SECTION 6A3 - ENGINE MECHANICAL -

GEN III V8 ENGINE

IMPORTANT

Before p erforming any Serv ice Operation or other procedu re described in this Section , refer to Section

00 CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property

damage.

1. GENERAL DESCRI PTI O N

The 2001 Model Year 5.7 litre, GEN III, V8 engine (production option LS1), carries over from earlier build engines,

except for the material presented here.

Introduced as a r unning change during the life of VT Series II Production fr om a vehic le tag number of L596754 on

June 1, 2000, the engine drive belt idler pulley was changed to a double row bearing, to improve durability. Pr ovided

the alternator mounting bracket and pulley combination are used, the new part will service back to earlier build

engines.

A single oversize valve stem has been r eleased f or both intak e and exhaust valves that, coupled with the release of

a fixed size reamer, now allows the reconditioning of the cylinder head valve guides that was previously not

possible. 1.1 SERVICE INFORMATION

In sum mary, the following reflects c hanges that have been introduc ed with the 2001 Model Year release of the GEN

III V8 engine.

1. Intake Manifold: Revised for improved air flow capability with a larger plenum volume, modified runner bell

mouth entrance and “filled” dead spots.

2. Fuel Injectors: Co-ordinated with the intake manifold change, the fuel injector specification has also been

revised, with an increased flow capacity.

3. Throttle Body: A revised IAC pintle design, for improved hot/cold climate driveability.

4. Vapour Vent System: The intake manifold design change has also resulted in the vapour vent system

requiring revision. Testing has shown that engine vapour venting is unaffected by the revised design.

5. Oil Pump: Closer manufacturing tolerances result in improved efficiency.

6. Oil Pan: The stud hole openings at the oil transfer cover have been chamfered to allow the fitment of O-ring

seals at each stud location. The O-rings prevent engine oil f rom wicking past the studs, resulting in an oil leak

from that area.

7. Valve Stem Oil Seals: There can be two different designs of valve stem oil seal fitted to 2001 MY engines.

Early build engines will retain the existing oil seal, whereas later build engines will be fitted with an oil seal/valve

spring shim combination. Should an earlier design seal require replacement, then the later design should be

fitted. In so doing, the or iginal valve spr ing shims ar e to be dis c arded. F itment of the new design oil seals do not

require the use of any special tools.

8. Engine Bearings: Oil clearance specifications have been modified.

9. Coolant Pump: A change in supplier has resulted in a changed housing, with revised specification pump

fasteners. The gasket material has also changed from paper to an aluminium carrier with a silicone bead.

Techline

Figure 6A3-1

Figure 6A3-2 - Lower Front of Engine

Legend

1. Tube - Oil Level Indi cator 18. Oil Seal - Crank shaft Front

2. O-ring Seal - Oil Lever I ndi cator Tube 19. Balancer - Crankshaft

3. Bolt - V al ve Lifter Guide 20. Bolt - Crank shaft Bal ancer

4. Guide - Valve Lif t er 21. Bolt - E ngi ne Front Cover

5. Lifter - V al ve 22. Cams haft

6. Engine Block 23. Retainer - Camshaft

7. Oil Seal - Crankshaft Rear 24. Sprock et - Camshaft

8. Bolt - E ngi ne Rear Cover 25. Locating Pin - Camshaft Sprocket

9. Cover - Engine Rear 26. Bolt - Camshaft Sprock et

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

11. Plug - Engine Block Rear Oi l Gal l ery 28. Bearings - Camshaft

12. Crankshaft Sprocket 29. Coolant Pump

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

14. Oil Pump Ass embly 31. Carrier Gaskets - Coolant P ump

15. Bolt - Oil Pump Assem bl y 32. Indicator - Oil Level

16. Gasket - E ngi ne Front Cover 33. Bolt - Oil Level Indicator Tube

17. Engine Front Cover

Figure 6A3-3 - Lower Engine Assembly

Legend

1. Bolt - Camshaft P osition Sensor 18. Tube - Oil Transfer 34. Oil Filter

2. Cams haf t Posit i on Sensor 19. Gasket - Oil Transfer Tube 35. Plug - Drain

3. Sensor - Oil P ressure 20. Gasket - Oil Pan 36. Bolt - Crank shaft Beari ng Cap Side

4. Engine Block 21. Bolt - Engi ne Fl ywheel/Fl explate 37. Caps - Cranks haft Main Bearing

5. Piston Rings 22. Bolt - Oil Pan Closeout Cover (RHS) 38. Stud - Main Beari ng Cap

6. Piston and Connecting Rod A ss’y 23. Cover - Oil Pan Clos eout (RHS) 39. Bolt - Main B eari ng Cap

7. Connecting Rod Bearings 24. Cover - Oil Pan Clos eout (LHS) 40. Bearings - Crankshaf t Main

8. Connecting Rod Cap 25. Bolt - Oil Pan Closeout Cover (LHS ) 41. Bearings - Crankshaft Main Thrust

9. Bolt - Connec ting Rod 26. Plug - Oil Pan Gal l ery 42. Plug - Rear Crankshaft

10. Crankshaf t Oi l Deflector 27. Bolt - Oil P an Transfer Tube 43. Bush - Manual Transmission Spigot

11. Engine Flywheel (Man. Trans.) 28. Oil Pan 44. O-Ring Seal - Oil Pump Pi ck-up

12. Engine Flexplate (Aut o. Trans.) 29a. O-Ring Seal - Oil Trans fer Cover Stud 45. Crankshaf t

13. Screen and Pi pe - Oi l Pump Pi ck-up 29. Gasket - Oi l Transfer Cover 46. Key - Cranks haf t Sprock et

14. Screw - Oil Pump Pick-up to Pump 30. Cover - Oil Transfer 47. Plug - Engine Block Front Oi l Gal l ery

15. Nut - Oil Def l ector and Oil Pump Pick-up 31. Nut - Oil Transf er Cover 48. Plug - Cylinder B l ock in Unus ed Hol e

16. Bolt - Oil P an Baffle 32. Valve - Oil Bypass

17. Baffl e - Oi l Pan 33. Adaptor - Oil Fil t er

Figure 6A3-4 - Cylinder Head/Upper Engine

Legend

1. Bolt - V al ve Rocker Arm Cover 16. Pushrod

2. Grommet - Valve Roc ker Arm Cover 17. Sensor - Coolant Temperature

3. Bolt - Cyl i nder Head (S hort) 18. Bolt - V al ve Rocker Arm

4. Bolt - Cyl i nder Head (Medium) 19. Arm - V al ve Rocker

5. Cylinder Head 20. Support - Val ve Rocker Arm Pivot

6. Bolt - Cyl i nder Head (Long) 21. Gasket - Cylinder Head

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

8. Cap - Valve Spring 23. Cap - Oil Fill Tube

9. Spring - Val ve 24. Cover - Valve Rocker Arm

10. Oil Seal/Valve Spring Shim - Valve St em 25. Tube - Oil Fill

11. V al ve 26. Ass embly - Ignit i on Coi l and Bracket

12. Gasket - Exhaust Manifold 27. St ud - Ignition Coil Bracket A ssem bl y

13. Manif ol d - Exhaust 28. Screw - Igniti on Coi l Bracket Assembly. Rear on each side

14. Heat Shield – Exhaust Manifol d 29. Bolt - E xhaust Manifold

15. B ol t – Exhaust Manifold Heat S hi el d

Figure 6A3-5 - Intake Manifold/Upper Engine

Legend

1. Stud – Fuel Rail to Intake Manif ol d (4 pl aces) 14. Oil Seal – K nock Sensor (2 pl aces)

2. Fuel Rail (with Injectors) 15. Knock S ensor (2 places)

3. Bracket – Fuel Rai l Stop 16. Knock Sensor Wire Harness

4. Gasket – Thrott l e Body 17. Hose – Vapour Vent Tube

5. Bolt – Intake Manifold (10 places) 18. Stud – Vapour Vent Tube (2 pl aces)

6. Gaskets – Intake Manifold (8 pl aces) 19. Vapour Vent Tube

7. Sensor – Manifold Absolute Pres sure (MAP) 20. Bolt – Vapour Vent Tube

8. Intake Manifol d 21. Cover – Vapour Vent (2 pl aces)

9. Throttle Body 22. Gasket – V apour Vent Tube (4 places )

10. Bolt – Throttle B ody (3 pl aces) 23. Brack et – Engine Dress Cover, Right Hand Side

11. Gasket – Vall ey Cover 24. Nut – Engine Dress Cover Brac ket

12. Valley Cover 25. Brack et – Engine Dress Cover, Left Hand Side

13. Bol t – Valley Cover (10 places)

1.2 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 ‘VF001524500’, is;

• First two numbers (‘01’ = 2001) 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

1.3 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, cas t iron c ylinder bore liners. T he five cr oss -

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 rankcase skirt length, bearing c ap 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 s tru ct 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 construc tion 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. Oil Seal/Valve Spring Shim - Valve Stem

6. Cylinder Head Core Plugs

7. Exhaust Valve

8. 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

rectangular intake manifold exit, thereby changing

velocity.

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 r ocker 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 m m

and exhaust of 39.4 mm.

Valve spr ings are conica l or ‘beehive’ in shape 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 keys. This

spring design also reduces spring mass and,

coupled with the increased stiffness in the valve

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

load, thereby reducing friction and valve train noise.

The roc ker ar ms are made of investment 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 mm 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 each side (A), c ompared

to a uniform undercut. 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 c lose 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 s teel and are a floating fit

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

manufacturing proc es s , using the ‘fractur e’ 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 s teel, one piec e c amshaf t is s upported by five

bearings pressed into the engine block. The

camshaft has a machined camshaft sensor reluctor

ring incor porated between the f ourth and fifth bearing

journals. To r educe valve train noise, both the intake

and exhaust cam lobes have slow closing velocity

ramps.

To reduce weight, the camshaft has a 17 mm 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 intake m anifold is sealed to the cylinder 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 pulsation damper (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 sy stem.

Figure 6A3-17

Each manifold (1) also has an externally mounted

dual wall heat shield (2) attached, that is made of

aluminiumised steel and attached by five screws

(3).

Figure 6A3-18

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.

The accessory drive belt pulley (6) was revised as a

running change for VT Series II vehicles, from a

vehicle tag number of L596754 on J une 1, 2000. T he

bearing was changed from a single to a double row

ball race and the drive belt changed fr om a neoprene

material to non-neoprene. The bearing change also

meant that the alternator mounting bracket design

was changed to accommodate the deeper bearing.

The new pulley will service back to earlier build

engines, provided the pulley, the revised material

drive belt and the alternator m ounting bracket are all

installed.

Figure 6A3-19

Legend

1. Accessory Drive Belt, Automatic Tensioner 7. Crankshaft Balancer Pul l ey

2. Wa t er Pump Pulley 8. Air Conditioning Compress or Dri ve B el t Automatic Tensioner

3. Power Steering Pum p Pulley 9. Air Condi tioning Com pressor Drive Bel t

4. Engine Acc essory Drive Belt 10. Air Condit i oni ng Compress or

5. A.C. Generator 11. Air Condit i oni ng Compress or Dri ve B el t, Idler P ul ley

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 c ontr ols windage, sc rapes oil fr om the

crankshaft, facilitates drainback and reduces

aeration.

The oil pan gasket (8), is a controlled compression

aluminium carrier gasket with silicone used as the

sealing agent.

Two O-ring seals (9) were introduced as a running

change during the production life of the MY 2000

GEN III V8 engine. The purpose is to stop oil

wicking along the s tuds, r es ulting in an oil leak from

this area. As the oil pan requires chamfers to be

machined around each of the two stud holes,

fitm ent of the O-rings to earlier build engines is not

possible without also changing the oil pan.

Figure 6A3-20

1.4 ENGINE LUBRICATION SYSTE M

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 thr ough a pick -up scr een and pipe. The oil is press urised as it passes through the pum p and is s ent 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 harm ful 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 6A3-21 - 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. Fr om there, oil is then directed to the c rank shaf t and cam s haft bearings . Oil that has enter ed the upper

ma in oil galleries also press urises the valve lif ter assem blies and is then pum ped through the pus hrods to lubricate

the valve rocker arms and valve stems.

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

Figure 6A3-22 - 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 inc ludes a PTFE (T eflon®) centre lip (1) to

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

The anti- f ric tion pr operties of the PTFE reduc es the

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

the lip (causing the lip to lift 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. The PTF E is actually deposited on the dry

crankshaft seal surface during initial operation by

the heat generated from the rotating shaft.

The outs ide of the seal may be lubric ated s paringly

to ease installation.

Figure 6A3-23

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 6A3-24

This “dual draw system” was developed to meet

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

cornering m anoeuvres. During sustained 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 r ocker cover

with the least resistanc e. This results 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 looking r earward from the

engine front.

Figure 6A3-25

1.5 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 ar e rem oved f or servic e, they should be mark ed, organis ed or retained in a specif ic order f or

reassembly. Refer to; ’Separating Parts’.

• 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 am ount 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 compound is a pliable sealer that does not com pletely harden. This type of s ealer is used where two

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

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

exhaust manifold, 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 sealant type material suc h as Loctite 565 ( or other c om m erc ial 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 emper ature Vulcanising (RT V) sealant hardens when exposed to air. T his type of sealer 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 extreme tem peratures 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 gasket elim inator or thread s ealant, hardens in the abs enc e of air. This type sealer is used where two

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

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

parts were probably assembled using a gasket eliminator.

