SECTION 6A3 - ENGINE MECHANICAL -

GEN III V8 ENGINE

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to Section

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

CONTENTS

1. GENERAL DESCRIPTION

1.1 SERVICE INFORMATION

1.2 ENGINE SERIAL NUMBER

1.3 ENGINE CONSTRUCTION

CYLINDER BLOCK

CYLINDER HEADS

VALVE TRAIN

CRANKSHAFT

PISTONS AND CONNECTING RODS

CAMSHAFT AND DRIVE

INTAKE MANIFOLD

EXHAUST MANIFOLD

ACCESSORY DRIVE

OIL PAN

1.4 ENGINE LUBRICATION SYSTEM

OIL PUMP

CRANKSHAFT OIL SEALS

POSITIVE CRANKCASE VENTILATION

SYSTEM

1.5 SERVICE NOTES

CLEANLINESS AND CARE

REPLACING ENGINE GASKETS

USE OF RTV AND ANAEROBIC

SEALER

SEPARATING PARTS

TOOLS AND EQUIPMENT

FASTENERS

2. MINOR SERVICE OPERATIONS

2.1 ENGINE OIL LEVEL CHECK

2.2 ENGINE OIL - CHANGE

2.3 ENGINE OIL FILTER & ADAPTOR

REPLACE

2.4 ENGINE OIL PRESSURE - CHECK

2.5 COMPRESSION CHECK

INTERPRETING COMPRESSION

READINGS

2.6 ENGINE DRIVE BELTS - REPLACE

ENGINE ACCESSORY BELT

AIR CONDITIONING COMPRESSOR

BELT

2.7 ACCESSORY BELT IDLER PULLEY

REPLACE

2.8 A/C BELT IDLER PULLEY

REPLACE

2.9 ACCESSORY BELT TENSIONER

REPLACE

2.10 A/C BELT TENSIONER

REPLACE

2.11 OIL PRESSURE SENSOR

REPLACE

2.12 MANIFOLD ABSOLUTE PRESSURE

SENSOR

REPLACE

2.13 FUEL SYSTEM PRESSURE RELIEF

2.14 INTAKE MANIFOLD

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

2.15 VAPOUR VENT PIPE

REMOVE

REINSTALL

2.16 ENGINE VALLEY COVER

REMOVE

CLEAN AND INSPECT

REINSTALL

2.17 VALVE ROCKER ARM COVER

REMOVE

CLEAN AND INSPECT

REINSTALL

2.18 VALVE ROCKER ARMS & PUSH RODS

REMOVE

CLEAN AND INSPECT

REINSTALL

2.19 VALVE STEM OIL SEAL AND/OR VALVE

SPRING

REPLACE

2.20 OIL LEVEL INDICATOR AND TUBE

REPLACE

2.21 EXHAUST MANIFOLD

REMOVE

INSPECT

REINSTALL

2.22 CYLINDER HEAD

REMOVE

DISASSEMBLE

CLEAN

INSPECT

REASSEMBLE

REINSTALL

2.23 VALVE LIFTERS

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

TEST LIFTER LEAKDOWN RATE

REINSTALL

2.24 CRANKSHAFT BALANCER

REMOVE

CLEAN AND INSPECT

REINSTALL

2.25 COOLANT PUMP

REMOVE

DISMANTLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

Techline

2.26 CRANKSHAFT FRONT OIL SEAL

REPLACE

2.27 ENGINE MOUNTS

CHECK

REMOVE

REINSTALL

3. MAJOR SERVICE OPERATIONS

3.1 ENGINE ASSEMBLY

REMOVE

DISASSEMBLE

REASSEMBLE

REINSTALL, SET-UP AND TESTING

3.2 CAMSHAFT LOBE LIFT

MEASURE

3.3 OIL PAN

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

3.4 ENGINE FRONT COVER

REMOVE

CLEAN AND INSPECT

REINSTALL

CRANKSHAFT FRONT SEAL -

REINSTALL

3.5 ENGINE FLYWHEEL/FLEXPLATE

REMOVE

CLEAN AND INSPECT

REINSTALL

3.6 ENGINE FLYWHEEL RING GEAR

REPLACE

3.7 CRANKSHAFT SPIGOT BEARING

REPLACE

3.8 ENGINE REAR COVER

REMOVE

CLEAN AND INSPECT

REINSTALL

CRANKSHAFT REAR SEAL - INSTALL

3.9 OIL PUMP, PUMP SCREEN AND

DEFLECTOR

REMOVE

OIL PUMP DISASSEMBLE

CLEAN AND INSPECT

OIL PUMP REASSEMBLE

