SECTION 6A3 - ENGINE MECHANICAL -

GEN III V8 ENGINE

CAUTION:

This v ehicle will be equipped with a Supplemental Restraint System (SRS). An SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air bags or seat belt pre-tensioners, driver’s and front passen ger’s air bag and lef t and right

hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M , Supplemental Restraint System of the

VT Series I Service Information before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service

Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as

detailed in 4. DIAGNOSIS, ABS or ABS/ET C FUNCTION CHECK, in Section 12L ABS & ABS/ET C, in either

VT Series I Service Information (V6 Engine) or 12L ABS & ABS/ETC of the VT Series II Service Information

(GEN III V8 Engine).

1. GENERAL DESCRIPTI ON

The 1999 Model Year 5.7 litre, GEN III, V8 engine ( produc tion option LS1) , is a 90°, V8, overhead valve des ign with

a bore of 99.00 mm and stroke of 92.00 mm. Displacement is 5,667 cm3 and compression ratio is 10.1:1.

Engine features include an aluminium cylinder block and heads, with cast iron sleeves cast into the cylinder block

during production. F our ‘torque to yield’ cylinder head bolts per cylinder have their thread boss es located deep into

the cylinder block to m inim ise distortion at the top of the bore. T he deep s kirt cylinder block also f eatures five m ain

bearings with each cap being secured by six bolts.

Powdered metal valves guides and seats are fitted to each cylinder head. The connecting rods are also

manufactured from forged powdered metal and the rodcap is separated during the manufacturing process, using

the ‘fractured’ method. This creates a stronger, visually seamless rod to cap union.

The five bearing camshaft is machined from 5150 steel billet and is drilled through the centre to reduce weight. A

reluctor ring for the cam position sensor is located between the fourth and fifth bearing journals.

The crank shaft is m anufactur ed from nodular cast iron and is dr illed through the centre of m ain bearing journals 2,

3, 4, and 5, also to reduce weight. A reluctor wheel is installed onto the rear of the crankshaft for the crankshaft

position sensor.

The firing order of 1-8-7-2-6-5-4-3, assists in achieving a smoother engine operation.

Techline

Figure 6A3-1

Figure 6A3-2 - Lower Front of Engine

Legend

1. Tube - Oil Level Indicator 18. Oil Seal - Crankshaft Front

2. O-ring Seal - Oil Lever Indicator Tube 19. Balancer - Crankshaft

3. Bolt - Valve Lifter Guide 20. Bolt - Crankshaft Balancer

4. Guide - Valve Lifter 21. Bolt - Engine Front Cover

5. Lifter - Valve 22. Camshaft

6. Engine Block 23. Retainer - Camshaft

7. Oil Seal - Crankshaft Rear 24. Sprocket - Camshaft

8. Bolt - Engine Rear Cover 25. Locating Pin - Camshaft Sprocket

9. Cover - Engine Rear 26. Bolt - Camshaft Sprocket

10.Gasket - Engine Rear Cover 27. Bolt - Camshaft Retainer

11.Plug - Engine Block Rear Oil Gallery 28. Bearings - Camshaft

12.Crankshaft Sprocket 29. Coolant Pump

13.Chain - Camshaft Timing 30. Bolt - Coolant Pump

14.Oil Pump Assembly 31. Gaskets - Coolant Pump

15.Bolt - Oil Pump Assembly 32. Indicator - Oil Level

16.Gasket - Engine Front Cover 33. Bolt - Oil Level Indicator Tube

17.Engine Front Cover

Figure 6A3-3 - Lower Engine Assembly

Legend

1. Bolt - Camshaft Position Sensor 17. Baffle - Oil Pan 33. Adaptor - Oil Filter

2. Cams haf t Position Sensor 18. Tube - Oil Transfer 34. Oil Filter

3. Sensor - Oil P ressure 19. Gasket - Oi l Transfer Tube 35. Plug - Drain

4. Engine Block 20. Gasket - Oi l P an 36. Bolt - Crank shaft B eari ng Cap Side

5. Pist on Rings 21. Bolt - E ngi ne Fl ywheel/F l explate 37. Caps - Cranks haft Main Bearing

6. Piston and Connecti ng Rod A ss’y 22. Bolt - Oi l P an Cl oseout Cover (RHS) 38. Stud - Main Beari ng Cap

7. Connecting Rod Bearings 23. Cover - Oil Pan Closeout (RHS) 39. Bolt - Main B eari ng Cap

8. Connecting Rod Cap 24. Cover - Oil Pan Closeout (LHS) 40. Bearings - Crankshaft Main

9. Bolt - Connecting Rod 25. Bolt - Oi l P an Cl oseout Cover (LHS) 41. Bearings - Crankshaft Main Thrust

10. Crankshaf t Oil Deflector 26. Plug - Oil P an Gal l ery 42. Plug - Rear Crankshaft

11. Engine Flywheel (Man. Trans.) 27. Bolt - Oil P an Transfer Tube 43. Bush - Manual Transmis sion Spigot

12. Engine Flexplate (Aut o. Trans.) 28. Oil Pan 44. O-Ring Seal - Oil Pump P i ck-up

13. Screen and Pi pe - Oi l P ump Pi ck-up 29. Gasket - Oi l Transfer Cover 45. Crankshaft

14. Screw - Oil Pump Pick-up to Pump 30. Cover - Oil Transf er 46. Key - Cranks haft Sproc ket

15. Nut - Oil Defl ector and Oil Pump P i ck-up 31. Nut - Oil Trans f er Cover 47. Plug - Engine Block Front Oi l Gal l ery

16. Bolt - Oil Pan Baff l e 32. Valve - Oil B ypas s 48. Plug - Cyli nder B l ock in Unused Hole

Figure 6A3-4 - Cylinder Head/Upper Engine

Legend

1. Bolt - Valve Rocker Arm Cover 16. Pushrod

2. Grommet - Valve Rocker Arm Cover 17. Sensor - Coolant Temperature

3. Bolt - Cylinder Head (Short) 18. Bolt - Valve Rocker Arm

4. Bolt - Cylinder Head (Medium) 19. Arm - Valve Rocker

5. Cylinder Head 20. Support - Valve Rocker Arm Pivot

6. Bolt - Cylinder Head (Long) 21. Gasket - Cylinder Head

7. Collets - Valve Stem Keys 22. Gasket - Valve Rocker Arm Cover

8. Cap - Valve Spring 23. Cover - Valve Rocker Arm

9. Spring - Valve 24. Tube - Oil Fill

10.Oil Seal - Valve Stem 25. Cap - Oil Fill Tube

11.Shim - Valve Spring 26. Assembly - Ignition Coil and Bracket

12.Valve 27. Stud - Ignition Coil Bracket Assembly

13.Gasket - Exhaust Manifold 28. Screw - Ignition Coil Bracket Assembly. Rear on each side

14.Manifold - Exhaust 29. Bolt - Exhaust Manifold

15.Bolt - Exhaust Manifold Heat Shield

Figure 6A3-5 - Intake Manifold/Upper Engine

Legend

1. Stud - Fuel Rail 13. Oil Seal - Knock Sensor

2. Fuel Rail (with Injectors) 14. Knock Sensor

3. Bracket - Fuel Rail Stop 15. Knock Sensor Wire Harness

4. Gasket - Throttle Body 16. Hose - Vapour Vent Tube

5. Bolt - Intake Manifold 17. Stud - Vapour Vent Tube

6. Gaskets - Intake Manifold 18. Vapour Vent Tube

7. Intake Manifold 19. Gasket - Vapour Vent Tube

8. Throttle Body 20. Bolt - Vapour Vent Tube

9. Bolt - Throttle Body 21. Bracket - Engine Dress Cover, Right Hand Side

10.Gasket - Valley Cover 22. Nut - Engine Dress Cover Bracket

11.Valley Cover 23. Bracket - Engine Dress Cover, Left Hand Side

12.Bolt - Valley Cover

1.1 ENGINE SERIAL NUMBER

The engine number is stamped on the right hand

side front of the engine cylinder block, as shown.

The number is prefixed by the letters ‘VF’.

A breakdown of the engine numbering system,

using and example of ‘VF991524500’, is;

• First two numbers (‘99’) indicates the engine

model year.

• Next three numbers (‘152’) is the Julian date

(day of the year), the engine was

manufactured.

• Next four numbers are the daily, sequential

build number.

Figure 6A3-6

1.2 ENGINE CONSTRUCTION

CYLINDER BLOCK

The engine cylinder block is a cam-in-block, deep

skirt, 90° ‘V’ configuration with five crankshaft

bearing caps, manufactured from forged powdered

metal. The engine block is aluminium with cast in

place, cast iron cylinder bore liners. The f ive cr os s-

bolted crankshaft bearing caps each have four

vertical M10 (2, 3, 4, and 5) and two horizontal M8

(1 and 6) mounting bolts. Only cylinder honing is

permitted.

The c rankcas e s k ir t length, bear ing cap width, deck

width and upper rails have been optimised for

strength, using finite element analysis.

The camshaft is supported by five camshaft

bearings pressed into the block.

Figure 6A3-7

The cylinder block incorporates enclosed valve

lifter bores (2) under each cylinder head, that

results in a more stiff structure with quiet operation.

Utilising a struct ural die c as t aluminium valley cover

(1), ties both cylinder banks together, increasing

the block’s torsional and bending frequencies.

Having a closed valley area also prevents hot oil

from contacting the lower surface of the intake

manifold, allowing cooler air to enter the cylinders.

Overall, the cylinder block cons truction weighs 48%

less than an equivalent cast iron block and the

structural design features, coupled with the

inherently light cylinder heads, combine into an

engine with unique stiffness and light weight.

T6A3008

Figure 6A3-8

CYLINDER HEADS

The cylinder head assemblies are cast aluminium

and have pressed in place, powdered metal valve

guides and valve seats.

Intake and exhaust ports are identical for each

cylinder, ensuring a balanced air-flow distribution

for balanced combustion, resulting in a smoother

running engine.

The cylinder head is attached using a four bolt per

cylinder, deep threaded arrangement for minimal

bore distortion, allowing low friction pistons and

rings for reduced fuel consumption.

Cylinder head gaskets are made of a steel core

between layers of graphite and features stainless

steel PTFE coated flanges and lacing. Cylinder

head gaskets are unique for right and left hand

sides with preferential coolant flow.

Legend

1. Cylinder Head

2. Valve Stem Collets

3. Valve Spring Cap

4. Valve Spring

5. Valve Stem Oil Seal

6. Valve Spring Shim

7. Cylinder Head Core Plugs

8. Exhaust Valve

9. Intake Valve Figure 6A3-9

The intake ports are very tall, which enhances fuel

injector targeting. As air flows down to the valve

guide, it widens and shortens to the size of the

intake valve seat.

Figure 6A3-10

VALVE TRAIN

Motion is transmitted from the camshaft through

the hydraulic roller valve lifters and tubular

pushrods to the rocker arms. The valve lifter

guides position and retain the roller hydraulic valve

lifters. The valve rocker arms for each bank of

cylinders are mounted on pedestals (pivot

supports) . Eac h ro cker ar m is retained on the pivot

support and cylinder head by a bolt. Valve lash is

adjusted automatically each cycle by the hydraulic

valve lifters.

Both valves are angled at 15° to the cylinder bore

centreline, which creates a shallow combustion

chamber and a flat top piston, creating a

compression ratio of 10.1:1.

Both the exhaust and intake valve seat angles are

45° with an intake valve head diameter of 50.8 mm

and exhaust of 39.4 mm.

Valve springs ar e conical or ‘beehive’ in s hape and

made from chromium Silicone wire. The springs

are double shot peened to provide maximum

reliability. The reduced diameter end coils allows a

smaller diameter, lower mass, steel spring retainer

to be used, with single bead, valve stem k eys. T his

spring design also reduces spring mass and,

coupled with the increased stiffness in the valve

train, results in a reduction in the valve spring pre-

load, thereby reducing friction and valve train noise.

The roc k er arm s are m ade of investm ent cast steel

and have a ratio of 1.7:1, that allows a lower cam

lobe lift, resulting in lower valve train loading and

less noise.

The valve rocker arm covers are cast aluminium

and use a pre-moulded silicone gasket for sealing.

Mounted to each rocker cover are four individual

ignition coils. Incorporated into the covers are the

oil fill tube, the Positive Crankcase Ventilation

(PCV) system passages, and the engine fresh air

passages.

Figure 6A3-11

CRANKSHAFT

Manufactured from cast nodular iron, the

crankshaft (1) is supported by five crankshaft

bearings and are retained by 6 bolt crankshaft

bearing caps. The main bearing caps are machined

with the engine block for the proper alignment and

clearance.

A 24X crankshaft position reluctor ring (2) is

mounted at the r ear of the num ber eight crank shaf t

counter weight. The reluctor ring is not serviced

separately.

Crankshaft thrust is taken by the centre (No. 3)

main bearing. This location is used to reduce the

expansion differences between the cast iron

crankshaft and the aluminium cylinder block.

By adopting a firing order of 1, 8, 7, 2, 6, 5, 4, 3,

crank throw stresses are reduced and main bearing

performance is improved.

The crankshaft has a drilled 25.4 m m hole through

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

from a reduction in crankshaft weight, this also

achieves engine breathing enhancement at low

speeds.

Figure 6A3-12

A variable radii undercut increases the effective

bearing widths by 0.4 m m eac h side (A), com pared

to a uniform undercut and rolled fillets are utilised

for improved fatigue strength.

Figure 6A3-13

PISTONS AND CONNECTING RODS

The pistons are cast aluminium and have two

compression rings and one oil control ring

assembly fitted. Piston rings are of a thin, low

fric tion design, with the top ring located close to the

top of the piston crown to reduce hydrocarbon

emissions. The piston is a low friction, lightweight

design with a flat top and barrel shaped skirt.

Piston pins are c hr omium steel and ar e a f loating f it

in the piston and a press fit in the connecting rod.

The connecting rods are forged powdered metal.

The connecting rod cap is separated during the

manufactur ing proc ess , us ing the ‘f r act ure’ method.

This creates a stronger, visually seamless rod to

cap union. The reassembled rod is then machined

for the proper clearance.

A 0.25 mm oversize piston and piston ring set are

available for service, should cylinder honing be

required. Figure 6A3-14

CAMSHAFT AND DRIVE

A billet steel, one piece camshaft is supported by

five bearings pressed into the engine block. The

cam s haf t has a machined c amshaft sens or r eluctor

ring incorporated between the fourth and fifth

bearing journals. To reduce vale train noise, both

the intake and exhaust cam lobes have slow

closing velocity ramps.

To reduc e weight, the cam shaft has a 17 m m gun-

drilled hole down its length.

The c amshaf t (1) is driven by a traditional 9.52 m m

pitch roller chain (2) and powdered metal timing

sprockets mounted to the front of the camshaft (3)

and crankshaft (4). The crankshaft sprocket (4) is

splined and drives the oil pump driven gear. A

retaining plate (5) mounted to the front of the

engine block maintains the camshaft location. No

chain tensioner is required.

Figure 6A3-15

INTAKE MANIFOLD

The intake manifold (1) is a one piece composite

design that incorporates metal threaded inserts for

mounting the fuel rail (2), throttle cable bracket, and

throttle body.

The intak e manif old is sealed to the c ylinder heads

by eight separate non-reusable silicone sealing

gaskets which press into the grooves of the intake

housing.

The cable-actuated throttle body assembly bolts to

the front of the intake manifold (A). The throttle

body is sealed to the intake manifold by a one

piece, push-in-place silicone gasket.

The fuel rail assembly (2) with eight separate fuel

injectors (3) is retained to the intake manifold by

four bolts (4). The injectors are seated in their

individual manifold bores with O-ring seals to

provide sealing. The fuel pressure regulator (5) is

incorporated into the fuel rail design. A fuel rail

stop bracket is retained at the rear of the left fuel

rail by the intake manifold mounting bolts (not

shown).

The Manifold Absolute Pressure (MAP) sensor is

installed in the snap fit MAP sensor housing that is

mounted at the rear of the manifold and sealed by

an O-ring seal (not shown).

There are no coolant passages within the intake

manifold.

Figure 6A3-16

EXHAUST MANIFOLD

The exhaust manifolds are one piece, of high

temperature silicone molybdenum cast iron and

direct exhaust gases from the combustion

chambers to the exhaust system.

Each m anifold also has an externally mounted dual

wall heat shield attached, that is made of

aluminiumised steel.

Figure 6A3-17

ACCESSORY DRIVE

The engine accessory drive consists of dual

serpentine belts, that decouple the generator and

air conditioning compressor for improved noise

isolation. Using dual belts also provides design

flexibility to optimise structural stiffness of support

brackets.

The system includes two automatic belt tensioners

with a low static tension for increased belt and

bearing life.

Figure 6A3-18

Legend

1. Accessory Drive Belt, Automatic Tensioner 7. Crankshaft Balancer Pulley

2. Water Pump Pulley 8. Air Conditioning Compressor Drive Belt Automatic Tensioner

3. Power Steering Pump Pulley 9. Air Conditioning Compressor Drive Belt

4. Engine Accessory Drive Belt 10. Air Conditioning Compressor

5. A.C. Generator 11. Air Conditioning Compressor Drive Belt, Idler Pulley

6. Accessory Drive Belt, Idler Pulley

OIL PAN

The oil pan (1) is cast aluminium and forms a

structural part of the powertrain, by providing a

360° mounting for the transmission, whether it be

Manual or Automatic.

Cast-in dams incorporated into the oil pan design,

minim ise oil m igration during br aking and cor nering

manoeuvr es and oil is guided to the pick -up sc reen

(2), via strategically placed openings in the dam

walls.

Incorporated into the design are the oil filter

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

(4), and a stamped, oil pan baffle (6).

The oil pan baf f le ( 6), maintains an area ar ound the

pick-up screen to prevent oil starvation/aeration.

A crankshaft oil deflector (7) mounted to the main

bearing caps controls windage, sc rapes oil f r om the

crankshaft, facilitates drainback and reduces

aeration.

The oil pan gasket (8), is a controlled com pression

aluminium carrier gasket with silicone used as the

sealing agent.

Figure 6A3-19

1.3 ENGINE LUBRICATION SYSTEM

OIL PUMP

Engine lubrication is supplied by a “gerotor” type oil pump assembly. The pump is mounted on the front of the

engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan

sum p through a pick - up scr een and pipe. The oil is press urised as it pass es through the pum p and is sent through

the engine block oil galleries.

Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified

range. Pressurised oil is directed through the lower gallery to the full flow oil filter where harmful contaminants are

removed. A bypass valve is incorporated into the oil filter that still allows oil to flow in the event that the filter

becomes blocked.

Figure 6A3-20 - Oil Pump Assembly

Legend

1. Driven Gear 4. Spring - Pressure Relief Valve 7. Bolt - Cover

2. Oil Pump Housing 5. Plug 8. Cover

3. Pressure Relief Valve 6. Drive Gear

At the rear of the block, oil is directed to the upper main oil galleries which are drilled just above the camshaft

assem bly. From there, oil is then direc ted to the crank s haft and c am shaf t bearings. O il that has enter ed the upper

ma in oil galleries also pres surises the valve lif ter ass emblies and is then pumped thr ough the pushrods to lubricate

the valve rocker arms and valve stems.

Oil returning to the pan is directed by the crankshaft oil deflector.

Figure 6A3-21 - Lubrication Flow Schematic

CRANKSHAFT OIL SEALS

The GEN III V8 engine uses a multiple lip

crankshaft rear main oil seal, designed for long life

operation.

The s eal includes a PTFE (Tef lon®) centre lip (1) to

m inimise a m ajor cause of r ear m ain oil seal leak s.

The anti-fric tion proper ties of the PT F E reduc es the

chances of “chok ing” or build-up of degraded oil on

the lip (causing the lip to lif t off the shaft), resulting

in a leak.

Like the rear main oil seal, the front crankshaft oil

seal also incorporates a PTFE lip.

Service implications for this seal material are that

no lubricant is to be added to the seal lip on

installation, as this will prevent correct ‘break-in’ of

the seal. T he PT F E is ac tually deposited on the dry

crankshaft seal surface during initial operation by

the heat generated from the rotating shaft.

The outside of the seal m ay be lubr icated sparingly

to ease installation.

Figure 6A3-22

POSITIVE CRANKCASE VENTILATION SYSTEM

The engine ventilation system was developed to

minimise oil consumption and ensure that oil

ingestion could not occur during severe vehicle

handling manoeuvres.

Filtered fresh air is routed from upstream of the

throttle blade to the front of the right rocker cover

via a formed rubber hose (2). To reduce the

potential of oil pullover into the throttle bore area

due to back flow of the ventilation system, the fitting

in the right side rocker cover is located in a “quiet”

area located between, and shielded from, the

rocker arms. Crankcase blowby gases are routed

from the rear of both rocker covers, through

moulded nylon lines to a tee fitting, located on the

centreline of the engine at the rear of the intake

manifold (4). From there, a single hose carries

crankcase vapours through an externally mounted,

horizontal PCV valve (3) and enters the intake

manifold behind the throttle body (1).

The hoses are foam insulated and the PCV valve

(3) is conduction-heated from the cylinder block.

Figure 6A3-23

This “dual draw system” was developed to meet

high ‘g’ forces (bold arrow) incurred during severe

cornering m anoeuvres . During sust ained m aximum

lateral accelerations, the outboard rocker cover (1)

may fill with oil.

The “dual draw” system “passively switches”,

allowing the PCV valve to draw on the rock er cover

with the least resis tance. This res ults in the system

drawing on the air filled, or inboard, rocker cover

(2) and eliminates oil pullover that would result from

drawing on the oil filled outboard rocker cover.

Sectioned view shown is look ing rearward f rom the

engine front.

Figure 6A3-24

1.4 SERVICE NOTES

CLEANLINESS AND CARE

• Throughout this Section, it must be understood that proper cleaning and protection of machined surfaces and

friction areas is a part of the repair procedure. This is considered standard Workshop practice, even if not

specifically stated.

• When any internal engine parts are serviced, care and cleanliness is important.

• When components are removed f or s ervice, they should be mar ked, or ganised or r etained in a specif ic or der for

reassembly. Refer to; ’Separating Parts’ below.

• At the time of installation, components should be installed in the same location and with the same mating

surface as when removed.

• Any engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are

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

damage.

• A liberal coating of clean engine oil should be applied to f ric tion areas dur ing assem bly, as proper lubr ication will

protect and lubricate friction surfaces during the initial engine start-up.

REPLACING ENGINE GASKETS

• Re-using gaskets and applying sealants.

− Do not reuse any gasket unless specified.

− Gaskets that can be reused will be identified in the service procedure.

− Do not apply sealant to any gasket or sealing surface unless called out in the service information.

• Separating components

− Use a rubber mallet to separate components.

− Bump the part sideways to loosen the components.

− Bumping should be done at bends or reinforced areas to prevent distortion of parts.

• Cleaning gasket surfaces

− Remove all gasket and sealing material from the part using a plastic or wood scraper (if required).

− Care must be used to avoid gouging or scraping the sealing surfaces.

− Do not use any other method or technique to remove sealant or gasket material from a part.

− Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces.

∗ These methods of cleaning can cause damage to the component sealing surfaces.

∗ Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil.

∗ This grit is abrasive and has been known to cause internal engine damage.

• Assembling components

− When assembling components, use only the sealant specified or equivalent in the service procedure.

− Sealing surfaces should be clean and free of debris or oil.

− Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during

assembly.

− Components requiring lubrication will be identified in the service procedure.

− When applying sealant to a component, apply the amount specified in the service procedure.

− Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping

properly or cause component damage when tightened.

− Only ever tighten bolts to specifications. Do not overtighten.

USE OF RTV AND ANAEROBIC SEALER

Important: A number of sealant types are commonly used in engines. Examples are; Room Temperature

Vulcanising (RTV) sealer, anaerobic gasket eliminator sealer, anaerobic thread sealant and pipe joint compound.

The correct sealant and amount must be used in the specified location to prevent oil leaks. DO NOT interchange

the different types of sealers. Use only the specific sealer or the equivalent as recommended in the service

procedure.

Pipe Joint Compound

• Pipe joint com pound is a pliable sealer that does not completely harden. T his type of s ealer is us ed where two

non-rigid parts (such as pressed steel and machined surfaces) are assembled together.

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

exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.

• Follow all safety recommendations and directions that are on the container.

• To remove the sealant or the gasket material, refer to ’Replacing Engine Gaskets’ in this Section.

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

Run the bead to the inside of any boltholes. Do not allow the sealer to enter any blind threaded holes, as it m ay

prevent the bolt from clamping properly or cause component damage when the bolt is tightened.

• Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must

be clean and dry.

• Tighten the bolts to specifications. Do not overtighten.

Exam ples of locations where a pipe s ealant type material suc h as Loctite 565 ( or other c om m ercial equivalent) is to

be used, are:

• Engine block coolant and oil gallery plugs.

• Oil pressure sensor threads.

• Engine block oil pan surface.

RTV Sealer

• Room T emperature Vulcanis ing (RT V) sealant hardens when exposed to air. T his type of s ealer is used where

two non-rigid parts (such as the intake manifold and the engine block) are assembled together.

• Do not use RTV sealant in areas where extrem e temperatures are experienced. These areas include: exhaust

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

• Follow all safety recommendations and directions that are on the container.

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

• Apply RTV to a clean surface. Use a bead size as specified in the service procedure. Run the bead to the

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

from clamping properly or cause damage when the bolt is tightened.

• Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.

• Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

• Anaerobic gask et elim inator or thread sealant, hardens in the absence of air. T his type sealer is us ed where two

rigid parts (s uch as c astings ) are ass em bled together or where f asteners are subj ected to vibration or where the

holes are not blind. W hen two rigid parts are disassembled and no sealer or gasket is readily noticeable, the

parts were probably assembled using a gasket eliminator.

• Follow all safety recommendations and directions that are on the container.

• To remove the sealant or the gasket material, refer to Replacing Engine Gaskets in this Section.

• Apply a continuous bead of gasket eliminator to one f lange or on the bolt/s tud thr ead. All s urf ac es must be c lean

and dry.

• Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.

• Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or

cause damage when tightened.

Important: Anaerobic sealed joints that are partially torqued and allowed to cure more than five minutes may

result in incorrect shimming and sealing of the joint.

• Only ever tighten bolts to specification. Do not overtighten.

• After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Exam ples where thread locking sealants suc h as Loc tite 242 or Loctite 272 ( or other c ommerc ial equivalents ) ar e to

be used, are the fasteners for:

• Fuel rail. .................................... ‘242’

• Intake manifold.......................... ‘242’

• Cylinder head M8...................... ‘242’

• Exhaust manifold. ..................... ‘272’

SEPARATING PARTS

Important: Many internal engine components will develop specific wear patterns on their friction surfaces. So, when

disassembling the engine, internal components MUST be separated, marked, or organised in a way to ensure

reinstallation to their original location and position.

Separate, mark, or organise the following components:

− Piston and the piston pin.

− Piston to the specific cylinder bore.

− Piston rings to the specific piston.

− Connecting rod to the crankshaft journal.

− Connecting rod to the bearing cap.

− Crankshaft main and connecting rod bearings.

− Camshaft and valve lifters.

− Valve lifters, guides, pushrods, pivot supports and rocker arms.

− Valve to the valve guide.

− Valve spring and shim to the cylinder head location.

− Engine block main bearing cap location and direction.

− Oil pump drive and driven gears.

TOOLS AND EQUIPMENT

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

These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations for which

they are intended. The use of these special tools will also minimise possible damage to engine components. Some

precision m easuring tools are required for inspection of certain critical components. Torque wrenches and torque

angle tools are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available:

− Approved eye protection and safety gloves.

− A clean, well-lit, work area.

− A suitable parts cleaning tank.

− A compressed air supply.

− Trays or storage containers to keep parts and fasteners organised.

− An adequate set of hand tools.

− Approved engine repair stand.

− An approved engine lifting device that will adequately support the weight of the components.

FASTENERS

Fasteners are central to the reliable operation of

any engine and the GEN III V8 engine is no

exception.

Whenever any bolt or any other threaded

component is removed from the engine, it is

necess ary to first allow the engine to cool ( inset ‘B’)

before attempting fastener removal.

Because of the greater thermal expansion of

aluminium , bolt threads will change dimension to a

greater extent when hot with this m ater ial (ins et ‘A’)

when compared to cast iron.

If a bolt or other threaded component is removed

before the engine is allowed to cool to at least

50° C, threads could be pulled from the cylinder

block or cylinder head.

Also, DO NOT use impact tools to remove bolts

during engine disassembly. While this may be

common practice with cast iron engine

components, use of these tools is more likely to pull

the aluminium threads in the cylinder bloc k or head

of this engine.

Figure 6A3-25

Clamp Load

When torque is applied to a fastener, the fastener

stretches and the joint compresses. The force

developed in the fastener due to its s tre tch is c alled

tension (‘C’), while the force applied to the joint is

called “clamp load” (‘B’).

As shown, only a small portion of the applied torque

(‘A’) is transferred to the clamp load (inset ‘1’).

Friction under the bolt head (inset ‘3’) and in the

threads (inset ‘2’) absorbs much of the applied

torque (‘A’). Typically, only 10% (inset ‘1’) of the

torque is available to develop st retch (or tens ion) in

the fastener and clamp load in the joint.

Therefore, a slight variation in friction in the thread

or under the bolt head, results in a wide variation in

the clamp load applied to the joint.

Torque Angle and Torque to Yield Fasteners

The torque angle method of applying torque to a

fastener has been developed to overcome the

effects of friction variation in fastener applications.

The application of the torque angle method does

not always mean that the fastener has to be

replaced after loosening. It is only when the

fastener has been angle tightened to the extent that

the “yield” point has been exceeded, that the

fastener must be replaced.

Examples in the GEN III V8 engine are the main

bearing caps that are angle tightened but the bolts

can be re-used, whereas the M11 cylinder head

bolts that are “T orque to Yield” fastener s, MUST be

replaced after loosening.

Figure 6A3-26

2. MI NOR SERVICE OPERATIONS

2.1 ENGINE OIL LEVEL CHECK

1. Engine must be at normal operating temperature (drive the vehicle for 15 minutes).

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 engine shut down to allow oil to drain back into the oil pan.

4. Remove dipstick and wipe clean.

5. Reinstall dipstick, with the “ADD/FULL” marks facing towards the centre of the engine, ensuring that it is fully

seated. After leaving for several seconds, slowly remove to avoid sm earing, then hold horizontally to avoid oil

running along dipstick.

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

7. When topping up the engine oil, allow approxim ately 15 minutes f or the oil added to fully drain into the oil pan.

Alternatively, add 55 ml of oil for each millimetre below the “FULL” mark on the dipstick.

2.2 ENGINE OIL - CHANGE

NOTE 1: Quicker and more complete draining will

occur if the engine oil is at operating temperature.

However, care must be taken to avoid scalding

from the hot oil.

NOTE 2: While the oil pan is aluminium, they are

fitted with steel thread inserts to increase durability

of the thread and to avoid thread tearing when the

drain plug is removed from the hot engine.

NOTE 3: It is als o r ec ommended that the oil f ilter is

changed at each engine oil change, refer

2.3 ENGINE OIL FILTER & ADAPTOR, in this

Section.

1. Raise the engine hood and remove the oil fill

cap.

2. Raise the vehicle front and rear to maintain a

level attitude and support with safety stands.

This is to ensure complete draining. Refer to

0A GENERAL INFORMATION in of the VT

Series I Service Information.

3. Remove the four bolts securing the oil pan

under-tray.

4. Clean any foreign m aterial from around the oil

pan drain plug.

5. Place an oil drain tray beneath the engine.

6. Using a 15 mm ring spanner, remove the

drain plug, taking care to avoid scalding with

the hot waste oil.

7. W hen the oil has drained sufficiently, reinstall

the drain plug, after inspecting and cleaning

the threads and inspecting the magnetic plug

end for f er rous material. T he dr ain plug O -r ing

seal may be re-used if not cut or damaged.

Tighten the drain plug to the correct torque

specification.