• Follow all safety 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 c ontinuous bead of gas k et eliminator to one f lange or on the bolt/stud thr ead. All s urfaces 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 loc king sealants s uc h as Loctite 242 or Loc tite 272 (or other com merc ial equivalents) are 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 measuring 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.

FA STENERS

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 ex tent when hot with this m ater ial (inset ‘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 alum inium threads in the c ylinder block or head

of this engine.

Figure 6A3-26

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 tr etc h 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, res ults 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” fas teners, MUST be

replaced after loosening.

Figure 6A3-27

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 smearing, 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. W hen topping up the engine oil, allow approxim ately 15 minutes for 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: Quic k e r and more complete dr aining will occu r

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, it is fitted with a

steel thread insert to increase durability of the thread

and to avoid thread tearing when the drain plug is

removed from a hot engine

NOTE 3: It is also recommended that the oil filter 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 of the VT Series I

Service Information.

3. Remove the four bolts securing the oil pan

under-tray.

4. Clean any foreign material from around the oil

pan drain plug.

5. Place an oil drain tray beneath the engine.

6. Using a 15 m m ring spanner , rem ove the drain

plug, taking care to avoid scalding with the hot

waste oil.

7. When the oil has drained sufficiently, reinstall

the drain plug, after inspecting and cleaning

the threads and inspecting the magnetic plug

end for ferrous material. T he drain plug O-ring

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

Tighten the drain plug to the correct torque

specification.

ENGINE OI L PAN DRAIN P L UG

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 BO LT

TORQUE SPECIFICATION ............................. 30 - 35 Nm

9. Lower the vehicle and fill the crankcase with

the required amount of GF2 10W - 30 SJ

lubricant.

Figure 6A3-28

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 m aintain a level

attitude and support with safety stands. This is to

ensure complete draining. Refer to

0A GENERAL INFORMATION 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 c heck 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. Smear som e new engine oil onto the new filter

seal, then install filter assembly to engine.

10. Tighten oil filter to the correct torque

specification.

ENGINE OIL FI LTE R

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 BO LT

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 Sec tion for

the recommended procedure.

13. Start the engine and check for oil leaks.

Figure 6A3-29

2.4 ENGINE OIL PRESSURE - CHECK

1. Ensure that engine is at operating temper ature.

Driving a cold vehicle f or 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

pressur e gauge (capable of reading 800 k Pa or

higher) and suitably rated pressure 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.

ENGINE OIL PRESSURE SPECIFICATION

ENGINE SPEED OIL PRESSURE READING

1,000 rpm 45 kPa (Minimum, Hot)

2,000 rpm 125 kPa (Minimum, Hot)

4,000 rpm 165 kPa (Minimum, Hot)

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.

8. After completing the pressure check, stop the

engine and remove the oil pressure gauge and

adaptor assembly.

T6A3082a

J 42907

Figure 6A3-30

9. Install the oil filter. Refer

2.3 ENGINE OIL FILTER & ADAPTOR, in this

Section.

10. Top up engine oil level as required.

2.5 COMPRE SSION CHECK

1. Before conducting this check, ensure that the:

a. 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 fuel injectors, by removing

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 compression, 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 6A3-31

INTERPRETING COMPRESSION READINGS

The minimum compression in any one cylinder should

not be less than 70% of the highes t 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 - Compress ion builds up quic kly and evenly to

the specified compression for each cylinder.

PISTON RINGS LEAKING - Com pression is low on the

first stroke. Compression then builds up with the

following strokes but does not reach normal.

Compression improves considerably when you add oil.

VALVES LEAKING - Compression is low on the first

stroke. Compression usually does not build up on the

following strok es. Compression does not im prove m uch

when you add oil.

CYLINDER HEAD GASKET LEAKING - If two adjacent

cylinders have lower than normal compression and

injecting oil into the cylinders does not increase the

compression, the cause may be a head gasket leaking

between the cylinders.

2.6 ENGINE DRIVE BELTS - REPLACE

1. Remove the four engine dres s 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 6A3-32

ENGINE A CCESSORY DRIVE BELT

1. Using a 15 mm ring spanner, rotate the

accessory automatic drive belt tensioner (1), in

the direction indicated, to reduce belt tension.

2. While holding the tensioner in the reduced

tension position, remove the accessory drive

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

NOTE: Use an assistant to maintain the tensioner

in the required position.

3. Clean the accessory drive belt running surfaces

and inspect the belt for damage.

4. 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.

5. Inspect the installation to ensur e that the belt is

correctly aligned on all pulleys.

6. Reinstall the engine dress cover, securing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVE R NUT

TORQUE SPECIFICATION ............................. 8.0 - 12 Nm

7. Start the engine to ensure correct operation.

Figure 6A3-33

Techline

AIR CONDITIONING COMPRESSOR BELT

NOTE: The accessory dr

ive 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

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, 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 indic ated, ins tall the drive belt over the

pulleys, routing the belt correctly, as shown.

7. Inspect the installation to ensur e that the belt is

correctly aligned on all pulleys.

Figure 6A3-34

8. Reinstall the accessory drive belt as described 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 BO LT

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 acc essory 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 accessor y drive belt. Refer to

Operation 2.6 in this Section f or the necessary

procedure.

Figure 6A3-35

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 mm set spanner, to relieve

belt tension.

4. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt fr om 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

TORQUE SPECIFICATION ............................. 40 - 60 Nm

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

Operation 2.6 in this Section f or the necessary

procedure.

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

bolts to the correct torque specification.

OIL PAN UNDER-TRAY BO LT

TORQUE SPECIFICATION ............................. 30 - 35 Nm

10. Lower the vehicle and test for correct

operation.

Figure 6A3-36

2.9 ACCESSORY BELT TENSIONER

REPLACE

1. Remove the engine acc essory 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 BE LT T ENSIONE R

TORQUE SPECIFICATION ............................. 40 - 60 Nm

5. Install the engine accessor y drive belt. Refer to

Operation 2.6 in this Section f or the necessary

procedure.

Figure 6A3-37

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 mm set spanner, to relieve

belt tension.

2. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt fr om 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

TORQUE SPECIFICATION ............................. 21 - 29 Nm

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

Operation 2.6 in this Section f or the necessary

procedure.

Figure 6A3-38

2.11 OIL PRESSURE SENSOR

REPLACE

1. Remove the four engine dres s cover decorative

nuts (2), then remove the dress cover (1) from

the engine.

Figure 6A3-39

2. Release the wiring harness connector locking

tang f rom the oil press ure sensor , then remove

the connector (2) from the sensor.

Figure 6A3-40

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

socket equipment, remove oil pressure sensor

(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 pres sure s ensor (1) and tighten

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

socket equipment, to the correct torque

specification.

OIL PRES SURE SENS OR

TORQUE SPECIFICATION ............................. 20 Nm

6. Reinstall the engine dress cover, securing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVE R NUT

TORQUE SPECIFICATION ............................. 8.0 - 12 Nm

7. Start the engine to ensure correct operation.

Figure 6A3-41

2.12 MANIFOLD ABSOLUTE PRESSURE SENSOR

REPLACE

1. Remove the four engine dres s cover decorative

nuts (2), then remove the dress cover (1) from

the engine.

Figure 6A3-42

2. Release the wiring harness connector locking

tang (1) from the manifold absolute pressure

(MAP) sensor, then rem ove the c onnector f rom

the sensor.

Figure 6A3-43

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 rubber 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 dress cover, securing with

the four decorative nuts and tighten to the

correct torque specification.

ENGINE DRESS COVE R NUT

TORQUE SPECIFICATION ............................. 8.0 - 12 Nm

8. Start the engine to ensure correct operation.

Figure 6A3-44

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 6A3-45

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 COOLING - GEN III V8

ENGINE of the VT Series II Service

Information.

3. Remove the engine dress cover retaining nuts

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

4. Loosen the two clamps securing the air intake

duct (3) to the throttle body and Mass 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 6A3-46

7. Using quick connect release Tool No. 7371

(not shown in Fig. 6A3-47), install over fuel line

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

push on T ool 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 6A3-47

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 6A3-48

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 Fig. 6A3-49.

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. Rem ove the inner throttle cable (7) from the throttle

body valve lever (3).

15. Set the cable/s to one side.

Figure 6A3-49

16. Disconnect the fuel injector wiring harness

connectors (1) from the right bank of fuel

injectors (4 places).

17. Remove the CPA lock (2) from 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 6A3-50

18. Disconnect the fuel injector wiring harness

connectors (1) from the left bank of fuel

injectors (4 places).

19. Remove the CPA lock (2) from the ignition coil

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

remove the wiring harness connector (3).

20. Rem ove the wiring harness connector from the

canister purge valve (4).

21. Remove the harness securing clips from the

fuel rail br ackets ( 5) and s et the har ness to one

side.

Figure 6A3-51

22. Disconnect the wiring harness connector (1)

from the MAP sens or, located at the rear of the

intake manifold.

23. Remove the knock sensor patch harness

connector retaining clip (3) from 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 6A3-52

25. Rem ove the fresh air hose f rom the f ront fitting

of the rocker cover and the throttle body.

Figure 6A3-53

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 6A3-54

29. Remove the engine coolant, vapour vent hose

from the throttle body and the vapour vent pipe.

Figure 6A3-55

30. Remove the engine coolant vapour vent outlet

hose (1) from the throttle body and left hand

radiator tank.

Figure 6A3-56

31. Remove the evaporative (EVAP) canister purge

valve tube f rom the purge valve and the throttle

body.

Figure 6A3-57

32. Remove the EVAP canister purge valve and

bracket from the intake manifold.

Figure 6A3-58

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.

Figure 6A3-59

35. Carefully bump the intake manifold assembly

(1) to break the gasket seal, then lift from the

engine.

Figure 6A3-60

36. Remove the intake manifold to cylinder head

gaskets (1) and discard.

Figure 6A3-61

DISASSEMBLE

If required, the following components can be

removed from the intake manifold:

1. Remove the Manifold Abs olute Pr es sur e ( MAP)

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

intake m anifo ld by twisting back and fort h while

pulling on the sensor.

2. Check the silicone rubber seal (2) on the MAP

sensor to ensure that it is not torn or damaged.

Figure 6A3-62

3. Remove the throttle body retaining bolts, then

the throttle body and gasket. Discard the

gasket.

Figure 6A3-63

4. Remove the O-ring seal and discard.

NOTE: Do not re-use this O-ring seal.

Figure 6A3-64

5. 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.

6. Remove the studs (4) sec uring 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 6C3-3 POWERTRAIN MANAGEMENT -

GEN III V8 ENGINE of the VX Series Service

Information.

Figure 6A3-65

CLEAN AND INSPECT

1. After cleaning the intake manifold in a suitable

solvent, dry off manifold using compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

2. Ensure that the intake m anifold gask et gr ooves and

vacuum passages in the rear of the intake manifold

are all clean and clear.

3. Inspect throttle body and fuel rail bolt inserts 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 manifold with warpage in excess of 0.5

mm, must be replaced.

REASSEMBLE

Manifold Absolute Pressure (MA P) 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. If nec essary apply a sm ear of petroleum

jelly (Vaseline™ or equivalent).

Figure 6A3-66

Fuel Rail and Injectors

1. Lubricate NEW injector O-ring seals with clean

engine oil.

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

3. Inst all the f uel rail ( with injec tor s ) into the intak e

manifold, pr ess ing 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 commercial 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

brackets (2) to the fuel rail attaching studs (4),

fit the retaining nuts (1) and tighten to the

correct torque specification.

ENGINE DRESS COVER BRACKET

TORQUE SPECIFICATION ............................. 4 - 6 Nm

Figure 6A3-67

THROTTLE BODY

1. Install a NEW throttle body O-ring seal (1) to

the intake manifold.

Figure 6A3-68

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 6A3-69

REINSTALL

1. Install NEW intake manifold to cylinder head

gaskets, then install the intake manifold

assembly (1).

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

Loctite 242 (or equivalent to Holden

Specific ation HN 1256, T ype 2, Clas s 2), to the

cleaned threads of the 10 intake manifold

attaching bolts (2).

3. Install all intak e m anif old bolts (2), including the

two at the left hand rear, also securing the fuel

rail stop bracket (3).

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,

possibly causing a fire and personal injury from

burns.

Figure 6A3-70

4. Tighten the intake m anifold bolts in two stages ,

in the sequence shown, to the correct torque

specification.

INTAKE MANIFOLD BOLTS

TORQUE SPE CIFICATI ON ..... .............. S tage 1 - 5 Nm

Stage 2 - 10 Nm

NOTE: The f uel stop brac ket is sec ured by bolts ‘3’

and ‘9’.

The remainder of the installation process is the

reverse of the removal operations, except for the

following;

5. Install Positive Crankcase Ventilation (PCV)

System heat conducting strap to the vapour

vent pipe stud at the front right of the engine,

install the retaining nut and tighten to the

correct torque specification.

PCV VALVE HEAT STRAP

RETAINING NUT

TORQUE SPECIFICATION ............................. 12 Nm

Figure 6A3-71

6. 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 6A3-72

c. Release the tension on the adjuster until

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

slightly compress the adjuster (2) about 1

mm to lock.

Figure 6A3-73

7. If fitted, the cruise control cable must be

adjusted, as follows:

a. Connect the inner cable (1) to the stud (2)

on the throttle cam (3), then slide the outer

cable into position in the throttle cable

bracket (4).

Figure 6A3-74

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 slack in the inner cable.

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

outer cable (2) into position.

Figure 6A3-75

8. Install engine dress cover and the four retaining

nuts and tighten to the correct torque specification.

