oil Pan Attaching Bolts 8 - 12

Oil Pan Drain Plug 30 - 60

Oil Pump Suction Pipe Flange to Cylinder

Block Bolts 8 - 12

Clutch Pressure Plate to Flywheel Bolts 20 - 30

Water Pump Pulley Bolts 10 - 16

Belt Tensioner Attaching Studs 40 - 60

Lower Belt Idler Housing Mounting Nuts

(Air Conditioning only) 20 - 30

Lower Idler Pulley Bolt (Air Conditioning

only) 40 - 50

Coolant Outlet to Inlet Manifold Bolts 20 - 34

Canister Purge Solenoid Bracket Attaching

Bolts 15 - 20

Upper Left Hand Side Screw

Plug (Cylinder block front face) 25 - 35

Oil Gallery Screw Plug (Front right hand

side cylinder block) 22 - 28

Throttle Cable Support Mounting Nuts 6 - 14

Throttle Cable Support Bracket Stud into

Manifold 20 - 25

Throttle Body Attaching Nuts 15 - 20

Front Engine Mount to Mounting Bracket

and Front Crossmember Attaching Nuts 36 - 65

Front Mounting Bracket to Cylinder Block

Attaching Bolts 35 - 65

Air Conditioning Compressor to Mounting

Bracket Bolts 35 - 65

Engine Rear Mounting to Rear Adaptor

Nuts 35 - 65

Engine Rear Mounting to Rear Extension

Bolt s (A/Trans) 50 - 65

Rear Crossmember to Side Frame Bolts 50 - 65

Cross Member to Rear Mounting Nuts 20 - 30

Clutch Housing to Beaming Brace Bolts 15 - 20

Beaming Brace to Torque Converter

Housing Bolts 15 - 20

Beaming Brace to Oil Pan Bolts 3 - 5

Battery Harness Retaining Bracket to Oil

Pan Bolt 3 - 5

Oil Cooler Line Retainer to Oil Pan Bolt 3 - 5

Generator Brace Bracket to Cylinder Head

Bolt 40 - 60

Spark Plugs 15 - 25

Harness mounting bracket to lower 5 - 10

manifold bolt

EGR Valve adaptor to head bolts 40 - 60

EGR Valve adaptor to exhaust manifold nut 20 - 30

EGR Valve to adaptor attaching nuts 20 - 27

EGR Pipe outlet to adaptor attaching bolt 25 - 35

7. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

6A22-2 SPIGOT BEARING REMOVER ALTERNATIVELY, USE J23907

OR E6668 WHICH INCLUDES

ITS OWN SLIDE HAMMER

6A23 VALVE LIFTER TESTER USED IN CONJUNCTION WITH

TESTING FLUID KENT MORE

NO. E1151

(PREVIOUSLY 361-1-93)

6A24 HYDRAULIC VALVE LIFTER ASSEMBLY

TOOLS

6A40A AIR LINE ADAPTOR - 14MM (CYLINDER

INFLATOR)

7370 QUICK CONNECT RELEASE TOOL USED FOR RELEASING THE

FUEL RETURN HOSE QUICK

CONNECTS AT THE DASH

PANEL AND FUEL RAIL

CONNECTIONS ONCE THE

FUEL SYSTEM HAS BEEN

DEPRESSURISED

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

AU354 SLIDE HAMMER USED IN CONJUNCTION WITH

6A22-2 TO REMOVE SPIGOT

BEARING. TO REMOVE REAR

BEARING CAP, TWO AU354’S

MUST BE USED.

AU384-B PULLER SCREW USED IN CONJUNCTION WITH

AU384-2, AU384-3, AU384-4,

AU384-7 AND AU384-6A

AU388 CONNECTING ROD GUIDE TOOLS USED IN CONJUNCTION WITH

AU388-1 AND AU388-2

AU424 CRANKSHAFT BALANCER PULLER

AU448 CRANKSHAFT BALANCER HOLDING

TOOL

BT3373-F BELT TENSION GAUGE

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

E1409 REAR MAIN SEAL HOUSING ALIGNING

TOOL

E308 SEAL REMOVER

E7115 ANGLE WRENCH USED TO TIGHTEN

COMPONENT FASTENERS

WHEN ANGLE TORQUE IS

REQUIRED.

J25359-8 TORX BIT HOLDER USED WITH ETX30H TORX BIT

J28540-A SEAL INSTALLER

J38196 SEAL INSTALLATION TOOL

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J38196-AUS MANDREL COLLAR

J41348 MAIN BEARING CAP PULLER USED IN CONJUNCTION WITH

J6125-B

J41349 REAR MAIN HOUSING ALIGNING TOOL

J41512 VALVE STEM INSTALLATION TOOL

J6125-B SLIDE HAMMER USED TO REMOVE INNER

AXLE SHAFTS FROM THE

FINAL DRIVE ASSEMBLY.

USED IN CONJUNCTION WITH

J41348

J8080 BEARING REMOVER AND INSTALLER

KD2078 VALVE SPRING COMPRESSOR