ENGINE OIL PAN DRAIN PLUG

TORQUE SPECIFICATION 25 Nm

8. Reinstall the oil pan under - tray and tighten the

four bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 - 35 Nm

9. Lower the vehicle and fill the crankcase with

the required amount of 10W - 30 SJ GF2

lubricant.

Figure 6A3-27

ENGINE OIL CAPACITY

Without Oil Filter Change 4.7 litres

With Oil Filter Change 5.0 litres

NOTE: Synthetic oils of this viscosity are also an

acceptable engine lubricant.

10. Start the engine and check for oil leaks.

2.3 ENGINE OIL FILTER & ADAPTOR

NOTE: The oil filter should be replaced at the time

or distance intervals, specified in the Owner’s

Handbook or whenever the engine oil is changed.

REPLACE

1. Raise the engine hood and remove the oil fill

cap.

2. Raise the vehicle front and rear to maintain a

level attitude and support with safety stands.

This is to ensure complete draining. Refer to

0A GENERAL INFORMATION in of the VT

Series I Service Information.

3. Remove the four bolts securing the oil pan

under-tray.

4. Drain the engine oil as detailed in

2.2 ENGINE OIL - CHANGE, in this Section.

5. Remove the oil filter (1), using a commercially

available tool, taking care to avoid being

scalded with the hot waste oil.

6. Should it be required, remove the oil filter

adaptor (2) from the oil pan filter mounting

flange, using a suitable socket.

7. After checking that the filter seal has not

adhered to the oil pan flange, inspect the oil

filter sealing surface for scratches or other

damage and check the oil filter adaptor

threads for damage.

8. If removed, reinstall the oil filter adaptor and

tighten to the correct torque specification.

OIL FILTER ADAPTOR

TORQUE SPECIFICATION 55 Nm

9. Sm ear s om e new engine oil onto the new f ilter

seal, then install filter assembly to engine.

10. Tighten oil filter to the correct torque

specification.

ENGINE OIL FILTER

TORQUE SPECIFICATION 30 Nm

11. Reinstall the oil pan under- tray and tighten the

four bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 - 35 Nm

12. Lower the vehicle and fill the crankcase with

the required amount of recommended, new

lubricant. Refer to 2.2 ENGINE OIL -

CHANGE, in this Section for the

recommended procedure.

13. Start the engine and check for oil leaks.

Figure 6A3-28

2.4 ENGINE OIL PRESSURE - CHECK

1. Ensure that engine is at operating

temperature. Driving a cold vehicle for 15

minutes, should be sufficient to normalise the

temperature.

2. Remove oil filter, as detailed in Operation 2.3.

3. Install adaptor J 42907 to the oil filter adaptor.

4. On a level surface, check engine oil level and

top up as required. See Operation 2.2 in this

Section.

5. Install commercially available, accurate oil

pressure gauge (capable of reading 800 kPa

or higher) and suitably rated pres sure hose, to

adaptor J 42907.

6. Start the engine and check the oil pressure

with the engine running with no load.

7. Check that the oil pressure is within the

following specifications.

NOTE: If the oil pressure check indicates that the

oil pressure is not to specification, then refer to

4.5 OIL PRESSURE DIAGNOSIS, in this Section.

T6A3082a

J 42907

Figure 6A3-29

8. After completing the pressure check, stop the

engine and remove the oil pressure gauge

and adaptor assembly.

9. Install the oil filter. Refer 2.3 ENGINE OIL

FILTER & ADAPTOR, in this Section.

10. Top up engine oil level as required.

ENGINE OIL PRESSURE SPECIFICATION

ENGINE SPEED OIL PRESSURE READING

1,000 rpm 50 kPa (Minimum , Hot)

2,000 rpm 125 k P a (Mini mum, Hot)

4,000 rpm 165 k P a (Mini mum, Hot)

2.5 COMPRE SSION CHECK

1. Before conducting this check, ensure that the:

a. Engine is at operating temperature.

b. Battery is at or near a full state of charge.

c. Spark plugs are all removed.

d. Throttle plate is held wide open.

2. With the ignition switched OFF, disable the

ignition system and f uel injectors, by rem oving

the EFI relay (1), located in the engine

compartment.

3. Install a suitable, commercially available and

accurate, compression tester, that has been

reset to zero.

4. Crank the engine through approximately four

compression strokes (four ‘puffs’). Record the

reading.

5. Repeat this compression check for each

cylinder. Again, record each reading.

6. If a cylinder has low compres sion, inject about

15 ml (one tablespoon) of engine oil into the

combustion chamber through the spark plug

hole.

7. Recheck the compression and record the

reading.

Figure 6A3-30

INTERPRETING COMPRESSION READINGS

The minimum compression in any one cylinder

should not be less than 70% of the highest

cylinder. No cylinder should read less than 690

kPa. For example, if the highest pressure in any

one cylinder is 1035 kPa, the lowest allowable

pressure for any other cylinder would be 725 kPa.

(1,035 x 70% = 725).

NORMAL - Compression builds up quickly and

evenly to the specified compression for each

cylinder.

PISTON RINGS LEAKING - Compression is low on

the first stroke. Compression then builds up with

the following strokes but does not reach normal.

Comp ression im proves cons iderably when you add

oil.

VALVES LEAKING - Compression is low on the

first strok e. Compression usually does not build up

on the following strokes. Compression does not

improve much when you add oil.

CYLINDER HEAD GASKET LEAKING - If two

adjacent cylinders have lower than normal

compression and injecting oil into the cylinders

does not increas e the com pres sion, the c ause m ay

be a head gasket leaking between the cylinders.

2.6 ENGINE DRIVE BELTS - REPLACE

1. Remove the four engine dress cover

decorative nuts (2), then remove the dress

cover (1) from the engine.

2. Loosen both hose clamps securing the intake

hose (3) to the MAF sensor and the throttle

body. Remove the hose from the engine.

Figure 6A3-31

ENGINE A CCESSORY DRIVE BELT

3. Using a 15 mm ring spanner, rotate the

acces sor y automatic drive belt tens ioner ( 1) , in

the direction indicated, to reduce belt tension.

4. While holding the tensioner in the reduced

tension position, remove the accessory drive

belt (2), taking note of the belt routing.

NOTE: Use an assistant to maintain the tensioner

in the required position.

5. Clean the accessory drive belt running

surfaces and inspect the belt for damage.

6. While rotating the accessory drive belt

tensioner (1) in the direction indicated, install

the drive belt (2) over the pulleys, routing the

belt correctly, as shown.

7. Inspect the installation to ensure that the belt

is correctly aligned on all pulleys.

8. Reinstall the engine dres s cover , secur ing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 8.0 - 12 Nm

9. Start the engine to ensure correct operation.

Figure 6A3-32

Techline

AIR CONDITIONING COMPRESSOR BELT

NOTE: The accessory drive belt must be

removed first to allow access to this belt. Refer

to the previous operation for details.

1. Raise the vehicle and support with safety

stands. Refer to Section 0A GENERAL

INFORMATION in of the VT Series I Service

Information.

2. Remove the four bolts securing the oil pan

under-tray.

3. From under the vehicle, rotate the A/C drive

belt tensioner in the direction shown, using a

15 mm set spanner, to relieve belt tension.

4. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt from the pulleys.

NOTE: An alternative to using an assistant,

would be to secure the spanner using tie wire.

5. Clean the A/C drive belt running surfaces and

inspect the belt for damage.

6. While holding the A/C drive belt tensioner in

the direction indicated, install the drive belt

over the pulleys, routing the belt correctly, as

shown.

7. Inspect the installation to ensure that the belt

is correctly aligned on all pulleys.

Figure 6A3-33

8. Reinstall the ac c es sor y drive belt as des cr ibed

in the previous operation.

9. Start the engine to ensure correct operation.

10. Reinstall the oil pan under- tray and tighten the

bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 - 35 Nm

11. Lower the vehicle and test for correct

operation.

2.7 ACCESSORY BELT IDLER PULLEY

REPLACE

1. Remove the engine accessory drive belt.

Refer to Operation 2.6 in this Section for the

necessary procedure.

2. Remove the idler pulley retaining bolt, then

remove the pulley from its mounting boss, on

the generator mounting bracket.

3. Install the idler pulley to its mounting boss.

4. Install the idler pulley retaining bolt and tighten

to the correct torque specification.

ACCESSORY BELT IDLER PULLEY

BOLT TORQUE SPECIFICATION 40 - 60 Nm

5. Install the engine accessory drive belt. Refer

to Operation 2.6 in this Section for the

necessary procedure.

Figure 6A3-34

2.8 A/C BELT IDLER PULLEY

REPLACE

1. Raise the vehicle and support with safety

stands. Refer to 0A GENERAL

INFORMATION of the VT Series I Service

Information.

2. Remove the four bolts securing the oil pan

under-tray.

3. From under the vehicle, rotate the A/C drive

belt tensioner in the direction shown in Figure

6A3-33, using a 15 m m s et s panner, to relieve

belt tension.

4. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt from the pulleys but leave hanging

on the crankshaft pulley.

NOTE: An alternative to using an assistant, would

be to secure the spanner using tie wire.

5. Using a commercially available Torx bit T50,

remove the bolt securing the A/C compressor

drive belt idler pulley to its mounting boss on

the coolant pump housing, then remove the

pulley assembly.

6. Install the idler pulley to its mounting boss.

7. Install the idler pulley retaining bolt and tighten

to the correct torque specification.

A/C COMPRESSOR BELT

IDLER PULLEY BOLT 40 - 60 Nm

TORQUE SPECIFICATION

8. Install the A/C compressor drive belt. Refer to

Operation 2.6 in this Section for the

necessary procedure.

9. Reinstall the oil pan under -tray and tighten the

bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 - 35 Nm

10. Lower the vehicle and test for correct

operation.

Figure 6A3-35

2.9 ACCESSORY BELT TENSIONER

REPLACE

1. Remove the engine accessory drive belt.

Refer to Operation 2.6 in this Section for the

necessary procedure.

2. Remove the tensioner pulley bracket retaining

bolts (1), then remove the assembly (2).

3. Install the tensioner assembly (2) and the two

mounting bolts.

4. Tighten both mounting bolts (1) to the correct

torque specification.

ACCESSORY BELT TENSIONER

BOLT TORQUE SPECIFICATION 40 - 60 Nm

5. Install the engine accessory drive belt. Refer

to Operation 2.6 in this Section for the

necessary procedure.

Figure 6A3-36

Techline

2.10 A/C BELT TENSIONER

REPLACE

1. From under the vehicle, rotate the A/C drive

belt tensioner in the direction shown in Figure

6A3-33, using a 15 m m s et s panner, to relieve

belt tension.

2. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt from the pulleys but leave hanging

on the crankshaft pulley.

NOTE: An alternative to using an assistant,

would be to secure the spanner using tie wire.

3. Remove the bolt (1) securing the A/C

compressor drive belt tensioner, then remove

the assembly.

4. Install the tensioner assembly and the

mounting bolt.

5. Tighten the tensioner mounting bolt to the

correct torque specification.

A/C COMPRESSOR BELT

TENSIONER BOLT 21 - 29 Nm

TORQUE SPECIFICATION

6. Install the A/C compressor drive belt. Refer to

Operation 2.6 in this Section for the necessary

procedure.

Figure 6A3-37

2.11 OIL PRESSURE SENSOR

REPLACE

1. Remove the four engine dress cover

decorative nuts (2), then remove the dress

cover (1) from the engine.

Figure 6A3-38

2. Release the wiring harness connector locking

tang from the oil pressure sensor, then

remove the connector (2) from the sensor.

Figure 6A3-39

3. Using T ool No. J 41712 and suitable 3/8” drive

sock et equipm ent, remove oil pressur e sens or

(1) from the left hand rear of the engine

cylinder block.

4. Prior to reinstallation apply Loctite 565 sealant

(or equivalent) to the cleaned oil pressure

sensor threads.

5. Reinstall the oil pressure sensor (1) and

tighten with Tool No. J 41712 and suitable 3/8”

drive socket equipment, to the correct torque

specification.

OIL PRESSURE SENSOR

TORQUE SPECIFICATION 20 Nm

6. Reinstall the engine dres s cover , secur ing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 8.0 - 12 Nm

7. Start the engine to ensure correct operation.

Figure 6A3-40

2.12 MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE

1. Remove the four engine dress cover

decorative nuts (2), then remove the dress

cover (1) from the engine.

Figure 6A3-41

2. Release the wiring harness connector locking

tang (1) from the manifold absolute pressure

(MAP) sensor, then remove the connector

from the sensor.

Figure 6A3-42

3. Grasp the MAP sensor (1) at the rear of the

intake manifold and twist back and forth while

pulling upward, to remove.

4. Check the silicone r ubber seal (2) on the MAP

sensor to ensure it is not torn or damaged.

5. Reinstall the MAP sensor by pushing it down,

into the fitting at the rear of the intake

manifold.

6. Reinstall the wiring harness connector to the

MAP sensor, ensuring that the lock ing tab is in

place.

7. Reinstall the engine dres s cover , secur ing with

the four decorative nuts and tighten to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 8.0 - 12 Nm

8. Start the engine to ensure correct operation. Figure 6A3-43

2.13 FUEL SYSTEM PRESSURE RELIEF

1. After removing the cover from the engine

compartment relay housing, remove the fuel

pump relay (1).

2. With the throttle closed, crank the engine.

NOTE: The engine may start and run until the fuel

supply remaining in the fuel delivery system is

burned.

3. When the engine stops, re-engage the starter

motor for 10 seconds to ensure that the line

pressure has been fully relieved.

4. Reinstall the fuel pump relay, taking care that

the wiring harness relay connector is not

dislodged and that the relay is fully installed.

CAUTION: Unless this procedure is followed

before servicing the fuel lines or fuel

connections, fuel spray into the engine

compartment could occur!

Figure 6A3-44

2.14 INTAKE MANIFOLD

NOTE: Unless individual components such as the

throttle body, fuel injection rail and/or injectors are

to be removed as individual components, then it is

recommended that the complete intake manifold

assembly is removed, as described in this service

operation.

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Drain the cooling system. Refer to

Section 6B3 ENGINE CO OLING - GEN III V8

ENGINE.

3. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

4. Loosen the two clam ps securing the air intake

duct (3) to the thr ottle body and Mas s Air Flow

(MAF) sensor.

5. Remove air intake duct (3) assembly from

throttle body and MAF sensor.

6. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section.

Figure 6A3-45

7. Using quick connect release Tool No. 7371,

install over fuel line.

8. While holding the fuel line quick connect (1),

push on Tool 7371 to release the quick

connect fitting (1) from the fuel rail. Pull back

on the quick connect and remove.

9. Disconnect the vapour line connector (2) from

the EVAP purge valve (3).

Important: Cap the fuel line fittings and plug the

holes after separating the fuel lines to prevent fuel

leaking and/or dirt and other contaminants from

entering the fuel system.

Figure 6A3-46

10. Disconnect wiring harness connector (1) from

the Intake Air Control (IAC) motor, at the

throttle body (3).

11. Disconnect the wiring harness connector (2)

from the Throttle Position (TP) sensor at the

throttle body (3).

Figure 6A3-47

Techline

12. Disconnect the cruise control cable (1) (if

fitted) from the stud (2) on the throttle body

valve lever (3), then remove the outer cable

(8) from the retainer bracket (4). Refer Figure

6A3-48.

13. Lift the throttle cable (5) from the clip at the

fuel rail crossover pipe (6), then lift the cable

(5) from the retainer bracket (4).

14. Remove the inner throttle cable (7) from the

throttle body valve lever (3).

15. Set the cable/s to one side.

Figure 6A3-48

16. Disconnect the fuel injector wiring harness

connectors (1) from the right bank of fuel

injectors (4 places).

17. Rem ove the CPA lock (2) f rom the ignition coil

main connector (3) on the right hand side,

remove the connector (3), then the harness

securing clips from the fuel rail brackets (4)

and set the harness to one side.

Figure 6A3-49

18. Disconnect the fuel injector wiring harness

connectors (1) from the left bank of fuel

injectors (4 places).

19. Rem ove the CPA lock (2) f rom the ignition coil

main connector (3) on the left hand side, then

remove the wiring harness connector (3).

20. Remove the wiring harness connector from

the canister purge valve (4).

21. Remove the harness securing clips from the

fuel rail brackets (5) and set the harness to

one side.

Figure 6A3-50

22. Disconnect the wiring harness connector (1)

from the MAP sensor, located at the rear of

the intake manifold.

23. Remove the knock sensor patch harness

connector r etaining clip (3) fr om the PCV hose

and disconnect the wiring harness connector.

24. Remove the PCV hose (4) from the PCV vent

valve grommet (5) (left bank).

Figure 6A3-51

25. Remove the fresh air hose from the front fitting

of the rocker cover and the throttle body.

Figure 6A3-52

26. Remove the nut (1) securing the PCV valve,

heat conducting strap (2) from the front right

hand vapour pipe screw (3).

27. Remove the PCV valve hose from the throttle

body and right hand rocker cover, rear fitting.

28. Remove the PCV valve and hose assembly

from the left hand rocker cover clip, then lift

hoses and valve assembly from the engine.

Figure 6A3-53

29. Remove the engine coolant, vapour vent hose

from the throttle body and the vapour vent

pipe.

Figure 6A3-54

30. Remove the engine coolant vapour vent outlet

hose (1) from the throttle body and left hand

radiator tank.

Figure 6A3-55

31. Remove the evaporative (EVAP) canister

purge valve tube fr om the purge valve and the

throttle body.

Figure 6A3-56

32. Remove the EVAP canister purge valve and

bracket from the intake manifold.

Figure 6A3-57

33. Progressively loosen the 10 intake manifold

retaining bolts (1), working diagonally from

outside to inside.

34. Remove the fuel rail stop bracket (2) with the

two, left rear bolts and set to one side.

35. Carefully bump the intake manifold to break

the gasket seal, then lift from the engine.

36. Remove the intake manifold to cylinder head

gaskets and discard.

Figure 6A3-58

DISASSEMBLE

If required, the following components can be

removed from the intake manifold:

1. Remove the Manifold Absolute Pressure

(MAP) sensor (1) from the fitting at the rear of

the intake manifold by twisting back and forth

while pulling on the sensor.

2. Check the silicone r ubber seal (2) on the MAP

sensor to ensure that it is not torn or

damaged.

Figure 6A3-59

3. Remove the throttle body retaining bolts, then

the throttle body and gasket. Discard the

gasket.

Figure 6A3-60

4. Remove the four nuts (1) securing the engine

dress cover brackets (2) to the fuel rail (3),

then lift the two brackets from the fuel rail.

5. Remove the studs (4) securing the fuel rail

and injectors to the intake manifold, then

carefully remove the fuel rail and injectors as

an assembly.

Should further disassembly of the fuel injectors be

required, refer to Section 6C3 POWERTRAIN

MANAGEMENT - GEN III V8 ENGINE.

Figure 6A3-61

CLEAN AND INSPECT

1. Af ter cleaning the intake m anifold in a s uitable

solvent, dry off manifold using compressed

air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Ensure that the intake manifold gasket

grooves and vacuum passages in the rear of

the intake manifold are all clean and clear.

3. Inspec t throttle body and fuel r ail bolt ins ert s in

the composite intake manifold, for looseness

and/or damaged threads.

4. Inspect the intake manifold for cracks or

damage, including the areas between the

intake runners.

5. Inspect the fuel injector bores for excessive

scoring or damage.

6. Inspect the intake manifold to cylinder head

faces for warpage, as follows:

a. Locate a straight edge across each of the

two surfaces and check for warpage,

using feeler gauges.

b. An intake manif old with warpage in excess

of 0.5 mm, must be replaced.

REASSEMBLE

Manifold Absolute Pressure (MAP) Sensor

If removed, install the MAP sensor as follows:

1. Check the MAP sensor seal (2) to ensure it is

seated correctly on the sensor.

2. Install the Manifold Absolute Pressure (MAP)

sensor (1) into the fitting at the rear of the

intake manifold by pushing the sensor into the

fitting.

Figure 6A3-62

Fuel Rail and Injectors

1. Lubric ate NEW injector O -r ing seals with clean

engine oil.

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

3. Install the fuel rail (with injectors) into the

intake manifold, pressing evenly on each side

until the injectors are all seated in their bores.

4. Apply a 5 mm band of thread sealant such as

Loctite 242 (or other c ommerc ial equivalent) to

the cleaned threads of the fuel rail attaching

studs (4) and install, tightening to the correct

torque specification.

FUEL RAIL ATTACHING BOLTS

TORQUE SPECIFICATION 8 - 12 Nm

5. Install the engine dress cover attaching

brack ets (2) to the fuel r ail attaching studs (4),

fit the retaining nuts (1) and tighten to the

correct torque specification.

ENGINE DRESS COVER BRACKET

NUT TORQUE SPECIFICATION 4 - 6 Nm

Figure 6A3-63

Throttle Body

1. Install a NEW throttle body gasket to the

intake manifold.

2. Install the throttle body and bolts to the intake

manifold.

3. Tighten the throttle body bolts to the correct

torque specification.

THROTTLE BODY BOLT

TORQUE SPECIFICATION 12 Nm

Figure 6A3-64

REINSTALL

1. Install NEW intake manifold to cylinder head

gaskets, then install the intake manifold.

2. Apply a 5 mm band of thread sealant such as

Loctite 242 (or equivalent to Holden

Specification HN 1256, Type 2, Class 2), to

the cleaned threads of the 10 intake manifold

attaching bolts (1).

Figure 6A3-65

3. Install, the intake manifold bolts and fuel rail

stop bracket, tightening the bolts in two

stages, in the sequence shown, to the correct

torque specification.

INTAKE MANIFOLD BOLTS Stage 1 - 5 Nm

TORQUE SPECIFICATION Stage 2 - 8 Nm

CAUTION: Do not overlook installing the fuel

stop bracket. The stop bracket serves as a

protective shield for the fuel rail in the event of

a vehicle frontal collision. If the fuel stop

bracket is not installed and the vehicle is

involved in a collision, fuel could be sprayed,

possible causing a fire and personal injury from

burns.

Figure 6A3-66

The remainder of the installation process is the

reverse of the removal operations, except for the

following;

4. After installation, the throttle cable is to be

adjusted, as detailed:

a. Attach all cable fittings.

b. With the outer cable adjuster unlocked,

apply a tension to the adjuster, until the

throttle cam (1) begins to move.

Figure 6A3-67

c. Release the tension on the adjuster until

the throttle cam is back at rest (1), then

slightly compres s the adjuster (2) about 1

mm to lock.

Figure 6A3-68

5. If fitted, the cruise control cable must be

adjusted, as follows:

a. Connect the inner cable ( 1) to the s tud ( 2)

on the throttle cam (3), then slide the

outer cable into position in the throttle

cable bracket (4).

Figure 6A3-69

b. Unlock the adjustment locking lever (1).

c. Ensure that the throttle is fully closed,

then adjust the outer cruise control cable

(2), to achieve minimum slac k in the inner

cable.

d. Flip the adjustment lever (1) to lock the

outer cable (2) into position.

Figure 6A3-70

6. Install engine dress cover and the four

retaining nuts and tighten to the cor rect torque

specification.

ENGINE DRESS COVER

RETAINING NUT 8 - 12 Nm

TORQUE SPECIFICATION

7. Fill the cooling system. Refer to

Section 6B3 ENGINE CO OLING - G EN III V8

ENGINE.

8. Start engine check for leaks and normal

operation.

2.15 VAPOUR VENT PIPE

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Drain the cooling system. Refer to

Section 6B3 ENGINE CO OLING - GEN III V8

ENGINE.

3. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

4. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section.

5. Loosen both hose clamps securing the intake

hose (3) to the MAF sensor and the throttle

body. Remove the hose from the engine.

Figure 6A3-71

6. Remove intake manifold. Refer to

Operation 2.14 INTAKE MANIFOLD.

7. Rem ove the wiring harnes s connec tor (1) f rom

the knock sensor patch harness (2).

Figure 6A3-72

8. Unclip the knock sensor wiring harness clips

from the vapour vent pipe.

9. Remove the vapour vent pipe retaining

studs/bolts.

NOTE: Both front studs are double sided, with the

right hand one (arrow) being used to secure the

PCV valve braided strap, disconnected during the

intake manifold removal operation.

10. Remove the vapour vent pipe and gaskets

from the cylinder heads.

11. Remove the vapour vent pipe gaskets and

discard.

Figure 6A3-73

REINSTALL

1. Correctly install NEW vapour pipe gaskets by

fitting the O-ring seal part, over the pipe fitting

nipple, as shown.

Figure 6A3-74

2. Install the vapour vent pipe and gaskets to the

cylinder heads.

3. Install the vapour vent pipe bolts/studs and

tighten to the correct torque specification.

VAPOUR VENT PIPE BOLT/STUD

TORQUE SPECIFICATION 12 Nm

4. Secure the knock sensor wiring harness clips

to the vapour vent pipe.

5. Install the intake manifold, as described in

2.14 INTAKE MANIFOLD - REINSTALL, in

this Section.

6. Install the vapour vent hose to the throttle body

and install the hose clamp securely.

Figure 6A3-75

2.16 ENGINE VALLEY COVER

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Drain the cooling system. Refer to

Section 6B3 ENGINE CO OLING - GEN III V8

ENGINE.

3. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

4. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section.

5. Loosen both hose clamps securing the intake

hose (3) to the MAF sensor and the throttle

body. Remove the hose from the engine.

6. Remove intake manifold. Refer to

Operation 2.14 INTAKE MANIFOLD.

7. Remove vapour vent pipe. Refer to

Operation 2.15 VAPOUR VENT PIPE.

Figure 6A3-76

8. To remove the knock sensor wiring harness,

carefully lift each sealing plug from the valley

cover, release each knock sensor harness

connector locking tab, then remove each

connector. Lift the knock sensor wiring

harness from the engine.

Figure 6A3-77

9. Remove both knock sensors, using a

commercially available, 22 mm deep socket.

NOTE: Unless a deep socket is used, damage to

the sensor connector will result.

Figure 6A3-78

10. Remove the valley cover retaining bolts.

11. Remove the valley cover and gasket from the

cylinder block. Discard the gasket.

Figure 6A3-79

CLEAN AND INSPECT

1. Remove both knock sensor oil seals from the

valley cover.

2. Clean the valley cover in suitable solvent and

dry off with compressed air

CAUTION: Wear safety glasses to avoid eye

injury.

3. Inspect the valley cover sealing surfaces and

oil seal bores for ex cessive scr atches or other

damage.

REINSTALL

Reinstallation is the reverse of rem oval operations,

except for the following items.

1. Install NEW knock sensor oil seals into the

valley cover and lubricate with clean engine

oil.

2. Fit a NEW gasket to the valley cover and

install cover to the engine (refer to Figure 6A3-

79).

3. Install valley cover bolts and tighten to the

correct torque specification.

VALLEY COVER BOLT

TORQUE SPECIFICATION 25 Nm

4. Install the knock sensors and tighten to the

correct torque specification.

KNOCK SENSOR

TORQUE SPECIFICATION 20 Nm

2.17 VALVE ROCKER ARM COVER

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

Figure 6A3-80

3. For the right hand rocker cover, remove the

fresh air hose from the front fitting of the

rocker cover and from the throttle body.

Figure 6A3-81

4. Remove the PCV hose connection from the

rear fitting at the end of the rocker cover,

being removed.

Figure 6A3-82

5. Using quick connect release Tool No. 7371,

install over fuel line.

6. While holding the fuel line quick connect (1),

push on Tool 7371 to release the quick

connect fitting (1) from the fuel rail. Pull back

on the quick connect and remove.

7. Disconnect the vapour line connector (2) from

the EVAP purge valve (3).

Important: Cap the fuel line fittings and plug the

holes after separating the fuel lines to prevent fuel

leaking and/or dirt and other contaminants from

entering the fuel system.

Figure 6A3-83

8. Remove the spark plug leads.

NOTE: Handle the boot only. DO NOT pull on the

lead. Twist the boot firs t to break the s eal, then pull

to remove.

Figure 6A3-84

9. Rem ove the CPA lock ( 4) f rom the ignition coil

main connector on the rocker cover being

removed, then remove the wiring harness

connector (3).

10. Remove the 4 studs (1) and one screw

securing the ignition coil mounting bracket (2)

to the rocker c over being r emoved, then lif t the

ignition coils, wiring and bracket from the

engine.

NOTE: The rear attaching bolt on each coil

assem bly (arrow) is a conventional scr ew and not a

stepped stud. Fitment of this screw in the correct

position on reassembly is important to avoid

possible chaffing.

Figure 6A3-85

11. Remove the 4 valve rocker cover bolts, then

rem ove the cover and gasket f rom the cylinder

head.

NOTE: Do not rem ove the oil fill tube f rom the right

hand rocker cover unless replacement is required.

Figure 6A3-86

12. If required, remove the oil fill cap(1) and/or fill

tube (2) from the right hand rocker cover (3).

Discard the oil fill tube (2), as permanent

damage will occur on removal.

Figure 6A3-87

13. Remove the bolts securing the ignition coils to

the mounting bracket and remove the coils

and wiring harness.

Figure 6A3-88

CLEAN AND INSPECT

1. Clean the rocker cover in a suitable solvent

and dry off with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the ventilation system passages for

restriction.

3. Inspect the rocker cover gasket groove for

damage.

4. Inspec t the ignition coil m ounting boss thr eads

for damage.

REINSTALL

Reinstallation of the rocker cover is the reverse to

the removal procedure except for the following

items.

1. If the oil fill tube (2) was removed from the

right hand rocker cover (3), it must be

replaced with a NEW part ( when installed, it is

permanent).

2. Lubricate the O-ring seal of the NEW oil fill

tube (2) with clean engine oil.

3. Install the oil fill tube into the rocker cover (3),

rotating the tube clockwise until locked into the

correct position.

4. Install the oil fill cap (1), rotating clockwise until

locked into place.

Figure 6A3-89

5. Install a NEW gasket to the rocker cover.

6. Install the rocker cover bolts.

7. Install the rocker cover onto the cylinder head

and tighten the rocker cover studs to the

correct torque specification.

ROCKER COVER BOLT

TORQUE SPECIFICATION 12 Nm

Figure 6A3-90

8. Install the ignition coils and coil wiring harness

to the mounting bracket and tighten the studs

and bolts to the correct torque specification.

IGNITION COILSTUD/ BOLT

TORQUE SP ECIFI CA T ION 12 Nm

9. Install the ignition coils and bracket assembly

to the rock er c over, and tighten the bolts to the

correct torque specification.

IGNITION COIL BRACKET BOLT

TORQUE SPECIFICATION 12 Nm

NOTE: The rear, left hand c oil brack et f astener is a

plain screw and not a stepped stud as are the

others. Fitment of this screw in the correct position

is important to avoid fuel/vapour line chaffing.

10. After installation of the ignition coil main

harness connector, install the CPA lock,

ensuring it is fitted securely. Figure 6A3-91

2.18 V ALVE ROCKER ARMS AND PUSH RODS

REMOVE

NOTE: While some views may show a cylinder

head that is not specif ic to the one required, unless

noted, it can be assumed that the operation is the

same for either cylinder head.

1. Rem ove the valve rock er arm cover/s. r efer to

2.17 VALVE ROCKER ARM COVER.

Important: Store all removed valve operating

mechanism com ponents in a suitable rack to avoid

being mixed. This will ensure that parts reinstalled

will be in the same relationship as on removal.

2. Remove all the rocker arm bolts on the

specific cylinder head.

3. Remove associated valve rockers arms.

Figure 6A3-92

4. Remove the valve rocker arm pivot support.

Figure 6A3-93

5. Remove the push rods.

Figure 6A3-94

CLEAN AND INSPECT

1. Mark, sort or organise removed parts to retain in order removed.

2. Clean parts in a suitable solvent, then dry with compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

3. Inspect parts, as follows:

a. Valve rocker arm bearings for binding or

roughness.

b. Valve rocker arm push rod sockets and

valve stem mating s ur f aces f or wear and/or

roughness.

c. Pushrods for worn or scored ends.

d. Also check for bent pushrods by rolling on

a flat surface.

e. Pushrod oil passages for restrictions.

f. Pivot supports for cracks, wear or other

damage.

REINSTALL

While the reinstallation process is the reverse of the

removal procedure, there are some specific

operations that must be complied with, and are

detailed here.