ENGINE DRESS COVER

RETAINING NUT

TORQUE SPECIFICATION ............................. 8 - 12 Nm

9. Fill the cooling system. Refer to

Section 6B3 ENGINE COOLING - GEN III V8

ENGINE of the VT Series II Service Information.

10. 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 COOLING - GEN III V8

ENGINE of the VT Series II Service

Information.

3. Remove 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 6A3-76

6. Remove intake manifold. Refer to

Operation 2.14 INTAKE MANIFOLD, in this

Section.

7. Remove the wiring harness connector (1) from

the knock sensor patch harness (2).

Figure 6A3-77

8. Remove the retaining bolts (1) from the rear

engine coolant vapour bleed vent covers (2).

Remove covers and gaskets (3). Discard the

gaskets.

9. Remove the vapour vent pipe retaining studs

(4) and the front engine coolant vapour bleed

pipe (5), together with both gaskets (6). Discard

the gaskets.

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.

Figure 6A3-78

10. If required, loosen the engine coolant to vent

pipe clam p, then remove the hose (2) from the

vent pipe (2).

Figure 6A3-79

REINSTALL

1. Correctly install NEW vapour pipe gaskets by

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

nipple, as shown.

Figure 6A3-80

2. Install the vapour vent pipe (5), vapour vent

covers (2) and gaskets (‘6’ and ‘3’) to the

cylinder heads.

3. Install the vapour vent pipe bolts/studs (‘1’ and

‘4’) and tighten to the correct torque

specification.

VAPOUR VENT PIPE BOLT/STUD

TORQUE SPECIFICATION ............................. 12 Nm

4. Install the intake manifold, as described in

2.14 INTAKE MANIFOLD - REINSTALL, in

this Section.

5. Install the vapour vent hose to the throttle body

and install the hose clamp securely.

Figure 6A3-81

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 COOLING - GEN III V8

ENGINE of the VT Series II Service

Information.

3. Remove 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 6A3-82

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. Lif t the knoc k sensor wiring harness

from the engine.

Figure 6A3-83

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 6A3-84

10. Remove the valley cover retaining bolts.

11. Remove the valley cover and gasket from the

cylinder block. Discard the gasket.

Figure 6A3-85

CLEAN AND INSPECT

1. Remove both knock sensor oil seals (1) from

the valley cover (2).

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 excessive scratches or other

damage.

Figure 6A3-86

REINSTALL

Reinstallation is the reverse of removal operations,

except for the following items.

1. Install NEW knock sensor oil seals into the valley

cover and lubricate with clean engine oil (refer Fig.

6A3-86).

2. Fit a NEW gasket to the valley cover and install

cover to the engine (refer to Fig. 6A3-85).

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. Remove the engine dress cover retaining nuts

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

Figure 6A3-87

3. For the right hand rocker cover, remove the

fres h air hose f rom the f ront fitting of the rocker

cover and from the throttle body.

Figure 6A3-88

4. Remove the PCV hose connection from the

rear f itting at the end of the rock er cover, being

removed.

Figure 6A3-89

5. Using quick connect release Tool No. 7371

(not shown in Fig. 6A3-90), install over fuel line.

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

push on T ool 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 6A3-90

8. Remove the spark plug leads.

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

lead. Twist the boot f irst to break the s eal, then pull

to remove.

Figure 6A3-91

9. Remove the CPA lock (4) from 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 rock er cover being removed, then lift the

ignition coils, wiring and bracket from the

engine.

NOTE: The rear attaching bolt on each coil

assem bly (arrow) is a c onventional sc rew and not a

stepped stud. Fitment of this screw in the correct

position on reassembly is important to avoid

possible chaffing.

Figure 6A3-92

11. Remove the 4 valve rocker cover bolts, then

remove the cover and gasket from the cylinder

head.

NOTE: Do not rem ove the oil fill tube fr om the right

hand rocker cover unless replacement is required.

Figure 6A3-93

12. Remove the gasket (1) from the cover and

discard.

NOTE: The cover securing bolt grommets may be

re-used if not damaged.

Figure 6A3-94

13. 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 6A3-95

14. If required, remove the bolts securing the

ignition coils to the mounting bracket and

remove the coils and wiring harness.

Figure 6A3-96

CLEAN AND INSPECT

1. Clean the rock er cover in a suitable solvent and dr y

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. Inspect the ignition coil mounting boss threads for

damage.

REINSTALL

Reinstallation of the rocker cover is the reverse to the

removal procedure except for the following items.

1. If the oil f ill tube (2) was r em oved from the right

hand rock er cover (3), it m ust 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 clock wis e until

locked into place.

Figure 6A3-97

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 COVE R BOLT

TORQUE SPECIFICATION ............................. 12 Nm

Figure 6A3-98

8. Install the ignition coils and coil wiring harness

to the mounting bracket and tighten the to the

correct torque specification.

IGNITION COIL SCREW

TORQUE SPECIFICATION ............................. 12 Nm

9. Install the ignition coils and bracket assembly

to the rocker cover, and tighten the studs and

screw to the correct torque specification.

IGNITION COIL BRACKET

STUD/SCREW

TORQUE SPECIFICATION ............................. 12 Nm

NOTE: The r ear, lef t hand coil brac k et fastener 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 6A3-99

2.18 VALVE ROCKER ARMS AND PUSH RODS

REMOVE

NOTE: While some views may show a cylinder

head that is not spec ific to the one requir ed, unless

noted, it can be assumed that the operation is the

same for either cy linder head.

1. Remove the valve rocker arm cover/s. refer to

2.17 VALVE ROCKER ARM COVER, in this

Section.

Important: Store all removed valve operating

mechanism components in a suitable rack to avoid

being mixed. This will ensure that parts reinstalled

will be in the same relationship as on removal.

2. Rem ove all the roc k er arm bolts on the specif ic

cylinder head.

3. Remove associated valve rockers arms.

Figure 6A3-100

4. Remove the valve rocker arm pivot support.

Figure 6A3-101

5. Remove the push rods.

Figure 6A3-102

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 surfaces for 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 r educe the ef fort r equired to turn 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-103

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 f inger 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 numbers ar e 1, 3, 5, 7, on the lef t

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

6. W ith No. 1 piston on TDC compression strok e,

tighten the following rocker arm bolts to the

correct torque specification:

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

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

7. Rotate the crankshaft 360°.

8. Tighten the following rocker arm bolts to the

correct torque specification:

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

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

Figure 6A3-104

9. Reinstall the rocker cover/s. See

Operation 2.14 in this Section, f or the neces sary

procedure.

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 a temperature

of 50° C or less. 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 6A3-105

3. Insert a suitable piece of wire into the spark

plug hole and turn the crankshaft balancer bolt

until the piston is at or near Top Dead Centre

(TDC).

4. Install Spark Plug Port Adaptor T ool J 22794 or

a com mercial equivalent to the spark plug hole

of the cylinder being serviced.

5. Using suitable adaptors, attach a compressed

air line to J 22794 and apply a constant supply

of compressed air to the cylinder being

serviced.

Figure 6A3-106

6. Compress one of the valve springs , using valve

spring compressor, KD2078.

Figure 6A3-107

7. Remove valve stem collets (2).

8. Release the valve spring compressor and

remove:

a. Valve spring cap (3).

b. Valve spring (4).

c. Valve spring oil seal (5) (if being replaced).

NOTE: The valve stem oil seal and shim

combination shown (5), are of the second design.

Figure 6A3-108

9. Install a new valve stem oil seal and shim

assembly (second design) to the valve guide,

by hand, until the shim seats against the

cylinder head. No special tools are required for

this operation.

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.

NOTE: Replacement valve stem oil seals should

always be of the second des ign. However, as there

may still be some old parts stock, the following

procedure is included for the first design oil seal.

10. 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 lubric ated valve stem oil s eal (1),

over the valve stem . Push down firm ly 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 6A3-109

11. Measure the installed height of the valve stem

oil seal with vernier calipers (first design only).

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 6A3-110

12. Install the valve spring with the smaller wound

coils facing up, then install the spring cap.

13. Compress the spring using Tool No. KD2078

until sufficient space is allowed for the valve

collets to be installed.

14. Install both valve stem collets, using clean

grease or petroleum jelly to retain.

15. Release the valve s pring c ompres sor , c hecking

that both valve stem collets are seated

correctly.

16. Lightly tap the valve stem with a soft faced

hammer to ‘seat’ the valve stem collets.

17. Remove the compressed air supply.

18. Remove the spark plug adaptor, Tool J22794.

19. Install the spark plug, tightening to the correct

torque specification.

SPARK PLUG 15

TORQUE SPECIFICATION Nm

20. Reverse the removal procedure to complete

this operation.

Figure 6A3-111

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 brack et bolt

from the right hand exhaust manifold

3. Remove the tube fr om 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 undamaged. 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 torque

specification.

OIL LEVEL TUBE RETAINI NG

TORQUE SPECIFICATION ............................. 25 Nm

7. Install the oil level indicator to the tube.

Figure 6A3-112

2.21 EXHAUST MANIFOLD

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Remove the engine dress cover retaining nuts

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

3. Loosen the two clamps securing the air intake

duct (3) to the throttle body and Mass 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 6A3-113

7. For the left hand side exhaust manifold:

a. Remove the engine coolant temperature

sensor (1) from the cylinder head to avoid

possible damage during exhaust manifold

removal.

8. Raise the front of the vehicle and place on

safety stands. Refer to

Section 0A GENERAL INFORMATION of the

VT Series I Service Informationfor location of

jacking and support points.

Figure 6A3-114

9. W hile not essential, it is recom mended that the

oxygen sensor/s (1) are removed 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 6A3-115

10. Remove the exhaust manifold to exhaust pipe

flange nuts.

11. Lower vehicle to the ground.

12. Remove the s par k plugs f rom the cylinder head

on the exhaust manifold side being removed,

taking note of the following;

a. The engine MUST be cold to a temperature

of 50° C or less. 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 plugs 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 plugs.

Figure 6A3-116

13. Progressively loosen, then remove exhaust

manifold bolts, working from the outside in to

the centre.

14. Rem ove exhaust m anifold and gask et from the

cylinder head.

Figure 6A3-117

15. If required, remove the heat shield retaining

bolts (1) and the heat shield (2) from the

exhaust manifold (3).

NOTE: W hile the right hand side exhaust manifold

is shown, the left hand side arrangement is similar.

Figure 6A3-118

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 str aight 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 6A3-119

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 manifold

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

compound such as Ampol Kopr-Kote (or equivalent

to Holden’s Specification HN 1325) to the cleaned

heat shield bolt thr eads , reins tall the heat s hield and

bolts to the exhaust manifold and tighten the

retaining bolts to the correct torque specification.

EXHAUST MANI F OLD 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 MANIF O LD BOLT

TORQUE SPECIFICATION ....................... Stage 1 - 15 Nm

St age 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 rem oved, install the oxygen 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 sensor is removed 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 6A3-120

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

Specification HN 1325) to the cleaned exhaust

pipe flange stud threads.

9. Install and tighten the exhaust pipe to manifold

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

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 6A3-121

2.22 CYLINDER HEAD

REMOVE

1. Disconnect the battery earth cable from the

battery.

2. Remove the engine dress cover retaining nuts

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

3. Loosen the two clamps securing the air intake

duct (3) to the throttle body and Mass 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 acc essory 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. Rem ove valve rock er arm cover on the cylinder

head to be removed. Refer to

2.17 VALVE ROCKER ARM COVER, in this

Section.

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.

Figure 6A3-122

11. Remove the s par k plugs f rom the cylinder head

being removed, noting the following:

a. The engine MUST be cold to a temperature

of 50° C or less. 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.

a. 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 6A3-123

12. For the right hand side cylinder head, first remove

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.

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 6A3-124

b. Remove the bolt securing the powertrain

harness earth strap from the front of the

right hand cylinder head.

Figure 6A3-125

15. For the left hand cy linder head:

a. Place a drain tray beneath power steering

pump assembly.

b. Remove the power steering fluid reservoir

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 the VT Series II

Service Information.

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 pum p and hose fittings

to prevent dirt entry.

Figure 6A3-126

d. 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.

e. Secure the reservoir and pum p to one side,

using tie wire or similar.

Figure 6A3-127

c. Remove the powertrain wiring harness

strap (1) from the brack et at the rear of the

cylinder head.

d. Remove the bolt (2) securing the

powertrain harness earth cable at the rear

of the cylinder head.

Figure 6A3-128

e. 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 6A3-129

16. Progressively loosen cylinder head bolts

starting with the M8 bolts (3) fir st, working f rom

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 6A3-130

18. Remove and discard the cylinder head gasket.

Figure 6A3-131

DISASSEMBLE

NOTE: Do not m ix rem oved com ponents. Organise

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 com pr essor with a plastic faced ham m er

to loosen jammed valve collets.

Figure 6A3-132

2. Remove the following components:

a. Valve stem collets (2).

b. Valve spring cap (3).

c. Valve spring (4).

d. Valves (9, 10).

e. Valve stem oil seal (5) (first design).

f. Valve spring shim (6) (first design.

g. Valve stem oil seal and shim assembly (7)

(second design).

NOTE: Do not remove coolant core plugs (8)

unless servicing is required.

Figure 6A3-133

CLEAN

1. Use a com m er cially available rotary wire brus h,

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 damage and remove

all threadlocking compound from both the

threaded holes and bolts.

Figure 6A3-134

INSPECT

Cylinder Head

1. Check cylinder head deck, inlet and exhaust

manif old mating surfaces for distortion, using a

straight edge (2) and f eeler gauges (1). Chec k

lengthwise, diagonally and crosswise, as

shown by the alphabetical order, in Fig. 6A3-

135.