REINSTALL

3.10 TIMING CHAIN AND SPROCKETS

REMOVE

CLEAN AND INSPECT

REINSTALL

3.11 CAMSHAFT

REMOVE

CLEAN AND INSPECT

REINSTALL

3.12 PISTON, CONNECTING ROD AND

BEARING

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

3.13 CRANKSHAFT AND BEARINGS

REMOVE

CLEAN AND INSPECT

REINSTALL

3.14 ENGINE BLOCK PLUGS

REMOVE

REINSTALL

3.15 CYLINDER BLOCK

CAMSHAFT BEARINGS - REPLACE

CYLINDER BLOCK CLEAN, INSPECT

AND MEASURE

CYLINDER BORING AND HONING

3.16 THREAD REPAIR

GENERAL INFORMATION

GENERAL THREAD REPAIR

CYLINDER HEAD BOLT HOLE

THREAD REPAIR

MAIN CAP BOLT HOLE THREAD

REPAIR

3.17 THREAD REPAIR SPECIFICATIONS

ENGINE BLOCK - FRONT VIEW

ENGINE BLOCK - REAR VIEW

ENGINE BLOCK - LEFT SIDE VIEW

ENGINE BLOCK - RIGHT SIDE VIEW

ENGINE BLOCK - BOTTOM VIEW

ENGINE BLOCK - TOP VIEW

CYLINDER HEAD - TOP VIEW

CYLINDER HEAD - END VIEW

CYLINDER HEAD – EXHAUST

MANIFOLD SIDE VIEW

CYLINDER HEAD - INTAKE MANIFOLD

SIDE VIEW

4. DIAGNOSIS

4.1 BASIC ENGINE MISFIRE DIAGNOSIS

GENERAL INFORMATION

DIAGNOSTIC PROCEDURE

4.2 ENGINE NOISE DIAGNOSIS

4.3 VALVE TRAIN DIAGNOSIS

GENERAL INFORMATION

DIAGNOSTIC PROCEDURE

DIAGNOSTIC TABLE

4.4 OIL CONSUMPTION DIAGNOSIS

4.5 OIL PRESSURE DIAGNOSIS

4.6 OIL LEAK DIAGNOSIS

5. SPECIFICATIONS

6. TORQUE WRENCH SPECIFICATIONS

7. SPECIAL TOOLS

1. GENERAL DESCRIPTION

The 2003 Model Year 5.7 litre, GEN III, V8 engine (production option LS1), carries over from earlier build engines,

except for minor changes, detailed here. Minor changes to some service operations have also been made, that

reflect a modified approach to various tasks. As a result, the procedures contained in this Section have been

reproduced in full and should be followed when service operations are carried out on MY 2003 GEN III V8 engines.

Note that some vehicle specifications may include manual transmission and/or automatic transmission fitment, in

addition to left and right hand drive. Unless noted otherwise, the information contained within this Section is

appropriate for all vehicle specifications.

1.1 SERVICE INFORMATION

In summary, the following reflects changes that have been introduced with the 2001 Model Year release of the

GEN III V8 engine.

1. The engine accessory drive belt, coolant pump pulley is an integral part of the coolant pump and is not serviced

separately.

2. The pistons and piston rings have been through several changes, involving different piston skirt treatments and

the second compression piston ring design has also changed. For these reasons, it is vital that only parts listed

in the current PartFinder® CD are fitted to this engine.

3. The cylinder head gasket material has changed from a graphite layered design to a laminated steel type.

Figure 6C3-1-1 GEN III V8 Engine View Left Hand Side

(Power Steering Pump and Air Conditioning Compressor Not Shown)