1. To reduc e the effor t required to tur n the engine

over by hand, remove the spark plugs, taking

note of the following;

a. The engine MUST be cold to at least

50° C. If not, then the spark plug and

cylinder head threads may bind, causing

the cylinder head threads to be torn.

b. When removing spark plug leads, only

handle the boot on each lead, twist to

break the seal, them pull to remove. DO

NOT pull on the lead itself.

c. Loosen the spark plug/s, then re-tighten to

break away any carbon deposits on the

threads.

d. Loosen the spark plug/s once again but,

this time, only one or two turns. Then use

compressed air to remove any foreign

material that may otherwise enter the

combustion chamber.

CAUTION: Wear eye protection to avoid injury.

e. Continue to remove the spark plug/s.

Figure 9A-95

2. Lubricate the following parts in clean engine oil

before installation:

a. All valve rocker arms and pushrods.

b. The flanges of all rocker arm bolts.

3. Install all push rods, checking that each seats

correctly to the hydraulic valve lifter sockets.

4. Install all rocker arms, bearings and NEW

retaining bolts but DO NOT TIGHTEN fully at

this time.

5. Rotate the crankshaft until No. 1 piston is at

Top Dead Centre (TDC), on the compression

stroke.

NOTE 1: Inserting a finger into the spark plug hole

will determine if the piston is rising on the

compression stroke, by the compressed air

escaping. Finally, a suitable piece of wire can be

used as shown, to determine when the piston is at

TDC.

NOTE 2: The engine firing order is 1, 8, 7, 2, 6, 5,

4, 3 and cylinder num bers are 1, 3, 5, 7, on the left

bank and 2, 4, 6, 8, are on the right bank.

6. W ith No. 1 piston on TDC com pression stroke,

tighten the following rocker arm bolts to the

correct torque specification:

7. Rotate the crankshaft 360°.

8. Tighten the following rocker arm bolts to the

correct torque specification:

9. Reinstall the rocker cover/s. See Operation

2.14 for the necessary procedure.

Figure 6A3-96

Exhaust Valve, Cylinder No. 3, 4, 5 and 6, to 30 Nm

Intake Valve, Cylinder No. 2, 6, 7 and 8, to 30 Nm

Exhaust Valve, Cylinder No. 1 , 2, 7 and 8, to 30 Nm

Intake Valve, Cylinder No. 1, 3, 4 and 5, to 30 Nm

2.19 VALVE STEM OIL SEAL AND/OR VALVE SPRING

REPLACE

1. Remove the spark plugs from the cylinder/s

being serviced, taking note of the following;

a. The engine MUST be cold to at least

50° C. If not, then the spark plug and

cylinder head threads may bind, causing

the cylinder head threads to be torn.

b. When removing spark plug leads, only

handle the boot on each lead, twist to

break the seal, them pull to remove. DO

NOT pull on the lead itself.

c. Loosen the spark plug/s, then re-tighten to

break away any carbon deposits on the

threads.

d. Loosen the spark plug/s once again but,

this time, only one or two turns. Then use

compressed air to remove any foreign

material that may otherwise enter the

combustion chamber.

CAUTION: Wear eye protection to avoid injury.

e. Continue to remove the spark plug/s.

2. Remove the valve rocker arms, valve rocker

arm pivot support, and valve pushrods. Refer

to 2.18 VALVE ROCKER ARMS & PUSH

RODS.

Figure 6A3-97

2. Insert a suitable piece of wire into the spark

plug hole and turn the crank shaf t balancer bolt

until the piston is at or near Top Dead Centre

(TDC).

3. Install Spark Plug Port Adaptor Tool J 22794

or a commercial equivalent to the spark plug

hole of the cylinder being serviced.

4. Using suitable adaptors, attach a compressed

air line to J 22794 and apply a cons tant supply

of compressed air to the cylinder being

serviced.

Figure 6A3-98

5. Compress one of the valve springs, using

valve spring compressor, KD2078.

Figure 6A3-99

6. Remove valve stem collets (1).

7. Release the valve spring compressor and

remove:

a. Valve spring cap (2).

b. Valve spring (3).

c. Valve spring oil seal (4) (if being

replaced).

Figure 6A3-100

Important: The valve stem oil seal alignment and

position on the valve stem is critical. An im properly

installed valve stem oil seal will lead to excessive

oil consumption and increased exhaust emissions.

8. Install the valve stem oil seal onto the valve

guide using the following method.

a. Lubricate the valve stem oil seal (1) and

the valve stem (2), with clean engine oil.

b. Install the lubricated valve stem oil seal

(1), over the valve stem. Push down

firmly until the seal contacts the valve

guide.

c. Using valve stem seal installer Tool J

42078, push or lightly tap the tool until the

tool bottoms against the valve spring

shim (3).

Figure 6A3-101

9. Measure the installed height of the valve stem

oil seal with vernier calipers. There should be

a gap (A) of 18.1 - 19.1 mm between the top

edge of the oil seal body and the top of the

spring shim surface.

Figure 6A3-102

10. Install the valve spring with the smaller wound

coils facing up, then install the spring cap.

11. Compress the spring using Tool No. KD2078

until sufficient space is allowed for the valve

collets to be installed.

12. Install both valve stem collets, using clean

grease or petroleum jelly to retain.

13. Release the valve spring compressor,

checking that both valve stem collets are

seated correctly.

14. Lightly tap the valve stem with a soft faced

hammer to ‘seat’ the valve stem collets.

15. Remove the compressed air supply.

16. Remove the spark plug adaptor, Tool J22794.

17. Install the spark plug, tightening to the correct

torque specification.

SPARK PLUG

TORQUE SPECIFICATION 15 Nm

18. Reverse the removal procedure to complete

this operation.

Figure 6A3-103

2.20 OIL LEVEL INDICATOR AND TUBE

REMOVE AND REINSTALL

1. Remove the oil level indicator from the tube.

2. Remove the oil level indicator tube bracket bolt

from the right hand exhaust manifold

3. Remove the tube from the engine, then

remove the O-ring.

NOTE: If the tube is not to be reinstalled

immediately, plug the opening in the engine

block to prevent dirt entry.

4. After cleaning the tube, inspect the O-ring,

which can be re-used if undam aged. Install O-

ring to the lower end of the tube

5. Install the tube to the engine and rotate to the

correct position.

6. Install the oil level indicator tube bracket bolt

and tighten in two stages, to the correct tor que

specification.

OIL LEVEL TUBE RETAINING

BOLT TORQUE SPECIFICATION 25 Nm

7. Install the oil level indicator to the tube.

Figure 6A3-104

2.21 EXHAUST MANIFOLD

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

3. Loosen the two clam ps securing the air intake

duct (3) to the thr ottle body and Mas s Air Flow

(MAF) sensor.

4. Remove air intake duct (3) assembly from

throttle body and MAF sensor.

5. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section.

6. For the right hand side exhaust manifold:

a. Remove the engine oil level indicator and

tube. Refer to 2.20 OIL LEVEL

INDICATOR AND TUBE, in this Section.

b. Plug the opening in the cylinder block to

prevent entry of foreign matter. Figure 6A3-105

7. For the left hand side exhaust manifold:

a. Remove the engine coolant temperature

sensor (1) f rom the cylinder head to avoid

possible dam age during ex haust m anifold

removal.

8. Raise the front of the vehicle and place on

safety stands. Refer to Sect ion 0A GENERAL

INFORMATION for location of jacking and

support points.

Figure 6A3-106

9. While not essential, it is recommended that

the oxygen sensor/s (1) are rem oved from the

exhaust pipe/s, to avoid accidental damage.

a. Disconnect the wiring harness

connector/s from the oxygen sensor/s.

b. Remove the oxygen sensor/s from the

exhaust pipe/s.

Figure 6A3-107

10. Rem ove the exhaust manif old to exhaus t pipe

flange nuts.

11. Lower vehicle to the ground.

12. Rem ove the spark plug from the cylinder head

on the exhaust manifold side being removed,

taking note of the following;

a. The engine MUST be cold to at least

50° C. If not, then the spark plug and

cylinder head threads may bind, causing

the cylinder head threads to be torn.

b. When removing spark plug leads, only

handle the boot on each lead, twist to

break the seal, them pull to remove. DO

NOT pull on the lead itself.

c. Loosen the spark plug/s, then re-tighten to

break away any carbon deposits on the

threads.

d. Loosen the spark plug/s once again but,

this time, only one or two turns. Then use

compressed air to remove any foreign

material that may otherwise enter the

combustion chamber.

CAUTION: Wear eye protection to avoid injury.

e. Continue to remove the spark plug/s.

Figure 6A3-108

13. Progressively loosen, then remove exhaust

manifold bolts, working from the outside in to

the centre.

14. Remove exhaust manifold and gasket from

the cylinder head.

15. If required, remove the heat shield retaining

bolts and the heat shield from the magnified.

NOTE: While the right hand side exhaust manifold

is shown, the left hand side arrangement is similar.

Figure 6A3-109

INSPECT

1. Inspect for a loose or damaged heat shield.

2. Inspect the exhaust pipe flange stud threads

for damage.

3. Inspect the exhaust pipe flange stud threads

for damage.

4. Inspect exhaust manifold to cylinder head

mounting surface for scratches or damage.

5. Using a straight edge and feeler gauges,

check that the cylinder head mounting face of

the exhaust manifold does not exceed the

maximum distortion specification of 0.25 mm.

An exhaust manifold exceeding this maximum,

must be machined to correct the

misalignment.

Figure 6A3-110

REINSTALL

The reinstallation procedure is the reverse of the

removal operation, except for the following items:

NOTE 1: Correct installation of the exhaust

manifold gaskets and the adherence to the

specified tightening sequence and torque applied

to the exhaust m anifold attaching bolts is critical to

ensure a gas tight seal and compliance with

emission regulations.

NOTE 2: The exhaust manifold bolt hole threads

must be clean and free of debris or threadlocking

compound.

NOTE 3: All gaskets, O-rings and seals must be

replaced with new parts on assembly.

NOTE 4: Do not apply thread sealant to the first

three threads of any exhaust manifold mounting

bolt.

1. If the heat shield was removed, apply an anti-

seize com pound such as Am pol Kopr-Kote ( or

equivalent to Holden’s Specification HN 1325)

to the cleaned heat shield bolt threads,

reinstall the heat shield and bolts to the

exhaust manifold and tighten the retaining

bolts to the correct torque specification.

EXHAUST MANIFOL D HEAT SHIELD

BOLT TORQUE SPECIFICATION 9 Nm

2. Apply a 5 mm wide band of Loctite 272 thread

sealant (or equivalent), to the threads of the

exhaust manifold mounting bolts.

3. Install a NEW exhaust manifold to cylinder

head gasket, install the manifold and bolts.

4. Tighten the exhaust manifold bolts to the

specified, two stage torque specification,

beginning with the centre two bolts, then

alternate from side to side, to the outside

bolts.

EXHAUST MANIFOLD BOLT Stage 1 - 15 Nm

TORQUE SPECIFICATION Stage 2 - 25 Nm

5. Using a flat punch, bend over the exposed

edge of the exhaust manifold gasket at the

front of the right hand cylinder head and the

rear of the left hand cylinder head.

6. If removed, ins tall the ox ygen sensor/s into the

exhaust pipe/s.

Important: A special anti-seize compound is used

on the oxygen sensor threads. New or service

sensors will already have the compound applied to

the threads. If an oxygen s ensor is re moved and is

to be reinstalled, then the threads must have the

specified anti-seize compound applied before

reinstallation.

This specific anti-seize compound is available

through Holden Service Parts Operations (HSPO),

as Part Number 5613695 and is to be applied to

the cleaned threads of the oxygen sensor.

Figure 6A3-111

7. Tighten the oxygen sensor/s to the correct

torque specification.

OXYGEN SENSOR

TORQUE SPECIFICATION 41 Nm

8. Apply an anti-seize compound such as Ampol

Kopr-Kote (or equivalent to Holden’s

Specific ation HN 1325) to the c leaned ex haust

pipe flange stud threads.

9. Install and tighten the ex haus t pipe to manif old

flange nuts to the correct torque specification.

EXHAUST PIPE FLANGE NUT

TORQUE SPECIFICATION 20 - 35 Nm

10. Apply thread sealant such as Loctite 565 (or

other commercial equivalent), to the cleaned

threads of the coolant temperature sensor (1).

11. Install and tighten the coolant temperature

sensor (1) to the correct torque specification.

COOLANT TEMPERATURE

SENSOR TORQUE SPECIFICATION 20 Nm

12. Reinstall spark plugs tightening to the correct

torque specification, then reinstall the spark

plug leads.

SPARK PLUG

TORQUE SPECIFICATION 15 Nm

Figure 6A3-112

2.22 CYLINDER HEAD

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

3. Loosen the two clam ps securing the air intake

duct (3) to the thr ottle body and Mas s Air Flow

(MAF) sensor.

4. Remove air intake duct (3) assembly from

throttle body and MAF sensor.

5. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section.

6. Remove the engine accessory drive belt.

Refer to 2.6 ENGINE DRIVE BELTS, in this

Section.

7. Remove intake manifold. Refer to

2.14 INTAKE MANIFOLD, in this Section.

8. Remove vapour vent pipe. Refer to

2.15 VAPOUR VENT PIPE, in this Section.

9. Remove valve rocker arm cover on the

cylinder head to be removed. Refer to

2.17 VALVE ROCKER ARM COVER, in this

Section.

Figure 6A3-113

10. Remove valve rocker arms and push rods on

the cylinder head to be removed. Refer to

2.18 VALVE ROCKER ARMS AND PUSH

RODS, in this Section

11. Rem ove the spark plug from the cylinder head

being removed, noting the following;

a. The engine MUST be cold to at least

50° C. If not, then the spark plug and

cylinder head threads may bind, causing

the cylinder head threads to be torn.

b. When removing spark plug leads, only

handle the boot on each lead, twist to

break the seal, them pull to remove. DO

NOT pull on the lead itself.

c. Loosen the spark plug/s, then re-tighten to

break away any carbon deposits on the

threads.

d. Loosen the spark plug/s once again but,

this time, only one or two turns. Then use

compressed air to remove any foreign

material that may otherwise enter the

combustion chamber.

CAUTION: Wear eye protection to avoid injury.

e. Continue to remove the spark plug/s.

12. For the right hand side cylinder head, first

rem ove the engine oil level indicator and tube.

Refer to 2.20 OIL LEVEL INDICATOR AND

TUBE, in this Section.

13. Remove the exhaust manifold on the cylinder

head to be removed. Refer to 2.21 EXHAUST

MANIFOLD, in this Section.

Figure 6A3-114

14. For the right hand cylinder head:

a. Remove the bolt securing the automatic

transmission dipstick tube bracket bolt

from the rear of the cylinder head (if

required).

Figure 6A3-115

b. Remove the bolt securing the powertrain

harness earth strap from the front of the

right hand cylinder head.

Figure 6A3-116

15. For the left hand cylinder head:

a. Place a drain tray beneath power steering

pump assembly.

b. Rem ove the power steer ing f luid r eser voir

from its bracket by levering the bracket

locking tab with a screwdriver or similar

lever, to release the reservoir. Refer to

Section 9A STEERING, of this Service

Information CD.

c. Loosen and remove high pressure line

flare nut (1) and O-ring (2) from pump

outlet fitting, using a back-up spanner on

the pump outlet fitting.

NOTE: Fluid will drain from the reservoir so

have a suitable container available.

d. Loosen low pressure hose clamp (3) and

remove hose from pump inlet fitting.

NOTE: Plug or tape the pump and hose

fittings to prevent dirt entry. Figure 6A3-117

e. Remove both bolts (2) securing the power

steering pump (1) to the front of the left

hand cylinder head.

NOTE: Access to the two bolts can be made

through the pulley holes, using a suitable

socket and extension.

f. Secure the reservoir and pump to one

side, using tie wire or similar.

Figure 6A3-118

g. Remove the powertrain wiring harness

strap (1) from the bracket at the rear of

the cylinder head.

h. Remove the bolt (2) securing the

powertrain harness earth cable at the rear

of the cylinder head.

Figure 6A3-119

i. Remove the coolant temperature sensor

(1).

NOTE: This step is necessary to allow the lower

left cylinder head bolt to be removed and to avoid

the risk of accidental damage to the sensor.

Figure 6A3-120

16. Progressively loosen cylinder head bolts

starting with the M8 bolts (3) first, working

from the outside to the centre.

NOTE: Discard all M11 bolts (1 and 2) after

removal, as these are ‘torque to yield’ bolts. Also

note the location of the two shorter, M11 bolts (2).

The M8 bolts (3) can be re-used.

17. Remove the cylinder head from the cylinder

block and place on two blocks of wood. This is

most important to avoid scratching the

machined surface.

Figure 6A3-121

18. Remove and discard the cylinder head gasket.

Figure 6A3-122

DISASSEMBLE

NOTE: Do not m ix r emoved c omponents. O rganis e

all parts in the order removed, to ensure that parts

reinstalled are fitted to their original locations.

1. Use a commercially available valve spring

compressor to compress the valve spring.

NOTE: It may be necessary to tap the valve spring

end of the compr essor with a plastic fac ed ham m er

to loosen jammed valve collets.

Figure 6A3-123

2. Remove the following components:

a. Valve stem collets (2).

b. Valve spring cap (3).

c. Valve spring (4).

d. Valves (8, 9).

e. Valve stem oil seal (5).

f. Valve spring shim (6).

NOTE: Do not remove coolant core plugs (7)

unless servicing is required.

Figure 6A3-124

CLEAN

1. Use a commercially available rotary wire

brush, clean all carbon deposits from the

combustion chambers and valve ports, taking

care not to scuff or damage the aluminium

cylinder head surfaces.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Clean carbon deposits from valve stems and

heads on a buffing wheel.

3. Check all bolt threads for dam age and rem ove

all threadlocking compound from both the

threaded holes and bolts.

Figure 6A3-125

INSPECT

Cylinder Head

1. Check cylinder head deck, inlet and exhaust

manifold mating surfaces for distortion, using

a straight edge (2) and feeler gauges (1).

Check lengthwise, diagonally and crosswise,

as shown by the alphabetical order, in Figure

6A3-125.

2. Check the cylinder head deck to exhaust

manifold the cylinder head deck to intake

manifold surfaces for flatness.

CYLINDER HEAD FLA T NE SS SPECIFICATI ON

(Measured Over the Cylinder Head Lengt h)

CYLINDER HEAD, E NGI NE BLOCK DE CK 0.22 m m

CYLINDER HEAD, EXHAUST MANIFO LD DECK 0.22 m m

CYLINDER HEAD, INTAKE MANIFOLD DECK 0.22 m m

Figure 6A3-126

NOTE: If any of these surfaces are outside

specification, the cylinder head may be machined,

provided the minimum overall height of 120.2 mm

(dimension ‘A’) is not exceeded.

3. Inspect all threaded holes for damage,

repairing as required with suitable thread

inserts. Refer to 3.16 THREAD REPAIR, in

this Section for more information

4. Clean any resisdue of cylinder head bolt

thread sealant from the cylinder block thr eads,

using installer, Tool No. J-42385-107 (this tool

is part of the thread repair kit, J-42385).

Important: Do not use anything but this thread

tool to clean the cylinder head threads in the

cylinder block.

5. Use compressed air to clean all residue from

bolt holes.

CAUTION: Wear safety glasses to avoid eye

injury.

6. Inspect coolant jacket expansion plugs for

signs of corrosion, replace plugs as

necessary.

NOTE: If replacing expansion plugs, apply a

coating of Loctite 242 or equivalent (Holden

Specification HN 1256, Class 2, Type 2) around

plug sealing surface.

7. Inspect cylinder head for cracks, especially

between valve seats or exhaust ports.

8. Inspect cylinder block deck surface for

distortion, refer to 3.15 CYLINDER BLOCK.

9. Clean the M8 cylinder head bolt threads,

replacing any bolt that has suspect threads,

stretched or damaged heads caused by

improper use of tools.

NOTE: Discard all M11 bolts after removal, as

these are “torque to yield” bolts.

Figure 6B3-127

Valve Springs

1. Check all valve springs for distortion. There

should be no more than 1.6 mm variance

(distance ‘1’) of the spring end, while the

spring is being rotated on a flat surface.

Replace springs that exceed this specification.

Figure 6A3-128

2. Use a commercially available valve spring

tester to measure each valve spring free

height and tension.

3. Discard any spring that does not conform to

specification.

VALVE SPRING FREE HEIGHT

(INTAKE and EXHAUST 52.9 m m

VALVE SPRING TE NS ION 310 N at 45.75 mm

SPECI F ICATION (Closed Val ve, Mini mum )

VALVE SPRING TENSION 980 N at 33.55 mm

SPECI F I CA T ION (Open Valve, Minimum)

Figure 6A3-129

Valves

1. Inspec t valve stem s for burr s and scratc hes. If

minor, these can be removed with an oil stone.

Valves with excessive stem wear or that are

warped (1 and 2), should be replaced.

Inspect the valve stem end (4) for wear. If

required wear can be corrected by grinding,

provided the stem end is ground at right

angles to the valve stem.

2. Inspect valve stem collet groove (3) for wear

or damage.

Figure 6A3-130

3. Check valve face for the following:

Either no margin (1) or less than 1.25 mm

after grinding (4).

Excessive pitting (2).

Burnt or corroded areas (3).

4. If an exhaust valve is to be reconditioned, the

face can be ground, using a valve refacing

machine. The valve seat angle is 45°.

The equipment manufacturer’s recommendations

must be carefully followed to achieve the required

standard of finish.

NOTE: If an ex haust valve face is r eground, it m ay

be necessary to shim the valve spring to achieve

the correct spring installed height. Refer to

Cylinder Head Reassemble in this Section, for

details.

Important: Intake valve faces must not be

refaced. Intake valves that are worn or have

face damage MUST be replaced.

Figure 6A3-131

Valve Guides

Excessive valve stem to guide clearance may

cause a noisy valve train, prem ature valve stem oil

seal wear, component dam age and/or ex cess ive oil

consumption.

Insuff icient valve s tem to guide c learance will res ult

in noisy or sticking valves. Valves that are too tight

may disturb engine smoothness or lead to

component damage.

Measure clearance as outlined in the following

steps.

1. Insert valve into its guide.

2. Clamp a dial indicator to a valve rocker arm

bolt that has been temporarily installed, in a

position where sideways movement of the

valve stem will cause movement of the

indicator needle.

To obtain a correct indication of wear, the

indicator stem must contact the side of the

valve stem , from 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 against the dial indicator using

light force, to obtain a clearance reading.

NOTE: Should any clearance measurement

exceed 0.093 mm (either intake or exhaust), the

cylinder head must be replaced.

Figure 6A3-132

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 transferred efficiently.

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.

1. 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

centre the valve seat grinder, it is essential that

valve guide wear is checked, as detailed in the

previous operation.

Both the intake and exhaust valve seat angles are

46° and seat width should not exceed specification.

VALVE SEAT WIDTH SPECIFICATION

INTAKE ................................................ 1.02 mm maximum

EXHAUST............................................. 1.78 mm maximum

If valve seats are reconditioned and the exhaust

valve faces ground, then light lapping will ensure a

gas tight seal when closed.

NOTE: New valves m ust not be lapped, as this will

destroy the protective coating on the valve face.

After refacing an existing valve or installing a new

valve, correct seating must be checked as follows:

a. Lightly coat valve face with bearing (Prussian)

blue.

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

turn.

c. Remove valve and check its contact with the

seat.

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

acceptable.

However, if only partial contact is shown,

reinstall the valve and rotate f or one full turn. If

blue now indicates a f ull c ontac t then the valve

must be refaced or replaced. If the blue

contact still only shows partial contact then

regrind the valve seat.

e. Clean all traces of blue from the valves and

seats, then clean thoroughly before applying

clean engine oil to both surfaces to protect

from rusting.

REASSEMBLE

NOTE: Ensure that all r e-used parts are reinstalled

to their original locations.

1. Lubricate all valve stems, guides and valve

faces with clean engine oil, then install valves

(8 and 9) to their correct ports.

2. Install valve spring shims (6).

Figure 6A3-133

3. Install valve stem oil seals (1) to each guide,

as follows:

a. Lubricate each valve stem (2) and valve stem

oil seal (1), with clean engine oil.

b. Install the valve stem oil seal (1) to the guide

and push down until the s eal contac ts the valve

guide.

c. Use Tool No. J 42078 to install the valve stem

oil seal, by pushing or lightly tapping until the

tool bottoms on the valve spring shim (3).

Figure 6A3-134

4. Measure the valve stem oil seal height above

the oil seal body and the valve spring shim

surf ace, as shown. Correct dis tance ‘A’ should

be between 18.1 - 19.1 mm

Figure 6A3-135

5. Install the valve springs and caps to each

valve stem.

6. Use a commercially available valve spring

compressor to compress the valve spring.

7. Install valve stem collets, retaining with

petroleum jelly if required.

8. Ensure that the both collets are correctly

located before releasing the valve spring

compressor.

9. Tap the end of each installed valve stem, with

a plastic faced hammer to seat the collets.

Figure 6A3-136

10. Measure the valve spring installed height

using a ruler or vernier caliper s. Measurem ent

is to be taken from the base of the valve

spring to the top.

11. If the measurement exceeds 46.25 mm, the

valve spring shim must be changed to one that

is approxim ately 0.5 mm thic k er to achieve the

required spring height.

NOTE 1: Do not shim the valve spring to obtain

less than the specified height.

NOTE 2: Do not assemble the valve spring

components without a spring shim at the cylinder

head.

NOTE 3: If a spring shim requires changing, the

valve stem oil seal must also be replaced.

12. Install the rem aining valves, springs and other

com ponents, c heck ing each spr ing height as it

is assembled.

13. If the cylinder head core plugs were removed,

install with sealant such as Loctite 565 (or

equivalent) before plug installation.

Figure 6A3-137

REINSTALL

Reinstallation of either or both cylinder heads is the

reverse to the removal procedure, except for the

following points.

NOTE 1: Do not refit removed M11 cylinder head

bolts. Always use NEW bolts when installing a

cylinder head.

NOTE 2: Do not use any sealant on the cylinder

head gask et, nor threadlock com pound on the M11

cylinder head bolts.

1. Check the cylinder head locating sleeves for

correct installation. Dimension ‘A’ is to be 6

mm.

Figure 6A3-138

2. Install a NEW cylinder head gasket correctly

over the locating sleeves.

NOTE: W hen correctly installed, the tab (arrow) on

the cylinder head gasket will be located to the front

half point (small arrow). This applies with either

cylinder head gasket.

Figure 6A3-139

3. Install the cylinder head over the locating

sleeves and the previously installed gasket.

4. Apply a 5 mm band of threadlock such as

Loctite 242 (or equivalent to Holden

Specification HN 1256, Class 2 Type 2), ONLY

to the threads of the M8 bolts (3).

5. Install the M8 cylinder head bolts (3), then

loosely install NEW M11 bolts (1 and 2).

Figure 6A3-140

6. Tighten the cylinder head bolts in the

sequence shown and to the correct torque

specification.

NOTE 1: Use a tor que angle meter s uc h as E 7115

to achieve an accurate turn angle reading.

NOTE 2: Bolt numbers 1 to 10 inclusive are the

M11 bolts, while bolts 11 to 15 are the M8 bolts.

CYLINDER HEAD BOLT TORQUE SPECIFICATION

Stage 1 (All M11 and M8 Bolts) 30 Nm

Stage 2 (Al l M11 Bol ts only) 90° turn angle

Stage 3 (M11 Bolts 1 to 8 only) 90° turn angle

(M11 Bolts 9 and 10 onl y) 50° turn angle

For the rem ainder of r einstallation process , refer to

the following procedures, in the order listed:

2.18 VALVE ROCKER ARMS AND PUSH RODS.

2.17 VALVE ROCKER ARM COVER.

2.15 VAPOUR VENT PIPE.

2.14 INTAKE MANIFOLD.

2.21 EXHAUST MANIFOLD/S.

NOTE: If a cylinder head is replaced, the initial

spark plug torque specification, must be amended

to:

SPARK PLUG

TORQUE SPECIFICATION 20 Nm

NEW CYLINDER HEAD

2.20 OIL LEVEL INDICATOR AND TUBE.

Figure 6A3-141

2.23 VALVE LIFTERS

REMOVE

NOTE: Ensure that all valve train components are

kept in order so they may be reinstalled, if required,

in their original locations.

1. Remove the cylinder head on the side

requiring hydraulic lifter removal. Refer

2.22 CYLINDER HEAD - REMOVE, in this

Section.

2. Remove both valve lifter guide retaining bolts.

3. Remove valve lifters and guides.

Figure 6A3-142

4. Remove the valve lifters from the guide/s.

Figure 6A3-143

Techline

DISASSEMBLE

1. Using a small, fine bladed screwdriver,

remove push rod seat retaining clip (10).

2. Remove push rod seat (9), oil metering valve

(8), plunger assembly (7) and plunger spring

(3) from lifter body (2).

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 this is not effective, soak lifter

assembly in a suitable cleaning fluid.

Legend:

1. Roller.

2. Lifter Body.

3. Plunger Spring.

4. Ball Check Retainer.

5. Ball Check Spring.

6. Ball Check.

7. Plunger.

8. Oil Metering Valve.

9. Push Rod Seat.

10.Push Rod Seat Retaining Clip.

Figure 6A3-144

3. Remove ball check retainer (4), ball check

spring (5) and ball (6) from the plunger (7).

Figure 6A3-145

CLEAN AND INSPECT

1. Thoroughly clean all parts in a suitable

cleaning fluid. Blow all parts dry with

compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect valve lifters for:

a. Bent or broken clip (1).

b. Worn pushrod socket (2). If the seat is worn,

inspect the matching push rod. Replace the

push rod if worn.

c. Scuffed or worn lifter body (3). Also inspect

lifter bore in the cylinder block.

d. Flat spots on roller (4). Replace lifter if the roller

is worn.

e. Loose or damaged pin (5).

f. Partially blocked oil hole (6).

g. W orn or damaged roller bearing. Replace lifter

if roller binds or roughness can be felt.

3. Inspect valve lifter guides for;

Cracks or damage.

Excessive wear in the lifter mounting bores. Figure 6A3-146

REASSEMBLE

NOTE 1: Do not attempt to recondition a lifter by

taking parts from other unserviceable lifters.

NOTE 2: Cleanliness is extremely important when

handling valve lifters. Lint or dirt can result in a

failed lifter.

1. Place check ball (3) on the small hole in the

plunger (4).

Figure 6A3-147

2. Carefully place check ball spring and retainer

over ball and press retainer into position in the

plunger with a small bladed screwdriver.

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

E1151.

Figure 6A3-148

4. Reinstall plunger spring into the lifter body.

5. Install plunger assembly in body, taking care

to align oil feed holes

6. Using a 1 mm diameter pin punch or similar,

unseat the check ball (2) in the plunger, then

push plunger down to the full extent of its

travel.

7. Use T ool 6A24 (or a suitable sized pin punch)

to align the oil feed holes (1) in the body and

plunger.

8. Fill the lifter with test fluid.

9. Reinstall the oil metering valve, push rod seat

(cup side facing out) and the retaining clip.

Figure 6A3-149

TESTING LIFTER LEAKDOWN RATE

After an hydraulic lifter has been cleaned,

inspected and reassembled, it must be tested

before being reinstalled. Lifter test fixture, Tool No

6A23 has been designed to test the leakdown rate

of the lifter, to ensure that the lifter will operate as

intended, when reinstalled.

1. Ensur e the test cup is c lean. Install the cup on

the fixture and place the lifter in the cup.

NOTE: Some versions of Tool No. 6A23 may

require modification to hold the base of the lifter

inside the tester cup.

2. Add test fluid, No. E1151 to completely cover

the lifter.

3. Place ball bearing supplied with test fixture in

the push rod seat of the 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 measure the time

required for the indicator needle on the tester

to travel from 'START' to the 0.125" position

on the scale.

Figure 6A3-150

8. The leak down rate (time between 'Start' and

the 0.125" position) m ust be between 10 to 30

seconds to assure satisfactory lifter operation.