2. Check the cylinder head deck to exhaust

manifold the cylinder head deck to intake

manifold surfaces for flatness.

CYLINDER HEAD FLATNESS SPECIFICATION

(Measured Over the Cylinder Head Lengt h)

CYLINDER HEAD, ENGI NE BLOCK DECK 0.22 m m

CYLINDER HEAD, EXHAUST MA NIFOLD DECK 0.22 m m

CYLINDER HEAD, INT AKE MANI F OLD DECK 0.22 m m

Figure 6A3-135

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 residue of cylinder head bolt thread

sealant from the cylinder block threads, 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 eye protection to prevent

injury.

Figure 6B3-136

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 c ylinder head for crack s, 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.

Valve Springs

1. Check all valve springs for distortion. There

should be no more than 1.6 mm variance

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

is being rotated on a flat surface. Replace

springs that exceed this specification.

Figure 6A3-137

2. Use a commercially available valve spring

tester to m easure eac h valve spring free height

and tension.

3. Discard any spring that does not conform to

specification.

VALVE SPRING SPECIFICATIONS

VALVE SPRING FREE HEIGHT

(INTAKE and EXHAUST 52.9 mm

VALVE S PRING TENSIO N 310 N at 45.75 mm

SPECIFICATION (Closed Valve, Minimum)

VALVE S PRING TENSIO N 980 N at 33.55 mm

SPECI F ICATION (Open Valve, Minimum)

Figure 6A3-138

Valves

1. Inspect valve stems for burrs and scratches. 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 6A3-139

3. Check valve face for the following:

Either no m argin (1) or les s than 1.25 m m after

grinding (4).

Excessive pittin g (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

recom m endations m ust be caref ully f ollowed to

achieve the required standard of finish.

NOTE: If an exhaust valve f ace is reground, 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.

5. Measure the valve stem diameter. A valve

stem diameter of less than 7.95 mm must be

replaced

Figure 6A3-140

Valve Guides

Excessive valve stem to guide clearance may

cause a noisy valve train, premature valve stem oil

seal wear, com ponent dam age and/or exc essive 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 , f rom 8 - 12 m m 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 agains t the dial indicator us ing light

force, to obtain a clearance reading.

NOTE: Provided the valve stem diameter is within

specifications but the valve stem to guide clearance

exceed 0.093 mm (either intake or exhaust), the

clearance must be corrected or the cylinder head

replaced.

Figure 6A3-141

4. Ream the valve guide using Tool J 37378-1.

5. Clean the valve guide bore of all metal

shavings and debris.

Figure 6A3-142

6. Install the oversize valve (2) into the reamed

valve guide.

7. The valve s hould slide freely without resistance

or drag. The clearance must also not exceed

specification.

Figure 6A3-143

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.

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 must 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 for one full turn. If blue now

indicates a full contact 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: Ens ure that all re-used parts are reinstalled

to their original locations.

1. Lubricate all valve stems, guides and valve

faces with clean engine oil, then install valves

(9 and 10) to their correct ports.

2. Install valve spring shims (6) (first design).

Figure 6A3-144

3. Install a new valve stem oil seal and shim

assembly (second design) to the valve guide,

by hand, until the shim seats against the

cylinder head. No special tools are required for

this operation.

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.

NOTE: Replacement valve stem oil seals should

always be of the second des ign. However, as there

may still be some old parts stock, the following

procedure is included for the first design oil seal.

4. 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 lubric ated valve stem oil s eal (1),

over the valve stem . Push down firm ly 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 6A3-145

5. Measure the installed height of the valve stem

oil seal with vernier calipers (first design only).

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 6A3-146

6. Install the valve spr ings and caps to each valve

stem.

7. Use a commercially available valve spring

compressor to compress the valve spring.

8. Install valve stem collets, retaining with

petroleum jelly if required.

9. Ensure that the both collets are correctly

located before releasing the valve spring

compressor.

10. Tap the end of each installed valve stem, with a

plastic faced hammer to seat the collets.

Figure 6A3-147

11. Measure the valve spring installed height using

a ruler or vernier calipers. Measurement is to

be taken from the base of the valve spring to

the top.

12. If the measurement exceeds 46.25 mm, a

commercially available, stainless steel shim

must be installed between the valve stem oil

seal/shim combination and the cylinder head,

to achieve the required spring height.

NOTE 1: Do not shim the valve spring to obtain

less than the specified height.

NOTE 2: W hen replacing valve s tem oil s eals, only

use the later design that combines the oil seal and

the valve spring shim.

13. Install the remaining valves, springs and other

components, checking each spring height as it

is assembled.

14. If the cylinder head core plugs were removed,

install with sealant such as Loctite 565 (or

equivalent) before plug installation.

Figure 6A3-148

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 6A3-149

2. Install a NEW cylinder head gasket correctly

over the locating sleeves.

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

the cylinder head gas ket will be located to the front

half point (small arrow). This applies with either

cylinder head gasket.

Figure 6A3-150

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

Specific ation HN 1256, Clas s 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 6A3-151

6. Tighten the c ylinder head bolts in the sequenc e

shown and to the correct torque specification.

NOTE 1: Use a torque angle m eter s uch 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 T ORQUE SPECIFICATION

Stage 1 (All M11 and M8 Bolts) ............. 30 Nm

Stage 2 (All M11 Bolts only)................... 90° turn angl e

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

(M11 Bolts 9 and 10 only)......... 50° turn angl e

For the remainder of reinstallation pr ocess, ref er 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.

2.20 OIL LEVEL INDICATOR A ND TUBE

NOTE: If a cylinder head is replaced, the initial

spark plug torque specification, must be amended

to:

SPARK PLUG TORQUE SPECIFICATION

(NEW CYLINDER HEAD) ................................ 20 Nm

Figure 6A3-152

2.23 VALVE LIFTERS

REMOVE

NOTE: Ensure that all valve train components are

kept in or der so they may be reinstalled, if required,

in their original locations.

1. Rem ove 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 6A3-153

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

Figure 6A3-154

Techline

DISASSEMBLE

1. Using a small, f ine bladed screwdriver, rem ove

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 stuc k in the lif ter body, tur n

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 6A3-155

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

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

Figure 6A3-156

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. Worn or damaged roller bearing. Replace

lifter if roller binds or roughness can be felt.

3. Inspect valve lifter guides for;

a. Cracks or damage.

b. Excessive wear in the lifter mounting bores.

Figure 6A3-157

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 6A3-158

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 6A3-159

4. Reinstall plunger spring into the lifter body.

5. Install plunger assem bly 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 Tool 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 6A3-160

TESTING LIFTER LEAKDOWN RATE

After an hydraulic lifter has been cleaned, inspected and

reassem bled, it m ust be tested before being r einstalled.

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. Ensure the test cup is clean. Install the cup on

the fixture and place the lifter in the cup.

NOTE: Some versions of Tool No. 6A23 may

require modification to hold the base of the lifter

inside the tester cup.

2. Add 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 com e

up to its retainer, then lower arm to rest on

ram.

7. Use a s top watch to meas ure the time r equired

for the indicator needle on the tester to travel

from 'START' to the 0.125" position on the

scale.

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

the 0.125" position) must be between 10 to 30

seconds to assure satisfactory lifter operation.

Figure 6A3-161

NOTE 1: A doubtf ul lifter should be test ed several tim es

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 ters have been tested, plac e a cover over

the test fixture to keep dirt and dust from 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 lifters 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 lifters and guide assembly 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 6A3-162

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 the VT Series II Service

Information.

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 ST ART ING SYSTEM of the VT

Series II Service Information.

5. Remove the right hand side close-out cover

retaining bolt, then the cover.

Figure 6A3-163

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 6A3-164

7. Remove the crankshaft balancer bolt. Do not

discard bolt as it will be required for the

reinstallation process.

Figure 6A3-165

8. Use crankshaft end protector J 41816-2 and

puller J41816 (or three legged commercial

equivalent), to remove the crankshaft balancer.

Figure 6A3-166

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 crank shaft balancer hub s eal surface with

excessive scoring, grooves, rust or other

damage must be replaced.

• Minor im perfec tions on the hub seal surf ace

may be removed with polishing compound

or fine grade emery cloth.

• Dirty or damaged belt grooves.

• The balancer belt grooves should be f ree of

any nicks, gouges, or other damage that

may not allow the belt to track properly.

• Minor im perfec tions 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, chunking or deteriorated rubber

between the hub and pulley.

Figure 6A3-167

REINSTALL

Important: The crankshaft balancer reinstallation

and bolt tightening involves a multi-s tage 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 used crank shaf t balancer bolt will be used only

during the first pass of the balancer installation

procedure. Only install a NEW crank shaft balanc er

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 sm ear 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 6A3-168

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 larger end of the

installer 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 6A3-169

4. Install the used crankshaft balancer bolt and

tighten to the specified torque.

CRANKSHAFT BALANCER

INSTALLATION

TORQUE SPECIFICATION ............................. 330 Nm

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 6A3-170

8. Install a NEW crankshaft balancer bolt.

9. Tighten the crankshaft balancer bolt to the

correct torque specification, in two stages.

CRANKSHAFT BALANCER BOLT

TORQUE SPE CI F ICATION ....... St age 1: 50 Nm

Stage 2: 140° Turn angle

10. Remove the ring gear lock ing tool No. J 42386-

11. Reinstall the close-out cover and tighten the

bolt to the correct torque specification.

RIGHT HAND CLOS E-OUT COVER

TORQUE SPECIFICATION ............................. 10 Nm

12. Install the starter motor. Refer to

Section 6D3-2 STARTING SYSTEM, of the

VX Series Service Information and tighten the

mounting bolts to the correct torque

specification.

STARTER MOTOR MOUNTING

TORQUE SPECIFICATION ............................. 40 - 55 Nm

13. Reinstall the radiator, refer

Section 6B3 ENGINE COOLING – GEN III V8

ENGINE of the VT Series II Service

Information.

Figure 6A3-171

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 slowly rem ove screw-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 6A3-172

6. Remove engine accessory drive belt (2), using

a 15 mm ring spanner to load the tensioner.

Refer 2.6 ENGINE DRIVE BELTS – REPLACE,

in this Section.

Figure 6A3-173

7. Drain engine coolant. Refer to

2.3 DRAINING AND FILLING COOLING

SYSTEM, in 6B3 ENGINE COO LING of the VT

Series II Service Information.

8. Disconnect both heater hoses, the outlet and

inlet hoses from the coolant pump.

CAUTION: ALWAYS WEAR PROTECTIVE

SAFETY GLASSES WHEN WORKING WITH

SPRING TY PE HOSE CLAMPS. FAILURE T O DO

SO COULD RESULT IN EYE INJURY.

Figure 6A3-174

9. 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-175

10. Loosen, then remove the six bolts (1) securing

the coolant pump (2) to the cylinder block.

11. If necessary, use a soft f aced ham m er to lightly

tap coolant pump housing (2) to dislodge it

from the cylinder block.

12. Rem ove coolant pump, car rier type gask ets (3)

and discard.

Figure 6A-176

DISMANTLE

NOTE: Apart from the service oper ations desc r ibed

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). Tap

with a soft fac ed hamm er to dislodge the c over

from the pump body.

2. Rem ove the sealing O- ring (1) f rom the c oolant

pump body (2).

3. For thermostat remove, test and reinstall

procedures, refer to

2.9 THERMOSTAT, in 6B3 ENGINE COOLING

of the VT Series II Service Information.

Figure 6A-177

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 c oolant leak age at the coolant outlet

housing or rear cover gask et (if these parts have

not been removed).

• Leakage at the coolant pump vent hole. A stain

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

TORQUE SPECIFICATION ............................. 13 - 15 Nm

REINSTALL

Installation is the reverse to removal except for the

following items:

1. Ensure that the coolant pump and cylinder block

surfaces are clean and dry.

2. Using two bolts inserted into the coolant pump on

each side as guides , ins tall NEW gas k ets 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

TORQUE SPECIFICATION ....................... Stage 1: 15 Nm

Stage 2: 30 Nm

4. Install the engine ac ces sory drive belt tensioner and

attaching bolts, tightening to the correct torque

specification.

ENGINE ACCESSORY DRIVE BELT

TENSIONER BOLT

TORQUE SPECIFICATION ............................. 40 - 60 Nm

5. 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.

6. Install the engine accessory drive belt. Refer

2.6 ENGINE DRIVE BELTS - REPLACE in this

Section.

7. Refill cooling system, refer to

2.3 DRAINING AND FILLING COOLING SYSTEM

in 6B3 ENGINE COOLING of the VT Series II

Service Information.

8. Check for cooling system leaks, refer to

2.8 PRESSURE TESTING in 6B3 ENGINE

COOLING of the VT Series II Service Information.

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 6A3-178

3. Lubricate 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 s eal) 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. Inspect the oil seal for correct installation. 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 6A3-179

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 COOLING - GEN III V8

ENGINE of the VT Series II Service

Information.

3. Remove the engine dress cover retaining nuts

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

4. Loosen the two clamps securing the air intake

duct (3) to the throttle body and Mass 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 of the

VT Series I Service 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 M ANIFOLD - REM OVE, in this

Section.

9. Use suitable engine lifting equipment to raise

the engine, removing the weight from the

engine mounts.

Figure 6A3-180

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 6A3-181

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 shield, then tighten the nut to the

correct torque specification.