Figure 6A3-2 - Lower Front of Engine

Legend

1. Tube – Oil Level Indicator

2. O-ring Seal – Oil Lever Indicator Tube

3. Bolt – Valve Lifter Guide

4. Guide – Valve Lifter

5. Lifter – Valve

6. Engine Block

7. Oil Seal – Crankshaft Rear

8. Bolt – Engine Rear Cover

9. Cover – Engine Rear

10. Gasket – Engine Rear Cover

11. Plug – Engine Block Rear Oil Gallery

12. Crankshaft Sprocket

13. Chain – Camshaft Timing

14. Oil Pump Assembly

15. Bolt – Oil Pump Assembly

16. Gasket – Engine Front Cover

17. Engine Front Cover

18. Oil Seal – Crankshaft Front

19. Balancer – Crankshaft

20. Bolt – Crankshaft Balancer

21. Bolt – Engine Front Cover

22. Camshaft

23. Retainer – Camshaft

24. Sprocket – Camshaft

25. Locating Pin – Camshaft Sprocket

26. Bolt – Camshaft Sprocket

27. Bolt – Camshaft Retainer

28. Bearings – Camshaft

29. Coolant Pump

30. Bolt – Coolant Pump

31. Carrier Gaskets – Coolant Pump

32. Indicator – Oil Level

33. Bolt – Oil Level Indicator Tube

Figure 6A3-3 - Lower Engine Assembly

Legend

1. Bolt – Camshaft Position Sens or

2. Camshaft Position Sensor

3. Oil Pressure Sensor

4. Engine Cylinder Block

5. Piston Rings

6. Piston and Connect i ng Rod Assembly

7. Connecting Rod Bearings

8. Connecting Rod Cap

9. Bolt – Connecting Rod

10. Crankshaft Oil Deflector

11. Engine Flywheel – Manual Trans.

12. Engine Flexplate – Automatic Trans.

13. Screen and Pipe – Oil Pump Pick-up

14. Screw – Oil Pump Pick-up to Pump

15. Nut – Oil Deflector and Oil Pump Pick-up

16. Bolt – Oil Pan Baffl e

17. Baffle – Oil Pan

18. Tube – Oil Transfer

19. Gasket – Oil Transfer Tube

20. Gasket – Oil Pan

21. Bolt – Engine Flexplate

22. Screw – Oil Pan Closeout Cover (RHS)

23. Cover – Oil Pan Closeout (RHS)

24. Cover – Oil Pan Closeout (LHS)

25. Screw – Oil Pan Closeout Cover (LHS)

26. Plug – Oil Pan Gallery

27. Bolt – Oil Pan Transfer Tube

28. Oil Pan

29. O-Ring Seal – Oil Transfer Cover Stud

29a. Gask et – Oil Transfer Cover

30. Cover – Oil Transfer

31. Nut – Oil Transfer Cover

32. Valve – Oil Bypass

33. Adaptor – Oil Filter

34. Oil Filter

35. Plug – Oil Drain

36. Bolt – Crankshaft Bearing Cap Side

37. Caps – Crankshaft Main Bearing

38. Stud – Main Bearing Cap

39. Bolt – Main Bearing Cap

40. Bearings – Crankshaft Main

41. Bearings – Crankshaft Main Thrust

42. Plug – Rear Crankshaft

43. Bush – Manual Transmission Spigot

44. O-Ring Seal – Oil Pump Pick-up

45. Crankshaft

46. Key – Crankshaft Sprocket

47. Plug – Engine Block Front Oil Gallery

48. Plug – Cylinder Block in Unused Hole

Figure 6A3-4 - Cylinder Head/Upper Engine

Legend

1. Bolt – Valve Rocker Arm Cover

2. Grommet – Valve Rocker Arm Cover

3. Bolt – Cylinder Head (Short)

4. Bolt – Cylinder Head (Medium)

5. Cylinder Head

6. Bolt – Cylinder Head (Long)

7. Collets – Valve Stem Keys

8. Cap – Valve Spring

9. Spring – Valve

10. Oil Seal/Valve Spring Shim – Valve Stem

11. Valve

12. Gasket – Exhaust Manifold

13. Manifold – Exhaust

14. Heat Shield – Exhaust Manifold

15. Bolt – Exhaust Manifold Heat Shield

16. Pushrod

17. Sensor – Coolant Temperature

18. Bolt – Valve Rocker Arm

19. Arm – Valve Rocker

20. Support – Valve Rocker Arm Pivot

21. Gasket – Cylinder Head

22. Gasket – Valve Rocker Arm Cover

23. Cap – Oil Fill Tube

24. Cover – Valve Rocker Arm

25. Tube – Oil Fill

26. Assembly – Ignition Coil and Bracket

27. Stud – Ignition Coil Bracket Assembly

28. Screw – Ignition Coil Bracket Assembly. Rear on each side

29. Bolt – Exhaust Manifold

Figure 6A3-5 - Intake Manifold/Upper Engine

Legend

1. Stud – Fuel Rail to Intake Manifold (4 places)

2. Fuel Rail (with Injectors)

3. Bracket – Fuel Rail Stop

4. Gasket – Throttle Body

5. Bolt – Intake Manifold (10 places)

6. Gaskets – Intake Manifold (8 places)

7. Sensor – Manifold Absolute Pressure (MAP)

8. Intake Manifold

9. Throttle Body

10. Bolt – Throttle Body (3 places)

11. Gasket – Valley Cover

12. Valley Cover

13. Bolt – Valley Cover (10 places)

14. Oil Seal – Knock Sensor (2 places)

15. Knock Sensor (2 places)

16. Knock Sensor Wire Harness

17. Hose – Vapour Vent Tube

18. Stud – Vapour Vent Tube (2 places)

19. Vapour Vent Tube

20. Bolt – Vapour Vent Tube

21. Cover – Vapour Vent (2 places)

22. Gasket – Vapour Vent Tube (4 places)

23. Bracket – Engine Dress Cover, Right Hand Side

24. Nut – Engine Dress Cover Bracket

25. Bracket – Engine Dress Cover, Left Hand Side

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 ‘VF031904500’, is;

• First two numbers (‘03’ = 2003) indicates the

engine model year.

• Next three numbers (‘190’) is the Julian date

(day of the year), the engine was

manufactured.