NOTE 1: A doubtful lifter should be tested several

times before being discarded.

NOTE 2: Clean cup and refill with fresh test fluid

after several lifters have been tested.

9. Stand tested lifters upright so that fluid does

not drain from oil holes.

10. After all lif ter s have been tes ted, plac e a c over

over the test f ixture to keep dirt and dust f rom

the cup.

REINSTALL

NOTE: Ensure that reinstalled lifters are fitted to

the original locations.

1. Check that all valve lifter bores and adjacent

areas are clean.

2. Lubricate valve lifter bodies and their bores

with Lubrizol 6612 (or equivalent to Holden

Specification HN1961), then install lifters.

3. Install valve lif ters into the guides, aligning the

flat area at the top of the lifter with the flats in

the lifter guide bore. Push the lifter completely

into the guide bore

4. Install the valve lif ters and guide as sem bly into

the engine block.

5. Install each valve lifter guide retaining bolt/s

and tighten to the correct torque specification.

VALVE LIFTER GUIDE BOLT

TORQUE SPECIFICATION 12 Nm

6. Reinstall the cylinder head/s. Refer to

2.22 CYLINDER HEAD – REINSTALL in this

Section.

Figure 6A3-151

2.24 CRANKSHAFT BALANCER

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Remove radiator, refer Section 6B3 ENGINE

COOLING – GEN III V8 ENGINE of this

Service Information CD.

3. Remove the engine accessory and air

conditioning compressor drive belts. Refer

2.6 ENGINE DRIVE BELTS – REPLACE, in

this Section.

4. Remove the starter motor. Refer to

Section 6D3-2 STARTING SYSTEM of this

Service Information CD.

5. Remove the right hand side close-out cover

retaining bolt, then the cover.

Figure 6A3-152

6. Using the two starter motor bolts, install ring

gear holding Tool No. J 42386-A and tighten

fasteners to 50 Nm.

NOTE: Ensure that the teeth of the holding tool

engage correctly with the ring gear, before

tightening the fasteners.

Figure 6A3-153

7. Remove the crankshaft balancer bolt. Do not

discard bolt as it will be required for the

reinstallation process.

Figure 6A3-154

8. Use crankshaft end protector J 41816-2 and

puller J41816 (or three legged commercial

equivalent), to remove the crankshaft

balancer.

Figure 6A3-155

CLEAN AND INSPECT

1. Clean the crankshaft balancer in suitable

solvent.

2. Clean the belt grooves of all dirt or debris with

a wire brush.

3. Dry the crankshaft balancer with compressed

air.

4. Inspect the crankshaft balancer for the

following:

Worn, grooved, or damaged hub seal surface.

• A crankshaft balancer hub seal surface with

excessive scoring, grooves, rust or other

damage must be replaced.

• Minor imperfections on the hub seal surface

may be removed with polishing compound or

fine grade emery cloth.

• Dirty or damaged belt grooves.

• The balancer belt grooves should be free of

any nicks, gouges, or other damage that may

not allow the belt to track properly.

• Minor imperfections may be removed with a

fine file.

Important: In order for the belt to track properly,

the belt grooves should be free of all dirt or debris.

• Worn, c hunking or deter iorated r ubber between

the hub and pulley.

Figure 6A3-156

REINSTALL

Important: The crankshaft balancer reinstallation

and bolt tightening involves a multi- stage tightening

process . T he firs t pass ens ures that the balanc er is

installed completely onto the crankshaft. The

rem aining passes tighten the new bolt to the proper

torque.

The us ed crank shaf t balancer bolt will be used only

during the first pass of the balancer installation

procedure. Only install a NEW crank shaf t balancer

bolt and tighten as described in the remaining

passes of the balancer bolt tightening procedure.

1. Ensure that the teeth of the ring gear locking

Tool No. J 42386-A are correctly engaged.

2. Apply a smear of clean engine oil onto the seal

surface of the balancer, then install the

balancer onto the end of the crankshaft.

Important: The balancer s hould be positioned onto

the end of the crankshaft as straight as possible,

before to tool installation.

Figure 6A3-157

3. Use installer, Tool No. J 41665 to install the

crankshaft balancer, as follows:

a. Select the threaded rod, nut, washer and

installer, from tool J 41478.

b. Insert the installer sleeve, J 41665-1 into the

front of the balancer and back up with the

plate, J 41665-2.

NOTE: Insert the stepped end of sleeve J 41665-1

into the balancer, in this initial stage.

c. Use a set spanner (1) to hold the hexagonal

end of the threaded rod.

d. Use a second spanner (2) to rotate the

installation tool nut clockwise until the balancer

is started onto crankshaft.

e. Remove the stepped sleeve of J 41665-1 and

reverse it, s o that the lar ger end of the ins taller

is against the front of the balancer.

f. Repeat steps ‘a.’ through ‘d.’ above, until the

balancer is installed onto the crankshaft.

g. Remove the balancer installation tool.

Figure 6A3-158

4. Install the used crankshaft balancer bolt and

tighten to the specified torque.

CRANKSHAFT BALANCER

INSTALLATION TORQUE 330 Nm

SPECIFICATION

5. Remove the used balancer bolt and discard.

6. Measure the distance the balancer protrudes

from the crankshaft nose and check that

dimension ‘A’ is to specification.

DISTANCE ‘A’ 2.40 - 4.48 mm

7. If the dimension is not correct, reinstall Tool J

41665 and repeat the installation procedure.

Figure 6A3-159

8. Install a NEW crankshaft balancer bolt.

9. Tighten the crankshaft balancer bolt to the

correct torque specification, in two stages.

CRANKSHAFT BALANCER BOLT Stage 1: 50 Nm

TORQUE SPECIFICATION Stage 2: 140° Turn angle

10. Remove the ring gear locking tool No. J

42386-A.

11. Reinstall the close-out cover and tighten the

bolt to the correct torque specification.

RIGHT HAND CLOSE-OUT COVER

BOLT TORQUE SPECIFICATION 10 Nm

12. Install the starter motor. Refer to

Section 6D3-2 STARTING SYSTEM, of this

Service Information CD and tighten the

mounting bolts to the correct torque

specification.

STARTER MOTOR MOUNTING

BOLT TORQUE SPECIFICATION 40 - 55 Nm

13. Reinstall the radiator, refer

Section 6B3 ENGINE COOLING – GEN III V8

ENGINE of this Service Information CD.

Figure 6A3-160

2.25 COOLANT PUMP

REMOVE

NOTE: Apart from the rear cover, O-ring and

thermostat assembly, the coolant pump is not

serviceable and if found to be faulty must be

replaced as an assembly.

1. allow engine to cool to ambient temperature

(less than 50°C), then s lowly rem ove sc rew-on

pressure cap from the coolant reservoir.

CAUTION: DO NOT REMOVE SCREW-ON

PRESSURE CAP WHILE THE ENGINE

COOLANT TEMPERATURE IS ABOVE 50°

°°

°C, AS

PERSONAL INJURY MAY RESULT.

2. Disconnect battery earth lead.

3. Remove engine dress cover decorative nuts

(2), then remove the cover (1).

4. Loosen the two intake hose clamps, then

remove the hose (3).

5. Loosen coolant pump drive pulley bolts. Figure 6A3-161

6. Rem ove engine acc esso ry drive belt (2) , us ing

a 15 mm ring spanner, refer to 2.6 ENGINE

DRIVE BELTS – REPLACE, in this Section.

Figure 6A3-162

7. Drain engine coolant. Refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM, in

Section 6B3 ENGINE COOLING of this

Service Information CD.

8. Disconnect both heater hoses, the outlet and

inlet hoses from the coolant pump.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TYPE HO SE CLAMPS. F AIL URE TO DO

SO COULD RESULT IN EYE INJURY.

Figure 6A3-163

9. Remove the loosened four bolts securing the

coolant pump pulley to the hub. Remove

pulley.

Figure 6A-164

10. Remove the two bolts (1) securing the drive

belt tensioner (2) to the coolant pump housing

and set the tensioner to one side.

Figure 6A-165

11. Loosen, then rem ove the s ix bolts (1) secur ing

the coolant pump (2) to the cylinder block (3).

12. If necessary, use a soft faced hammer to

lightly tap coolant pump housing (2) to

dislodge it from the cylinder block.

13. Remove coolant pump gaskets (3) and

discard.

Figure 6A-166

DISMANTLE

NOTE: Apart f rom the s ervic e operations des c ribed

here, there are no other serviceable parts in the

coolant pump assembly and if required, then the

assembly must be replaced as a complete unit.

1. If required, remove the five bolts (4) securing

the rear cover (3) to the coolant pum p (2). T ap

with a soft faced hammer to dislodge the cover

from the pump body.

2. Remove the sealing O-ring (1) from the

coolant pump body (2).

3. For thermostat remove, test and reinstall

procedures, refer to 2.9 THERMOSTAT, in

Section 6B3 ENGINE COOLING of this

Service Information CD.

Figure 6A-167

CLEAN AND INSPECT

1. Remove the old gasket or gasket material

from the coolant pump sealing surfaces and

cylinder block, taking care not to scratch the

machined surfaces.

2. Clean all dirt and debris from the coolant

pump housing.

3. Inspect the coolant pump for the following:

• Gasket surfaces for excessive scratches or

gouging.

• Hose sealing surfaces for scratches, gouging

or corrosion.

• Restrictions, corrosion or evidence of cavitation

within the internal coolant passages or on the

pump impeller.

• Excessive side-to-side play in the pulley shaft.

• A loose belt pulley or a pulley with excessive

wear or scoring on the belt tracking area.

• Evidence of coolant leakage at the coolant

outlet housing or rear cover gasket (if these

parts have not been removed).

• Leakage at the coolant pump vent hole. A st ain

around the vent hole is acceptable. If leakage

occurs (dripping) with the engine running and

the cooling system pressurised, replace the

coolant pump.

REASSEMBLE

1. Install a new O-ring seal to the cleaned groove

in the pump housing, then install the cover

and retaining bolts.

2. Gradually tighten every second bolt until the

correct torque specification is reached.

COOLANT PUMP REAR COVER

BOLT TORQUE SPECIFICATION 13 - 15 Nm

REINSTALL

Installation is the r everse to rem oval except for the

following items:

1. Ensure that the coolant pump and cylinder

block surfaces are clean and dry.

2. Using two bolts ins erted into the coolant pum p

on each side as guides, install NEW gaskets

over them and install the coolant pump to the

cylinder block.

3. Install remaining bolts and tighten to the

correct torque specification, in two stages.

COOLANT PUMP BOLT Stage 1: 15 Nm

TORQUE SPECIFICATION Stage 2: 30 Nm

4. Install the coolant pump pulley and attaching

bolts, tightening to the correct torque

specification.

COOLANT PUMP PULLEY BOLT

TORQUE SPECIFICATION 15 Nm

5. Install the engine accessory drive belt

tensioner and attaching bolts , tightening to the

correct torque specification.

ENGINE ACCESSORY DRIVE BELT

TENSIONER BOLT 40 - 60 Nm

TORQUE SPECIFICATION

6. Install all removed radiator hoses and clamps.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TYPE HOSE CLAMPS. FAILURE TO DO

SO COULD RESULT IN EYE INJURY.

7. Install the engine accessory drive belt. Refer

2.6 ENGINE DRIVE BELTS - REPLACE in

this Section.

8. Refill cooling system, refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM in

Section 6B3 ENGINE COOLING of this

Service Information CD.

9. Check for cooling system leaks, refer to

2.8 PRESSURE TESTING in

Section 6B3 ENGINE COOLING of this

Service Information CD.

2.26 CRANKSHAFT FRONT OIL SEAL

REPLACE

1. Remove the crankshaft balancer. Refer

2.24 CRANKSHAFT BALANCER in this

Section.

2. Using Tool No. 56750 (or commercial

equivalent) remove seal from the front cover.

Figure 6A3-168

3. Lubric ate the outer edge of a NEW oil seal ( 1)

and the front cover oil seal bore with clean

engine oil.

Important: Do not lubricate the oil seal sealing

surface.

4. Install the crankshaft front oil seal (1) onto the

guide of Tool No. J 41478.

5. Install the threaded rod (with nut, washer,

guide, and oil seal) of Tool No. J 41478 into

the end of the crankshaft.

6. Using a set spanner, hold the head of the

installer bolt, then rotate the installer nut

clockwise, using a second set spanner, until

the seal bottoms in the cover bore.

7. Remove the tool from the crankshaft.

8. Inspec t the oil seal for c orrect ins tallation. The

oil seal should be installed evenly and

completely into the front cover bore.

9. Install the crankshaft balancer, refer

2.24 CRANKSHAFT BALANCER, in this

Section.

Figure 6A3-169

2.27 ENGINE MOUNTS

CHECK

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

fluid leakage. If oil leakage from a mount is

visible, the mount is defective and must be

replaced.

2. Using a suitable engine lifting crane, raise the

engine to remove the weight from the mounts

and to place rubber in slight tension.

Check that the mounting rubber has not

deteriorated, split or separated from its metal

plates.

Replace mount if found to be defective.

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Drain the cooling system. Refer to

Section 6B3 ENGINE CO OLING - GEN III V8

ENGINE.

3. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

4. Loosen the two clam ps securing the air intake

duct (3) to the thr ottle body and Mas s Air Flow

(MAF) sensor.

5. Raise front of vehicle and place on safety

stands. For location of jacking and support

points, refer to Section 0A GENERAL

INFORMATION.

6. Remove the exhaust pipe to manifold flange

nuts on the engine mount side to be removed.

7. From under the vehicle, remove the lower

mounting to crossmember nut for both

mounts.

NOTE: A commercially available, 18 mm deep

socket will be required for this operation.

8. Lower the vehicle to the ground, then remove

the exhaust manifold on the engine mounting

side to be removed. Refer to

2.21 EXHAUST MANIFOLD - REMOVE, in

this Section.

Figure 6A3-170

9. Use suitable engine lifting equipment to raise

the engine, removing the weight from the

engine mounts.

10. Remove the mount bracket to engine block

bolts.

11. Lift the mount and bracket assembly from the

crossmember and remove from the vehicle.

12. Remove the engine mount to bracket nut and

separate the heat shield and mount from the

bracket.

NOTE: While the left hand mount is shown, the

operation is similar for either engine mount except

that, for the right hand engine mount, remove the

battery harness bracket bolt, before removing the

mounting bracket to engine block bolts.

Figure 6A3-171

REINSTALL

Reinstallation of either or both engine mounts is the

reverse to removal, except for the following points.

1. If removed from the bracket, reinstall the

engine mount and heat s hield, then tighten the

nut to the correct torque specification.

ENGINE MOUNT TO BRACKET NUT

TORQUE SPECIFICATION 70 - 90 Nm

2. Install the engine mount stud into the

crossmember, then install the bracket to

cylinder block bolts and tighten to the correct

torque specification.

ENGINE MOUNTING BRACKET BOLT

TORQUE SPECIFICATION 40 - 60 Nm

3. Lower the engine allowing the weight to settle

on the crossmember, install both engine

mount nuts and tighten to the correct torque

specification.

ENGINE MOUNT TO CROSSMEMBER

NUT TORQUE SPECIFICATION 70 - 90 Nm

4. Install exhaust manifold. Refer to

2.21 EXHAUST MANIFOLD - REINSTALL in

this Section.

3. MAJOR SERVICE OPERATIONS

3.1 ENGINE ASSEMBLY

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Loosen the screw-on pressure cap on the

coolant surge tank to relieve any system

pressure, then remove cap.

CAUTION: To avoid serious personal injury,

never remove the screw-on pressure cap when

the engine is hot. Sudden release of cooling

system pressure is very dangerous and could

cause personal injury.

3. Rem ove the engine dress cover retaining nuts

(2), then remove the cover (1).

4. Loosen the two clam ps securing the air intake

duct (3) to the thr ottle body and Mas s Air Flow

(MAF) sensor.

5. Remove air intake duct (3) assembly from

throttle body and MAF sensor.

6. De-pressurise fuel rail. Refer to

Operation 2.13, in this Section. Figure 6A3-172

7. Remove the screw-on pressure cap from the

surge tank.

8. Place a s uitable drain tray beneath the engine,

then loosen the worm drive hose clam p (1) on

the lower hose at the left hand radiator tank,

remove the hose and drain the coolant.

9. Loosen the spring clamp securing the lower

left hand hose to the tr ansf er tube and rem ove

the lower left hand hose from the vehicle.

CAUTION: Wear safety glasses to avoid eye

injury.

NOTE: If access to the transfer tube hose clamp is

poor, then disconnect the lower hose from the

radiator, left hand tank. After the radiator is

removed (Step 10), the transfer tube and all lower

hoses can then be removed as an assembly.

10. Loosen top radiator hose (2) clamps and

remove hose from the engine.

11. Remove the engine cooling fans and radiator.

Refer to Section 6B3, ENGINE COOLING –

GEN III V8 ENGINE.

Figure 6A3-173

Techline

12. Recover refrigerant charge, refer to Section

2C AIR CONDITIONING - SERVICING AND

DIAGNOSIS.

13. Remove the suction/discharge hose pad (2)

retaining nut (1) from the com pressor (3), then

remove O-rings (4) and immediately cap or

plug all openings to prevent moisture entry

from the atmosphere.

Figure 6A3-174

14. After removing the four oil pan under-tray

bolts, remove the tray from the vehicle.

15. Rem ove oil pan drain plug and drain engine oil

into a suitable container.

Reinstall drain plug once oil has drained

sufficiently.

16. Disconnect windshield washer hose (1) at the

in-line connector located at the rear, left hand

side of the engine hood.

Figure 6A3-175

17. With engine hood adequately supported,

remove clips (2) securing upper ends of struts

(1) to hood pivots (3).

Disengage struts (1) from hood pivots (3) and

lay struts onto inner fender panel.

18. Using an ass istant to hold the hood assem bly,

remove the engine hood bracket to hinge

attaching bolts (4) , as shown, then caref ully lift

the hood assembly clear of the vehicle.

Figure 6A3-176

19. Remove both heater hose clamps at the

engine water pump, taking note of the hose

layout. Plug open ends to prevent dirt entry.

Figure 6A3-177

20. Remove the nut (1) securing the battery

harness earth terminal (2) from ABS/CRUISE

CONTROL bracket stud (4).

21. Remove the engine cooling fan relay

assembly (7), then disconnect the engine fan

wiring harness connector (8) from the relay

and battery harness.

22. Remove the clip holding the battery harness

(5) to the side rail bracket (6) and lay the

harness on the engine.

Figure 6A3-178

23. Disconnect main wiring harness to powertrain

and battery harness connectors (2) from the

main wiring harness connectors (1), at the

dash panel.

Figure 6A3-179

24. Disconnec t powertrain wiring harnes s clips (6)

from the engine compartment dash panel

retaining bracket (‘5’, view D), refer Figure

6A3-180.

25. Disconnect powertrain wiring harness

connectors from the:

• Surge tank, low coolant switch (‘1’, view

A).

• Theft deterrent horn (‘4’, view C).

Figure 6A3-180

26. Loosen hose clamps and remove hoses from

the coolant surge tank. Then grasp the surge

tank and firmly pull to remove it from the

retaining pegs.

27. Rem ove the c over f r om the Powertrain Contr ol

Module (PCM).

28. Rem ove both PCM c onnector s (s ee ‘3’, view B

in Figure 6A3-180) in the engine bay, after

removing the retaining screw (bold arrows)

from each connector.

29. Rem ove the PCM wiring harness r etaining clip

from the PCM container, to free the harness.

Figure 6A3-181

30. From inside the passenger compartment of

the vehicle, remove the lef t hand shroud panel

trim, and glove box assembly. For details,

refer Section 1A1 and Section 1A3,

respectively, of the VT Series I Service

Information.

31. Rem ove the wiring harness c onnec tor ( 1) f r om

the Powertrain Interface Module (PIM).

32. Remove the Throttle Relaxer Module (TRM)

connector (2) (if fitted), as follows:

Lift the locking lever on the TRM connector (2),

pivot down and remove the c onnec tor f r om the

lower hook.

33. To remove the PIM, either use the fingers (or

a flat bladed screwdriver) to push on and

dislodge the retaining hook (bold arrow), then

remove the PIM and TRM as an assembly.

34. Cut the wiring harness straps (4) and discard.

35. Release the harness to dash panel grommet

(3) and feed the harness and connectors out

into the engine bay.

36. Lay the powertrain wiring harness on top of the

engine.

Figure 6A3-182

37. Disconnect the cruise control cable (1) (if

fitted) (r efer Figure 6A3- 183) from the stud (2)

on the throttle body valve lever (3), then

remove the outer cable (8) from the retainer

bracket (4).

38. Lift the throttle cable ( 5) f r om the clip ( 6) at the

fuel rail crossover pipe, then lift the cable (5)

from the retainer bracket (4).

39. Remove the inner throttle cable (7) from the

throttle body valve lever (3).

40. Set the cable/s to one side.

Figure 6A3-183

41. Using quick connect release Tool No. 7371,

open tool and install over fuel rail line.

42. Close 7371 and pull into fuel rail line quick

connect (1) to release it from the fuel rail, pull

back on the quick connect (1), to remove.

Remove the quick connect release tool from

the fuel rail line.

43. Disconnect the vapour line (2) connection to

the EVAP purge control valve (3) and set to

one side.

Important: Plug all openings to prevent fuel

leaking and dir t/contaminants f r om entering the f uel

system.

Figure 6A3-184

44. Loosen the hose clamp on the return hose at

the power steering reservoir end.

45. After placing a suitable container under the

reservoir, remove the hose and drain the

reservoir fluid.

Important: Plug both openings to prevent dirt

entry.

46. Using tie wire or similar, secure the hose to

one side.

Figure 6A3-185

47. Loosen and remove the high pressure line

flare nut (1) and O-ring (2) from the pump

outlet fitting at the rear of the power steering

pump. Use a back-up spanner on the outlet

fitting when loosening the flare nut.

Important: Plug both openings to prevent fluid loss

and/or dirt entry.

Figure 6A3-186

48. Disconnect the brake booster and heater

control, vacuum hoses from the rear of the

intake manifold.

Figure 6A3-187

49. Remove number 3 spark plug lead and plug

from the left bank, then remove the upper left

engine mount to engine bracket nut, using a

socket, universal joint, long extension and

ratchet.

50. For the right hand engine mount, repeat the

above process by removing the number 2

spark plug lead and plug (or number 4 spark

plug), to gain access to the upper, right hand

engine mount nut.

NOTE: To improve access to these two nuts, an

alternative method is to remove both exhaust

manifolds. Refer to 2.21 EXHAUST MANIFOLD, in

this Section, for the necessary procedure, if

required.

Figure 6A3-188

51. Raise vehicle front and rear and support on

safety stands. For location of jacking and

support points, r ef er to Section 0A GENERAL

INFORMATION.

52. Remove propeller shaft, refer to Section 4C

PROPELLER SHAFT AND UNIVERSAL

JOINTS, in of the VT Series II Service

Information. Install a suitable plug in the rear

of the transmission.

53. Disconnect the gear shift control from the

transm ission. Refer to Section 7B3 M ANUAL

TRANSMISSION - GEN III V8 ENGINE, or

Section 7C4 AUT OM ATIC TRANSMISSION -

ON-VEHICLE SERVICING, in of the VT

Series II Service Information.

54. From under the front of the vehicle, remove

the oil pan under-tray. Refer 6B3 ENGINE

COOLING - GEN III V8 ENGINE, of this

Service Information CD.

55. Remove the two bolts holding the power

steering, high pressure line brackets to the oil

pan.

Figure 6A3-189

56. While not essential, it is recommended that

the oxygen sensors (1) are removed from the

exhaust pipes, to avoid accidental damage.

a. Disc onnect the wiring har nes s c onnec tors

from each oxygen sensor.

b. Remove both oxygen sensors from the

exhaust pipes.

c. Plug openings in exhaust pipes.

57. Remove both exhaust pipe to manifold flange

nuts.

Figure 6A3-190

58. Remove the two bolts (2) securing the catalytic

converter bracket (1).

NOTE: While Figure 6A3-191 shows an automatic

transm ission equipped vehicle, this operation is the

same for manual transmission vehicles as well.

59. Lower the vehicle to the ground.

Figure 6A3-191

60. Attach a suitable lif ting chain and hooks to the

engine lifting brackets located at the left hand

front (1) and right hand rear (2) of the engine.

61. Using a suitable lifting crane, raise the engine

slightly to take the weight off the engine

mounts.

Figure 6A3-192

Vehicles with Manual Transmission

62. Mark the relationship of the engine rear

crossmember (2) to the frame, to assist with

alignment on reassembly.

63. Remove the four bolts (3) holding the rear

crossmember (2) to the frame, remove the

rear mounting to crossmember nuts (4), then

remove the crossmember from the vehicle.

64. Remove the catalytic converter bracket to

transmission extension bolts (7) and nuts, then

remove the bracket (6) from the vehicle and

set to one side.

Figure 6A3-193

Vehicles with A utomatic Transmission

65. Using a scriber or similar, mark the

relationship of the engine rear crossmember

(2) to the frame, to assist with alignment on

reassembly.

66. Remove the four bolts (3) holding the rear

crossmember (2) to the frame, remove the

rear support to crossmember nuts (4), then

remove the crossmember from the vehicle.

67. Remove the rear mount to transmission

extension housing bolts (5), then remove the

mount (1) and the catalytic converter bracket

(6).

Figure 6A3-194

68. Raise engine and transmission assembly with

front tilted upward and a floor jack supporting

the rear of the transmission assembly.

Important: Take care when removing engine and

transmission assembly, that no part of the

assembly is allowed to rest on the power steering

rack.

NOTE: Do not allow the engine to swing forward

and damage the air conditioning condenser (if

fitted).

69. Continue to lift and m anoeuvre the engine and

transmission assembly clear of the engine

bay.

DISASSEMBLE

1. Remove the wiring harness connectors and

earth connections from the engine and

transmission assembly and carefully set the

wiring harness to one side.

2. Remove the transmission and mount the

engine assembly in a suitable engine stand.

The m os t practic al position over all, is to mount

the engine on the side, using the engine

mount bolt holes.

Important: If the engine is to be dism antled and in

particular, the camshaft is to be rem oved, then the

cam shaf t lobe lift check should be car ried out, prior

to the removal of the cylinder heads. See

Operation 3.2 for details.

3. Drain engine oil into a suitable, clean

container.

4. Remove the following components, as

described in either this Section or other,

designated Sections:

a. Oil filter, refer to Operation 2.3.

b. Engine drive belts, refer to Operation 2.6.

c. Air conditioning compressor, refer

Section 2B, AIR CONDITIONING -

REMOVAL AND INSTALLATION

d. Engine accessory drive belt idler and

tension pulley assemblies, refer to

Operation 2.7 and 2.9.

e. Air conditioning drive belt idler and

tension pulley assemblies, refer to

Operation 2.8 and 2.10.

f. Generator and mounting brackets, refer

Section 6D3-1 CHARGING SYSTEM -

GEN III V8 ENGINE, of this Service

Information CD.

g. Intake manifold, refer to Operation 2.14.

h. Vapour vent pipe, refer to Operation 2.15.

i. Engine valley cover, refer to Operation

2.16.

j. Valve rocker arm covers, refer to

Operation 2.17.

k. Valve rocker arm s and push rods , refer to

Operation 2.18.

l. Oil level indicator and exhaust manifolds

(if not already removed), refer to

Operation 2.20 and 2.21. Plug the oil

level indicator hole in the oil pan to avoid

dirt entry.

m. Cylinder heads and valve lifters, refer to

Operation 2.22 and 2.23

n. Starter motor, refer Section 6D3-2

STARTING SYSTEM - GEN III V8

ENGINE, of this Service Information CD.

o. Crankshaft balancer, refer to Operation

2.24.

p. Coolant pump assembly, refer to

Operation 2.25.

REASSEMBLE

Reassembly of the components listed in step 4. of

the DISASSEMBLE description above, is the

reverse of the disassembly procedures, except for

specific points stated in each description for that

component.

For other engine components that are detailed in

this Section of MAJOR SERVICE OPERATIONS,

the reassembly process is also detailed.

REINSTALL, SETUP AND TESTING

Installation of the engine assembly is the reverse of

removal procedures, noting the following points:

1. Ensure that all fasteners are tightened to the

correct torque specifications, as detailed in

6. TORQUE SPECIFICATIONS, at the end of

this Section.

2. Use only the specified engine lubricant type

and quantity. It is recommended that a

fluoresc ent oil dye, such as that contained in J

28481-B, be added to assist in any future oil

leak diagnosis.

3. Fill the cooling system with the proper quantity

and grade of coolant. Refer Section 6B3

ENGINE COOLING - GEN III V8 ENGINE,of

this Service Information CD.

4. Check transmission fluid level, topping up as

required, using the specified lubricant for the

transmission fitted. Refer Section 7C4

AUTOMATIC TRANSMISSION - ON-

VEHICLE SERVICING, of this Service

Information CD.

5. Disable the ignition system. Refer to

2.5 COMPRESSION CHECK, for details.

6. Crank the engine several tim es. Listen for any

unusual noises or evidence that parts are

binding.

7. Enable the ignition system, start the engine

and listen for unusual noises.

8. Check the vehicle oil pressure gauge or

warning lamp and confirm that the engine has

acceptable oil pressure. If necessary, install

an oil pressure gauge and measure the

engine oil pressur e. Refer to 2.4 ENGINE OIL

PRESSURE - CHECK, in this Section.

9. Run the engine speed at about 1,000 rpm until

the engine has reached normal operating

temperature.

10. Listen for sticking lifters and other unusual

noises.

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

while the engine is running, correcting as

required.

12. Perform a final inspection for the proper engine

oil and coolant levels.

13. Check engine hood alignment.

3.2 CAMSHAFT LOBE LIFT

MEASURE

Important: Measuring camshaft lobe lift is a

procedure used to determine if the camshaft lobes

have worn. This test is to be performed prior to

engine disassembly and with the camshaft, push

rods and valve lifters installed in the engine.

1. T o measure the c amshaf t lobe lift, proceed as

follows:

a. Remove the valve rocker arm s and bolts.

Refer Operation 2.18, in this Section.

b. Install an M8 x 1.25 dial indicator

mounting stud into the valve rocker arm

bolt hole.

c. Assemble the components of a

commercially available dial indicator (or

Tool J 8520) and position onto the

installed stud, as shown.

d. Position the shaf t of the dial indic ator onto

the end of the pushrod.

e. Zero the dial indicator dial.

f. Slowly rotate the crankshaft clockwise

until the dial indicator obtains its highest

and lowest readings.

g. Repeat for all valves and compare the

readings obtained against specifications.

CAMSHAFT LOBE LIFT Intake Lobe 7.43 mm

SPECIFICATION Exhaust Lobe7.43 mm

NOTE: If the readings are not within specification,

then the camshaft lobes are worn and require

further investigation when the camshaft is removed.

Figure 6A3-195

3.3 OIL PAN

REMOVE

Important: Because of critical alignment

procedures required for oil pan installation, it is

strongly recom mended that the engine as sembly is

removed from the vehicle, before oil pan removal.

1. Remove the left close-out cover and bolt.

Figure 6A3-196

2. Remove the right close-out cover and bolt.

Figure 6A3-197

3. Invert the engine assembly.

4. Remove the oil pan bolts, loosening gradually

from the ends and work ing inwards toward the

centre.

5. Bump the oil pan sideways with the heel of a

hand or a rubber hammer, to dislodge the

seal.

Figure 6A3-198

Techline

DISASSEMBLE

NOTE: The original oil pan gasket is retained and

aligned to the oil pan by rivets. When installing a

new gasket as a service replacement, it is not

necessary to install new oil pan gasket rivets.

Important: Do not allow metal shavings or other

foreign material to enter the oil passages in the oil

pan during gasket removal. Plug all openings

before commencing drilling operations.

1. Use a sharp twist drill (3) to drill out each of

the retaining rivets (2), as required.

2. Remove the oil pan gasket (1) from the oil

pan.

3. Discard the gasket and rivets.

Figure 6A3-199

4. Remove the oil transfer cover nuts (3), cover

(2), and gasket (1). Discard the gasket (1).