ENGINE MOUNT TO BRACKE T NUT

TORQUE SPECIFICATION ............................. 70 - 90 Nm

2. Install the engine m ount stud into the crossm em ber ,

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 T O CROS SMEMBER

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. Remove the engine dress cover retaining nuts

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

4. Loosen the two clamps securing the air intake

duct (3) to the throttle body and Mass 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 6A3-182

7. Place a suitable drain tray beneath the engine,

then loosen the worm drive hose clamp (1) on

the lower hose at the left hand radiator tank,

remove the hose and drain the coolant.

8. Loosen the spr ing clam p secur ing the lower left

hand hose to the transfer tube and remove the

lower left hand hose from the vehicle.

CAUTION: Wear safety glasses to avoid eye

injury.

NOTE: If ac cess to the transf er tube hose clam p 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.

9. Loosen top radiator hose (2) clamps and

remove hose from the engine.

10. Remove the engine cooling fans and radiator.

Refer to 6B3, ENGINE COOLING - GEN III V8

ENGINE of the VT Series I Service Information.

Figure 6A3-183

11. Recover refrigerant charge, refer to

Section 2C AIR CONDITIONING -

SERVICING AND DIAGNOSIS of the VT

Series I Service Information.

Figure 6A3-184

13. After rem oving the four oil pan under-tray bolts,

remove the tray from the vehicle.

14. Remove oil pan drain plug and drain engine oil

into a suitable container.

Reinstall drain plug once oil has drained

sufficiently.

15. Disconnect windshield washer hose (1) at the

in-line connector located at the rear, left hand

side of the engine hood.

Figure 6A3-185

16. 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.

17. Using an assistant to hold the hood assembly,

remove the engine hood bracket to hinge

attaching bolts (4), as shown, then carefully lift

the hood assembly clear of the vehicle.

Figure 6A3-186

18. Remove both heater hos e clamps at the engine

water pump, taking note of the hose layout.

Plug open ends to prevent dirt entry.

Figure 6A3-187

19. Remove the nut (1) securing the battery

harness earth terminal (2) from ABS/CRUISE

CONTROL bracket stud (4).

20. Remove the engine cooling fan relay assembly

(7), then disconnect the engine fan wiring

harness connector (8) from the relay and

battery harness.

21. Rem ove the clip holding the battery harnes s (5)

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

on the engine.

Figure 6A3-188

22. Disconnect main wiring harness to powertrain

and battery harness connectors (2) from the

main wiring harness connectors (1), at the

dash panel.

Figure 6A3-189

23. Disconnect powertrain wiring harness clips (6)

from the engine compartment dash panel

retaining bracket (‘5’, view D), refer Fig. 6A3-

186.

24. Referring to Fig. 6A3-186, disconnect

powertrain wiring harness connectors from the:

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

• Theft deterrent horn (‘4’, view C).

Figure 6A3-190

25. 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.

26. Remove the cover from the Powertrain Control

Module (PCM).

27. Remove both PCM connectors (see ‘3’, view B

in Fig. 6A3-186) in the engine bay, after

removing the retaining screw (bold arrows)

from each connector.

28. Remove the PCM wiring harness retaining clip

from the PCM container, to free the harness.

Figure 6A3-191

29. From inside the passenger c ompartm ent of the

vehicle, remove the left hand shroud panel trim,

and glove box assembly. For details, refer

Section 1A1 and Section 1A3 of the VT Series

I Service Information, respectively.

30. Remove the wiring harness connector (1) from

the Powertrain Interface Module (PIM).

31. Remove the Throttle Relaxer Module (TRM)

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

Lift the lock ing lever on the TRM connector (2),

pivot down and remove the connector from the

lower hook.

32. T o rem ove 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.

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

34. Release the harness to dash panel grommet

(3) and feed the harness and connectors out

into the engine bay.

35. Lay the powertrain wiring harnes s on top of the

engine.

Figure 6A3-192

36. Disconnect the cruise control cable (1) (if fitted)

(refer Fig. 6A3-189) from the stud (2) on the

throttle body valve lever (3), then remove the

outer cable (8) from the retainer bracket (4).

37. Lift the throttle cable (5) from the clip (6) at the

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

from the retainer bracket (4).

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

throttle body valve lever (3).

39. Set the cable/s to one side.

Figure 6A3-193

40. Using quick connect release Tool No. 7371,

open tool and install over fuel rail line.

41. 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.

42. 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/c ontaminants f rom entering the f uel

system.

Figure 6A3-194

43. Loosen the hose clamp on the return hose at

the power steering reservoir end.

44. After placing a suitable container under the

reservoir, remove the hose and drain the

reservoir fluid.

Important: Plug both openings to prevent dirt

entry.

45. Using tie wire or similar, secure the hose to one

side.

Figure 6A3-195

46. Loosen and remove the high pres sure line f lare

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 f luid loss

and/or dirt entry.

Figure 6A3-196

47. Disconnect the brake booster and heater

control, vacuum hoses from the rear of the

intake manifold.

Figure 6A3-197

48. 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.

49. 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 6A3-198

50. Raise vehicle front and rear and support on

safety stands. For location of jacking and

support points, refer to

Section 0A GENERAL INFORMATION of the

VT Series I Service Information.

51. Remove propeller shaft, refer to Section 4C

PROPELLER SHAFT AND UNIVERSAL JOINT S

in the VT Series II or VX Series Service

Information. Install a suitable plug in the rear of

the transmission.

52. Disconnect the gear shift control from the

transmission. Refer to Section 7B3 MANUAL

TRANSMISSION - GEN III V8 ENGINE, or

Section 7C4 AUTOMATIC TRANSMISSION -

ON-VEHICLE SERVICING of the VT Series II

Service Information.

53. From under the f ront of the vehicle, rem ove the

oil pan under-tray. Refer

6B3 ENGINE COOLING - GEN III V8 ENGINE

of the VT Series II Service Information.

54. Remove the two bolts (2) holding the power

steering, high pressure line (1) brackets to the

oil pan.

Figure 6A3-199

55. While not es sential, it is recom m ended that the

oxygen sensors (1) are removed from the

exhaust pipes, to avoid accidental damage.

a. Disconnect the wiring harness connectors

from each oxygen sensor.

b. Remove both oxygen sensors from the

exhaust pipes.

c. Plug openings in exhaust pipes.

56. Remove both exhaust pipe to manifold flange

nuts.

Figure 6A3-200

57. Rem ove the two bolts (2) securing the catalytic

converter bracket (1).

NOTE 1: Take note of any spacers (3) that may

be installed, remove with the bolts and set to one

side

NOTE 2: While Figure 6A3-201 shows an

automatic transmission equipped vehicle, this

operation is the same for manual transmission

vehicles.

58. Lower the vehicle to the ground.

Figure 6A3-201

59. Attach a suitable lifting chain and hooks to the

engine lifting brackets located at the left hand

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

60. Using a suitable lifting crane, raise the engine

slightly to take the weight off the engine

mounts.

Figure 6A3-202

VEHICLES WITH MANUAL TRANSMISSION

61. Mark the relationship of the engine rear

crossmember (2) to the frame, to assist with

alignment on reassembly.

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

cross m em ber (2) to the fram e, r em ove the rear

mounting to crossmember nuts (4), then

remove the crossmember from the vehicle.

63. Remove the catalytic converter bracket to

transm ission extension bolts (7) and nuts, then

rem ove the br acket (6) f r om the vehicle and set

to one side.

Figure 6A3-203

VEHICLES WITH AUTOMA TIC TRANSMISSION

64. Using a scriber or sim ilar, mark the r elationship

of the engine rear crossmember (2) to the

frame, to assist with alignment on reassembly.

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

cross m em ber (2) to the fram e, r em ove the rear

support to crossmember nuts (4), then remove

the crossmember from the vehicle.

66. Remove the rear mount to transmission

extension housing bolts (5), then remove the

mount (1) and the catalytic converter bracket

(6) from the vehicle.

Figure 6A3-204

67. Raise engine and transmission assembly with front tilted upward and a floor jack supporting the rear of the

transmission assembly.

Important: Tak e ca re when removing engine and trans mission as sembly, that no part of the ass embly 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).

68. Continue to lift and manoeuvre the engine and transmission assembly clear of the engine bay.

DISASSEMBLE

1. Remove the wiring harness connector s and earth connections from the engine and transm ission ass embly and

carefully set the wiring harness to one side.

2. Remove the transmission and mount the engine assembly in a suitable engine stand. The most practical

position overall, is to mount the engine on the side, using the engine mount bolt holes.

Important: If the engine is to be dismantled and in particular, the camshaft is to be removed, then the camshaft

lobe lift check should be carried 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 Section 2.3.

b. Engine drive belts, refer to Section 2.6.

c. Air conditioning compressor, refer Section 2B, AIR CONDITIONING - REMOVAL AND INSTALLATION of

the VT Series II Service Information.

d. Engine accessory drive belt idler and tension pulley assemblies, refer to Section 2.7 and Section 2.9.

e. Air conditioning drive belt idler and tension pulley assemblies, refer to Section 2.8 and Section 2.10.

f. Generator and m ounting brack ets, ref er Section 6D3-1 CHARGING SYSTEM - GEN III V8 ENGINE of the

VT Series II Service Information.

g. Intake manifold, refer to Section 2.14.

h. Vapour vent pipe, refer to Section 2.15.

i. Engine valley cover, refer to Section 2.16.

j. Valve rocker arm covers, refer to Section 2.17.

k. Valve rocker arms and push rods, refer to Section 2.18.

l. Oil level indicator and ex haust manif olds (if not already rem oved), refer to Sectio n 2.20 and Section 2.21.

Plug the oil level indicator hole in the oil pan to avoid dirt entry.

m. Cylinder heads and valve lifters, refer to Section 2.22 and Section 2.23.

n. Starter motor, refer Section 6D3-2 STARTING SYST EM - GEN III V8 ENGINE of the VT Series II Ser vic e

Information.

o. Crankshaft balancer, refer to Section 2.24.

p. Coolant pump assembly, refer to Section 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 c omponents that ar e detailed in this Section of MAJOR SERVICE OPERAT IONS, the reass embly

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 specif ied engine lubricant type and quantity. It is recom m ended that a fluoresc ent oil dye, suc h 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

6B3 ENGINE COOLING - GEN III V8 ENGINE of the VT Series II Service Information.

4. Check transm ission fluid level, topping up as required, using the specified lubricant for the transmission fitted.

Refer 7C4 AUTOMATIC TRANSMISSION - ON-VEHICLE SERVICING of the VT Series II Service Information.

5. If spacers were removed from the catalytic converter (if fitted) bracket on removal, ensure that

they are reinstalled and bolts tightened to the correct torque specification (refer

6. TORQUE WRENCH SPECIFICATIONS, in this Section). Check the exhaust system alignment and

clearances. Refer Section 8B in the VT Series II, SIP CD-ROM for details.

6. Disable the ignition system. Refer to 2.5 COMPRESSION CHECK in this Section, for details.

7. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.

8. Enable the ignition system, start the engine and listen for unusual noises.

9. 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 pressure. Refer to

2.4 ENGINE OIL PRESSURE - CHECK, in this Section.

10. Run the engine speed at about 1,000 rpm until the engine has reached normal operating temperature.

11. Listen for sticking lifters and other unusual noises.

12. Check for oil, fuel, coolant and exhaust leaks while the engine is running, correcting as required.

13. Perform a final inspection for the proper engine oil and coolant levels.

14. 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. To measure the camshaft lobe lift, proceed as

follows:

a. Remove the valve rocker arms 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 shaft of the dial indicator 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 Specification:

Intake Lobe 7.43 mm

Exhaust Lobe 7.43 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 6A3-205

3.3 OIL PAN

REMOVE

Important: Because of critical alignment

procedures required for oil pan installation, it is

strongly recom mended that the engine assem bly is

removed from the vehicle, before oil pan removal.

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

Figure 6A3-206

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

Figure 6A3-207

3. Invert the engine assembly.

4. Remove the oil pan bolts, loosening gradually

from the ends and working 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 6A3-208

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 shar p 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 6A3-209

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

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

5. Remove the two O-rings (4) and discard.

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 6A3-210

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 socket to remove

the oil gallery plugs (4).

NOTE: Because of thread sealant applied to the

threads, it is recommended that the front studs are

left attached to the transfer tube assembly and the

whole assembly withdrawn from inside the oil pan.

Figure 6A3-211

9. Remove the oil pan baff le bolts (six places) and

baffle.

Figure 6A3-212

CLEAN AND INSPECT

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

that all oil pass ages and rec esses are thoroughly

cleaned.

2. Clean the oil pan gas k et s ur f ac es, us ing a plas tic

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 (A) for scratches or

gouging.

d. Oil filter adaptor (1) for a loose fit or

damaged threads.

e. Oil passages for restrictions.

f. Oil filter bypass valve (2) in the oil filter

flange f or proper oper ation Lightly push the

bypass valve into the bore. The valve

spring should r eseat the valve to the proper

position.

Figure 6A3-213

5. Inspect the oil transfer tube for damage or

restrictions.

REASSEMBLE

1. Install the oil pan baffle and retaining bolts and

tighten to the correct torque specification.

OIL PAN BAFFLE BOLT

TORQUE SPECIFICATION ............................. 12 Nm

Figure 6A3-214

2. If removed, apply thread lock compound such

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 P LUG

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

TORQUE SPECIFICATION ............................. 12 Nm

Figure 6A3-215

7. Install NEW oil pan transfer cover O-rings (4),

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

10. If required, install a NEW oil f ilter bypass valve,

using a suitable size socket and hammer to

fully seat in the oil filter flange.