• Next four numbers are the daily, sequential

build num ber .

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, m anufactured from forged powdered

metal. The engine block is aluminium with cast in

place, cast iron cylinder bore liners. The five

cross-bolted crankshaft bearing caps each have

four ver tical M10 ( 2, 3, 4, a nd 5) and t wo hor izontal

M8 (1 and 6) mounting bolts. Only cylinder honing

is permitted.

The c rank c ase sk ir t length, beari ng c ap width, dec k

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 structural die cast 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 construction 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 eng ine .

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 now a laminated steel

type and feature stainless steel PTFE coated

flanges and lacing. The revised material gaskets

are now common for both right and left hand sides.

Legend

1. Cylinder Head

2. Valve Stem Collets

3. Valve Spring Cap

4. Valve Spring

5. Valve Stem Oil Seal/S him Com binati on

6. Cylinder Head Core P l ugs

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

intake valve seat.

Figure 6A3-10

VALVE TRAIN

Motion is transmitted from the camshaft through

the hydraulic roller valve lifters and tubular

pushrods to the rocker arms. The valve lifter

guides pos ition and r etain the roller h ydraulic valve

lifters. The valve rocker arms for each bank of

cylinders are mounted on pedestals (pivot

supports) . Eac h rocker arm is r etaine d on t he pi vot

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 i ntake valv e head diam eter of 50.8 mm

and exhaust of 39.4 mm .

Valve spr ings are con ical or ‘beeh ive’ in s hape and

made from chromium Silicone wire. The springs

are double shot peened to provide maximum

reliability. The reduced diam eter end coils allo ws a

smaller diameter, lower mass, steel spring retainer

to be used, with s ingle bea d, valve s tem ke ys. 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 ro cker arms are made of inves tment c ast 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 number eight c ranks haft

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 crankshaf t has a drilled 25.4 m m hole through

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

from a reduction in crankshaft weight, this also

achieves engine breathing enhancement at low

speeds.

Figure 6A3-12

A variable radii undercut increases the effective

bearing widths by 0.4 m m each side ( A), c om pared

to a uniform undercut and rolled fillets are utilised

for improved fatigue strength.

Figure 6A3-13

PISTONS AND CONNECTING RODS

The pistons are cast aluminium and have two

compression rings and one oil control ring

assembly fitted. Piston rings are of a thin, low

fric tion desi gn, with t he top r ing loc ate d c lose t o 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 chromium steel 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 pr oces s , us ing the ‘f r actur 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

CAM SHAFT AND DRIVE

A billet st eel, o ne piece c am shaf t is suppor ted b y five bear ings pressed i nto the eng ine bl ock . T he cam shaft has a

machined camshaft sensor reluctor ring incorporated between the fourth and fifth bearing journals. To reduce

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 amshaft (1) is dr iven by a traditiona l 9.52 mm

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 tensi oner is req uired.

Figure 6A3-15

INTA KE MANIFOLD

The intake manifold (1) is a one piece composite

design that incorporates metal threaded inserts for

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

and throttle body.

The intak e m anifold is sealed t o the c ylinder he ads

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

installe d in the snap f it MAP sensor housing th at is

mounted at the rear of the manifold and sealed by

an O-ring seal (not shown).

There are no coolant passages within the intake

manifold.

Figure 6A3-16

EXHAUST MANIFOLD

The exhaust manifolds are one piece, of high

temperature silicone molybdenum cast iron and

direct exhaust gases from the combustion

chambers to the exhaust system.

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.

Figure 6A3-19

Legend

1. Accessory Drive Belt, Automatic Tensioner

2. Water Pump Pulley

3. Power Steering Pump Pulley

4. Engine Accessory Drive Belt

5. AC Generator

6. Accessory Drive Belt, Idler Pulley

7. Crankshaft Balancer Pulley

8. Air Conditioning Compressor Drive Belt Automatic Tensioner

9. Air Conditioning Compressor Drive Belt

10. Air Conditioning Compressor

11. Air Conditioning Compressor 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 igrati on duri ng br ak ing and cor ner ing

manoeuvr es a nd oil is gui ded to the p ick -up s creen

(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 baffle (6), maintains an area around the

pick-up screen to prevent oil starvation/aeration.

A crankshaft oil deflector (7) mounted to the main

bearing caps controls windage, scrapes oil from

the crankshaft, facilitates drainback and reduces

aeration.

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

aluminium carrier gasket with silicone used as the

sealing age nt.

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

change to stop oil wicking along the studs,

resulti ng in an oi l l eak from this are a. As the o il pan

requires chamfers to be machined around each of

the two stud holes, fitment of the O-rings to earlier

build engines without the machined chamfers, is

not possible without also changing the oil pan.