5. Remove the oil filter adaptor (4) if required.

NOTE: If removal of the oil transfer cover nuts (3)

is required while the oil pan is still installed (e.g.

during fitment of an external oil cooler), the studs

MUST NOT be removed. Otherwise the transfer

pipes and gasket inside the oil pan, may become

dislodged.

Figure 6A3-200

6. Remove the two oil filter transfer tube bolts

(3).

7. Remove the oil filter transfer tubes (1) and

discard the gaskets (2).

8. If required, use an Allen key sock et to r emove

the oil gallery plugs (4).

NOTE: Because of thread sealant applied to the

threads, it is recom mended that the front studs are

left attached to the transfer tube assembly and the

whole assembly withdrawn from inside the oil pan.

Figure 6A3-201

9. Remove the oil pan baffle bolts (six places)

and baffle.

Figure 6A3-202

CLEAN AND INSPECT

1. Clean the oil pan in a suitable solvent. Ensure

that all oil passages and recesses are

thoroughly cleaned.

2. Clean the oil pan gasket surfaces, using a

plastic scraper to avoid scratching or

damaging the machined surfaces.

3. Dry the oil pan with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

4. Inspect the oil pan for the following:

a. Gasket sealing surfaces for excessive

scratches or gouging.

b. Oil pan drain plug and threaded drain hole

for damaged threads. The drain plug O-

ring seal may be reused if not cut or

damaged.

c. Oil filter sealing surface for scratches or

gouging.

d. Oil f ilter adaptor for a loos e f it or damaged

threads.

e. Oil passages for restrictions.

f. Oil f ilter bypass valve in the oil filter f lange

for proper operation Lightly push the

bypass valve into the bore. The valve

spring should reseat the valve to the

proper position.

5. Inspect the oil transfer tube for damage or

restrictions.

REASSEMBLE

1. Install the oil pan baffle and r etaining bolts and

tighten to the correct torque specification.

OIL PAN BAFFLE BOLT

TORQUE SPECIFICATION 12 Nm

Figure 6A3-203

2. If removed, apply thread lock com pound suc h

as Loctite 242 (or equivalent) to the cleaned

threads of the oil gallery plugs (4).

3. Use an Allen key socket and tighten the oil

gallery plugs to the correct torque

specification.

OIL GALLERY PLUG

TORQUE SPECIFICATION 25 Nm

4. Apply thread lock compound such as Loctite

242 (or equivalent) to the cleaned threads of

the oil transfer tube bolts (3)

5. Using NEW gaskets (2), install the oil filter

transfer tubes (1).

6. Install the two bolts (3) and tighten to the

correct torque specification.

OIL FILTER TRANSFER TUBE

BOLT TORQUE SPECIFICATION 12 Nm Figure 6A3-204

7. Install NEW oil pan transfer cover gasket (1),

cover (2) and nuts (3).

8. Tighten the nuts to the correct torque

specification.

OIL PAN TRANSFER COVER NUT

TORQUE SPECIFICATION 12 Nm

9. If removed, install the oil filter adaptor and

tighten to the correct torque specification.

OIL FILTER ADAPTOR

TORQUE SPECIFICATION 55 Nm

Figure 6A3-205

Techline

REINSTALL

Important: The alignment of the structural oil pan

is critical. T he rear bolt hole locations of the oil pan

provide mounting points for the transmission bell

housing. To ensure the rigidity of the powertrain

and correct transmission alignment, it is important

that the rear of the engine block and the rear of the

oil pan are flush. The rear of the oil pan must

NEVER protrude beyond the engine block and

transmission bell housing plane.

NOTE 1: Do NOT reuse the oil pan gasket.

NOTE 2: It is not necessary to rivet the NEW

gasket to the oil pan.

1. Apply a 5 mm wide bead of sealant such as

Loctite 565 or equivalent, 20 mm long to the

engine block, as shown. Apply the sealant

directly onto the tabs of the front cover gasket

that protrude into the oil pan surface.

Figure 6A3-206

2. Apply a 5 mm wide bead of sealant such as

Loctite 565 or equivalent, 20 mm long, to the

engine block, as shown. Apply the sealant

directly onto the tabs of the rear cover gasket

that protrude into the oil pan surface.

Figure 6A3-207

3. Pre-assemble the oil pan gasket to the oil pan.

Important: Be sure to align the oil gallery passages

in the oil pan and engine block properly with the oil

pan gasket.

4. Install the oil pan bolts to the pan and through

the gask et. Install the oil pan, gask et and bolts

to the engine block. Tighten bolts finger tight.

Do not over-tighten.

5. Place a straight edge across the rear of the

engine block and the rear of the oil pan at the

transmission bell housing mounting surfaces.

Figure 6A3-208

6. Align the oil pan until the rear of engine block

and rear of oil pan are flush or even.

7. Install the oil pan to front cover bolts and the

oil pan to rear cover bolts, tighten to the

correct torque specifications.

OIL PAN TO FRONT COVER

BOLT TORQUE SPECIFICATION 25 Nm

OIL PAN TO REAR COVER BOLT

TORQUE SPECIFICATION 12 Nm

NOTE: T his prelim inary step is required to avoid oil

pan ‘creep’ and create a misalignment condition.

8. Place a straight edge across the rear of the

engine block and rear of oil pan at the

transmission bell housing mounting surfaces.

9. Insert a feeler gauge between the straight

edge and the oil pan transm iss ion bell housing

mounting s ur f ac e and chec k to make sur e that

the oil pan is flus h to no more than a 0.25 m m

gap between the pan and straight edge

(dimension ‘A’).

Important: The rear of the oil pan must NEVER

protrude beyond the engine block and transm ission

bell housing mounting surfaces.

10. Install remaining oil pan to cylinder block bolts

and tighten to the correct torque specifications.

OIL PAN TO CYLINDER BLOCK

BOLT TORQUE SPECIFICATION 25 Nm

If the oil pan alignment is not within specification,

remove the oil pan and repeat the above

procedure.

Figure 6A3-209

3.4 ENGINE FRONT COVER

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recomm ended

that the engine assembly is removed from the

vehicle, before oil pan removal.

1. Remove the crankshaft balancer. Refer

2.24 CRANKSHAFT BALANCER - REMOVE,

of this Service Information CD.

2. Remove the front cover bolts.

3. Remove the front cover and gasket. If the

gasket is undamaged, it may be re-used.

Figure 6A3-210

CLEAN AND INSPECT

1. Prise the old oil seal from the front cover and

discard.

2. Clean the front cover in a suitable solvent and

blow dry.

CAUTION: Wear safety glasses to avoid eye

injury.

3. Inspect the front cover sealing surfaces for

excessive scratches and/or gouges.

4. Inspect the front cover gasket for damage to

the membrane or distortion to the aluminium

carrier.

5. Inspect the front cover to oil pan threaded

holes for damaged threads or debris. Refer to

3.16 THREAD REPAIR, in this Section, if

rectification is required.

6. Inspect the cover crankshaft oil seal bore for

damage.

REINSTALL

NOTE 1: Do not reuse the crankshaft oil seal if

inspection shows it t o be damaged in nay way.

NOTE 2: Do not apply any type sealant to the front

cover gasket.

NOTE 3: The special tools in this procedure are

used to properly align the engine front cover at the

oil pan surface and to centre the crankshaft front oil

seal.

NOTE 4: All gasket surfaces should be free of oil

or other foreign material during assembly.

Techline

NOTE 5: The crankshaft front oil seal MUST be

centred in relation to the crankshaft. The oil pan

sealing surf ace at the front cover and engine block

MUST also be aligned within specifications.

NOTE 6: An improperly aligned front cover may

cause premature front oil seal wear and/or engine

assembly oil leaks.

1. Install the front cover gasket, cover, and bolts

onto the engine.

2. Tighten the cover bolts finger tight only. Do

not tighten.

Figure 6A3-211

3. Assemble alignment tool J 41480 to front

cover and install bolts (1) (part of Tool J

41480), in the locations shown but do not

tighten.

4. Install the alignm ent tool bolts (2) (part of Tool

J 41480) to the engine block and tighten to the

specified torque.

FRONT COVER ALIGNMENT TOOL

BOLT TO ENGINE BLOCK 25 Nm

TORQUE SPECIFICATION

Figure 6A3-212

5. Install c entralising T ool J 41476 as shown and

hold in position by hand.

NOTE: DO NOT install the crank shaf t balancer bolt

to retain. If the bolt is installed and over tightened

the alignment tool will be destroyed.

Important: Align the tapered legs of the tool with

the machined alignment surfaces on the front

cover.

6. Tighten the two bolts (1) securing Tool J

41480 to the front cover, to the specified

torque.

ALIGNMENT TOOL TO FR ONT

COVER BOLT 25 Nm

TORQUE SPECIFICATION

7. Tighten the engine front cover bolts to the

correct torque specification.

ENGINE FRONT COVER BOLT

TORQUE SPECIFICATION 25 Nm

8. Remove the alignment tools.

Figure 6A3-213

9. Measure the oil pan surface to front cover for

flatness, as follows:

a. Place a straight edge across the engine

block and front cover oil pan sealing

surf aces . Avoid c ontact with the portion of

the gasket that protrudes into the oil pan

surface.

b. Insert a feeler gauge between the front

cover and the straight edge tool. The

cover must be flush with the oil pan

surface or no more than 0.25 mm below

flush (dimension ‘A’).

c. If the front cover-to-engine block oil pan

surface alignment is not within

specif ications, repeat the cover alignm ent

procedure.

10. If the correct front cover to engine block

alignment cannot be obtained, replace the

front cover.

Figure 6A3-214

CRANKSHAFT FRONT OIL SEAL - INSTALL

Important: Do not lubricate the oil seal sealing

surface.

11. Lubricate the outer edge of the oil seal (1) and

the front cover oil seal bore with clean engine

oil.

12. Install the crank shaft front oil seal (1) onto the

guide of Tool No. J 41478.

13. Install the threaded rod (with nut, washer,

guide, and oil seal) of Tool No. J 41478 into

the end of the crankshaft.

14. Using a set spanner, hold the head of the

installer bolt, then rotate the installer nut

clockwise, using a second set spanner, until

the seal bottoms in the cover bore.

15. Remove the tool from the crankshaft.

16. Inspect the oil s eal for co rrect inst allation. The

oil seal should be installed evenly and

completely into the front cover bore.

17. Install the crankshaft balancer, refer

2.24 CRANKSHAFT BALANCER, in this

Section.

18. Reinstall oil pan. Refer 3.3 OIL PAN -

REINSTALL, in this Section.

Figure 6A3-215

3.5 ENGINE FLYWHEEL/FLEXPLATE

REMOVE

Important: Note the position and direction of the

engine flywheel before removal. The flywheel does

not use a locating pin f or alignment. Mark or sc ribe

the end of the crankshaft and the flywheel before

component removal. The engine flywheel must be

reinstalled to the original position and dir ec tion. The

engine flywheel will not initially seat against the

crankshaft flange, but will be pulled onto the

crankshaft by the engine flywheel bolts. This

procedure requires a three stage tightening

process.

If replacing a flywheel, note the location of any

existing balance weight pins (relative to the pos ition

of the flywheel locating hole). If replacing the

flywheel and balance weight pins are installed in

the original flywheel, then use a suitable pin punch

and rem ove the pins f rom the old f lywheel and then

reinstall them in the same relative location in the

replacement part.

NOTE 1: Balance weight pins will only be fitted to

some engines that may have been dynamically

balanced at manufacture, where balance weight

pins are required to balance the crankshaft/flywheel

assembly, hence the need to reinstall them to a

new flywheel, in the same position.

NOTE 2: A correctly installed balance weight pin

will be either flush or below f lush with the mac hined

surface of the flywheel.

1. If this operation is to be carried out with the

engine installed in the vehicle, remove the

transmission and c lutch as s embly (if requir ed).

Refer Section 7B3 MANUAL

TRANSMISSION - GEN III V8 ENGINE,

Section 7A1 CLUTCH - GEN III V8

ENGINE or Section 7C4 AUTOMATIC

TRANSMISSION, of this Service Information

CD.

2. Mark the end of the crankshaft and the

flywheel/ flexplate, using a felt tipped pen or

similar. Remove the engine flywheel/ flexplate

bolts.

3. Remove the engine flywheel/flexplate.

Figure 6A3-216

CLEAN AND INSPECT

Flywheel

1. Clean the flywheel in a suitable solvent and

blow dry with compressed air.

Important: In order to maintain the proper

com ponent balanc e, contac t s urf ac e taper and heat

transf er, m anual trans m ission flywheels are NOT to

be machined.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the flywheel for loose or improperly

installed balance weights (if applicable). A

correctly installed balance weight should be

either flush or below the machined surface of

the flywheel.

3. Inspect the flywheel for the following:

a. Damaged ring gear teeth (1).

b. Grooves or scoring (2).

c. Rusted surface (3).

d. Pitted surfaces (4).

e. Loose or incorrectly positioned ring gear.

The ring gear is an interference fit onto the

flywheel and should be positioned

completely against the flange of the

flyw heel.

f. Missing, bent or damaged pressure plate

locating pins. The two locating pins are

pressed into the flywheel and are spaced

170° apart.

Figure 6A3-217

Flexplate

4. Inspect the flexplate for the following:

a. Damaged ring gear teeth.

b. Stress cracks around the crankshaft bolt

hole locations.

c. Welded areas that retain the ring gear to

the flexplate.

Important: Do not attempt to repair any welded

areas that retain the ring gear to the flexplate.

Replace the flexplate assembly if welds are

cracked.

Figure 6A3-218

REINSTALL

1. If replacing a flywheel;

a. Install any balance weights, as required, in

the same locations as noted on the old

flywheel. Location is important, as the

presence of balance weight pins in the old

flywheel are an indication that the

crankshaft and flywheel were balanced as

a complete unit in original manufacture.

b. Use the flywheel locating hole as refer ence

and scribe an alignment mark

corresponding to the one on the original

flywheel.

2. Install the flywheel/flexplate, aligning the

scribed marks on the crankshaft and

flywheel/flexplate.

Figure 6A3-219

3. Loosely install NEW flywheel/flexplate bolts,

tightening in the sequence shown in Figure

6A3-221, to an initial torque specif ication of 20

Nm.

4. Install the ring gear holding Tool No. J 42386-

A, using the two starter motor bolts. Tighten

both bolts to 50 Nm.

NOTE: Ensure that the teeth of the holding tool

engage correctly with the ring gear teeth , before

tightening the fasteners.

Figure 6A3-220

5. Continue to tighten the flywheel/flexplate bolts

in the sequence shown, in two additional

stages and to the correct torque specification.

FLYWHEEL/FLEXPLATE BOLTS Stage 2: 50 Nm

TORQUE SPECIFICATION Stage 3: 100 Nm

6. Reinstall clutch and transm ission, as required.

Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION, of this Service Information

CD.

Figure 6A3-221

3.6 ENGINE FLYWHEEL RING GEAR

REPLACE

Automatic Transmission:

The ring gear is welded to the flexplate and is

serviced only as an assembly. Refer to

3.5 ENGINE FLYWHEEL/FLEXPLATE, in this

Section.

Manual Transmission:

1. Remove flywheel, refer to

3.5 ENGINE FLY WHEEL /FLEXPLATE, in this

Section.

2. After marking with a centre punch and

hammer, drill an 8 mm diameter hole through

the ring gear, between two teeth.

Figure 6A3-222

3. Secure the flywheel in a vice fitted with soft

jaws, then use a sharp cold chisel and

hamm er to split the ring gear at the drill point.

Remove the ring gear from the flywheel.

Figure 6A3-223

4. Check that there are no burrs or foreign

material on the new ring gear and flywheel

mating surfaces. If present, burrs can be

removed with a fine mill file.

5. Heat and shrink the replacement ring gear,

using either one of the next two methods;

1.1 Heat the new ring gear, uniformly in an

oven to a temperature between 180 -

230° C. This temperature can be

achieved by using a thermal indicating

crayon such as Faber-Castell

Thermocrom 2815-200.

2.1 Polish several places on the ring gear

using emery cloth.

2.2 Use a hot plate or a slowly moving torch

to heat the ring gear until the polished

spots turn blue (approximately 300° C).

NOTE: Heating the ring gear above 427° C

will destroy the ring gear teeth heat treatment.

6. Using protective gloves and two pairs of pliers ,

quick ly place the ring gear against the f lywheel

shoulder. Allow the ring gear to cool until it

contracts and is firmly held in place.

7. Reinstall flywheel. Refer to 3.5 ENGINE

FLYWHEEL/FLEXPLATE, in this Section.

8. Reinstall clutch and tr ansmiss ion, as required.

Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION, of this Service Information

CD.

3.7 CRANKSHAFT SPIGOT BUSH

REPLACE

1. Disconnect battery earth lead.

2. Remove manual transmission and the clutch

assembly, refer to 7B3, MANUAL

TRANSMISSION - GEN III V8 ENGINE of this

Service Information CD and 7A1 CLUTCH -

GEN III V8 ENGINE in this Section.

3. Using Tool J 23907, (also released as Tool

6A22-2 and slide hammer 7A28) or

commercial equivalent, remove the spigot

bush from the rear of the crankshaft.

Figure 6A3-224

4. Check that the crankshaft rear oil gallery plug

is not a loose fit, damaged or leaking.

5. If replacement is required, apply sealant such

as Loctite 242 or equivalent, to the sides of a

new plug (1) and install to the correct depth.

Crankshaft Rear Oil gallery Plug Depth

Specification

Distance ‘A’......................... 31.2 - 31.6 mm

Figure 6A3-225

6. Using a suitable, stepped (or piloted ) driver

such as Tool J 38836 and flat washer (2),

install a replacem ent bush ( 1) to the rear of the

crankshaft, until flush with the crankshaft

counter-bore, as shown.

7. Lubricate the bearing with a small amount of

SAE 90 gear oil.

8. Reinstall clutch assembly and manual

transmission, refer to 7A1 CLUTCH - GEN III

V8 ENGINE and 7B3 MANUAL

TRANSMISSION - GEN III V8 ENGINE of this

Service Information CD.

9. Reinstall the starter motor. Refer 6D3-2

STARTING SYSTEM - GEN III V8 ENGINE of

this Service Information CD.

10. Reconnect battery earth lead.

11. Check starter motor operation and road test

vehicle to check transmission and clutch

operation.

Figure 6A3-226

Techline

3.8 ENGINE REAR COVER

REMOVE

Important: Because of critical alignment

procedures required f or the r eins tallation of the rear

cover and oil pan, it is strongly recommended that

the engine assembly is removed from the vehicle,

before oil pan removal.

1. With the flywheel/flexplate removed, refer

3.5 ENGINE F LYWHEEL /FLEXPLATE, in this

Section, remove the rear cover bolts.

2. Remove the rear cover and gasket. If the

gasket is undamaged, it may be re-used.

3. Prise the rear main oil seal from the housing,

taking care not to distort the rear cover nor

scratch the oil seal bore in the rear housing.

Figure 6A3-227

CLEAN AND INSPECT

1. Clean the cover in a suitable solvent and blow

dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the gasket sealing surface for

excessive scratching or gouging.

3. Inspect the gasket for damage to the seal

membrane or distortion to the aluminium

carrier.

4. Inspec t the cover to oil pan threaded holes f or

debris or damage. Refer to 3.16 THREAD

REPAIR, in this Section, if rectification is

required.

5. Inspect the rear main oil seal bore for

damage.

Techline

REINSTALL

NOTE 1: Do not reuse the crankshaft rear oil seal.

NOTE 2: Do not apply any type of sealant to the

rear cover gasket.

NOTE 3: The special tools in this procedure are

used to properly align the engine rear cover at the

oil pan surface and to centre the crankshaft rear

main oil seal.

NOTE 4: All gasket surfaces should be free of oil or

other foreign material during assembly.

NOTE 5: The crankshaft rear main oil seal MUST

be centred in relation to the c ranks haft and is to be

installed after the rear cover installation. The oil pan

sealing surface at the rear cover and engine block

MUST also be aligned within specifications.

NOTE 6: An improperly aligned rear cover may

cause premature oil seal wear and/or engine

assembly oil leaks.

1. If removed, inspect the rear main oil gallery

plug and ensure that is installed below the

engine block machined surface by dimension

‘A’, which is between 0.08 - 1.4 mm.

Figure 6A3-228

2. Install the rear cover gasket, the rear cover

and bolts.

NOTE: If undamaged, the original cover gasket can

be re-used.

3. Only tighten the rear cover bolts finger tight.

Do not overtighten.

Figure 6A3-229

4. Assemble the alignment tool J 41480 to rear

cover and install bolts (1) (part of Tool J

41480) in the locations shown but do not

tighten.

5. Install bolts (2) (part of Tool J 41480) to the

engine block and tighten to the specified

torque.

REAR COVER ALIGNMENT TOOL

BOLT TO ENGINE BLOCK 25 Nm

TORQUE SPECIFICATION

Figure 6A3-230

6. Rotate the crankshaft until two opposing

flywheel/ flexplate mounting bolt holes are

parallel to the oil pan surface of the engine

block (arrows).

7. Install alignment Tool J 41476 to the rear of

the crankshaft.

NOTE: The taper ed legs of the alignm ent tool m ust

enter the rear cover oil seal bore.

8. Install the two screws supplied with Tool J

41476 and tighten with a screwdriver until

snug. Do not over-tighten.

Figure 6A3-231

9. Tighten the alignment Tool J 41480 bolts (1) to

the rear cover to the specified torque.

REAR COVER ALIGNMENT TOOL

BOLT TO REAR COVER 12 Nm

TORQUE SPECIFICATION

10. Tighten the engine rear cover bolts to the

correct torque specification.

ENGINE REAR COVER BOLT

TORQUE SPECIFICATION 25 Nm

11. Remove the alignment tools.

Figure 6A3-232

12. Measure the oil pan surface to rear cover for

flatness, as follows:

a. Place a straight edge across the engine

block and rear cover oil pan sealing

surf aces . Avoid c ontac t with the portion of

the gasket that protrudes into the oil pan

surface.

b. Insert a feeler gauge between the rear

cover and the straight edge tool. The

cover must be flush with the oil pan

surface or no more than 0.25 mm below

flush (dimension ‘A’).

c. If the rear cover-to-engine block oil pan

surface alignment is not within

specif ications, repeat the cover alignm ent

procedure.

13. If the correct rear cover to engine block

alignment cannot be obtained, r eplace the r ear

cover.

Figure 6A3-233

CRANKSHAFT REAR OIL SEAL - INSTALL

Important: Do not lubricate the oil seal inside

diameter (ID) nor the crankshaft seal surface

1. Lubricate the outer edge of the oil seal (OD)

with clean engine oil.

DO NOT allow oil or other lubricants to come

into contact with the seal surface.

2. Lubricate the rear cover oil seal bore (2) with

clean engine oil.

DO NOT allow oil or other lubricants to come

into contact with the crankshaft seal surface.

3. Install the cone (2) of installation Tool No. J

41479 with bolts, to the rear of the crank shaft.

Tighten the bolts until snug. Do not over-

tighten.

4. Install a NEW oil s eal (3) onto the taper of the

installation tool (2) and push the seal to the

rear cover bore.

5. Install the threaded rod of the installation Tool

No. 41479 (1), into the tapered part (2), until

the tool contacts the oil seal.

6. Align the oil seal (3) with the tool, then rotate

the handle of the tool (1) clockwise until the

seal enters then bottoms into the rear cover

bore.

7. Remove both parts of the installation tool.

8. Reinstall flywheel. Refer to 3.5 ENGINE

FLYWHEEL/FLEXPLATE, in this Section.

9. Reinstall clutch and transm ission, as required.

Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION, of this Service Information

CD.

Figure 6A3-234

3.9 OIL PUMP, PUMP SCREEN, AND DEFLECTOR

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

2. If the harmonic balancer and front cover have

not already been removed, refer to

2.24 HARMONIC BALANCER - REMOVE and

3.4 ENGINE FRONT COVER - REMOVE, in

this Section.

3. Remove the oil pump pick-up screen bracket

nut from the crankshaft oil deflector and the

tube retaining screw from the oil pump body.

4. Remove the oil pump screen and tube

assembly, and the O-ring seal from the oil

pump bore.

Discard the O-ring. Figure 6A3-235

5. Rem ove the remaining crankshaft oil deflector

nuts.

6. Remove the crankshaft oil deflector, noting

that the cover orientation is stamped ‘REAR’ to

assist in correct installation.

Figure 6A3-236

7. Remove the four bolts securing the oil pump to

the front of the engine, then remove the oil

pump from the crankshaft.

8. If the oil pump is not being opened, plug all

openings to avoid the entry of dirt or debris or

wrap in a plastic bag.

Figure 6A3-237

OIL PUMP DISASSEMBLE

1. Remove oil pump cover bolts, then remove the

cover.

Figure 6A3-238

Important: Mark or identify the relationship of the

gears for reassembly.

2. Remove the inner drive gear and outer driven

ring, from the oil pump body.

Figure 6A3-239

3. Unscrew the oil pressure relief valve plug and

remove spring and valve from the oil pump

body.

Figure 6A3-240

CLEAN AND INSPECT

NOTE: Apart from the oil pressure relief valve

spring, there are no other parts of the oil pum p nor

the oil pump pick-up screen and pipe that are

serviced s eparately. If either com ponent is f ound to

be worn or damaged, then that assembly must be

replaced. Do not attempt any repairs to either

component.

1. Clean all parts in a suitable solvent and blow

dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the oil pump housing for cracks,

excessive wear, scoring or casting

imperfections.

3. Inspect the oil pump housing to engine block

oil gallery surface for scratches or gouging.

4. Inspec t the oil pump housing f or damaged bolt

hole threads. See Section 3.16 THREAD

REPAIR, if required.

5. Inspec t the oil pum p relief valve plug and bore

for scratched or damaged surfaces and the

screw thread for damage. The pressure relief

valve must move freely in its bore with no

restrictions.

6. Inspect the oil pump internal oil passages for

restrictions.

7. Inspec t the drive and driven gears for chipping

galling or wear. Minor burrs or imperfections

on the gears can be removed with a fine oil

stone.

8. Inspect the inner gear drive splines for

excessive wear.

Replace the oil pump assembly if any of the

above conditions are observed.

9. Inspect the oil pump pick-up screen for

clogging with debris or restriction.

10. Inspect the screen mesh for broken or loose

strands.

Replace the oil pump pick-up screen and pipe

assembly as required.

OIL PUMP REASSEMBLE

Reassembly is the reverse of the disassembly

process, except for the following items:

1. Liberally coat all oil pump components with

clean engine oil before assembly.

2. Take note of the relationship of the inner to

the outer oil pump gears when assembling.

3. Tighten the oil pump cover screws to the

correct torque specification.

OIL PUMP COVER TO BODY SCREW

TORQUE SPECIFICATION 12 Nm

4. Install a NEW pressure relief valve spring.

5. Tighten the pressure relief valve plug to the

correct torque specification.

OIL PUMP PRESSURE RELIEF PLUG

TORQUE SPECIFICATION 12 Nm

6. Rotate the assembled pump, checking for

smoothness of operation by rotating the inner

drive gear.

REINSTALL

1. Check the oil pump and engine block oil

gallery passages to ensure that any debris is

removed.

2. Align the splined surfaces of the crankshaft

sprocket and the oil pump drive gear and

install the oil pum p onto the sprocket, until the

pump housing contacts the face of the engine

block.

3. Install the oil pump bolts and tighten to the

correct torque specification.

OIL PUMP BOLT

TORQUE SPECIFICATION 25 Nm

Figure 6A3-241

4. Install the crankshaft oil deflector, noting that

the ‘REAR’ stamping on the deflector is

located at the rear of the engine.

Figure 6A3-242

5. Lubric ate a NEW oil pum p pick -up tube O-r ing

with clean engine oil and install onto the oil

pump pick-up tube.

6. Fully install the pick-up tube into the oil pump

housing, aligning the support bracket with the

main bearing cap stud.

7. Install the pick-up tube screw and tighten to

the correct torque specification.

OIL PUMP PICK-UP TUBE SCREW

TORQUE SPECIFICATION 12 Nm

NOTE: Ensure that the pick-up tube is fully

installed before tightening the retaining screw.

8. Install all the crankshaft oil deflector nuts to

the main bearing cap studs and tighten to the

correct torque specification.

CRANKCASE OIL DEFLECTOR

NUT TORQUE SPECIFICATION 25 Nm

9. Reinstall the oil pan, refer to 3.3 OIL PAN -

REINSTALL, in this Section.

10. Reinstall the front cover, refer to 3.4 ENGINE

FRONT COVER - REINSTALL and

2.24 HARMONIC BALANCER - REINSTALL,

in this Section.

Figure 6A3-243

3.10 TIMING CHAIN AND SPROCKETS

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

2. If the harmonic balancer and front cover have

not already been removed, refer to

2.24 HARMONIC BALANCER - REMOVE and

3.4 ENGINE FRONT COVER - REMOVE, in

this Section.

3. Remove the oil pump, refer 3.9 OIL PUMP,

PUMP SCREEN AND DEFLECTOR, in this

Section.

NOTE: If the c ylinder heads and valve tr ain are s till

installed, temporarily install the harmonic balancer

bolt and turn engine until the timing marks on the

camshaft and crankshaft sprockets are aligned,

refer Figure 6A3-246. Remove the harmonic

balancer bolt.

4. Remove the camshaft sprocket bolts (1), then

remove the sprocket (2) and chain (3) from the

camshaft and crankshaft sprocket.

Figure 6A3-244

5. Use Tool No’s J 41558, J 41816-2, the bolts

from J 21427-01 and puller J 8433-1,

assemble as shown and remove the

crankshaft sprocket from the nose of the

crankshaft

6. Remove the crankshaft sprocket drive key

from the crankshaft nose, if required.

Figure 6A3-245

CLEAN AND INSPECT

1. Clean the sprockets and timing chain in

suitable solvent and blow dry with compr esse d

air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the timing chain for binding or wear.

Figure 6A3-246

3. Inspect the camshaft and crankshaft

sprockets for:

a. Worn teeth (1).

b. Damaged teeth (2).

c. Chipped teeth (3).

d. Worn valleys between the sprocket teeth.

Figure 6A3-247

4. Inspec t the crankshaf t sprock et keyway (1) f or

wear.

5. Inspec t the crankshaf t sprock et oil pump drive

splines (2) for wear.

Figure 6A3-248

REINSTALL

1. If removed, install the crankshaft sprocket

drive key into the crankshaft.

The key should be tapped into place until eac h

end bottoms on the crankshaft.

Figure 6A3-249

2. Install the crankshaft sprocket onto the

crankshaft nose, aligning the keyway with the

key.

3. Use installer J 41665 to install the crankshaft

sprocket, as follows:

a. Install the threaded bolt, nut and flat

washer from Tool J 41478) through the

end plate and stepped sleeve of Tool J

41665.

b. Screw threaded bolt into the crankshaft,

using set spanner (1).

c. While holding the threaded bolt with set

spanner (1), turn the nut on the threaded

bolt with a second set spanner (2),

m oving installer J 41665 to fully install the

crankshaft sprocket onto the crankshaft

nose.

d. W hen crankshaft sprocket has been fully

installed, remove installation tools.

4. If required, temporarily install the harmonic

balancer bolt and rotate the crankshaft until

the timing alignment mark is at the 12 o’clock

position. Refer Figure 6A3-252.

Figure 6A3-250

5. Install the camshaft sprocket (3), aligning the

peg on the camshaft with the sprocket hole.

Check that the timing mark is at the 6 o’clock

position. Refer Figure 6A3-252.

6. If required, temporarily install the camshaft

sprocket bolts and use a suitable lever to

rotate the camshaft sprocket until the timing

ma rk is c or re ctly aligned. Remove the bolts ( 1)

and sprocket (3).

7. Install the timing chain (2) to the camshaft

sprocket (3), align the camshaft peg with the

cam shaft sproc ket hole by eye, then ins tall the

timing chain to the crankshaft sprocket.

8. Install the camshaft sprocket over the

camshaft peg.

Figure 6A3-251

9. Before installing the camshaft sprocket bolts

(1 in Figure 6A3-251), check that the timing

marks are aligned as shown. If not, repeat

Steps 4 to 8 above.