Figure 6A3-216

Techline

REINSTALL

Important: The alignment of the structural oil pan

is critic al. The rear bolt hole loc ations 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 6A3-217

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 6A3-218

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 gasket. Install the oil pan, gasket 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 6A3-219

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 f ront cover bolts and the oil

pan to r ear cover bolts , tightening to the cor rec t

torque specifications.

OIL PAN TO FRONT COVER

TORQUE SPECIFICATION ............................. 25 Nm

OIL PAN T O REAR COVER B O LT

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 f eeler gauge between the straight edge

and the oil pan transmission bell housing

mounting surface and check to make sure that

the oil pan is flush to no more than a 0.25 mm

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 specification.

OIL PAN T O CY LINDER BLOCK

TORQUE SPECIFICATION ............................. 25 Nm

If the oil pan alignment is not within specification,

remove the oil pan and repeat the above

procedure.

Figure 6A3-220

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 recom mended

that the engine assembly is removed from the

vehicle, before oil pan removal.

1. Remove the crankshaft balancer. Refer

2.24 CRANKSHAFT BALANCER - REMOVE,

in this Section.

2. Remove the front cover bolts.

3. Remove the front cover and gasket. If the

gasket is undamaged, it maybe re-used.

Figure 6A3-221

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 fr ont cover to oil pan thr eaded 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 to be damaged in any 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 surf ac e and to centr e the c rankshaf t f r ont oil

seal.

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

other foreign material during assembly.

NOTE 5: The crankshaft front oil seal MUST be

centred in relation to the crankshaft. The oil pan

sealing surface 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 6A3-222

3. Assem ble alignm ent tool J 41480 to f ront c over

and install bolts (1) (part of Tool J 41480), in

the locations shown but do not tighten.

4. Install the alignment 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

TORQUE SPECIFICATION ............................. 25 Nm

Figure 6A3-223

5. Install centralising Tool J 41476 as shown and

hold in position by hand.

Important: DO NOT install the crankshaft

balancer bolt to retain the alignment tool. If the

bolt is installed and over-tightened the

alignment tool will be destroyed.

NOTE: Align the tapered legs of the tool with the

machined alignment surfaces on the front cover.

6. Tighten the two bolts (1) s ecuring T ool J 41480

to the front cover, to the specified torque.

ALIGNMENT TOOL TO FRONT

COVER BOLT

TORQUE SPECIFICATION ............................. 25 Nm

7. Tighten the engine front cover bolts to the

correct torque specification.

ENGINE FRONT COVE R BOLT

TORQUE SPECIFICATION ............................. 25 Nm

8. Remove the alignment tools.

Figure 6A3-224

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

surfaces. Avoid contact with the portion of

the gasket that protrudes into the oil pan

surface.

b. Insert a feeler gauge between the front

cover and the str aight edge tool. The cover

mus t be f lush with the oil pan surf ace or no

mor e than 0.25 mm below flush (dimension

‘A’).

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

surface alignment is not within

specifications, repeat the cover alignment

procedure.

10. If the correct front cover to engine block

alignment c annot be obtained, replace the front

cover.

Figure 6A3-225

CRANKSHAFT FRONT OIL SEAL - INSTALL

Important: Do not lubricate the oil seal sealing

surface.

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

the front cover oil seal bore with clean engine

oil.

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

guide of Tool No. J 41478.

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

guide, and oil s eal) of Tool No. J 41478 into the

end of the crankshaft.

4. 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.

5. Remove the tool from the crankshaft.

6. Inspect the oil seal for correct installation. The

oil seal should be installed evenly and

completely into the front cover bore.

7. Install the crankshaft balancer, refer

2.24 CRANKSHAFT BALANCER, in this

Section.

8. Reinstall oil pan. Refer

3.3 OIL PAN - REINSTALL, in this Section.

Figure 6A3-226

3.5 ENGINE FLYWHEEL/FLEXPLATE

REMOVE

Important: Note the position and direction of the

engine flywheel before removal. The flywheel does

not use a loc ating pin for alignm ent. Mark or sc ribe

the end of the crankshaft and the flywheel before

component removal. The engine flywheel must be

reinstalled to the original pos ition 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 balanc e weight pins (relative to the position

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.

IMPORTANT: In order to maintain the correct

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

transfer, manual transmission flywheels MUST

NOT be machined.

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 requir ed to balance the crank s haf t/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 m achined

surface of the flywheel.

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

engine installed in the vehicle, remove the

transmission and clutch assembly (if required).

Refer 7B3 MANUAL TRANSMISSION - GEN

III V8 ENGINE, 7A1 CLUTCH - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION of the VT Series II Service

Information.

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 fly wheel/flexplate.

Figure 6A3-227

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 interfer ence 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 6A3-228

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 6A3-229

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

crank shaft and flywheel wer e balanced as a

complete unit in original manufacture.

b. Use the flywheel locating hole as reference

and scribe an alignment mark

corresponding to the one on the original

flyw heel.

2. Install the flywheel/flexplate, aligning the

scribed marks on the crankshaft and

flyw heel/flexplate.

Figure 6A3-230

3. Loosely install NEW flywheel/flexplate bolts,

tightening in the sequence shown in Fig. 6A3-

228, to an initial torque specification 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 6A3-231

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

TORQUE SPECIFICATION ....................... Stage 2: 50 Nm

Stage 3: 100Nm

6. Reinstall clutch and transmission, as required.

Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION of the VT Series II Service

Information.

Figure 6A3-232

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 FLYWHEEL/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 6A3-233

3. Secure the flywheel in a vice fitted with soft

jaws, then use a shar p cold chis el and ham m er

to split the ring gear at the drill point. Remove

the ring gear from the flywheel.

Figure 6A3-234

4. Check that there are no bur rs or f oreign m ater ial on the new ring gear and flywheel m ating sur fac es. 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, unif orm ly in an oven to a temperatur e between 180 - 230° C. This tem perature 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 flywheel 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 transmission, as required. Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8 ENGINE or 7C4 AUTOMATIC TRANSM ISSION of the VT Series

II Service Information.

3.7 CRANKSHAFT SPIGOT BEARING

REPLACE

1. Disconnect battery earth lead.

2. Remove manual transmission and the clutch

assembly, refer to

7B3, MANUAL TRANSMISSION - GEN III V8

ENGINE of the VX Series Service Information

and 7A1 CLUTCH - GEN III V8 ENGINE of the

VT Series II Service Information.

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

6A22-2 and slide hammer 7A28) or commercial

equivalent, remove the spigot bearing from the

rear of the crankshaft.

Figure 6A3-235

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 6A3-236

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

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

install a replacement bearing (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

10% molybendum disulphide grease, such as

Molybond GA 10 (or equivalent).

8. Reinstall clutch assembly and manual

transmission, refer to

7A1 CLUTCH - GEN III V8 ENGINE of the VT

Series II Service Information and

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE of the VX Series Service Information.

9. Reinstall the starter motor. Refer

6D3-2 STARTING SYSTEM - GEN III V8

ENGINE of the VT Series II Service

Information.

10. Reconnect battery earth lead.

11. Check starter motor operation and road test

vehicle to check transmission and clutch

operation.

Figure 6A3-237

Techline

3.8 ENGINE REAR COVER

REMOVE

Important: Because of critical alignment

procedures requir ed f or the reins 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 FLYWHEEL/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 6A3-238

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. Inspect the cover to oil pan threaded holes for

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 centr ed in relation to the crank shaft 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 6A3-239

2. Install the rear c over gas ket, the rear c over and

bolts.

NOTE: If undamaged, the original cover gasket can

be re-used.

3. Only tighten the rear c over bolts f inger tight. Do

not overtighten.

Figure 6A3-240

4. Assemble the alignment tool J 41480 to rear

cover and inst all bolts ( 1) (par t 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 COVE R ALIGNMENT TOOL

BOLT TO ENGINE BLOCK

TORQUE SPECIFICATION ............................. 25 Nm

Figure 6A3-241

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 alignm ent T ool 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 6A3-242

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

the rear cover to the specified torque.

REAR COVE R ALIGNMENT TOOL

BOLT TO REAR COVER

TORQUE SPECIFICATION ............................. 12 Nm

10. Tighten the engine rear cover bolts to the

correct torque specification.

ENGINE RE AR COVER BOLT

TORQUE SPECIFICATION ............................. 25 Nm

11. Remove the alignment tools.

Figure 6A3-243

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

surfaces. Avoid contact with the portion of

the gasket that protrudes into the oil pan

surface.

b. Insert a feeler gauge between the rear

cover and the str aight edge tool. The cover

mus t be f lush with the oil pan surf ace or no

mor e than 0.25 mm below flush (dimension

‘A’).

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

surface alignment is not within

specifications, repeat the cover alignment

procedure.

13. If the correct rear cover to engine block

alignment cannot be obtained, replace the rear

cover.

Figure 6A3-244

CRANKSHA FT 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 crankshaft.

Tighten the bolts until snug. Do not over-

tighten.

4. Install a NEW oil seal (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 transmission, as required.

Refer 7A1 CLUTCH - GEN III V8 ENGINE,

7B3 MANUAL TRANSMISSION - GEN III V8

ENGINE or 7C4 AUTOMATIC

TRANSMISSION of the VT Series II Service

Information.

Figure 6A3-245

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 recom mended

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 6A3-246

5. Remove the remaining crankshaft oil deflector

nuts.

6. Rem ove the crank shaf t oil def lector, noting that

the cover orientation is stamped ‘REAR’ to

assist in correct install ation.

Figure 6A3-247

7. Remove the four bolts securing the oil pum p 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 6A3-248

OIL PUMP DISASSEMBLE

1. Remove oil pump c over bolts, then remo ve the

cover.

Figure 6A3-249

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 6A3-250

3. Unscrew the oil pressure relief valve plug and

remove spring and valve from the oil pump

body.

Figure 6A3-251

CLEAN AND INSPECT

NOTE: Apart f rom the oil pres s ur e relief valve spring,

there are no other parts of the oil pump nor the oil

pump pick-up screen and pipe that are serviced

separately. If either component is found 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. Inspect the oil pump housing for damaged bolt

hole threads. See

Section 3.16 THREAD REPAIR, if required.

5. Inspect the oil pump 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. Inspect 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 sp lines for exces sive

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 pum p co m ponents 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 pum p 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 pum p and engine bloc k oil gallery

passages to ensure that any debris is removed.

2. Align the splined surfaces of the crankshaft

sproc k et and the oil pum p drive gear and ins tall

the oil pump 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 6A3-252

4. Install the crankshaft oil deflector, noting that

the ‘REAR’ stam ping on the def lector is loca ted

at the rear of the engine.

Figure 6A3-253

5. Lubricate a NEW oil pump pick-up tube O-ring

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 s crew 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 crank shaft oil def lector nuts to the

main bearing cap studs and tighten to the

correct torque specification.

CRANKCASE OIL DEFLECTOR

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 6A3-254

3.10 TIMING CHAIN AND S P ROCKE TS

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recom mended

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 cylinder heads and valve train are s till

installed, temporarily install the harmonic balancer

bolt and turn engine until the timing marks on the

crankshaft and camshaft sprockets are aligned,

refer Fig. 6A3-253. Remove the harm onic balancer

bolt.

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

rem ove the sprock et (2) and chain (3) f rom the

camshaft and crankshaft sprocket.

Figure 6A3-255

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 c rankshaf t s proc ket drive k ey from

the crankshaft nose, if required.

Figure 6A3-256

CLEAN AND INSPECT

1. Clean the sprockets and timing chain in

suitable solvent and blow dry with compressed

air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the timing chain for binding or wear.

Figure 6A3-257

3. Inspect the cam shaft and crankshaft sprockets

for:

a. Worn teeth (1).

b. Damaged teeth (2).

c. Chipped teeth (3).

d. Worn valleys between the sprocket teeth.

Figure 6A3-258

4. Inspect the crankshaft sprocket keyway (1) for

wear.

5. Inspect the crankshaft sprocket oil pump drive

splines (2) for wear.

Figure 6A3-259

REINSTALL

1. If removed, inst all the crank shaf t sprock et drive

key into the crankshaft.

The key should be tapped into place until each

end bottoms on the crankshaft.

Figure 6A3-260

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 T ool 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), moving

installer J 41665 to fully install the

crankshaft sprocket onto the crankshaft

nose.

d. When crankshaft sprocket has been fully

installed, remove installation tools.

4. If required, temporarily install the harmonic

balancer bolt and rotate the c ranks haft until the

timing alignment mark is at the 12 o’clock

position. Refer Fig. 6A3-259.

Figure 6A3-261

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 Fig. 6A3-263.

6. If required, temporarily install the camshaft

sprocket bolts and us e a s uitable lever to r otate

the camshaft sprocket until the timing mark is

correctly 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

camshaft sprocket hole by eye, then install the

timing chain to the crankshaft sprocket.

8. Install the c amshaf t s pr ocket over the c amshaf t

peg.

Figure 6A3-262

9. Before installing the camshaft sprocket bolts

(‘1’ in Fig. 6A3-258), check that the timing

marks are aligned as shown. If not, repeat

Steps 4 to 8 above.

10. Install the camshaft 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 6A3-263

3.11 CAMSHAFT

REMOVE

Important: Because of critical alignment

procedures required for the reinstallation of the

front cover and oil pan, it is strongly recom mended

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 INT AKE MANIFOLD - REMOVE, in

this Section.

2. Remove the camshaft sensor bolt and sensor

from the engine block.