Figure 6A3-20

1.4 ENGINE LUBRICATION SYSTEM

OIL PUMP

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

engine b lock and driven directly by the crankshaft sprock et. The pump gears rotate and draw oil from the oil pan

sump thr ough a pick - up screen a nd pip e. The oil is pr ess urised as it pass es thro ugh the pump and is s ent throug h

the engine block oil galleries.

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

range. Pr essurised o il is dir ected throug h the lower ga llery to the full flow oil filter where harmf ul contaminant s 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

2. Oil Pump Housing

3. Pressure Relief Valve

4. Spring – Pressure Relief Valve

5. Plug

6. Drive Gear

7. Bolt – Cover

8. Cover

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

assem bly. From ther e, oil is then dir ected t o the crank shaft and c ams haft bear ings. O il that has entered t he upper

ma in oil galler ies als o pr es suris es the va lve l ifter assem blies and is then pum ped throug h the pus hrods to lu bric ate

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 inclu des a PTFE (Teflon®) centre lip (1) to

minim ise a major caus e of rear m ain oil seal leak s.

The anti-friction pr oper t ies of the PT FE r educes the

chances of “chok ing” or build-up of degraded oi l 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 PTFE 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 s eal m ay be lubr icat ed spar ingl y

to ease installation.

Figure 6A3-23

POSIT IVE CR ANKCASE VENT IL ATION 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 fr om 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 throug h an externally mounte d,

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 manoeuvr es. Dur ing sust ained m aximum

lateral accelerations, the outboard rocker cover (1)

may fill with oil.

The “dual draw” system “passively switches”,

allowing the PCV v alve to d r aw on th e roc ker c over

with the leas t resistance . This res ults in the s ystem

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.

Sectione d view shown is look ing rear ward 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.

• W hen components are rem ove d f or se rv ic e, they shou l d be mark ed, or gan is ed or r etain ed in a s pec if ic ord er f or

reassem bly. 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 co a tin g of c lean e ngi ne oil s hou ld be ap pl ie d to fric tion areas dur in g ass embl y, as proper lubricati o n wil l

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

REPL ACING ENG INE G ASKET S

• 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 requir i ng lubric ation will be ide nt if ied in th e servic e proced ur e.

− 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 a mount 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 joi nt com pound is a pliable s ealer th at does n ot com pletel y harden. Th is type of sealer is used where tw o

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 i ns ide of any bolt ho les . Do not al low the seal er to e nter a ny blind t hr ead ed hol es, as it may

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 loc atio ns where a pipe s ea la nt type mater ial suc h as Loc tit e 56 5 ( or other c om merc ial equivalen t) is to

be used, are:

• Engine block coolant and oil gallery plugs.

• Oil pressure sensor threads.

• Engine block oil pan surface.

RTV Sealer

• Room T emperature Vulc anising ( RTV) seala nt harden s when expose d to air. T his type of s ealer is used where

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

• Do not use RT V sealant in areas where ex treme tem peratures are exper ienced. T hese areas incl ude: 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 eliminator or thread sealant, hardens in the absence of air. This type sealer is used where

two rigid parts (s uch as c astings ) ar e ass embled toget her or wher e f as teners ar e subj ec ted to vibr at ion or wh ere

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

and dry.

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

• Do not allow the sealer to enter an y blind threaded holes, as it m ay prevent the bolt from clamping pr operly or

cause damage when tightened.

IMPORTANT: Anaerob ic s ealed j oi nts that are par t ia lly torqued and a ll o wed to c u re m or e than f ive 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.

Examples where thread locking sealants such as Loctite 242 or Loctite 272 (or other commercial 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.

TO OL S AND EQUIPM ENT

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 operat ions 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, wor k area.

− A suitable parts cleaning tank.

− A compressed air supply.

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

− An adequate set of hand tools.

− Approved engine repair stand.

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

FASTENERS

Fasteners are central to the reliable operation of

any engine and the GEN III V8 engine is no

exception.

Whenever any bolt or any other threaded

component is removed from the engine, it is

necessary 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 ext ent when hot with this materia l (ins et ‘ A’)

when compared to cast iron.

If a bolt or other threaded component is removed

before the engine is allowed to cool to at least 50°

C, threads could be pulled from the cylinder block

or cylinder head.

Also, DO NOT use impact tools to remove bolts

during engine disassembly. While this may be

common practice with cast iron engine

components, use of these tools is more likely to

pull the aluminium threads in the cylinder 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

develope d in the fas tener d ue to its stretc h is cal le d

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

call ed “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 a vailabl e to deve lop str etch (or tension) i n

the fastener and clamp load in the joint.

Therefore, a slight variation in friction in the thread

or under th e b olt he ad, r es ults in a wide v ariat io n i n

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 ar e “Torque to Yi eld” fastener s, MUST be

replaced after loosening.

Figure 6A3-27

2. MINOR 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 alo ng dipstick .

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

7. W hen topping up th e engin e oil, al low appr oximatel y 15 m inutes for the oil added to f ully dra in into t he oil pan.