10. Install the cam shaft sprocket bolts and tighten

to the correct torque specification.

CAMSHAFT SPROCKET BOLT

TORQUE SPECIFICATION 35 Nm

11. Reinstall the oil pump, refer 3.9 OIL PUMP,

PUMP SCREEN AND DEFLECTOR, in this

Section.

12. Reinstall oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

13. Reinstall the front cover and harmonic

balancer. Refer 3.4 ENGINE FRONT COVER

- REINSTALL and 2.24 HARMONIC

BALANCER - REINSTALL, in this Section. Figure 6A3-252

3.11 CAMSHAFT

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove the intake manifold assembly, if this

operation has not already been carried out.

Refer 2.14 INTAKE MANIFOLD - REMOVE,

in this Section.

2. Remove the camshaft sensor bolt and sensor

from the engine block.

Figure 6A3-253

3. Remove oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

4. If the harmonic balancer and front cover have

not already been removed, refer to

2.24 HARMONIC BALANCER - REMOVE and

3.4 ENGINE FRONT COVER - REMOVE, in

this Section.

5. Remove the oil pump, refer 3.9 OIL PUMP,

PUMP SCREEN AND DEFLECTOR, in this

Section.

6. Remove the camshaft chain and sprocket.

Refer 3.10 TIMING CHAIN AND

SPROCKETS - REMOVE in this Section.

7. Remove the camshaft retainer bolts then

remove the retainer and gasket.

Figure 6A3-254

8. Install three, M8 x 1.25 x 100 mm bolts (e.g.

removed water pump bolts) in the front of the

camshaft and use as a handle to rotate and

remove the camshaft from the engine block.

NOTE: As all camshaft bearing journals are the

same size, care must be taken when removing the

camshaft, to avoid damaging the bearings.

9. Remove the three bolts from the camshaft.

Figure 6A3-255

CLEAN AND INSPECT

1. Clean all components with a suitable solvent

and blow dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the camshaft for:

a. Scoring or excessive wear to the bearing

journals (1).

b. Scoring or excessive wear to the

camshaft lobes (2).

c. Damaged threads (3) or debris in

threaded holes.

d. Damage to the camshaft sprocket pin (4).

e. Nicks or dam age to the c am shaf t pos ition

reluctor ring.

Figure 6A3-256

3. Measure the camshaft journals for wear and

out-of-round, using a micrometer.

Replace the camshaft if either of these

measurements is outside specification.

Camshaft Journal Specifications

Cams haft Journal Out-of-Round ..... .... .. 0. 025 mm Maximum

Cams haft Bearing Journal Diameter.. ... 54.99 mm Minimum

Figure 6A3-257

4. Measure camshaft lobes for wear, using a

micrometer

Replace the camshaft when the cam lobe

dimension is to the minimum specification or

less, for either the intake or exhaust lobes.

Camshaft Lobe Specifications

Intake Lobe Height................................ 46.67 mm Minimum

Exhaust Lobe Height............................. 46.67 mm Minimum

Figure 6A3-258

5. Mount the camshaft either in Vee blocks or

between centres.

6. Using a suitable dial indicator mounted as

shown, rotate the camshaft and check the

runout on the centre bearing journal.

Replace the camshaft if the runout exceeds

the specification.

Camshaft Runout Specification

Camshaft Runout.................................. 0.05 mm Maximum

7. Inspec t the cams haft retainer plate for wear or

a damaged sealing gasket.

If the gasket is not cut or damaged, it may be

re-used. Figure 6A3-259

REINSTALL

NOTE: If the c amshaf t r eplac ement is r equired, the

valve lifters must also be renewed.

1. Lubricate camshaft journals and the bearings

with clean engine oil.

2. Install thr ee M8 x 1.25 x 100 m m bolts into the

camshaft front journal.

3. Using the bolts as a handle, carefully install

the camshaft into the engine block.

NOTE: As all the cams haft bear ing journals are the

same size, care must be taken to avoid bearing

damage during camshaft installation.

4. Remove the three bolts after camshaft

installation.

Figure 6A3-260

5. Ensure that the engine block surface is clean

and free of debris, then install the camshaft

retainer plate with the sealing gasket facing

the engine block.

6. Install the camshaft retainer bolts and tighten

to the correct torque specification.

CAMSHAFT RETAINER BOLT

TORQUE SPECIFICATION 25 Nm

Figure 6A3-261

7. Inspect the camshaft position sensor O-ring,

renewing if it is cut or damaged.

8. Lubricate the O-ring with clean engine oil,

install to the sensor.

9. Install the camshaft position sensor and the

retaining bolt and tighten to the correct torque

specification.

CAMSHAFT POSITION SENSOR

BOLT TORQUE SPECIFICATION 25 Nm

10. Reinstall the camshaft chain and sprocket.

Refer 3.10 TIMING CHAIN AND

SPROCKETS, in this Section.

11. Reinstall the oil pump, refer 3.9 OIL PUMP,

PUMP SCREEN AND DEFLECTOR, in this

Section.

12. Reinstall the front cover and harmonic

balancer. Ref er 2.24 HARMONIC BALANCER

and 3.4 ENGINE FRONT COVER, in this

Section.

13. Remove oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

14. If required, reinstall the intake manifold

assembly. Refer 2.14 INTAKE MANIFOLD, in

this Section.

Figure 6A3-262

3.12 PI STON, CONNECTING ROD AND BEARING

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the oil

pan, it is strongly recommended that the engine

assembly is removed from the vehicle, before this

service operation is carried out.

1. Remove both cylinder heads. Refer

2.22 CYLINDER HEAD - REMOVE, in this

Section.

2. Remove oil pan, pump screen and deflector,

refer 3.3 OIL PAN - REMOVE and

3.9 OIL PUMP, PUMP SCREEN AND COVER

- REMOVE, in this Section.

3. If required, use a commercially available

cylinder ridge rem over, to remove any cylinder

ridge present, adopting the following

procedure:

a. Rotate the crankshaft until the piston is at the

bottom of its stroke (BDC).

b. Place a cloth on top of the piston.

c. Use the cylinder ridge remover to remove the

cylinder ridge.

d. Again rotate the crankshaft until the piston is

at the top of its stroke (TDC).

e. Remove the cloth and any metal shavings

from the piston crown.

Figure 6A3-263

4. Using a paint stick or etching tool, matchmark

each connecting rod and its cap. The

connecting rod caps MUST be assembled to

the original position and direction.

DO NOT apply a stamping m ar k on the side of

the connecting rod and/or cap as this may

affect alignment and the geometry of the

assembly.

5. Mark the top of each piston to identify its

specific bore.

6. Remove the connecting rods bolts, loosening

progressively from side to side.

Important: Ensure that the connecting rod

bearings are organised so they will be installed in

the original position and location.

7. Remove each connecting rod cap.

Figure 6A3-264

8. Install guide pins Tool J 41556 to the

connecting rod to be removed.

Figure 6A3-265

9. Use a hamm er handle to tap lightly on the end

of the guide pin Tool J 41556 and remove the

piston and connecting rod from the cylinder

bore.

10. Once removed, assemble the connecting rod

cap, bearing shells and bolts to the matching

connecting rod.

Figure 6A3-266

DISASSEMBLE

1. Remove the piston rings from the piston.

Figure 6A3-267

2. Insert fork insert J 24086-905 onto the bridge

of Tool J 24086-C. Mount the piston assem bly

so that the fork insert is between the

connecting rod and the piston. Install pin

remover J 24086-8A.

3. Place the assembly under an hydraulic press

and remove the piston pin f rom the piston and

connecting rod assembly.

NOTE: The piston and pin are a matched set and

are not serviced separately. Mark the pin to piston

to ensure correct reas sembly if original parts ar e to

be re-used.

Figure 6A3-268

CLEAN AND INSPECT

Piston and Pin

1. Clean any varnish from the piston and pin,

with a suitable cleaning solvent. DO NOT use

a wire brush for this process.

2. Dry the cleaned parts with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

3. Clean the piston ring grooves with a

commercially available tool.

4. Clean the oil lubrication holes and slots in the

ring grooves.

Figure 6A3-269

5. Inspect each piston and pin for the following:

a. Cr acks in the piston lands, sk irt or the pin

bosses.

b. Piston ring grooves for nicks, burrs or

warpage which may cause the piston r ing

to bind. MINOR imperfections may be

removed by using a fine file.

c. Eroded areas on top of the piston (1).

d. Scuffed or damaged skirts (2).

e. Scoring to the piston pin bore (3) or the

piston pin.

Figure 6A3-270

6. Measure the piston ring to piston groove side

clearance, as follows:

a. Insert the edge of a NEW piston ring into

the correct piston ring groove.

b. Roll the piston ring around the groove.

NOTE 1: If binding is caused by a distorted piston

ring groove, MINOR ring gr oove imperfec tions m ay

be removed with a fine file.

NOTE 2: If binding is caused by a distorted piston

ring, replace the ring.

Figure 6A3-271

NOTE: For each of the following measurements,

ensure that the micrometer zeroing has been

carried out and the measurements are all taken

with components at room temperature.

7. Again using a new piston ring in the correct

location, check the side clearance using a

feeler gauge. If side clearance exceeds

specif ication, try another piston r ing set before

condemning the piston.

Piston Ring Side Clearance Specification

Top compression ring .................... 0.040 - 0.085 mm

Second compression ring .............. 0.040 - 0.080 mm

Oil control ring................................ 0.010 - 0.220 mm

8. If the piston ring side clearance exceeds

specification, the piston and pin assembly

must be replaced.

Figure 6A3-272

9. To measure the pin-to-bore clearance, first

measure the pin with a micrometer.

Piston Pin Specification

Piston Pin Diameter.................... 23.997 - 24.000 mm

Figure 6A3-273

10. Using a suitable inside micrometer, measure

the matching piston pin bore on each side.

11. Subtract the piston pin dimension from the

piston pin bore size to obtain the clearance.

12. If the clearance exceeds specification, the

piston and pin assembly must be replaced.

Piston Pin to Bore Clearance Specification

Piston pin clearance (Maximum).... 0.010 - 0.020 mm

Figure 6A3-274

13. Measure the piston for out-of-round, as

follows:

a. With a suitable sized micrometer at right

angles to the piston pin bore, measure

the piston skirt dimension, 11 mm above

the bottom of the skirt.

b. Measure the piston at two different points

and compare the readings

c. If the difference exceeds specification,

then replace the piston and pin assembly.

Piston Skirt Out-of Round Specification

Piston skirt dimension variation .. 0.018 mm Maximum

Figure 6A3-275

Connecting Rods and Bea rings

NOTE: The powdered metal connecting rod and

cap are machined for the correct clearances. The

connecting rod and the cap must be used as an

assembly, with no repairs or modifications carried

out to either mating surface.

1. Clean each connecting rod and matching cap

in a suitable solvent.

2. Clean the connecting rod bolt threads and

inspect for damage. Do not attempt to repair

damaged threads in this location. Replace the

connecting rod, cap and bolts as an assembly

if thread damage is found.

3. Blow parts dry using compressed air.

CAUTION: Wear safety glasses to avoid

eye injury.

4. Inspect the connecting rod for the following

defects:

a. Twisting, using commercially available

alignment equipment.

b. Bending. Check length with suitable

measuring equipment.

c. Nicks or gouging in the bearing bore.

d. Damage to the bearing locating slots in

the bearing bore.

e. Correct fit of the connecting rod and cap

mating surfaces.

Connecting Rod Specification

Centre to Centre Length.............. 154.90 ± 0.02 mm

Width........................................... 24.00 ± 0.05 mm

Twist............................................ 0.010 mm Maximum

Bend............................................ 0.02 mm Maximum

Figure 6A3-276

5. Reinstall the connecting rod big end cap and

bolts. Tighten bolts to the correct torque

specification.

CONNECTING ROD CAP BOLT Stage 1: 20 Nm

TORQUE SPECIFICATION Stage 2: 60° turn angle

6. Measure the connecting rod big end bore,

using a suitable inside micrometer, checking

for ovality. Replace any connecting rod

assembly that exceeds specification.

Connecting Rod Big End Ovality Specification

Connecting rod big end ovality.... 0.008 mm Maximum

Figure 6A3-277

7. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves also indicate fatigue.

Figure 6A3-278

8. Inspect connecting rod bearing halves for

excessive scoring or discolouration.

9. Inspect the connecting rod bearings for dirt or

debris embedded into the bearing material or

backing metal.

Figure 6A3-279

10. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-280

Measuring Piston Ring End Gap

1. Insert a new piston ring into the bore that it is

to be fitted and push it down the bore, using

the piston, inverted in the bor e, until the ring is

approximately 6.5 mm below the piston ring

travel area.

2. Insert a feeler gauge and measure the piston

ring end gap. End gap specifications are as

follows:

Piston Ring End Gap Specifications

Top compression ring .................... 0.230 - 0.380 mm

Second compression ring .............. 0.440 - 0.640 mm

Oil control ring................................ 0.180 - 0.690 mm

Figure 6A3-281

REASSEMBLE

Piston Selection

NOTE 1: All measurements should be taken at

normal room temperature.

NOTE 2: A used piston and pin set may be

reinstalled if, after cleaning and inspection, they are

both within specification.

1. With a microm eter at right angles to the piston

pin bore, measure the piston skirt at 11 mm

from the lower edge.

2. Record the piston diameter.

Figure 6A3-282

3. Check that the micrometer is at the recorded

piston diameter.

4. With Tool J 8087 (or commercial equivalent),

held between the micr ometer anvils as shown,

zero the dial indicator.

Figure 6A3-283

5. Use bore gauge J 8087 (or commercial

equivalent), measure the cylinder bore

diameter , at a point 57 mm fr om the top of the

bore.

6. Record the cylinder bore diameter.

7. Subtract the piston diameter from the cylinder

bore measurement, in order to determine the

piston to bore clearance.

Piston to Bore Clearance Specification

Clearance range ............................ 0.018 - 0.054 mm

8. If the clearance is outside this specification,

select another piston and measure it and re-

calculate the clearance. If the correct

clearance cannot be obtained using this

method, then the cylinder bore may require

honing for an oversize piston fitment, or the

cylinder block will need to be replaced.

9. When the correct piston to bore clearance is

obtained, mark the piston crown for correct

installation.

NOTE: The cylinder bore must be checked for

ovality and taper bef ore this oper ation is attempted.

Refer 3.15 CYLINDER BLOCK - Cylinder Block

Clean, Inspect and Measure, in this Section.

Figure 6A3-284

Piston to Connecting Rod

NOTE: Take particular care when assembling the

piston to the connecting rod, that component

matching and orientation is correct.

1. The connecting rod alignment should be with

the flat portion of the bolt flange (1) facing

forward. Also note that the piston alignment

mark has the correct orientation.

2. Lubricate the piston pin bore and piston pin

with clean engine oil.

Figure 6A3-285

3. With the connecting rod inserted with the

correct orientation into the piston, insert the

Black piston pin guide, J 24086-1A from Tool J

24086-C, into the lower piston pin boss to pre-

align the piston and connecting rod pin holes.

4. Insert fork insert J 24086-905 between the

piston and connecting rod, around the piston

pin guide J 24086-1A, then mount the

assembly into the fork bridge of

Tool J 24086-C.

Figure 6A3-286

5. Adjus t installer, J 24086-9, to a setting of “I-9”,

as shown. Lock this position with the knurled

ring.

Figure 6A3-287

6. Insert the adjusted installer to Tool J 24086-C

and press the piston pin into the connecting

rod, until the installer bottoms out.

7. Check that the piston pin has been installed

correctly.

The piston pin will be installed correctly, if the

piston pin is centred in the piston and the

connecting rod is also centred between the

piston pin bosses, i.e. the connecting rod

should have equal spacing on each s ide of the

piston pin boss.

Figure 6A3-288

Piston Rings

NOTE: Use commercially available piston rings

pliers and only expand the piston ring suff iciently to

slide over the piston. Excessive expansion will

permanently distort the piston ring.

1. Install the piston rings to each piston, in the

following manner:

a. Install the oil control spacer to the lower

ring groove. Ensure that the ends do not

overlap.

b. Install the lower oil control ring segment.

There are no identifying mark s, indicating

orientation, as this ring may be installed in

either direction.

c. Install the upper oil control ring segment

in a similar manner.

d. Stagger the ends of the three oil control

ring components by at least 90°.

e. Using commercially available piston ring

pliers, install the second compression

ring, noting that the dimple or orientation

mark must face upwards to the piston

crown.

f. Using commercially available piston ring

pliers, install the top compression ring.

This ring has no orientation marks and

may be installed in either direction.

g. Stagger the compression ring gaps a

minimum of 25 mm. Figure 6A3-289

REINSTALL

NOTE 1: Before installation, check that the piston

ring end gaps are staggered correctly and that the

piston has been assembled to the connecting rod

in the correct manner.

NOTE 2: Before honing the cylinders, refer to

3.15 CYLINDER BLOCK, Boring and Honing, in

this Section for important information, relating to

this task.

1. Lightly lubricate the piston, cylinder bore,

piston rings and bearing surfaces with clean

engine oil.

2. Remove the connecting rod cap and bearing

shell from the connecting rod being installed

and install the connecting rod guide pins , Tool

J 41556.

3. Install a commercially available piston ring

compressor over the piston rings and

compress.

4. Install the pis ton and connecting rod assem bly

into the correct cylinder bore, checking that the

piston alignm ent m ark is f acing the f ront of the

engine.

5. While holding the piston ring compressor

squarely and firmly against the engine block,

gently tap the piston into the bore, using a

wooden hammer handle, until all piston rings

have entered the bore.

6. Com plete installation by using the pins, Tool J

41556 to guide the connecting rod onto the

crankshaft journal.

T6A3274a

Figure 6A3-290

7. Remove connecting rod guides, Tool J 41556

and check that the upper bearing shell is

correctly installed in the connecting rod. Apply

clean engine oil to the upper bearing shell.

8. Install lower connecting rod bearing into the

cap, lubricate with clean engine oil and install,

ensuring that the cap orientation is correct.

Refer Figure 6A3-285.

Important: The bearing oil clearance must be

checked before final installation of the connecting

rod caps. Refer to 3.13 CRANKSHAFT AND

BEARINGS, Main Bearing Oil Clearance - Check,

in this Section.

Figure 6A3-291

9. Install NEW connecting rod cap bolts and

tighten in two stages, to the correct torque

specification.

NOTE: Since inception, there have a been a

number of changes to the connecting rod bolts.

Regardless of when the engine was built, the

critical aspect relating to connecting rod bolts is

that a ‘matched pair’ must be used on each

connecting rod.

The most visible identification of a ‘matched pair’

can be determined by the presence of 'dimples' on

the bolt head, witnessed by one, two or three, as

shown.

IMPORTANT: As bolt design 'A' has a different

torque specification than bolts 'B' and 'C',

replacement connecting rod bolts, MUST be of the

same design for each connecting rod. Using

diff erent design bolts on the one connecting rod will

apply uneven clamp loads and/or connecting rod

bore distortion.

DESIGN 'A' CONNECTING ROD CAP

BOLT TORQUE SPECIFICATION Stage 1: 20 Nm

Stage 2: 60°

turn angle

DESIGNS 'B' and 'C'

CONNECTING ROD CAP

BOLT TORQUE SPECIFICATION Stage 1: 20 Nm

Stage 2: 75°

turn angle

NOTE: Use torque angle meter Tool E7115 to

achieve the second reading.

Figure 6A3-292

10. With a pair of connecting rods installed onto

the same crankshaft journal, use a plastic

faced hammer to lightly tap each connecting

rod sideways to settle and ensure that side

clearance exists.

11. Using feeler gauges c heck that the connecting

rod side clearance is to specification.

Connecting Rod Side Clearance Specification

Side Clearance ....................... 0.11 - 0.51 mm

NOTE: If side clearance is insufficient, re-check

bearing oil clearance and/or connecting rod

alignment.

12. Reinstall oil deflector, oil pump screen and oil

pan, refer 3.9 OIL PUMP, PUMP SCREEN

AND COVER - REINSTALL and 3.3 OIL PAN

- REINSTALL, in this Section.

13. Reinstall both cylinder heads. Refer

2.22 CYLINDER HEAD - REINSTALL, in this

Section.

Figure 6A3-293

3.13 CRANKSHAFT AND BEARINGS

REMOVE

1. Remove engine from vehicle, refer

3.1 ENGINE ASSEMBLY - REMOVE, in this

Section.

2. Remove the following items from the engine

assembly;

a. Starter motor, refer 6D3-2 STARTING

SYSTEM – GEN III V8 ENGINE, of this

Service Information CD.

b. Oil pan, refer 3.3 OIL PAN, in this

Section.

c. Crankshaft balancer, refer

2.24 CRANKSHAFT BALANCER, in this

Section.

d. Front cover, refer 3.4 FRONT COVER, in

this Section.

e. Oil pump, screen and deflector, refer

3.9 OIL PUMP, PUMP SCREEN AND

DEFLECTOR, in this Section.

f. Timing chain, refer 3.10 TIMING CHAIN

AND SPROCKETS, in this Section.

g. Flywheel/Flex plate, refer

3.5 FLYWHEEL/ FLEXPLATE, in this

Section.

h. Rear cover, refer 3.8 ENGINE REAR

COVER, in this Section.

3. Remove the crankshaft position sensor

retaining bolt, then remove the sensor from

the cylinder block.

Figure 6A3-294

4. Remove the crankshaft main bearing cap M8

side bolts (1). While these bolts must be

renewed on final as sem bly, place the rem oved

bolts to one side, as they will be required when

checking the main bearing oil clearance.

5. Remove the main bearing cap M10 bolts and

studs, loosening each pair gradually. Take

note of the stud positions for reassembly.

Figure 6A3-295

6. Loosen the bolts of m ain bearing rem oval T ool

J 41818 to separate the chamfered collets.

Then install the chamfered sections into each

main bear ing c ap bolt hole, aligning the f lats of

the collets with those in the holes.

7. Tighten the bolts of Tool J 41818 to 11 Nm.

8. Install slide hammer, Tool J 6125-1B to J

41818 and remove main bearing cap.

Figure 6A3-296

9. Remove the remaining main bearing caps in

the same way. Check that the lower main

bearing shells are also removed with each

cap.

Figure 6A3-297

10. Remove the crankshaft from the cylinder

block, lifting evenly to avoid jamming against

the main thrust bearing.

Figure 6A3-298

Important: When the crankshaft (1) has been

removed, take particular care that the reluctor ring

(2) is not damaged, as this part is an integral part of

the crankshaft and is not serviced separately.

Therefore, it is suggested that the removed

crankshaft be supported on two wooden ‘V’ blocks

or other suitable soft surface.

Figure 6A3-299

11. Remove the crankshaft main bearings from

the cylinder block and the main bearing caps.

NOTE: Tak e particular care to organis e all parts so

they can be reinstalled in their original positions.

Figure 6A3-300

CLEAN AND INSPECT

Important: Take care not to damage the reluctor

ring on the crankshaft, as this part is non-

serviceable.

1. Clean the crankshaft with a suitable solvent.

2. Thoroughly clean all oil passages and inspect

for restrictions or burrs.

3. Blow dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

4. Carry out a visual inspection of the crankshaft

for damage.

5. Inspect the crankshaft reluctor ring lobes for

damage. The reluctor ring teeth should not

have imperfections on either the rising or

falling edges.

Figure 6A3-301

6. Inspect the crankshaft journals for wear (1).

Journals should be smooth with no signs of

scoring, wear or damage.

7. Inspect the crankshaft journals for grooves or

scoring (2).

8. Inspect the crankshaft journals for scratches

or wear (3).

9. Inspect the crankshaft journals for pitting or

embedded bearing material (4).

Figure 6A3-302

10. Inspect the c ranks haft key (1), k eyway ( 2) and

threaded hole (3) for damage.

Figure 6A3-303

11. Meas ure all cranks haft journals f or wear and

out-of-round.

Crankshaft Journal Specifications

Connecting Rod Journal Diameter.... .... .... . 53.308 mm Min.

Connecting Rod Journal Out-of-Round. .... . 0.010 mm Max.

Connecting Rod Journal Taper.... .... .... . .... . 0.010 mm Max.

Main Bearing Journal Di ameter.... .... .... .... .. 64.993 mm Min.

Main Bearing Journal Out-of-Round.... .... ... 0.008 mm Max.

Main Bearing Journal Taper....................... 0.020 m m Max.

Figure 6A3-304

12. Support the crankshaft, either on ‘V blocks on

a flat surface or in a commercial jig as shown.

13. Using a commercially available dial indicator,

mounted to a magnetic stand, measure the

following crankshaft main bearing journal

runout dimensions:

Crankshaft runout at the front and rear,

intermediate main bearing journals.

Crankshaft rear flange.

Reluctor ring (measured 1.00 mm below the

minimum tooth diameter), at the rear surface.

Crankshaft thrust wall at the centre main

bearing.

Main Bearing Journal Runout Specifications

Reluctor Ring Lateral Runout............. 0.250 m m Maximum

Crankshaf t Thrust Wal l Runout...... .... 0.025 mm Maximum

Crankshaft Rear Flange Runout..... .... 0.050 mm Maximum Figure 6A3-305

14. Check the rear cr ankshaf t oil gallery plug for a

loose fit or leaking.

15. If replacement is required, apply sealant such

as Loctite 242 or equivalent, to the sides of a

new plug (1) and install to the correct depth.

Crankshaft Rear Oil gallery Plug Depth Specification

Distance ‘A’............................. 31.2 - 31.6 mm

NOTE: If a manual transmission is fitted to the

vehicle, it will be necessary to first remove the

spigot bush. Refer to 3.7 CRANKSHAFT SPIGOT

BUSH - REPLACE, in this Section.

Figure 6A3-306

Main Bearings - Inspect

1. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves also indicate fatigue.

Figure 6A3-307

2. Inspect connecting rod bearing halves for

excessive scoring or discolouration.

3. Inspect the connecting rod bearings for dirt or

debris embedded into the bearing material or

backing metal.

Figure 6A3-308

4. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-309

Main Bearing Oil Clearance - Check

1. After thoroughly cleaning all relevant parts,

install bearing halves into the cylinder block

and main bearing caps.

Figure 6A3-310

2. Install crankshaft to cylinder block, ensuring

that the crankshaft is held square to avoid

jamming/ damaging the centre main thrust

bearing.

3. Install a small strip of plastic gauging material

across the full width of the main bearing

journal.

NOTE 1: Do not place the gauging material across

an oil feed hole.

NOTE 2: Ensure that the crankshaft does not

rotate during this process.

Figure 6A3-311

4. Install m ain bearings, caps, bolts and studs in

the same order as removal.

Figure 6A3-312

5. Tighten main bearing cap bolts and studs to

the correct torque specification and in the

correct sequence.

MAIN BEARING INNER BOLTS Stage 1: 20 Nm

(1 - 10) TORQUE SPECIFICATION Stage 2:

80° turn angle

MAIN BEARING OUTER STUDS Stage 1: 20 Nm

(11 - 20) TORQUE SPECIFICATION Stage 2:

53° turn angle

NOTE: Use torque angle meter E7115 to achieve

an accurate second reading.

6. T ighten the side c ap bolts to the c or rec t torque

specification, first on one side, then on the

other.

MAIN BEARING CAP SIDE BOLTS

TORQUE SPECIFICATION 25 Nm

Figure 6A3-313

7. Remove the main bearing cap M8 side bolts

(1) and disc ard, as new bolts m us t be used on

final assembly.

Figure 6A3-314

8. Loosen the bolts of m ain bearing rem oval T ool

J 41818 to separate the chamfered collets,

then install the chamfered sections into each

main bear ing c ap bolt hole, aligning the f lats of

the collets with those in the holes.

9. Tighten the bolts of Tool J 41818 to 11 Nm.

10. Install slide hammer, Tool J 6125-1B to J

41818 and remove main bearing caps.

Figure 6A3-315

11. Remove the remaining main bearing caps in

the same way.

Figure 6A3-316

12. Using the scale supplied with the gauging

plastic, measure the deformed plastic at its

widest part.

• If the deformed strip shows an irregularity

in the journal exceeding 0.025 mm,

remove the crankshaft and measure the

journal with a micrometer.

• If the bearing clearance is greater than

0.054 mm, select and install an

undersized bearing set, then re-check the

oil clearance.

• If clearance specification cannot be

obtained, the crankshaft must be reground

for use with the next under-sized bearings.

Figure 6A3-317

REINSTALL

1. Apply clean engine oil to the bearing halves

and crankshaft journals.

Figure 6A3-318

2. Install crankshaft to cylinder block, ensuring

that the crankshaft is held square to avoid

jamming/ damaging the centre main thrust

bearing.

Figure 6A3-319

3. Install main bearings, caps, bolts and studs in

the correct order.

NOTE: All m ain bearing c aps are num ber ed from 1

to 5 (front to rear). The numbers on the first four

caps are on one side while the rear main bearing

cap number is on the opposite side.

Also, the crankshaft bearing half locating notches

are on opposite sides, top to lower bearing, for all

main bearings.

Figure 6A3-320

4. Tighten main bearing cap bolts and studs to

the correct torque specification, in the correct

sequence.

ALL MAIN BEARING BOLTS Stage 1: 20 Nm

MAIN BEARING INNER BOLTS

(1 - 10) TORQUE SPECIFICATION Stage 2:

80° turn angle

MAIN BEARING OUTER STUDS

(11 - 20) TORQUE SPECIFICATION Stage 2:

53° turn angle

NOTE: Use torque angle meter E7115 to achieve

an accurate second reading.

5. Install NEW M8 main bearing cap side bolts

and tighten to the correct torque specification,

first on one side, then on the other.

MAIN BEARING CAP SIDE BOLTS

TORQUE SPECIFICATION 25 Nm

NOTE: New main bearing cap side bolts have a

sealant patch applied to the bolt flange.

Figure 6A3-321

6. Thrust the crankshaft rearward then forward,

using a suitable lever.

7. Inser t a feeler gauge between the centr e main

bearing and the crankshaft thrust bearing

surface.

Crankshaft End Play Specification

Crankshaft End Play............... 0.040 - 0.20 mm

NOTE 1: If the bearing clearance is not within

specification, inspect the thrust surfaces for nicks,

gouges or rais ed metal. Minor imperf ec tions c an be

removed with a fine stone.

NOTE 2: After measuring crankshaft end float,

leave the crankshaft in the forward position.

Particularly when a manual transmission if fitted to

the engine, this will lessen bearing shock when the

engine is started and the clutch is first released.

Figure 6A3-322

8. Inspect the crankshaft position sensor O-ring

for nicks, cuts or other damage. If

undamaged, the O-ring may be re-used.

9. Coat the O-ring with clean engine oil.

10. Install the sensor, aligning the retaining

bracket notch with the threaded holed in the

cylinder block.

11. Install the retaining bolt, tightening to the

correct torque specification.

CRANKSHAFT POSITION SENSOR

BOLT TORQUE SPECIFICATION 25 Nm

12. Reinstall the following items to the engine

assembly;

a. Rear cover and flywheel/Flex plate, refer

3.8 ENGINE REAR COVER and

3.5 FLYWHEEL/ FLEXPLATE, in this

Section

b. Timing chain, refer 3.10 TIMING CHAIN

AND SPROCKETS, in this Section.

c. Oil pump, screen and deflector, refer

3.9 OIL PUMP, PUMP SCREEN and

DEFLECTOR, in this Section.

d. Front cover and crankshaft balancer,

refer 3.4 FRONT COVER and

2.24 CRANKSHAFT BALANCER in this

Section.

e. Oil pan, refer 3.3 OIL PAN, in this

Section.

f. Starter motor, refer Section 6D3-2

STARTING SYSTEM - GEN III V8

ENGINE.

13. Reinstall engine into vehicle, refer

3.1 ENGINE ASSEMBLY - REMOVE, in this

Section.

Figure 6A3-323

3.14 ENGINE BLOCK P LUGS

REMOVE

1. Using an 8 mm Allen key socket and bar,

remove the coolant drain plug from the right

hand rear of the cylinder block.