Figure 6A3-264

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 6A3-265

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

rem oved coolant 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 6A3-266

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 damage to the camshaft position

reluctor ring.

Figure 6A3-267

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

Camshaft Journal Out-of-Round 0.025 mm

Max.

Camshaft Bearing Journal Diameter 54.99 mm

Min.

Figure 6A3-268

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 Journal Specifications

Intake Lobe Height 46.67 mm

Min.

Exhaust Lobe Height 46.67 mm

Min.

Figure 6A3-269

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 c am shaf t if the runout exceeds the

specification.

Idler Gear End Play Spec.

Camshaft Runout Specification

Camshaft Runout 0.05 mm

Maximum

7. Inspect the camshaft retainer plate for wear or

a damaged sealing gasket.

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

re-used.

Figure 6A3-270

REINSTALL

NOTE: If the camshaft replacem ent is required, the

valve lifters must also be renewed.

1. Lubricate camshaft journals and the bearings

with clean engine oil.

2. Install three M8 x 1.25 x 100 m m bolts into the

camshaft front journal.

3. Using the bolts as a handle, car efully install the

camshaft into the engine block.

NOTE: As all the cam shaf t bearing j ournals ar e the

same size, care must be taken to avoid bearing

damage during camshaft installation.

4. Remove the three bolts after camshaft

installation.

Figure 6A3-271

5. Ensure that the engine block surface is clean

and free of debris, then install the camshaft

retainer plate with the sealing gask et facing the

engine block.

6. Install the c amshaf t r etainer bolts and tighten to

the correct torque specification.

CAMSHAFT RETAINER BOLT

TORQUE SPECIFICATION ............................. 25 Nm

Figure 6A3-272

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

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. Refer 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 6A3-273

3.12 PI S TON, 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 remover, 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 6A3-274

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 ark 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 6A3-275

8. Install guide pins Tool J 41556 to the

connecting rod to be removed.

Figure 6A3-276

9. Use a hammer 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 6A3-277

DISASSEMBLE

1. Remove the piston rings from the piston.

Figure 6A3-278

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

of Tool J 24086-C. Mount the piston assembly

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 from 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 cor rect reass embly if original parts are to

be re-used.

Figure 6A3-279

CLEAN AND INSPECT

Piston and Pin

1. Clean any varnish f rom 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 6A3-280

5. Inspect each piston and pin for the following:

a. Cracks in the piston lands, skirt or the pin

bosses.

b. Piston ring grooves for nicks, burrs or

warpage which may cause the piston ring

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 6A3-281

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, MINO R ring groove imperf ections m ay

be removed with a fine file.

NOTE 2: If binding is caused by a distorted piston

ring, replace the ring.

Figure 6A3-282

NOTE: For each of the following measurements,

ensure that the micrometer zeroing has been

carried out and the measurements ar e all tak en 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

specification, try another piston ring 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

specif ication, the pis ton and pin assem b ly m us t

be replaced.

Figure 6A3-283

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

Figure 6A3-284

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 6A3-285

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 dif f er ence ex c eeds spec if ic ation, then

replace the piston and pin assembly.

Piston Skirt Out-of Round Specification

Piston skirt dimension variation 0.018 mm

Maximum

Figure 6A3-286

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 s lots 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 6A3-287

5. Reinstall the connecting rod big end cap and

bolts. Tighten bolts to the correct torque

specification.

CONNECTING ROD CA P BOLT

TORQUE SPE CI F ICATION .......... Stage 1: 20 Nm

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 6A3-288

7. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves also indicate fatigue.

Figure 6A3-289

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 6A3-290

10. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-291

Measuring Piston Ring End Gap

1. Inser t a new piston r ing into the bore that it is to

be fitted and push it down the bore, using the

piston, inverted in the bore, until the ring is

approximately 6.5 mm below the piston ring

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 6A3-292

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. W ith a micrometer 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 6A3-293

3. Check that the micrometer is at the recorded

piston diameter.

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

held between the micrometer anvils as shown,

zero the dial indicator.

Figure 6A3-294

5. Use bore gauge J 8087 (or commercial

equivalent), measure the cylinder bore

diameter, at a point 57 mm from the top of the

bore.

6. Record the cylinder bore diameter.

7. Subtract the piston diameter from the cylinder

bore measurement, in order to determine the

piston to bore clearance.

Piston to Bore Clearance Specification

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 c learanc e. If the cor r ect c learanc e

cannot be obtained using this m ethod, then the

cylinder bore may require honing for an

oversize piston fitment, or the c ylinder 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 attem pted.

Refer

3.15 CYLINDER BLOCK - Cylinder Block Clean,

Inspect and Measure, in this Section.

Figure 6A3-295

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 6A3-296

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 6A3-297

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

as shown. Lock this position with the knurled

ring.

Figure 6A3-298

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 side of the

piston pin boss.

Figure 6A3-299

Piston Rings

NOTE: Use commercially available piston rings

pliers and only expand the piston ring suf ficiently 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. Ins tall the oil contr ol 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 marks, 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 contr ol 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 6A3-300

REINSTALL

NOTE 1: Before installation, check that the piston

ring end gaps are staggered correctly and that the

piston has been as sembled to the c onnecting 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 piston and connecting rod assembly

into the c orrect cylinder bore, check ing that the

piston alignment mark is facing the front 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. Complete installation by using the pins, Tool J

41556 to guide the connecting rod onto the

crankshaft journal.

T6A3274a

Figure 6A3-301

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 Fig. 6A3-292.

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 6A3-302

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 'dim ples' on

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

shown.

Important: As bolt design 'A' has a diff erent torque

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

connecting rod bolts , MUST be of the sam e design

for each connecting rod. Using different 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 6A3-303

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 check 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 6A3-304

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 the VT Series II Service

Information.

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 T IMING 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 rem ove the sensor from the

cylinder block.

Figure 6A3-305

4. Remove the crankshaft main bearing cap M8

side bolts (1). While these bolts must be

renewed on final assembly, place the removed

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, loos ening each pair gradually. Tak e note

of the stud positions for reassembly.

Figure 6A3-306

6. Loosen the bolts of main bearing removal Tool

J 41818 to separate the chamfered collets.

Then install the chamfered sections into each

main bearing cap bolt hole, aligning the flats 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 6A3-307

9. Remove the remaining main bearing caps in

the same way. Check that the lower main

bearing shells are also removed with each cap.

NOTE: Keep all main bearing caps in order and

note the orientation of the cap to the engine block.

Figure 6A3-308

10. Remove the c rank shaf t fr om the cylinder block,

lifting evenly to avoid jamm ing agains t the main

thrust bearing.

Figure 6A3-309

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 6A3-310

11. Rem ove the crank shaf t main bearings from the

cylinder block and the main bearing caps.

NOTE: Ta ke partic ular care to organis e all par ts so

they can be reinstalled in their original positions.

Figure 6A3-311

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 imperf ect ions on either the r ising or f alling

edges.

Figure 6A3-312

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 crank shaft journals for sc ratches or

wear (3).

9. Inspect the crankshaft journals for pitting or

embedded bearing material (4).

Figure 6A3-313

10. Inspect the crankshaft key (1), keyway (2) and

threaded hole (3) for damage.

Figure 6A3-314

11. Measure all crankshaft journals for wear and

out-of-round.

Crankshaft Journal Specifications

Connecting Rod Journal Diameter 53.308 mm Min.

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

Connecting Rod Journal Taper 0.010 m m Max.

Main Bearing Journal Diameter 64.993 m m Min.

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

Main Bearing Journal Taper 0.020 mm Max.

Figure 6A3-315

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 Spec ifications

Reluctor Ri ng Lateral Runout 0.250 mm Maximum

Crankshaf t Thrust Wall Runout 0.025 m m Maximum

Crankshaf t Rear Fl ange Runout 0.050 mm Maximum

Figure 6A3-316

14. Check the rear crankshaft 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 6A3-317

Main Bearings - Inspect

1. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves also indicate fatigue.

Figure 6A3-318

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 6A3-319

4. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-320

Main Bearing Oil Clearance - Check

1. After thoroughly cleaning all relevant parts,

install bearing halves into the cylinder block

and main bearing caps.

Figure 6A3-321

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 6A3-322

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

the same order as removal.

Figure 6A3-323

5. Tighten main bearing cap bolts and studs to the

correct torque specification and in the correct

sequence.

MAIN BEARING INNER BOLTS (1 - 10)

TORQUE SPE CI F ICATION ............. Stage 1: 20 Nm

Stage 2: 80° turn angle

MAIN BEARING OUTER S T UDS (11 - 20)

TORQUE SPE CI F ICATION ............. Stage 1: 20 Nm

Stage 2: 53° turn angle

NOTE: Use torque angle meter E7115 to achieve

an accurate second reading.

6. Tighten the side cap bolts to the correct torque

specification, first on one side, then on the

other.

MAIN BEARING CAP SIDE BOLTS

TORQUE SPECIFICATION ............................. 25 Nm

Figure 6A3-324

7. Remove the m ain bear ing cap M8 side bolts (1)

and discard, as new bolts must be used on final

assembly.

Figure 6A3-325

8. Loosen the bolts of main bearing removal Tool

J 41818 to separate the chamfered collets,

then install the chamfered sections into each

main bearing cap bolt hole, aligning the flats 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 6A3-326

11. Remove the remaining main bearing caps in

the same way.

Figure 6A3-327

12. Using the scale supplied with the gauging

plastic, measure the deformed plastic at its

widest part.

• If the def orm ed str ip shows a width variation

exceeding 0.020 mm, remove the

crankshaft and measure the journal with a

micrometer.

• If the bearing clearance is greater than

0.076 mm (connecting rod) or 0.065 mm

(main), 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 6A3-328

REINSTALL

1. Apply clean engine oil to the bearing halves

and crankshaft journals.

Figure 6A3-329

2. Install crankshaft to cylinder block, ensuring

that the crankshaft is held square to avoid

jamming/ damaging the centre main thrust

bearing.

Figure 6A3-330

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

the correct order.

NOTE: All m ain bearing caps are num bered f rom 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 6A3-331

4. Tighten main bearing cap bolts and studs to the

correct torque specification, in the correct

sequence.

MAIN BEARING INNER BOLTS (1 - 10)

TORQUE SPECIFICATION.............. Stage 1: 20 Nm

Stage 2: 80° turn angle

MAIN BEARING OUTER STUDS (11 - 20)

TORQUE SPECIFICATION.............. Stage 1: 20 Nm

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 6A3-332

6. Thrust the crankshaft rearward then forward,

using a suitable lever.

7. Insert a feeler gauge between the centre 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 6A3-333

8. Inspect the crankshaft position sensor O-ring

for nic ks, cuts or other damage. If undamaged,

the O-ring may be re-used.

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

10. Inst all the sensor, aligning the retaining brack et

notch with the threaded holed in the cylinder

block.

11. Install the retaining bolt, tightening to the

correct torque specification.

CRANKSHAFT POSITION SENSOR

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

6D3-2 STARTING SYSTEM - GEN III V8

ENGINE of the VT Series II Service

Information.

13. Reinstall engine into vehicle, refer

3.1 ENGINE ASSEMBLY - REMOVE, in this

Section.

Figure 6A3-334

3.14 ENGINE BLOCK PLUGS

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 6A3-335

2. Remove the three plugs from the left hand side

of the cylinder 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 6A3-336

3. If not removed in previous operations, remove

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

cylinder block, at the left hand rear, using Tool

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

Figure 6A3-337

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 6A3-338

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 6A3-339

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 c orrec t torque

specification, using an 8 mm Allen key socket.

COOLANT DRAI N P LUG

TORQUE SPECIFICATION ............................. 60 Nm

Figure 6A3-340

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 6A3-341

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

Figure 6A3-342

10. Apply sealant such as Loc tite 565 or equivalent

to the cleaned threads of the oil pressure

sensor ( 1) and r eins tall, us ing T ool No. J 41712

and suitable 3/8” drive socket equipment.

Tighten to the correct torque specification.

OIL PRES SURE SENS OR

TORQUE SPECIFICATION ............................. 20 Nm

Figure 6A3-343

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 lifters.

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.

Figure 6A3-344

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.

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. To replace the camshaft 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 6A3-345

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 6A3-346

5. Once installed, ensure that the separations in

the expander assembly segments, are aligned

with those of the expanding driver as shown

(‘A’).

Figure 6A3-347

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 c omponents s hown in Fig. 6A3-349 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 6A3-348

10. Push the guide cone into the front camshaft

bearing to align the driver bar.

11. W hile 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 6A3-349

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 6A3-350.

Figure 6A3-350

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

way to bearing removal, except for the following

items:

a. The join in the new camshaft bearing (‘A’)

must be aligned with the top of the engine

block . To assis t with alignm ent, us e a f elt tip

pen to mark the back of the bearing, 180°

from the join, as this will be visible when

installing the bearing.

b. W hile the oil feed is generous in length and

allows some degree of hole misalignment,

as much care as possible must be made

during installation.

c. 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 .

d. To install the front camshaft bearing, install

the driver bar into the rear bearing and use

the guide cone at that location.

Important: Take car e when installing the driver

bar through the newly installed bearings to

avoid damage.

Figure 6A3-351

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 232° C (450° F).

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 sur f aces , 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 from the cylinder block threads, 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.

7. Use c ompres sed air to c lean all res idue f rom 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 6A3-352

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 6A3-353

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 bor e out-of - round 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 6A3-354

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 s ets 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 c lean, shar p stones of the pr oper grade for

the amount of material you remove. Dull, dirty

stones cut unevenly and generate excessive

heat. Do not hone to final clearance with a

coarse or medium-grade stone. Leave

suff icient metal so that all stone marks may 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 fit with the selected piston. 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. W hen honing to eliminate taper in the cylinder,

make full strokes for the complete bore length.