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

2.2 ENGINE OIL - CHANGE

NOTE 1: Quicker and more complete draining will occur if the engine oil is at operating temperature. However, care

must be taken to avoid scalding from the hot oil.

NOTE 2: W hile the oil pan is alum inium, it is fitted with a s teel thread inser t to incr ease durabi lity of the thr ead 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 Section 0A GENERAL 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 mm ring s p ann er, r emove t he drai n

plug, tak ing care to avoid sc alding 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 m aterial. The drain plug O-ring

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

Tighten the drain plug to the correct torque

specification.

ENGINE OIL PAN DRAIN PLUG

TORQUE SPECIFICATION 25 Nm

8. Reinstall the oil pa n under-tra y and tighten th e

four bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 32 Nm

9. Lower the vehicle and fill the crankcase with

the required am ount of 10W 30 SJ ILSAC GF2

engine oil.

NOTE: If this oil is unavailable, a 20W50 SJ or

15W/40 SJ engine oil should be used.

Figure 6A3-28

ENGINE OIL CAPACITY

Without Oil Filter

Change 5.2 litres

With Oil Filter Change 5.7 litres

NOTE: Synthetic oils of this viscosity are also an

acceptab le eng in e lubr icant.

10. Start the engine and check for oil leaks.

2.3 ENGINE OIL FILTER & ADAPTOR

LT Section No. – 01-500

NOTE: The oil filter should be replaced at the time or distance intervals, specified in the Owner’s Handbook or

whenever the engine oil is changed.

REPLACE

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

2. Raise the vehicle front and rear to maintain a level attitude and support with safety stands. This is to ensure

complete draining. Refer to Section 0A GENERAL 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 Sec ti on.

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

available tool, taking care to avoid being

scalded wit h 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 f ilter ad aptor t hreads

for damage.

8. If removed, reinstall the oil filter adaptor and

tighten to the correct torque specification.

OIL FILTER ADAPTOR

TORQUE SPECIFICATION 55 Nm

9. Sm ear some new engine oil o nto the new filter

seal, then install filter assembly to engine.

10. Tighten oil filter to the correct torque

specification.

ENGINE OIL FILTER

TORQUE SPECIFICATION 30 Nm

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

four bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 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 ti on f or the r ec om mended

procedure.

13. Start the engine and check for oil leaks.

Figure 6A3-29

2.4 ENGINE OIL PRESS URE - CHECK

1. Ensur e that en gi ne is at op er atin g t emperatur e.

Driving a cold vehicle for 15 minutes, should be

sufficient to normalise the temperature.

2. Remove oil filter; refer 2.3 ENGINE OIL

FILTER & ADAPTOR, in this Section.

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

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

top up as re quired. Refer to 2. 2 ENG INE O IL –

CHANGE, in this Section.

5. Install commercially available, accurate oil

pressur e gau ge (c ap ab le of r eading 800 kPa or

higher) and suitably rated pressure hose, to

adaptor J 42907.

6. Start the engine and check the oil pressure

with the engin e runnin g 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 90 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.

Figure 6A3-30

8. After completing the pressure check, stop the engine and remove the oil pressure gauge and adaptor

assembly.

9. Install the oil filter. Refer 2.3 ENGINE OIL FILTER & ADAPTOR, in this Sec t ion.

10. Top up engine oil level as required.

2.5 COMPRES SION 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 Engine Control (EFI) relay X4, located in

the underhood electrical centre.

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. Ag ai n, recor d each readin g.

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 highest cylinder. No cylinder

should read less than 690 kPa. For example, if the highest pressure in any one cylinder is 1035 kPa, the lowest

allowable pressure for any other cylinder would be 725 kPa. (1,035 x 70% = 725).

NORMAL - Compression builds up quickly and evenly to the specified compression for each cylinder.

PISTON RINGS LEAKING - Compression is lo w on the first stroke. Compression then builds up with the following

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

VALVES LEAKING - Compression is low on the first stroke. Compression usually does not build up on the following

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

CYLINDER HEAD GASKET LEAKING - If two adjacent cylinders have lower than normal compression and

injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking

between the cylinders.

2.6 ENGINE DRIV E BELTS – REPLACE

LT Section No. – 01-003

1. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

2. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing t he int ak e hose (4 ) to the MAF s ensor

and the throttle body. Remove the hose (4)

from the engine.

Figure 6A3-32

ENGINE ACCESSORY DRIVE BELT

1. Using a 15 mm ring spanner, rotate the

acces sory autom atic 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 i nstallat ion to ens ure that the b elt is

correctly aligned on all pulleys.

6. Reinst all the engine dr ess cover, securing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 10 Nm

7. Start the eng ine to ensure corr ec t operat ion .

Figure 6A3-33

A IR CONDITIONING COMPRESSOR BELT

NOTE: The accessory drive belt must be removed

first to allow access to this belt. Refer to the

previous operation for details.