Figure 6A3-324

2. Remove the three plugs from the left hand

side of the c ylinder block, using an 8 mm Allen

key socket and bar for plugs ‘1‘ and ‘3’ and a

17 mm Allen key socket for plug ‘2’.

T6A3200a

Figure 6A3-325

3. If not removed in previous operations, rem ove

the oil pressure sensor (1) from the top of the

cylinder block, at the lef t hand rear, using T ool

J 41712 and suitable 3/8” drive socket bar.

Figure 6A3-326

Techline

NOTE: Only remove the plug from the front of the

engine block, if replacement is required.

4. Remove the engine block, front oil gallery

plug.

Figure 6A3-327

5. Remove the engine block, rear oil gallery plug.

6. Inspect the O-ring seal and, if undamaged it

may be re-used during assembly.

Figure 6A3-328

REINSTALL

1. Apply a 3 mm bead of sealant such as Loctite

565 or equivalent, to the right hand rear,

engine block coolant drain plug sealing

washer.

2. Install the plug and tighten to the correct

torque specification, using an 8 mm Allen key

socket.

COOLANT DRAIN PLUG

TORQUE SPECIFICATION 60 Nm

Figure 6A3-329

3. Apply a 3 mm bead of sealant such as Loctite

565 or equivalent, to the sealing washer on

each of the left hand side engine block plugs.

4. Install each plug and tighten to the correct

torque specification, using an 8 mm Allen key

sock et for plugs ‘1’ and ‘3’ and a 17 mm Allen

key socket for plug ‘2’.

COOLANT DRAIN PLUG - ALL

TORQUE SPECIFICATION 60 Nm

T6A3200a

Figure 6A3-330

5. Inspect the O-ring seal and, if undamaged it

may be re-used.

6. Lubricate the O-ring seal with clean engine oil

and install on the engine block rear oil galley

plug.

7. Install the rear oil gallery plug to the oil galley,

to the specified depth.

Rear Oil Gallery Plug Installation Specification

Distance ‘A’............................. 0.8 - 1.4 mm

Figure 6A3-331

8. Apply a sealant such as Loctite 242 or

equivalent to the side of a NEW front oil

gallery plug.

9. Install the NEW, front oil gallery plug to the

engine block to the specified depth.

Front Oil Gallery Plug Installation Specification

Below Flush ............................ 2.2 - 2.8 mm

Figure 6A3-332

10. Apply sealant such as Loctite 565 or

equivalent to the cleaned threads of the oil

pressure sensor (1) and reinstall, using Tool

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

equipment. Tighten to the correct torque

specification.

OIL PRESSURE SENSOR

TORQUE SPECIFICATION 20 Nm

Figure 6A3-333

3.15 CYLINDER BLOCK

CAMSHAFT BEARINGS - REPLACE

NOTE 1: Care must be taken during bearing

removal and installation, not to damage bearings

that are not being replaced.

NOTE 2: The following operations involve the use

of universal camshaft bearing remover/installer,

Tool J 33049 and finished size camshaft bearings.

If installing unfinished size bearings, installation

must be carried out by a specialist machine shop

and then line bored to the correct finished size.

NOTE 3: While it is preferred that the camshaft

bearings are removed and installed in a bare

cylinder block, the operation can be carried out by

removing the crankshaft and the camshaft, even

though it is difficult to negotiate the tool past the

connecting rod big end journals.

The camshaft can be removed without having to

firs t remove the c ylinder heads and hydraulic lif ter s .

By removing the push rods and inverting the

engine, the hydraulic lifters will drop sufficient to

clear the camshaft journals.

1. Prior to bearing removal, inspect all camshaft

bearings for a loose fit in the engine block

bearing bores.

NOTE: If a bearing is found to be loose, it may

have been caused by an enlarged, out of round or

damaged engine block bearing bore.

Figure 6A3-334

2. The universal camshaft bearing

remover/installer, Tool J 33049, consists of the

following components;

Nylon Guide Cone (1).

Small Driving Washer (2).

Large Driving Washer (3).

Expanding Drivers and Rubber Sleeves (4 - 8).

Driver Extension Bar (9).

Driver Bar (10).

Expander Assembly (15). Consists of parts 11 - 14.

3. T o replace the cam shaft bearings on the GEN

III V8 engine, select the following components

from Tool J 33049:

Nylon Guide Cone (1).

Large Driving Washer (3).

Expanding Drivers and Rubber Sleeve (7).

Driver Bar (10).

Expander Assembly (15).

T6A3275a

15 4

Figure 6A3-335

4. Install expanding driver with its rubber sleeve

(1), over the expander assembly (2), with the

numbered flanges of the expanding driver

facing the threaded end of the expander

assembly (2), as shown.

Figure 6A3-336

5. Once installed, ensure that the separations in

the expander ass embly segments, are aligned

with those of the expanding driver as shown

(‘A’).

Figure 6A3-337

6. Manoeuvre the assembly into the cylinder

block, in front of the bearing to be removed,

then install the large driving washer (3) over

the threaded end of the expander assembly

(5).

7. Slide the nylon cone (1) over the driver bar (2)

with the smaller diameter toward the cylinder

block.

NOTE: The components shown in Figure 6A3-337

are shown removed from the cylinder block for

clarity.

8. Carefully insert the driving bar through the

camshaft bearings, from the front of the

cylinder block and screw the bar to the

expander assembly.

9. With the expander assembly inserted into the

camshaft bearing, hold the hexagonal end of

expander assembly (5) with a spanner and

hand tighten the driver bar until the expanding

driver (4) is tight in the bearing shell.

Important: Do not overlook fitting the driving

washer over the threaded end of the expander

assembly before installing the driver bar.

Figure 6A3-338

10. Push the guide cone into the front camshaft

bearing to align the driver bar.

11. While holding the guide cone in place with one

hand, drive the bearing from the cylinder

block.

12. Repeat this process with the remaining

bearings being removed.

Figure 6A3-339

NOTE: To remove the front bearing, install the

driver bar from the rear of the cylinder block, using

the guide cone in the rear camshaft bearing bore,

as shown in Figure 6A3-339.

Figure 6A3-340

13. To install a new bearing, proceed in a similar

way to bearing removal, except for the

following items:

• The j oin in the new cam shaf t bearing ( ‘A’)

mus t be aligned with the top of the engine

block. To assist with alignment, use a felt

tip pen to mark the back of the bearing,

180° from the join, as this will be visible

when installing the bearing.

• While the oil feed is generous in length

and allows some degree of hole

misalignment, as much care as possible

must be made during installation.

• Install each bearing until it is centrally

located in the cylinder block bore, then

use a thin piece of wire to ensure that the

oil feed passage is not obstructed in any

way.

• To install the front camshaft bearing,

install the driver bar into the rear bearing

and use the guide cone at that location.

Important: Take care when installing the

driver bar through the newly installed bearings

to avoid damage.

Figure 6A3-341

CYLINDER BLOCK, CLEAN, INSPECT AND MEASURE

Clean

NOTE 1: Do not use a caustic solution to clean the aluminium engine block.

NOTE 2: When cleaning an engine block in a thermal type oven, do not exceed 450° F (232° C).

1. Clean the engine block in a suitable solvent, to remove all sludge, dirt, or debris.

2. Dry the block with compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

3. Clean all gasket surfaces, taking care to only use a plastic scraper to avoid damaging machined surfaces.

4. After removing all engine block plugs (Refer 3.14 ENGINE BLOCK PLUGS, in this Section), clean all coolant

passages and oil galleries.

5. Clean the main bearing caps, taking care not to mix them from their original order.

6. Clean any residue of cylinder head bolt thread sealant fr om the c ylinder block threads, using ins taller, T ool No.

J-42385-107 (this tool is part of thread repair kit, J-42385).

Important: Do not use anything but this thread tool to clean the cylinder head threads in the cylinder block.

7. Use compressed air to clean all residue from bolt holes.

CAUTION: Wear eye protection to prevent injury

Inspect

Inspect the following areas:

1. The cylinder walls for excessive scratches, gouging, or ring ridge.

2. The coolant jacket for cracks.

3. The valve lifter bores for excessive scoring or wear.

4. The crankshaft bearing webs for cracks.

5. The gasket sealing surfaces for excessive scratches or gouging.

6. The oil galleries for restrictions.

7. All threaded bolt holes for damage.

Measure Cylinder Bore

1. Adjust the micrometer to 96.0 mm.

2. Insert the bore gauge into the micrometer and

zero the bore gauge dial, Tool J 8087 (or

commercial equivalent).

Figure 6A3-342

3. Use a bore gauge and measure the cylinder

bore for taper.

• Slide the bore gauge up and down

throughout the length of the cylinder bore.

Check the bore both parallel and

perpendicular to the centreline of the

crankshaft.

• Recondition cylinders with less than 0.018

mm taper with a hone. Refer CYLINDER

BORING AND HONING, in this Section.

• Cylinders with more than 0.018 mm taper

must be fitted with an oversize piston.

Figure 6A3-343

4. Use a bore gauge and measure the cylinder

bore for out-of-round:

• Measure the bore, both in line with the

centreline and perpendicular to the engine

centreline. Check f or bore out- of-r ound at a

depth of 9 mm (‘A’), 57 mm (‘B’) and 127

mm (‘C’) from the cylinder head surfaces.

• Calculate the difference between the two

measurements at each location. The

results will indicate any out-of-round bore

condition.

• Cylinders with more than 0.018 mm out-of-

round must be honed and fitted with an

oversize piston.

Figure 6A3-344

Measure Engine Block Cylinder Head Deck

1. Using a straight edge and feeler gauges,

check the flatness of the engine block,

cylinder head deck surfaces.

If found to be outside specification, the engine

block must be replaced, as machining is not

recommended.

Engine Block Cylinder Head Deck Flatness

Specification

Measured within a 150 mm area..0.11 mm Maximum

Measured over block length......... 0.22 mm Maximum

CYLINDER BORING AND HONING

Boring Pr ocedure

1. Oversize service piston and piston ring sets

are available in 0.25 mm.

Important: GEN III V8 Cylinder boring is not

permitted.

2. It is recommended to hone the cylinder to

achieve proper fit for the oversize piston.

Refer to the Cylinder Honing information for

the proper honing procedure.

Honing Procedure

1. When honing the cylinders, follow the

manufacturer's recommendations for

equipment use, cleaning, and lubrication. Use

only clean, sharp stones of the proper grade

for the amount of material you remove. Dull,

dirty stones cut unevenly and generate

excess ive heat. Do not hone to final clearance

with a coarse or medium-grade stone. Leave

suff icient m etal so that all stone m ark s m ay be

removed with fine-grade stones. Perform final

honing with a fine-grade stone, honing the

cylinder to the proper clearance.

2. During the honing operation, thoroughly clean

the cylinder bore. Repeatedly check the

cylinder bore for f it with the selected pis ton. All

measurements of the piston or the cylinder

bore should be made with the components at

normal room temperature.

3. When honing a cylinder for fit to an oversize

piston, first perform the preliminary honing with

a 100 grit stone.

4. Perform final cylinder honing with a 240 grit

stone and obtain a 45 degree cross hatch

pattern.

5. A 240 grit stone is preferred for final honing. If

a 240 grit stone is not available, a 220 grit

stone may be used as a substitute.

6. When honing to elim inate taper in the c ylinder,

ma ke fu ll strok es for the c om plete bore length.

Repeatedly check the measurement at the

top, the middle, and the bottom of the bore.

T6A3228

Figure 6A3-345

7. The finish marks should be clean but not

sharp. The finish marks should also be free

from embedded particles and torn or folded

metal.

8. By measuring the s elected piston at the sizing

point and by adding the average of the

clearance specification, the final cylinder

honing dimension required, can be

determined.

9. When finished, the reconditioned cylinder

bores should have less than or meet the

specified out-of-round and taper requirements.

10. After final honing and before the piston is

checked for fit, clean the cylinder bores with

hot water and detergent. Scrub the bores with

a stiff bristle brush and rinse the bores

thoroughly with hot water. Do not allow any

abrasive material to remain in the cylinder

bores. This abrasive material may cause

premature wear of the new piston rings and

the cylinder bores. Abrasive material will also

contaminate the engine oil and may cause

prem ature wear of the bearings . After washing

the cylinder bore, dry the bore with a clean

rag.

11. Perform final measurements of the piston and

the cylinder bore.

12. Perm anently m ark the top of the piston f or the

specific cylinder to which it has been fitted.

13. Apply clean engine oil to each cylinder bore in

order to prevent rusting.

Deglazing Procedure

Using a ball type or self centring honing tool,

deglaze the cylinder bore lightly. Deglazing should

be done only to remove any deposits that may

have formed. Use a 240 grit stone of silicone

carbide or equivalent m aterial when perform ing the

deglazing procedure.

A 240 grit stone is preferred for final honing. If a

240 grit stone is not available, a 220 grit s tone m ay

be used as a substitute.

3.16 THREAD REPAIR

GENERAL INFORMATION

With the extensive use of aluminium alloy in the

construc tion of the GEN III V8 engine, thread repair

skills are required to repair damaged threads

caused by careless handling or over-torquing of

fasteners.

This Section describes the recommended method

of repairing threads in three specific areas of the

engine;

• General Thread Repair.

• Cylinder Head Bolt Hole Thread Repair.

• Main Cap Bolt Hole Thread Repair.

Section 3.17 THREAD REPAIR

SPECIFICATIONS in this Section, contains

detailed descriptions of all thread specifications

used in this engine.

The available Thread Repair Kit, Tool J

42385/100/200/ 300, uses the Time Sert thread

repair process that involves a solid, thin walled,

self-locking, carbon steel, bushing type insert (1).

During the bushing installation process, the driver

tool expands the bottom external threads of the

insert into the base material (2). This action

mechanically locks the insert in place.

Also, when installed to the proper depth, the flange

of the insert will be seated against the counterbore

of the repaired hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Important: The use of a cutting type fluid GM P/N

1052864, (or WD 40, or equivalent) is

recommended when performing the drilling,

counterboring, and tapping procedures.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a

suitable tap wrench or drill motor.

Figure 6A3-346

GENERAL THREAD REPAIR

1. Drill out the threads of the damaged hole (1) to

the correct depth for the thread being repaired:

• M6 inserts require a m inimum drill depth of

15 mm.

• M8 inserts require a m inimum drill depth of

20 mm.

• M10 inserts require a minimum drill depth

of 23.5 mm.

2. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-347

3. Counterbore the hole to the full depth

permitted by the tool (1).

4. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-348

5. Using a tap wrench (2), tap the threads of the

drilled hole to the correct depth for the thread

being repaired.

• M6 inserts require a minimum tap depth of

15 mm.

• M8 inserts require a minimum tap depth of

20 mm.

• M10 inserts require a minimum tap depth

of 23.5 mm.

6. Using compressed air, clean out any chips.

7. Spray a suitable cleaner such as GM P/N

12346139, P/N 12377981 or equivalent, into

the hole.

Important: Do not use any cleaning agents that

contain Trichloralethane, as this is harmful to

aluminium.

8. Using compressed air, clean any cutting oil

and chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-349

9. Lubricate the threads of the installer tool (2)

with the driver oil (1).

Important: Do not allow oil or other foreign

mater ial to contac t the outs ide diam eter ( OD) of the

insert.

Figure 6A3-350

10. Install the insert (2) onto the driver tool (1).

Figure 6A3-351

11. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-352

12. Using the inst aller tool (1), install the ins ert (2)

into the hole.

13. Continue to install the insert until the flange of

the insert contacts the counterbored surface.

14. Continue to rotate the installer tool (1) through

the insert. The installer tool (1) will tighten up

before screwing completely through the insert.

This is normal s ince the bottom threads of the

insert are being formed and mechanically

locked into the hole.

15. Remove the driver. The repair is complete.

Figure 6A3-353

16. Inspect the insert for proper installation into

the hole.

17. A properly installed insert (1) will be either

flush or slightly below flush with the surface of

the base material (2).

Figure 6A3-354

CYLINDER HEAD BOLT HOLE THREAD REPAIR

The cylinder head bolt hole thread repair kit

consists of the following items:

1. Drill

2. Tap

3. Installer

4. Sleeve

5. Alignment Pin

6. Bushing

7. Bolts

8. Fixture Plate

Figure 6A3-355

CAUTION: Wear safety glasses to avoid eye

injury.

Important: The use of a cutting type fluid GM P/N

1052864, (or WD 40, or equivalent) is

recommended when performing the drilling,

counterboring, and tapping procedures.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a

suitable tap wrench or drill motor.

1. Install the fixture plate (3), bolts (1), and

bushing (2) onto the engine block deck.

2. Position the fixture plate and bushing over the

hole that is to be repaired (4).

Figure 6A3-356

3. Position the alignment pin (1) through the

bushing and into the hole.

4. With the alignment pin in the desired hole,

tighten the fixture retaining bolts (2).

5. Remove the alignment pin from the hole.

Figure 6A3-357

6. Cylinder head bolt holes 1-8 are the deep

holes and will be drilled without the drill sleeve.

7. Cylinder head bolt holes 9 and 10 are the

more shallow holes, so drilling MUST be done

with the drill sleeve in place

Figure 6A3-358

8. Install the sleeve (2) onto the drill (1) (if

required).

Figure 6A3-359

9. Drill out the threads of the damaged hole.

10. Drill the hole until the stop collar of the drill bit

or the sleeve contacts the bushing.

11. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-360

12. Using a tap wrench, tap the threads of the

drilled hole.

Figure 6A3-361

13. In order to tap the new threads to the proper

depth, rotate the tap into the hole until the

marks (1 or 4) on the tap align with the top of

the drill bushing (3), as follows:

• For the deeper cylinder head bolt holes

(1-8), rotate the tap until the upper mark

on the tap (4) aligns with the top of the

drill bushing.

• For the shallower cylinder head bolt holes

(9 and 10), rotate the tap until the lower

mark on the tap (1) aligns with the top of

the drill bushing.

14. Remove the fixture plate (2), bushing (3), and

bolts.

15. Using compressed air, clean out any chips.

16. Spray a suitable cleaner such as GM P/N

12346139, P/N 12377981 or equivalent, into

the hole.

Important: Do not use any cleaning agents

that contain Trichloralethane, as this is harmful

to aluminium.

17. Using compressed air, clean any cutting oil

and chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-362

18. Lubricate the threads of the installer tool (2)

with the driver oil (1).

Important: Do not allow oil or other foreign

mater ial to contac t the outs ide diam eter ( OD) of the

insert.

Figure 6A3-363

19. Install the insert (2) onto the driver tool (1).

Figure 6A3-364

20. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-365

21. Install the insert and driver (1) into the hole.

22. Continue to install the insert until the flange of

the insert contacts the counterbored surface.

23. Continue to rotate the installer tool (1) through

the insert. The installer tool (1) will tighten up

before screwing completely through the insert.

This is normal s ince the bottom threads of the

insert are being formed and mechanically

locked into the hole.

24. Remove the driver. The repair is complete.

Figure 6A3-366

MAIN CAP BOLT HOLE THREAD REPAIR

The m ain cap bolt hole thread r epair kit consists of

the following items:

1. Drill

2. Tap

3. Installer

4. Fixture Plate

5. Long Bolts

6. Short Bolts

7. Alignment Pin

8. Bushing

Figure 6A3-367

CAUTION: Wear safety glasses to avoid eye

injury.

Important: The use of a cutting type fluid GM P/N

1052864, (or WD 40, or equivalent) is

recommended when performing the drilling,

counter-boring, and tapping procedures.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a

suitable tap wrench or drill motor.

1. Position the fixture plate and bushing over the

hole that is to be repaired. Position the

alignment pin in the desired hole and tighten

the fixture retaining bolts.

Figure 6A3-368

2. Drill out the damaged hole.

NOTE: The outer bolt hole locations (11-20) have

the shallower counter-bores. Use bushing (8), J

42385-316 with the drill.

3. Drill until the stop collar of the drill bit or the

sleeve contacts the bushing.

4. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-369

5. In order to tap the new threads to the proper

depth, rotate the tap into the hole until the

marks (1 or 4) on the tap align with the top of

the drill bushing (3), as follows:

• For the deeper main cap holes (1-10),

rotate the tap until the upper mark (4) on

the tap aligns with the top of the bushing

(3).

• For the shallower main cap holes (11-20),

rotate the tap until the lower mark (1) on

the tap aligns with top of the bushing (3).

6. Remove the fixture plate (2), bushing (3), and

bolts.

7. Using compressed air, clean out any chips.

8. Spray a suitable cleaner such as GM P/N

12346139, P/N 12377981 or equivalent, into

the hole.

Important: Do not use any cleaning agents that

contain Trichloralethane, as this is harmful to

aluminium.

9. Using compressed air, clean any cutting oil

and chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-370

10. Lubricate the threads of the installer tool (2)

with the driver oil (1).

Important: Do not allow oil or other foreign

mater ial to contac t the outs ide diam eter ( OD) of the

insert.

Figure 6A3-371

11. Install the insert (2) onto the driver tool (1).

Figure 6A3-372

12. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-373

Important: The fixture plate (1) and bushing (2)

remains installed onto the engine block during the

insert installation procedure.

13. Install the insert and driver (3) through the

fixture plate and bushing and into the hole.

14. Rotate the driver tool until the m ar k on the tool

(4) aligns with the top of the bushing (2).

NOTE: The installer tool will tighten up before

screwing completely through the insert. This is

normal since the bottom threads of the insert are

being formed and mechanically locked into the

hole.

15. Remove the driver. The repair is complete.

Figure 6A3-374

3.17 THREAD REPAIR SPECIFICATIONS

ENGINE BLOCK - FRONT VIEW

Figure 6A3-375

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1-6 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

7 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 25.0 19.5

8 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 32.5 25.0

9 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

10 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 Through Through

11-13 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

14 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Through 18.0

15 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

16 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Through 18.0

17-27 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

ENGINE BLOCK - REAR VIEW

Figure 6A3-376

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21.5

2-4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

5-6 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21.5

7-13 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

14-16 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21.5

17-18 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

ENGINE BLOCK - LEFT SIDE VIEW

Figure 6A3-377

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

2-3 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 16.0

6-7 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

9 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 69.0 60.0

10 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

11 

12-17 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 23.0

18 M28 x 1.25 

19-20 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

21 M16 x 1.5 

22 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21.5

23 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

24 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 69.0 60.0

25 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

26-27 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

28 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 16.0

29 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

• Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm counterbore included in the 124.0 mm drill depth.

• Bolt holes 9 and 24 have a 30 mm counterbore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the drill

and tap.

ENGINE BLOCK - RIGHT SIDE VIEW

Figure 6A3-378

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

2-3 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 15.0

6-7 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

9 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 69.0 60.0

10 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

11-14 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21.5

15-19 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 23.0

20 M16 x 1.5   

21 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

22 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

23 M11 x 2 J 42385-108 J 42385-105 J 42385-106 J 42385-107 69.0 60.0

24 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

25-26 M11 x 2.0 J 42385-108 J 42385-105 J 42385-106 J 42385-107 124.0 115.0

27 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 15.0

28 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

• Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have a 85 mm counterbore included in the 124.0 mm drill depth.

• Bolt holes 9 and 23 have a 30 mm counterbore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the drill

and tap.

ENGINE BLOCK - BOTTOM VIEW

Figure 6A3-379

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

2 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

3 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

4 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

5 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

6 M16 x 1.5   

7N/A  

8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

9 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

10-11 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

12 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

13-14 M10 x 1.5 J 42385-215 J 42385-101 J 42385-213 J 42385-214 42.5 37.0

15 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

16 M16 x 1.5   

17 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5

18 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

19 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

20 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

21 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

22 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

23 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

24 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

25-26 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

27 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

28-29 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

30 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

31 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

32 M28 x 1.25   

33 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

34 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 53.5 44.0

35 M10 x 2.0 J 42385-104 J 42385-101 J 42385-102 J 42385-103 31.0 25.5

36 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

• Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm counterbore included in the 53.5 mm drill depth.

• Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm counterbore included in the 31.0 mm drill depth. Use

sleeve J 42385-316 with the drill and tap..

• Bolt holes 13 and 14 have a 11.5 mm counterbore included in the 42.5 mm drill depth. Use sleeve J 42385-311 with the

drill and tap.

ENGINE BLOCK - TOP VIEW

Figure 6A3-380

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1-4 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

5 M16 x 1.5  

6-7 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

8 M10 x 1.5 J 42385-216 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 17.0

9-10 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

11 M10 x 1.5 J 42385-216 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 17.0

12-14 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

CYLINDER HEAD - TOP VIEW

Figure 6A3-381

Hole Thread

Size Insert Drill Counterbo

re Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1-5 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-

207 J 42385-

208 J 42385-

209 26.5 19.0

6-9 M6 x 1.0 J 42385-

205 J 42385-

201 J 42385-

202 J 42385-

203 J 42385-

204 20.05 16.05

10-12 M8 x 1.25 J 42385-

210 J 42385-

206 J 42385-

207 J 42385-

208 J 42385-

209 26.5 19.0

CYLINDER HEAD - END VIEW

Figure 6A3-382

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

2N/A  

3 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

4N/A  

5-6 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

CYLINDER HEAD - EXHAUST MANIFOLD SIDE VIEW

Figure 6A3-383

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1-2 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

3 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

4 M14 x 1.25   

5 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

6 M14 x 1.25   

7-8 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

9 M14 x 1.25   

10 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

11 M14 x 1.25   

12 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16.0

13 M12 x 1.5   

14-15 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

CYLINDER HEAD - INTAKE MANIFOLD SIDE VIEW

Figure 6A3-384

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver Maximum

Drill Depth

Maximum

Tap Depth

1-2 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 Through Through

3-4 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 15.0

5-7 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 Through Through

4. DIAGNOSIS

4.1 BASIC ENGINE MISFIRE DIAGNOSIS

GENERAL INFORMATION

1. Engine perf ormanc e diagnosis procedures ar e covered in Section 6C3 POWERTRAIN MANAGEMENT GEN

III V8 ENGINE, of the VT Series II Service Information and should be referred to for diagnosis of any

Driveability, Emissions, or Check Powertrain Lamp concerns.

2. The following diagnosis covers common concerns and possible causes.

3. When the proper diagnosis is m ade, the concern should be c orrected by adjustm ent, repair or replacem ent as

required.

4. Refer to the appropriate section of this Service Information CD for each specific procedure.

5. This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty

camshaft, worn or damaged bearings or bent pushrod.

6. This table will not isolate a crossed injector wire, faulty injector or any other driveability component failure that

may cause a misfire.

7. The Powertrain On-Board Diagnostic System checks must be performed first. Refer to Section 6C3-2A

POWERTRAIN MANAGEMENT GEN III V8 ENGINE, DIAGNOSTIC CHARTS, of the VT Series II Service

Information.

8. W hen using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below

and then proceed to the specific category.

DIAGNOSTIC PROCEDURE

Checks Action

Preliminary 1. Perform a visual inspection of the following:

• A loose or improperly installed engine flywheel or crankshaft balancer.

• Worn, damaged, or misaligned accessory drive system components.

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

3. Inspect the engine for acceptable oil pressure. Refer to 2.4 ENGINE OIL

PRESSURE - CHECK in this Se ction.

4. Verify if the engine has excessive oil consumption. Refer to 4.4 OIL

CONSUMPTION DIAGNOSIS, in thi s Section.

5. Verify if the engine has coolant consumption.

6. Perform a compression test on the engine.

Intake Manifold Leaks 1. An intake manifold that has a vacuum leak may cause a misfire.

2. Inspect for the following:

• Improperly installed or damaged vacuum hoses.

• Faulty or improperly installed intake manifold and/or gaskets.

• Cracked or damaged intake manifold.

• Inspect the areas between the intake runners.

• Improperly installed or damaged Manifold Absolute Pressure (MAP) sensor

housing (located at the rear of the intake manifold).

• Improperly installed or damaged MAP sensor housing O-ring seal.

• Improperly installed MAP sensor.

• The sealing grommet of the MAP sensor should not be torn or damaged.

• Improperly installed throttle body or damaged gasket.

• Warped intake manifold.

• Warped or damaged cylinder head sealing surface.

Techline

Checks Action

Coolant Consumption 1. Coolant consumption may or may not cause the engine to overheat. Inspect for

the following:

• External coolant leaks.

• Faulty cylinder head gasket.

• Warped cylinder head.

• Cracked cylinder head.

• Damaged engine block.

Oil Consumption 1. Oil consumption may or may not cause the engine to misfire. Remove the spark

plugs and inspect for an oil fouled spark plug.

2. Perform a cylinder compression test. Refer to 2.5 COMPRESSION CHECK in

this Section.

3. If the compression test indicates worn valves or valve guides, inspect for the

following:

• Worn valve guides.

• Worn valve stems.

• Worn or burnt valves or valve seats.

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

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

following:

• Broken or improperly seated piston rings.

• Excessive piston ring end gap.

• Excessive cylinder bore wear or taper.

• Cylinder damage.

• Piston damage.

Abnormal Internal Engine Noises 1. With the engine running, try and determine if the noise is timed to camshaft

speed or crankshaft speed.

NOTE: Using a timing light, two knocks per flash is crankshaft speed and one knock

per flash is camshaft speed.

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

• Missing or loose valve train components.

• Worn or loose valve rocker arms.

• Worn or bent pushrods.

• Faulty valve springs.

• Bent or burnt valves.

• Worn camshaft lobes.

• Worn or damaged timing chain and/or sprockets.

Important: A slight COLD knock or piston slapping noise could be considered

normal if not present after the engine has reached normal operating temperatures.

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

• Worn crankshaft main or connecting rod bearings.

• Piston or cylinder damage.

• Worn piston or piston pin.

• Damaged or faulty connecting rod.

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

No Abnormal Internal Engine Noise 1. Inspect for a worn or improperly installed timing chain and/or sprockets.

2. Remove the valve rocker arm cover on the side of the engine with the cylinder

that is misfiring.

3. Inspect for the following:

• Loose valve rocker arm bolts.

• Bent push rods.

• Faulty valve springs.

• Faulty valve lifters (bleeding down).

• Worn or improperly seated valves.

• Worn camshaft lobes.

4.2 ENGINE NOISE DIAGNOSIS

There are four steps to diagnosing engine noise. You must determine the following:

The type of noise. For example, is the noise a light rattle/tapping or a low rumble/knocking?

The exact operating condition under wh ich the noise exists. Note f actor s suc h as the ambient tem per ature, the

amount of engine warm-up time, the engine temperature, engine speed other specifics.

At what rate the noise occurs, and at what location in the engine. Remember, engine noises are generally

synchronised to either engine speed (crankshaft, flywheel, connecting rods, balancer, or pistons and related

com ponents ) or one-half engine speed (valve train noise such as r oc k er ar ms, valve lif ter s , and timing chain). Try to

determine the rate at which the noise is occurring.

Compare the engine sounds to other engines. This is required to make sure you are not trying to correct a

normal condition.

Checks Action

Noise on Start-Up but Only Lasts a

Few Seconds • Improper oil viscosity. Install the recommended oil viscosity for the expected

temperatures.

• Incorrect oil filter without the anti-drainback feature.

• Worn or dirty hydraulic valve lifters.

• Excessive piston to bore clearance.

• Excessive piston pin to piston clearance.

• Excessive crankshaft bearing clearance.

Knocks Cold and Continues for 1 to

2 Minutes • Loose or broken crankshaft balancer or accessory drive components.

• Excessive piston to bore clearance.

• A cold piston knock which disappears in 1.5 minutes should be considered

acceptable.

• A cold engine knock usually disappears when the specific cylinders secondary

ignition circuit is earthed.

Intermittent Noise on Idle,

Disappearing When Engine Speed

is Increased

• Improper oil viscosity. Install the recommended oil viscosity for the expected

temperatures.

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

engine oil pressure.

• Dirty or worn hydraulic valve lifter.

Valve Train Noise (Rattle/Tapping) 4. The following conditions may cause valve train noise:

• Lower than specified oil pressure.

• Worn or faulty oil pump.

• Loose oil pump-to-engine block bolts.

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

• Loose valve rocker arm attachments.

• Worn valve rocker arm bearings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticking valves.

• Worn, dirty, or faulty hydraulic valve lifters.

• Worn camshaft lifter lobes.

• Worn valve guides or valve stems.