Repeatedly check the m easurement at the top,

the middle, and the bottom of the bore.

T6A3228

Figure 6A3-355

7. The finis h mark s should be c lean but not sharp. T he finish m arks should also be f ree from em bedded particles

and torn or folded metal.

8. By measuring the selected piston at the sizing point and by adding the average of the clearance specification,

the final cylinder honing dimension required, can be determined.

9. W hen finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and

taper requirements.

10. After final honing and befor e the pist on is chec ked f or f it, 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 m aterial to rem ain in the cylinder bores. Th is abrasive m aterial may cause premature wear of the new

piston rings and the cylinder bores. Abrasive material will also contaminate the engine oil and may cause

premature wear of the bearings. After washing the cylinder bore, dry the bore with a clean rag.

11. Perform final measurements of the piston and the cylinder bore.

12. Permanently mark the top of the piston for 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 material when

performing the deglazing procedure.

A 240 gr it stone is preferred for f inal honing. If a 240 gr it stone is not available, a 220 grit stone 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 T HREAD 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 ins talled 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 6A3-356

GENERAL THREAD REPAIR

1. Drill out the threads of the dam aged hole (1) to

the correct depth for the thread being repaired:

• M6 inserts require a minimum drill depth of

15 mm.

• M8 inserts require a minimum drill depth of

20 mm.

• M10 inserts require a m inim um drill depth of

23.5 mm.

2. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-357

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 6A3-358

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 inser ts requir e a m inimum 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 com pr essed air , clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-359

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 6A3-360

10. Install the insert (2) onto the driver tool (1).

Figure 6A3-361

11. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-362

12. Using the installer tool (1), install the insert (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 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 6A3-363

16. Inspect the ins ert for proper installation into the

hole.

17. A properly installed insert ( 1) will be either flus h

or slightly below flush with the surface of the

base material (2).

Figure 6A3-364

CYLINDER HEAD BOLT 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 6A3-365

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 6A3-366

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 6A3-367

6. Cylinder head bolt holes 1-8 ar e 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 6A3-368

8. Install the sleeve (2) onto the drill (1) (if

required).

Figure 6A3-369

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 6A3-370

12. Using a tap wrench, tap the threads of the

drilled hole.

Figure 6A3-371

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 c ylinder 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 com pr essed air , clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-372

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 6A3-373

19. Install the insert (2) onto the driver tool (1).

Figure 6A3-374

20. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-375

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 since the bottom threads of the

insert are being formed and mechanically

locked into the hole.

24. Remove the driver. The repair is complete.

Figure 6A3-376

MAIN CAP BOLT HOLE THREAD REPAIR

The main cap bolt hole thread repair 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 6A3-377

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 6A3-378

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 6A3-379

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 m ark ( 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 com pr essed air , clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-380

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 6A3-381

11. Install the insert (2) onto the driver tool (1).

Figure 6A3-382

12. Apply threadlock Loctite 272 (1) or equivalent

(GM P/N 12345493) to the insert OD threads

(2).

Figure 6A3-383

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 mark 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 6A3-384

3.17 THREAD REPAIR SPECIFICATIONS

ENGINE BLOCK - FRONT VIEW

Figure 6A3-385

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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 6A3-386

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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 6A3-387

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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 inc l uded in the 124.0 mm drill depth.

• Bolt holes 9 and 24 have a 30 mm counterbore included in t he 69. 0 mm drill dept h. Use sleeve J 42385-315 with t he drill and tap.

ENGINE BLOCK - RIGHT SIDE VIEW

Figure 6A3-388

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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 i n the 124. 0 mm drill depth.

• Bolt holes 9 and 23 have a 30 mm counterbore included in t he 69. 0 mm drill dept h. Use sleeve J 42385-315 with t he drill and tap.

ENGINE BLOCK - BOTTOM VIEW

Figure 6A3-389

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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       

7 N/A       

8 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

9 M10 x 2. 0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

10-11 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 53.5 44.0

12 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

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

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

Maximum

Tap Depth

23 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

24 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 53.5 44.0

25-26 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

27 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

28-29 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 53.5 44.0

30 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

31 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

32 M28 x 1.25       

33 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

34 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 53.5 44.0

35 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 31.0 25.5

36 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm counterbore included in the 53.5 mm drill depth.

• Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1. 5 mm counterbore included in t he 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 inc l uded in t he 42.5 mm drill depth. Use sleeve J 42385-311 with the drill and tap.

ENGINE BLOCK - TOP VIEW

Figure 6A3-390

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dep th

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 6A3-391

Hole Thread Size Insert Drill Counterbore

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 6A3-392

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

2 N/A       

3 M10 x 1. 5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

4 N/A       

5-6 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 20.0

CYLINDER HEAD - EXHAUST MANIFOLD SIDE VIEW

Figure 6A3-393

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 6A3-394

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 perform ance diagnosis procedures are covered in Section 6C3 POWERTRAIN M ANAGEMENT - GEN

III V8 ENGINE of the VX Series Service Inf ormationand 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. W hen the proper diagnosis is m ade, the concern should be corrected by adjustment, repair or replacement as

required.

4. Refer to the appropriate section of the VX Series Service Informationfor 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 VX Series

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 Section.

4. Verify if the engine has excessive oil consumption. Refer to 4.4 OIL

CONSUMPTION DIAGNOSIS, in this 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.

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.

• Wa rped cylinder head.

• Cracked cylinder head.

• Damaged engine block.

Techline

Checks Action

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 w h ich the noise exists. Note f actor s suc h as the ambient temperatur e, 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 s peed (valve train nois e s uc h as roc ker arms, valve lifter s, and tim ing chain). Tr y 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.

• Wo rn 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 Lift er Diagnos is is nec ess ary, always use a listening devic e such 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).

• Wo rn 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 TABLE

DEFINITION: A light tapping noise at one half engine speed, or any varying frequency.

Step Action Value(s) Yes No

1 Is there valve train noise? − Go to Step 2 System OK

2 Check 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

3 Drain engine oil until level is correct.

Is there valve train noise? − Go to Step 4 System OK

4 Check 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

5 Add oil as required.

Is there valve train noise? − Go to Step 6 System OK

6 Check 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

7 1. Check the oil pump screen for damage or a loose fit to the

oil pump.

2. 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

8 Repair as required.

Is there valve train noise? − Go to Step 9 System OK

9 Check 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.

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

Techline

Step Action Value(s) Yes No

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

8 1. 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 (5,670 cm3 - 346 in3)

Bore ................................................................................... 99.0 – 99.018 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 or Denso PTJ16R15

Spark Plug Gap.................................................................. 1.52 ± 0.05 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 Ty pe.............................................................................. 10W - 30 ILSAC GF2 (Service Refill)

.................................................................................... If unavailable, use SG, SH or SJ engine oil, with

.................................................................................... Viscosity of 20W/50 or 15W/40.

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)......................................... 0.023 - 0.065 mm

Bearing Clearance (Service Limit)..................................... 0.023 - 0.076 mm

Side Clearance .................................................................. 0.110 - 0.510 mm

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

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

CRANKSHAFT

End Play............................................................................. 0.040 - 0.200 mm

Connecting Rod Journal

Bearing Clearance (Production) ................................... 0.023 - 0.065 mm

Bearing Clearance (Service Limit)................................ 0.023 - 0.076 mm

Diameter (Production)................................................... 53.318 - 53.338 mm

Diameter (Service Limit)............................................... 53.308 mm (Minimum)

Taper (Production)........................................................ 0.005 mm (Maximum for 1/2 of the Journal Length)

Taper (Service Limit) .................................................... 0.020 mm (Maximum)

Out-of-Round (Production) ........................................... 0.005 mm

Out-of-Round (Service Limit)........................................ 0.010 mm

Main Journal

Bearing Clearance (Production) ................................... 0.020 - 0.052 mm

Bearing Clearance (Service Limit)................................ 0.020 - 0.065 mm

Diameter (Production)................................................... 64.993 - 65.007 mm

Diameter (Service Limit)............................................... 64.993 mm (Minimum)

Out-of-Round (Production) ........................................... 0.003 mm

Out-of-Round (Service Limit)........................................ 0.008 mm

Taper (Production)........................................................ 0.010 mm

Taper (Service Limit) .................................................... 0.020 mm (Maximum)

Reluctor Ring Runout

(Measured 1.0 mm below Tooth Diameter).................. 0.700 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)............................................... 26.2 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)................................ 0.080 mm

Engine Block Deck Flatness

(Measured over Full Length of Cylinder Head)............. 0.100 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)................................ 0.080 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 ...................................... 0.005 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 Margin......................................................................... 1.25 mm (Minimum)

Valve Face Angle.................................................................. 45 degrees

Valve Seat Angle................................................................... 46 degrees

Valve Seat

Runout ............................................................................... 0.050 mm (Maximum)

Width (Intake) .................................................................... 1.020 mm (Maximum)

Width (Exhaust)................................................................. 1.780 mm (Maximum)

Valve Stem

Clearance (Production-Intake)........................................... 0.025 - 0.066 mm

Clearance (Production-Exhaust)........................................ 0.025 - 0.066 mm

Clearance (Service-Intake)................................................ 0.093 mm (Maximum)

Clearance (Service-Exhaust)............................................. 0.093 mm (Maximum)

Diameter (Production)........................................................ 7.955 - 7.976 mm

Diameter (Service)............................................................. 7.95 mm (Minimum)

Valve Spring

Free Length........................................................................ 52.9 mm

Pressure (Closed Valve).................................................... 340 N at 45.75 mm (Minimum)

Pressure (Open Valve) ...................................................... 980 N at 33.55 mm (Minimum)

Installed Height (Intake)..................................................... 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 (Early Type)

(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)

Engine Flywheel Bolt Threads .............................................. Loctite 242 or equivalent (GM P/N 12345382)

Exhaust Manifold Bolt Threads............................................. Loctite 272 or equivalent (GM P/N 12345493)

Fuel Rail Bolt Threads .......................................................... Loctite 242 or equivalent (GM P/N 12345382)

Ignition Coil and Bracket Assembly 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 SPECIFICATIONS

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 (if fitted) ............... 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

Clutch Housing to Engine Block Bolt (Manual Transmission)........................ 40 – 60

Connecting Rod Bolts Stage 1 ('A', 'B' and 'C' designs) ................................. 20

Stage 2 ('A' design only)............................................. 60 degrees turn angle

Stage 2 ('B' and 'C' designs)...................................... 75 degrees turn angle

Coolant Temperature Sensor......................................................................... 20

Coolant Inlet Housing Bolts ............................................................................ 15

Coolant Pump Bolts First Pass...................................................................... 15

Final Pass ..................................................................... 30

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 Bolts Stage 1 .................................................................... 15

Stage 2 .................................................................... 25

Exhaust Manifold Heat Shield Bolt................................................................. 9

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................................................... 10

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

Positive Crankcase Ventilation (PCV) System Strap Nut.................................. 12

Spark Plugs (New Cylinder Head - ‘Coining’)) .................................................. 20

Spark Plugs....................................................................................................... 15

Starter Motor Bolt.............................................................................................. 40 – 55

Throttle Body Bolts............................................................................................ 12

Torque Converter Housing to Engine Block Bolts (Automatic Transmission)... 40 – 60

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

Previously released.

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

Previously released.

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

Previously released.

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

Previously released.

Universal tool containing selective

components to suit multiple engine

applications.

J 37378-1 VALVE GUIDE REAMER New release.

Used to ream worn valve guides to

suit oversize valve stem.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 38836 PILOTED DRIVER

T6A3 189b

Previously released.

Used to install the spigot bush in

the crankshaft.

J 41476 FRONT AND REAR COVER ALIGNMENT TOOL

T6A3257a

Previously released.

Used to align both the front and

rear engine covers during

installation.

J 41478 CRANKSHAFT FRONT OIL SEAL INSTALLER

T6A3258a

Previously released.

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

T6A3259a

Previously released.

J 41480 FRONT AND REAR COVER ALIGNMENT TOOL

T6A3260a

Previously released.

Used in conjunction with alignment

tool J 41476, to correctly align the

front and rear engine covers.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 41556 CONNECTING ROD GUIDES

Previously released.

Used to assist in piston and

connecting rod installation.

J 41558 CRANKSHAFT SPROCKET REMOVER

Previously released.

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

Previously released.

Comprises stepped sleeve, J

41665-1 and end plate J 41665-2.

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

Previously released.

Used in conjunction with 3/8” drive

socket equipment to

remove/reinstall oil pressure

sensor.

J 41816 THREE LEGGED PULLER

Previously released.

Also commercially available.

Used in conjunction with J 41816-2

to remove crankshaft balancer.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 41816-2 ADAPTOR

Previously released.

Used in conjunction with puller J

41816 to remove crankshaft

balancer.

J 41818 CRANKSHAFT BEARING CAP REMOVER

Previously released.

Used in conjunction with slide

hammer J 6125-1B to remove main

bearing caps.

J 42078 VALVE STEM OIL SEAL INSTALLER

Previously released.

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

Previously released.

Comprises;

Cylinder Head/Rear Main

Bearing Cap Kit J 42385-100

General Kit J 42385-200

Fixtures/Hardware Kit J 42385-300

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J 42386 FLYWHEEL HOLDING TOOL

Previously released.

J 42907 OIL PRESSURE ADAPTOR

Previously released.

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.