1. Raise the vehicle and support with safety

stands. Refer to Section 0A GENERAL

INFORMATION.

2. Remove the four bolts securing the oil pan

under-tray.

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

belt tensioner in the direction shown, using a

15 mm set spanner, to relieve belt tension.

4. While using an assistant to maintain the

tensioner in the required position, remove the

drive belt from the pulleys.

NOTE: An alternative to using an assistant, would

be to secure the spanner using tie wire.

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

inspect the belt for damage.

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

the direction indicated, install the drive belt

over the pulleys, routing the belt correctly, as

shown.

7. Inspect the i nstallat ion to ens ure that the b elt is

correctly aligned on all pulleys.

8. Reinstall the accessory drive belt as described

in the previous operation.

9. Start the eng ine to ensure corr ec t operat ion .

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

bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 Nm

11. Lower the vehicle and test for correct

operation.

Figure 6A3-34

2.7 ACCESSORY BELT IDLER PULLEY

LT Section No. – 01-020

REPLACE

1. Remove the e ngine acces sory drive belt . Refer

to 2.6 ENG INE DRIV E BELT S – REPL ACE, 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 t ighten

to the correct torque specification.

ACCESSORY BELT IDLER PULLEY

TORQUE SPECIFICATION 50 Nm

5. Install t he engin e acces sor y driv e bel t. Ref er to

2.6 ENGINE DRIVE BELTS – REPLACE, in

this Section for the necessary procedure.

Figure 6A3-35

2.8 A/C BELT IDLER PULLEY

LT Section No. – 01-020

REPLACE

1. Raise the vehicle and support with safety

stands. Refer to Section 0A GENERAL

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

6A3-34, 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 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 t ighten

to the correct torque specification.

A/C COMPRESSOR BELT

IDLER PULLEY BOLT

TORQUE SPECIFICATION 50 Nm

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

2.6 ENGINE DRIVE BELTS – REPLACE, in

this Section for the necessary procedure.

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

bolts to the correct torque specification.

OIL PAN UNDER-TRAY BOLT

TORQUE SPECIFICATION 30 Nm

10. Lower the vehicle and test for correct

operation.

Figure 6A3-36

2.9 ACCESSORY BELT TENSIONER

LT Section No. – 01-020

REPLACE

1. Remove the e ngine acces sory drive belt . Refer

to 2.6 ENG INE DRIV E BELT S – REPL ACE, in

this Section for the necessary procedure.

2. Remove the tensioner pulley bracket retaining

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

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

mounting bolts.

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

torque specification.

ACCESSORY BELT TENSIONER

BOLT TORQUE SPECIFICATION 50 Nm

5. Install t he engin e acces sor y driv e bel t. Ref er to

2.6 ENGINE DRIVE BELTS – REPLACE, in

this Section for the necessary procedure.

Figure 6A3-37

2.10 A/C BELT TENSIONER

LT Section No. – 01-020

REPLACE

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

belt tensioner in the direction shown in Figure

6A3-34, 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 from the pulleys but leave hanging on

the crankshaft pulley.

NOTE: An alternative to using an assistant, would

be to secure the spanner using tie wire.

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

compressor drive belt tensioner, then remove

the assembly.

4. Install the tensioner assembly and the

mounting bolt.

5. Tighten the tensioner mounting bolt to the

correct torque specification.

A/C COMPRESSOR BELT TENSIONER

BOLT TORQUE SPECIFICATION 25 Nm

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

2.6 ENGINE DRIVE BELTS – REPLACE in

this Section for the necessary procedure.

Figure 6A3-38

2.11 OIL PRESSURE SENSOR

LT Section No. – 02-000

REPLACE

1. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

Figure 6A3-39

2. Release the wiring harness connector locking

tang from the oil pres sure s ensor, then r emove

the connector (2) from the sensor.

Figure 6A3-40

3. Using Tool N o. J 41712 and suitab le 3/8” dri ve

socket equipment, remove oil pressure sensor

(1) from the left hand rear of the engine

cylinder bl oc k.

4. Prior to reinstallation apply Loctite 565 sealant

(or equivalent) to the cleaned oil pressure

sensor threads.

5. Reinstall the oil pressure sensor (1) and tighten

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

socket equipment, to the correct torque

specification.

OIL PRESSURE SENSOR

TORQUE SPECIFICATION 20 Nm

6. Reinst all the engine dr ess cover, securing with

the four decorative nuts and tightening to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 10 Nm

7. Start the eng ine to ensure corr ec t operat ion .

Figure 6A3-41

2.12 MANIFOLD ABSOLUTE PRESSURE SENSOR

LT Section No. – 02-000

REPLACE

1. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

Figure 6A3-42

2. Release the wiring harness connector locking

tang (1) from the manifold absolute pressure

(MAP) se nsor , then rem ove the c onnec tor 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 sens or, ensur ing that the locking t ab is in

place.