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

Checks Action

Knocks at Idle Hot

(Rumble/Knocking) 1. The following conditions may cause a knocking noise:

• Malfunctioning accessory drive system components.

• Loose or broken crankshaft balancer.

• Detonation or spark knock.

• Check for proper operation of the cooling, knock, and ignition control

components.

• Refer to diagnostic information in 6C3 POWERTRAIN MANAGEMENT - GEN III

V8 ENGINE, of the VT Series II Service Information.

• Excessive connecting rod bearing clearance.

• Excessive piston pin to bore clearance.

• Bent connecting rod.

• Excessive crankshaft main or thrust bearing clearance.

• Loose torque converter bolts.

• Cracked or damaged flywheel.

• Exhaust leak at the manifold.

Exhaust System Noise and/or

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

conditions:

• Improperly installed or misaligned exhaust system components.

• A cracked or broken exhaust manifold.

• Damaged or worn gaskets and/or seals.

• Burned or rusted out exhaust system components.

• A broken or loose exhaust clamp and/or bracket.

4.3 VALVE TRAIN DIAGNOSIS

GENERAL INFORMATION

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

These tapping noises will typically increase with engine speed.

• Before attempting to diagnose valve train noise, check for the proper oil level and thoroughly warm up the

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

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

• Whenever Valve Lifter Diagnosis is neces sary, always use a listening devic e s uch as a stethos cope. T ools s uch

as this will help to isolate any lifter noise and identify noises that could be mis-diagnosed as lifter noise.

DIAGNOSTIC PROCEDURE

Checks Action

A light tapping noise similar to

valve train noise. 1. This light type of noise mat be caused by the following components:

• Fuel injectors.

• Evaporative emission (EVAP) purge solenoid.

• Detonation.

• Loose heat shields.

Causes of Valve Train Noise 1. Any or a combination of the following can cause valve train noise:

• Poor oil quality caused by water contamination, aeration, or fuel dilution.

• Low engine oil pressure.

• Worn or faulty oil pump.

• A loose or plugged oil pump screen.

• Loose or damaged oil transfer tube.

• Loose valve rocker arm attachments (causing excessive valve lash).

• Worn or damaged valve rocker arm bearings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticking valves.

• Valve lifters worn, dirty, or faulty.

• Broken valve lifter guide.

• Camshaft valve lifter lobes worn.

• Worn valve guides or valve stems.

• Worn, damaged, or missing valve keys.

• Bent pushrods.

• Excessive play in the camshaft timing chain.

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

DIAGNOSTIC TA BLE

DEFINITION: A light tapping noise at one half engine speed, or any varying frequency.

Step Action Value(s) Yes No

1Is there valve train noise? −Go to Step 2 System OK

2Check for a high engine oil level. A engine with the oil level

above the FULL mark allows the crankshaft counterweights to

churn the oil into foam. When foamy oil is pumped into the

lifters, the lifters become noisy. A solid column of oil ensures

proper lifter operation.

Is the oil level too high?

−Go to Step 3 Go to Step 4

3Drain engine oil until level is correct.

Is there valve train noise? −Go to Step 4 System OK

4Check for a low engine oil level. A engine with the oil level

below the ADD mark may allow the oil pump to pump air at

high engine speeds.

Is the oil level too low?

−Go to Step 5 Go to Step 6

5Add oil as required.

Is there valve train noise? −Go to Step 6 System OK

6Check for proper engine oil pressure. Refer to 2.4 ENGINE

OIL PRESSURE - CHECK, in this Section.

Is the engine oil pressure within specifications?

−Go to Step 7 Go to Step 7

7Check the oil pump screen for damage or a loose fit to the oil

pump.

Inspect for a missing or damaged oil pump screen O-ring seal.

Is the oil pump screen loose or is the screen or O-ring seal

damaged?

−Go to Step 8 Go to Step 9

8Repair as required.

Is there valve train noise? −Go to Step 9 System OK

9Check for a damaged oil pump or loose mounting bolts. Refer

to Oil Pump Clean and Inspect, in this Section.

Is the oil pump damaged or are the fasteners loose?

−Go to Step 10 Go to Step 11

10 Repair as required.

Is there valve train noise? −Go to Step 11 System OK

11 Remove and inspect the valve lifters, guides, rocker arms,

and pushrods. Refer to Valve Rocker Arm and Push Rods

Clean and Inspect and Valve Lifters and Guides Clean and

Inspect, in this Section.

Are components worn or damaged?

−Go to Step 12 Go to Step 13

12 Repair as required.

Is there valve train noise? −Go to Step 13 System OK

13 Perform a camshaft lobe lift test. Refer to 3.2 CAMSHAFT

LOBE LIFT - Measure in this Section.

Is the test within specification?

Go to Step 17 Go to Step 14

14 Remove the engine front cover and inspect the timing chain

and sprockets for excessive wear or damage. Refer to 3.8

TIMING CHAIN AND SPROCKETS, in this Section.

Important: Pushrod engines are designed so that a timing

chain more than one tooth improperly positioned will cause

valve interference with the piston.

Are the components worn or damaged, or improperly

positioned?

−Go to Step 15 Go to Step 16

15 Replace components as required.

Is there valve train noise? −Go to Step 16 System OK

16 Replace camshaft and/or bearings and all hydraulic valve

lifters. Refer to 3.9 CAMSHAFT, in this Section.

Is there valve train noise?

−Go to Step 17 System OK

17 Perform a complete disassembly of the engine and inspect all

components.

Are components worn or damaged?

−Go to Step 18 System OK

18 Replace the worn/damaged components as required. −System OK −

4.4 OIL CONSUMPTION DIAGNOSIS

DEFINITION: Excessive oil consumption (not due to leaks) is the use of 0.95 litres or more of engine oil within

2,500 kilometres.

Checks Action

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

• External oil leaks. Refer to 4.5 OIL LEAK DIAGNOSIS in this Section.

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

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

drain down time (2-3 minutes) and check for the correct engine oil level.

• Improper oil viscosity. Refer to the vehicle Owners Manual and use the

recommended SAE grade and viscosity for the prevailing temperatures.

• Continuous high speed driving and/or severe usage.

• Crankcase ventilation system restrictions or malfunctioning components.

• Worn valve guides and/or valve stems.

• Worn or improperly installed valve stem oil seals.

• Piston rings broken, worn, not seated properly. Allow adequate time for the

rings to seat. Replace worn piston rings as necessary.

• Piston and rings improperly installed or incorrectly fitted to the cylinder bore.

• Excessive piston to bore clearance.

Techline

4.5 OIL PRESSURE DIAGNOSIS

Conduct an oil pressure check, as detailed in 2.4 ENGINE OIL PRESSURE - CHECK, in this Section

Checks Action

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

• Oil pump worn or dirty.

• Oil pump to engine block bolts loose.

• Oil pump screen loose, plugged or damaged.

• Oil pump screen O-ring seal missing or damaged.

• Malfunctioning oil pump oil pressure relief valve.

• Excessive bearing clearances.

• Cracked, porous or restricted oil galleries.

• Oil gallery plugs leaking, missing or incorrectly installed.

• Broken/malfunctioning hydraulic valve lifters.

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

• Plugged or incorrect oil filter fitted.

• Malfunctioning oil by-pass valve.

• Malfunctioning oil pressure gauge or sensor.

Techline

4.6 OIL LEAK DIAGNOSIS

NOTE: Most fluid leaks can be repaired by visually locating the leak, repairing or replacing the component, or by

resealing the gasket surface.

When a leak has been located, determine the cause of the leak. Otherwise the leak will most probably re-occur.

Step Action Value(s) Yes No

1 1. Operate the vehicle until it reaches normal operating

temperature.

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

paper or other clean surface.

3. Wait for at least 15 minutes.

4. Check for oil drips.

Are oil drips present?

−Go to Step 2 Go to Step 3

2 Identify the type of fluid and the approximate location of the

leak.

Can you identify the type of fluid and the approximate location

of the leak?

−Go to Step 10 Go to Step 3

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

assist in looking at hard to see areas.

2. Check for leaks at the following locations:

• Sealing surfaces.

• Fittings

• Cracked or damaged components.

Can you identify the source of the leak?

−Go to Step 10 Go to Step 4

4 1. Completely clean the entire engine and surrounding

components.

2. Operate the vehicle for several miles at normal operating

temperature and at varying speeds.

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

paper or other clean surface.

4. Wait for at least 15 minutes.

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

the leak.

Can you identify the type of fluid and the approximate location

of the leak?

−Go to Step 10 Go to Step 5

5 1. Visually inspect the suspected area. Use a small mirror to

assist in looking at hard to see areas.

2. Check for leaks at the following locations:

• Sealing surfaces.

• Fittings.

• Cracked or damaged components.

Can you identify the source of the leak?

−Go to Step 10 Go to Step 6

6 1. Completely clean the entire engine and surrounding

components.

2. Apply an aerosol-type powder (baby powder, foot powder,

etc.) to the suspected area.

3. Operate the vehicle for several miles at normal operating

temperature and at varying speeds.

4. Identify the type of fluid, and the approximate location of

the leak, from the discolorations in the powder surface.

Can you identify the type of fluid and the approximate location

of the leak?

−Go to Step 10 Go to Step 7

7 1. Visually inspect the suspected area. Use a small mirror to

assist in looking at hard to see areas.

2. Check for leaks at the following locations:

• Sealing surfaces.

• Fittings.

• Cracked or damaged components.

Can you identify the source of the leak?

−Go to Step 10 Go to Step 8

Techline

Step Action Value(s) Yes No

8 Using the Dye and Black Light Kit, Tool J 42220, identify the

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

the manufacturer's instructions when using the tool.

Can you identify the type of fluid and the approximate location

of the leak?

−Go to Step 10 Go to Step 9

9 1. Visually inspect the suspected area. Use a small mirror to

assist in looking at hard to see areas.

2. Check for leaks at the following locations:

• Sealing surfaces.

• Fittings.

• Cracked or damaged components.

Can you identify the source of the leak?

−Go to Step 10 System OK

10 1. Check for the following conditions:

• Higher than recommended fluid levels.

• Higher than recommended fluid pressures.

• Plugged or malfunctioning fluid filters or pressure

bypass valve.

• Plugged or malfunctioning engine ventilation system.

• Improperly tightened or damaged fasteners.

• Cracked or porous components.

• Improper sealants or gaskets where required.

• Improper sealant or gasket installation.

• Damaged or worn gaskets or seals.

• Damaged or worn sealing surfaces.

2. Is there mechanical damage to the engine?

−Go to Step 11 −

11 Repair or replace all damaged components. −Go to Step 1 −

5. SPECIFICATIONS

GENERAL

Engine Type....................................................................... V8 OHV

Displacement ..................................................................... 5.7 litre (5,667 cm3 - 346 in3)

Bore.................................................................................... 99.0 mm

Stroke................................................................................. 92.0 mm

Compression Ratio............................................................. 10.1:1

Firing Order........................................................................ 1-8-7-2-6-5-4-3

Spark Plug Type................................................................. AC 41-952

Spark Plug Gap.................................................................. 1.5 mm

LUBRICATION SYSTEM

Oil Capacity (without Oil Filter Change) ............................. 4.7 litres

Oil Capacity (with Oil Filter Change) .................................. 5.0 litres

Oil Pressure (Minimum-Hot)............................................... 45 kPa @ 1,000 rpm

125 kPa @ 2,000 rpm

165 kPa @ 4,000 rpm

Oil Type.............................................................................. 10W - 30 SJ GF2 (Service Refill)

CAMSHAFT

End Play............................................................................. 0.025 - 0.305 mm

Journal Diameter................................................................ 54.99 - 55.04 mm

Journal Diameter Out-of-Round......................................... 0.025 mm (Maximum)

Lobe Lift (Intake and Exhaust)........................................... 7.43 mm

Lobe Height (Intake and Exhaust)...................................... 46.67 mm (Minimum)

Runout (Measured at the Intermediate Journals)............... 0.050 mm

CONNECTING ROD

Centre to Centre Length..................................................... 154.90 ± 0.02 mm

Width.................................................................................. 24.00 ± 0.05 mm

Bearing Bore Diameter....................................................... 56.505 - 56.525 mm

Bearing Bore Out-of-Round (Production)........................... 0.004 mm

Bearing Bore Out-of-Round (Service Limit) ...................... 0.008 mm

Bearing Clearance (Production)......................................... 0.015 - 0.063 mm

Bearing Clearance (Service Limit) ..................................... 0.015 - 0.076 mm

Side Clearance................................................................... 0.110 - 0.510 mm

Twist................................................................................... 0.010 mm Maximum

Bend................................................................................... 0.02 mm Maximum

CRANKSHAFT

Bearing Clearance (Production)......................................... 0.018 - 0.054 mm

Connecting Rod Journal

Diameter (Production)................................................... 53.318 - 53.338 mm

Diameter (Service Limit) ............................................... 53.308 mm (Minimum)

Taper (Production)........................................................ 0.005 mm (Maximum for 1/2 of the Journal Length)

Taper (Service Limit)..................................................... 0.01 mm (Maximum)

Out-of-Round (Production)............................................ 0.005 mm

Out-of-Round (Service Limit) ........................................ 0 0.01 mm

End Play........................................................................ 0.04 - 0.2 mm

Main Journal

Diameter (Production)................................................... 64.993 - 65.007 mm

Diameter (Service Limit) ............................................... 64.993 mm (Minimum)

Out-of-Round (Production)............................................ 0.003 mm

Out-of-Round (Service Limit) ........................................ 0.008 mm

Taper (Production)........................................................ 0.010 mm

Taper (Service Limit)..................................................... 0.020 mm (Maximum)

Reluctor Ring Runout

(Measured 1.0 mm below Tooth Diameter) .................. 0.250 mm (Maximum)

Runout (at Rear Flange)..................................................... 0.050 mm (Maximum)

Thrust Wall Runout ............................................................ 0.025 mm

Thrust Wall Width (Production).......................................... 26.14 - 26.22 mm

Thrust Wall Width (Service)............................................... 26.32 mm (Maximum)

CYLINDER BORE

Cylinder Bore Diameter...................................................... 99.0 - 99.018 mm

Cylinder Bore Taper and Out-of-Round ............................. 0.018 mm (Maximum)

CYLINDER HEAD

Engine Block Deck Flatness

(Measured within a 150 mm area) ................................ 0.110 mm

Engine Block Deck Flatness

(Measured over Full Length of Cylinder Head)............. 0.220 mm

Exhaust Manifold Deck Flatness........................................ 0.220 mm

Intake Manifold Deck Flatness........................................... 0.220 mm

Height (Measured from the Cylinder Head Deck to

the Valve Rocker Arm Cover Seal Surface).................. 120.2 mm (Minimum)

ENGINE BLOCK

Camshaft Bearing Bore Diameter...................................... 55.063-55.088 mm

Cylinder Head Deck Surface Flatness

(Measured within a 150 mm area) ................................ 0.110 mm

(Measured over Full Length of Block Deck).................. 0.220 mm

Cylinder Head Deck Height

(Measured from Crankshaft centreline to Deck Face).. 234.57-234.82 mm

Main Bearing Bore Diameter (Production) ......................... 69.871-69.889 mm

Main Bearing Bore Out-of-Round....................................... 0.050 mm

Valve Lifter Bore Diameter (Production) ............................ 21.417-21.443 mm

INTAKE MANIFOLD

Intake Manifold Cylinder Head Deck Flatness

(Measured at Gasket Sealing Surfaces)....................... 0.50 mm

OIL PAN AND FRONT/REAR COVER ALIGNMENT

Oil Pan to Rear of Engine Block Alignment

(at Transmission Housing Mounting Surface)............... 0.000 - 0.250 mm (Maximum)

Front Cover Alignment (at Oil Pan Surface)....................... 0.00 - 0.50 mm

Rear Cover Alignment (at Oil Pan Surface) ....................... 0.00 - 0.50 mm

PISTON

Piston Outside Diameter (at Size Point)................................ 98.964-98.982 mm

Piston Skirt, Dimensional Variation....................................... 0.018 mm (Maximum)

Piston to Bore Clearance (Production).................................. 0.018-0.054 mm

Piston to Bore Clearance (Service Limit) .............................. 0.018-0.054 mm (Maximum)

Piston Pin

Pin Clearance to Piston Bore (Production) ................... 0.010 - 0.020 mm

Pin Clearance to Piston Bore (Service Limit)................ 0.010 - 0.020 mm (Maximum)

Pin Diameter ................................................................. 23.997 - 24.0 mm

Pin Fit in Connecting Rod ............................................. 0.020 - 0.043 mm (Interference)

Piston Rings

Top Compression Ring End Gap (Production)

(Measured in Cylinder Bore) ......................................... 0.230 - 0.380 mm

2nd Compression Ring End Gap (Production)

(Measured in Cylinder Bore) ......................................... 0.440 - 0.640 mm

Oil Control Ring End Gap (Production)

(Measured in Cylinder Bore) ......................................... 0.180 - 0.690 mm

Top Compression Ring End Gap (Service)

(Measured in Cylinder Bore) ......................................... 0.230 - 0.380 mm (Maximum)

2nd Compression Ring End Gap (Service)

(Measured in Cylinder Bore) ......................................... 0.440 - 0.640 mm (Maximum)

Oil Control Ring End Gap (Service)

(Measured in Cylinder Bore) ......................................... 0.180 - 0.690 mm (Maximum)

Top Compression Ring Groove Clearance (Production) ... 0.040 - 0.085 mm

2nd Compression Ring Groove Clearance (Production).... 0.040 - 0.080 mm

Oil Control Ring Groove Clearance (Production)............... 0.010 - 0.220 mm

Top Compression Ring Groove Clearance (Service)......... 0.040 - 0.085 mm (Maximum)

2nd Compression Ring Groove Clearance (Service)......... 0.040 - 0.080 mm (Maximum)

Oil Control Ring Groove Clearance (Service Limit)............ 0.010 - 0.220 mm (Maximum)

VALVE SYSTEM

Valve Lifter ............................................................................ Hydraulic Roller

Valve Rocker Arm Ratio........................................................ 1.70:1

Valve Lash............................................................................. Net Lash-No Adjustment

Valve Face Angle .................................................................. 45 degrees

Valve Seat Angle................................................................... 46 degrees

Valve Seat

Runout................................................................................ 0.050 mm (Maximum)

Width (Intake)..................................................................... 1.020 mm (Maximum)

Width (Exhaust).................................................................. 1.780 mm (Maximum)

Valve Stem

Clearance (Production-Intake)........................................... 0.025 - 0.066 mm

Clearance (Production-Exhaust)........................................ 0.025 - 0.066 mm

Clearance (Service-Intake) ................................................ 0.093 mm (Maximum)

Clearance (Service-Exhaust) ............................................. 0.093 mm (Maximum)

Diameter (Production)........................................................ 7.955 - 7.976 mm

Diameter (Service) ............................................................. 7.95 mm (Minimum)

Valve Spring

Free Length........................................................................ 52.9 mm

Pressure (Closed Valve) .................................................... 310 N at 45.75 mm (Minimum)

Pressure (Open Valve)....................................................... 980 N at 33.55 mm (Minimum)

Installed Height (Intake) ..................................................... 45.75 mm

Installed Height (Exhaust).................................................. 45.75 mm

Valve Lift

Intake.................................................................................. 11.99 mm

Exhaust .............................................................................. 12.15 mm

Valve Guide Installed Height

(From Cylinder Head Spring Seat Surface to

Top of the Valve Guide)................................................ 17.32 mm

Valve Stem Oil Seal Installed Height

(From Valve Spring Shim to Top Edge of Seal Body)........ 18.10 - 19.10 mm

SEALANTS AND ADHESIVES

Coolant Sensor Threads ....................................................... Loctite 565 or equivalent (GM P/N 12346004)

Crankshaft Rear Oil Gallery Plug.......................................... Loctite 242 or equivalent (GM P/N 12345382)

Cylinder Head Core Hole Plugs............................................. Loctite 242 or equivalent (GM P/N 12345382)

Cylinder Head Expansion Plugs............................................ Loctite 242 or equivalent (GM P/N 12345382)

Cylinder Head M8 Bolt Threads ............................................ Loctite 242 or equivalent (GM P/N 12345382)

Engine Block Front Oil Gallery Plug...................................... Loctite 242 or equivalent (GM P/N 12345382)

Engine Block Coolant Drain Plug Sealing Washers.............. Loctite 565 or equivalent (GM P/N 12346004)

Exhaust Manifold Bolt Threads ............................................. Loctite 272 or equivalent (GM P/N 12345493)

Fuel Rail Bolt Threads........................................................... Loctite 242 or equivalent (GM P/N 12345382)

Intake Manifold Bolt Threads................................................. Loctite 242 or equivalent (GM P/N 12345382)

Oil Pan Surface at Front and Rear Covers............................ Loctite 565 or equivalent (GM P/N 12378190)

Oil Pressure Sensor Threads................................................ Loctite 565 or equivalent (GM P/N 12346004)

Oil Transfer Tube Bolts and Stud Threads............................ Loctite 242 or equivalent (GM P/N 12345382)

6. TORQUE WRENCH SPECIFI CATIONS

Air Conditioning Compressor Drive Belt Idler Pulley Bolt............................... 40 - 60

Air Conditioning Compressor Drive Belt Tensioner Bolt................................. 21 - 29

Air Conditioning Compressor Mounting Bracket to Cylinder Block Bolts ....... 40 - 60

Air Conditioning Compressor to Mounting Bracket Bolts ............................... 40 - 60

Accelerator Control Cable Bracket Bolts........................................................ 10

Accessory Drive Belt Idler Pulley Bolt............................................................. 40 - 60

Accessory Drive Belt Tensioner Bolt.............................................................. 40 - 60

Alternator Bracket to Cylinder Block Bolts...................................................... 40 - 60

Alternator Support Bracket to Cylinder Block Bolts........................................ 20 - 35

Catalytic Converter Bracket Bolts to Catalytic Converters ............................. 25

Catalytic Converter Bracket Bolts/Nuts to Manual Transmission Extension.. 40 - 60

Camshaft Retainer Bolts ................................................................................ 25

Camshaft Position Sensor Bolt....................................................................... 25

Camshaft Sprocket Bolts................................................................................ 35

Close-out Cover Retaining Bolt (Each Side) .................................................. 10 - 14

Connecting Rod Bolts

Design ‘A’

Stage 1....................................................................... 20

Stage 2....................................................................... 60 degrees turn angle

Design ‘B’ and ‘C’

Stage 1....................................................................... 20

Stage 2....................................................................... 75 degrees turn angle

Coolant Temperature Sensor......................................................................... 20

Coolant Inlet Housing Bolts ............................................................................ 15

Coolant Pump Bolts First Pass...................................................................... 15

Final Pass ..................................................................... 30

Coolant Pump Pulley Bolts............................................................................. 15

Crankshaft Balancer Bolt: Stage 1 with replacement NEW Bolt..................... 50

Stage 2 with replacement NEW Bolt..................... 140 degrees turn angle

Crankshaft Main Bearing Cap Bolts (Inner Bolts - Stage 1 in Sequence) ...... 20

(Inner Bolts - Stage 2 in Sequence) ...... 80 degrees turn angle

Cap Side Bolts....................................................... 25

Cap Studs (Outer Studs - Stage 1 in Sequence) .. 20

(Outer Studs - Stage 2 in Sequence).. 53 degrees turn angle

Crankshaft Oil Deflector Nuts......................................................................... 25

Crankshaft Position Sensor Bolt..................................................................... 25

Cylinder Head Bolts (in Sequence)

Stage 1 - all M11 and M8 Bolts ............................................... 30

Stage 2 - all M11 Bolts ............................................................ 90 degrees turn angle

Stage 3 - all M11 Bolts - Except Medium Length Bolts ........... 90 degrees turn angle

Stage 3 - M11 - Medium Length Bolts..................................... 50 degrees turn angle

Cylinder Head Coolant Plug ........................................................................... 20

Cylinder Head Core Hole Plug........................................................................ 20

Engine Block Coolant Drain Plugs.................................................................. 60

Engine Block Oil Gallery Plugs....................................................................... 60

Engine Dress Cover Bracket Nut ................................................................... 4 - 6

Engine Dress Cover Retaining Nut................................................................. 8 - 12

Engine Flywheel/Flexplate Bolts (in Sequence) Stage 1.............................. 20

Stage 2.............................. 50

Stage 3.............................. 100

Engine Front Cover Bolts ............................................................................... 25

Engine Mount to Bracket or Crossmember Nut ............................................. 70 - 90

Engine Mount Bracket to Cylinder Block Bolt................................................. 40 - 60

Engine Rear Cover Bolts................................................................................ 25

Engine Rocker Cover Bolts ............................................................................ 12

Engine Service Lift Bracket M10 Bolts ........................................................... 50

Engine Service Lift Bracket M8 Bolt............................................................... 25

Engine Valley Cover Bolts.............................................................................. 25

Exhaust Manifold Heat Shield Bolt................................................................. 9

Exhaust Manifold Bolts Stage 1..................................................................... 15

Stage 2..................................................................... 25

Fuel Rail Bolts ................................................................................................ 8 - 12

Ignition Coil-to-Bracket Bolts.......................................................................... 12

Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts ................................. 12

Intake Manifold Bolts (in Sequence) Stage 1 ............................................... 5

Stage 2................................................ 8

Knock Sensors ............................................................................................... 20

Oil Filter .......................................................................................................... 30

Oil Filter Adaptor............................................................................................. 55

Oil Level Indicator Tube Bolt ......................................................................... 25

Oil Pan Blanking Screw Plug.......................................................................... 25

Oil Pan Baffle Bolts......................................................................................... 12

Oil Pan Closeout Cover Bolt (Either Side)...................................................... 8 - 12

Oil Pan Drain Plug.......................................................................................... 25

Oil Pan Gallery Screw Plug ............................................................................ 25

Oil Pan M8 Bolts (Oil Pan to Engine Block and to Front Cover)..................... 25

Oil Pan M6 Bolts (Oil Pan-to-Rear Cover)...................................................... 12

Oil Pan Transfer Cover Nut............................................................................ 12

Oil Pan Under-Tray Bolt ................................................................................. 30 - 35

Oil Pressure Sensor ....................................................................................... 20

Oil Pump-to-Engine Block Bolts ..................................................................... 25

Oil Pump Cover Bolts..................................................................................... 12

Oil Pump Relief Valve Plug ............................................................................ 12

Oil Pump Pick-Up Tube to Oil Pump Screw................................................... 12

Oil Transfer Cover Nuts.................................................................................. 12

Oil Transfer Tube Bolts .................................................................................. 12

Oil Transfer Tube Nuts................................................................................... 12

Oxygen Sensor............................................................................................... 41

Spark Plugs (New Cylinder Head - ‘Coining’))................................................ 20

Spark Plugs .................................................................................................... 15

Starter Motor Bolt ........................................................................................... 40 - 55

Throttle Body Bolts ......................................................................................... 12

Transmission Crossmember to Side Frame Bolts ......................................... 20 - 30

Transmission Support to Crossmember Nuts................................................ 50 - 65

Transmission Support to Transmission Extension Housing Bolts.................. 20 - 30

Valve Lifter Guide Bolts.................................................................................. 12

Valve Rocker Arm Bolts ................................................................................. 30

Vapour Vent Pipe Bolts and Studs ................................................................. 12

7. SPECIAL TOOLS

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

56750 SEAL REMOVER Previously released.

Also numbered, E308.

6A23 HYDRAULIC VALVE LIFTER TESTER

T6A3114b

Previously released.

Used in conjunction with testing

fluid SPx No. E1151

6A24 VALVE LIFTER ASSEMBLY TOOLS Previously released.

Used to assist in assembly of

the hydraulic valve lifters.

J6125-1B SLIDE HAMMER Previously released.

Used in conjunction with J

41818 to remove main bearing

caps.

7371 QUICK CONNECT RELEASE TOOL Previously released for

releasing fuel line quick

connects on V6 supercharged

engine after fuel system has

been de-pressurised.

Used on GEN III V8 engine for

the same purpose

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

E 7115 TORQUE ANGLE WRENCH Previously released.

Used to accurately tighten

fasteners when an angle torque

is required.

J 8087 CYLINDER BORE CHECKING GAUGE New release.

Also as a commercial

equivalent.

J 8433-1 PULLEY PULLER Previously released.

Used to remove GEN III V8

engine crankshaft timing gear

sprocket, in conjunction with

J 41558 and J 41816-2

J 21427-01 PULLER ADAPTOR Previously released to remove

automatic transmission speed

sensor ring.

Used in conjunction with J

8433-1, J 41558 and J 41816-2

to remove crankshaft timing

gear sprocket.

J 22794 ADAPTOR

T6A3256a

New release.

Used to facilitate the application

of air pressure to a cylinder

when replacing a valve spring or

valve stem oil seal with the

cylinder head installed.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 23907 SLIDE HAMMER Previously released.

Also released as remover,

6A22-2 and slide hammer

7A28.

J 24086-C PISTON PIN REMOVER/INSTALLER New release.

Universal tool containing

selective components to suit

multiple engine applications.

J 28431-B FLUID DYE Previously released.

Supplied in packs of 24, 1

ounce bottles.

Used in conjunction with black

light, leak detection lamp

J 42220 to locate various types

of vehicle fluid leaks.

J 33049 CAMSHAFT BEARING

REMOVER/INSTALLER New release.

Universal tool containing

selective components to suit

multiple engine applications.

J 38836 PILOTED DRIVER

T6A3 189b

New release.

Used to install the spigot bush

in the crankshaft.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 41476 FRONT AND REAR COVER ALIGNMENT

TOOL

T6A3257a

New release.

Used to align both the front and

rear engine covers during

installation.

J 41478 CRANKSHAFT FRONT OIL SEAL

INSTALLER

T6A3258a

New release.

Threaded bolt, nut and washer

are also used in conjunction

with

J 41665 to install the crankshaft

balancer.

J 41479 CRANKSHAFT REAR OIL SEAL

INSTALLER New release.

J 41480 FRONT AND REAR COVER ALIGNMENT

TOOL

T6A3260a

New release.

Used in conjunction with

alignment tool J 41476, to

correctly align the front and rear

engine covers.

J 41556 CONNECTING ROD GUIDES New release.

Used to assist in piston and

connecting rod installation.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 41558 CRANKSHAFT SPROCKET REMOVER New release.

Used in conjunction with the

bolts from J 21427-01 and

pulley puller J 8433, to remove

the crankshaft sprocket.

J 41665 CRANKSHAFT BALANCER INSTALLER New release.

Comprises stepped sleeve, J

41665-1 and end plate J 41665-

Used in conjunction with the

threaded bolt, nut and washer

of Tool J 41478, to install the

crankshaft balancer and

crankshaft sprocket.

J 41712 OIL PRESSURE SENSOR SOCKET New release.

Used in conjunction with 3/8”

drive socket equipment to

remove/reinstall oil pressure

sensor.

J 41816 THREE LEGGED PULLER New release.

Also commercially available.

Used in conjunction with J

41816-2 to remove crankshaft

balancer.

J 41816-2 ADAPTOR New release.

Used in conjunction with puller J

41816 to remove crankshaft

balancer.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 41818 CRANKSHAFT BEARING CAP REMOVER New release.

Used in conjunction with slide

hammer J 6125-1B to remove

main bearing caps.

J 42078 VALVE STEM OIL SEAL INSTALLER New release.

J 42220 BLACK LIGHT, LEAK DETECTION LAMP Previously released.

Used with dye, Tool J 28431-B

to locate the source of various

vehicle fluid leaks.

J 42385 THREAD REPAIR KIT New release.

Comprises;

Cylinder Head/Rear Main

Bearing Cap Kit .... J 42385-100

General Kit ........... J 42385-200

Fixtures/Hardware KitJ 42385-30

J 42386 FLYWHEEL HOLDING TOOL New release.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 42907 OIL PRESSURE ADAPTOR New release.

Fitted to the oil filter adaptor

and used in conjunction with a

commercially available oil

pressure gauge and hose.

KD 2078 VALVE SPRING COMPRESSOR Previously released for the V6

engine.

Used to remove valve springs

with cylinder head/s installed.

Used in conjunction with spark

plug adaptor J 22794.