7. Reinst all the engine dr ess cover, securing with

the four decorative nuts and tighten to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 10 Nm

8. Start the eng ine to ensure corr ec t operat ion .

Figure 6A3-44

2.13 FUEL SYSTEM PRESSURE RELIEF

1. After removing the cover from the underhood

electrical centre, remove the fuel pump relay,

X16 (1).

2. With the throttle closed, crank the engine.

NOTE: The engine m ay 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

LT Section No. – 00-375

REMOVE

NOTE: Unless components such as the throttle body, fuel injection rail and/or injectors are to be removed

individually, then it is recommended that the com plete intake manifold assembly be rem oved, as described in this

service operation.

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES befor e disc onn ec tin g the battery.

2. Drain the cooling system. Refer to Section 6B3 ENGINE COOLING - GEN III V8 ENGINE.

3. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

5. De-pressurise fuel rail. Refer to

2.13 FUEL SYSTEM PRESSURE RELIEF, in

this Section.

Figure 6A3-46

6. Using quick connect release Tool No. 7371

(not shown in Figure 6A3-47), install over fuel

line .

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

push on Tool 7371 to release the quick

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

on the quick connect and remove.

8. 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

9. Disconnect wiring harness connector (1) from

the Intake Air Control (IAC) motor, at the

throttle body (3).

10. Disconnect the wiring harness connector (2)

from the Throttle Position (TP) sensor at the

throttle body (3).

Figure 6A3-48

11. Disconnect the cruise control cable (1) (if fitted) from the stud (2) on the throttle body valve lever (3), then

remove the outer cable (8) from the retainer bracket (4). Refer Figure 6A3-49.

12. Lift the throttle cable (5) from the clip at the f uel rail crossover pipe (6), then lift the cable (5) from the retainer

bracket (4).

13. Remove the inner throttle cable (7) from the throttle body valve lever (3).

14. Set the cable/s to one side.

Figure 6A3-49 – (RHD Shown, LHD Similar)

15. Disconnect the fuel injector wiring harness

connectors (1) from the right bank of fuel

injectors (4 places).

16. 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

17. Disconnect the fuel injector wiring harness

connectors (1) from the left bank of fuel

injectors (4 places).

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

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

remove the wiring harness connector (3).

19. Remove the wiring harness c onnector from the

canister purge valve (4).

20. Remove the harness securing clips from the

fuel rail br ackets ( 5) and set the harness to on e

side.

Figure 6A3-51

21. Disconnect the wiring harness connector (1)

from the MAP sensor , loc ated at t he rear of the

intake manifold.

22. Remove the knock sensor patch harness

connector retaining clip (3) from the PCV hose

and disconnect the wiring harness connector.

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

valve grommet (5) (left bank).

Figure 6A3-52

24. Remove the f resh air hose from the front f itting

of the rocker cover and the throttle body.

Figure 6A3-53

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

heat conducting strap (2) from the front right

hand vapour pipe screw (3).

26. Remove the PCV valve hose from the throttle

body and right hand rocker cover, rear fitting.

27. 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

28. Remove the engine coolant, vapour vent hose

from the throttle body and the vapour vent

pipe.

Figure 6A3-55

29. Remove the engine coolant vapour vent outlet

hose (1) from the throttle body and left hand

radiator tank.

Figure 6A3-56

30. Remove the evaporative (EVAP) canister

purge valve tube from the purge valve and the

throttle body.

Figure 6A3-57

31. Remove the EVAP canister purge valve and

bracket from the intake manifold.

Figure 6A3-58

32. Progressively loosen the 10 intake manifold

retaining bolts (1), working diagonally from

outside to inside.

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

two, left rear bolts and set to one side.

Figure 6A3-59

34. Carefully bump the intake manifold assembly

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

engine.

Figure 6A3-60

35. 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 Absolute Pressure

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

the intake manifold by twisting back and forth

while pulling on the sensor.

2. Check the silicone 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 st uds (4) sec uring the fuel r ail 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 SERVICE

OPER ATION S – GEN III V8 ENGINE.

Figure 6A3-65

CLEAN AND INSPECT

1. After cleaning the intake manifold in a suitable solvent, dry off using compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

2. Ensure that the intake m anifold gask et grooves and v acuum passages in the rea r of the intak e manif old 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 (MAP) Sensor

If removed, install the MAP sensor as follows:

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

seated correctly on the sensor.

2. Install the Manifold Absolute Pressure (MAP)

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

intake manifold by pushing the sensor into the

fitting. If necess ary appl y a sm ear of petrole um

jelly (Vaseline™ or equivalent).

Figure 6A3-66

Fuel Rail and Injectors

1. Lubricate NEW injector O-ring seals with c lean

engine oil.

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

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

intake manifold, pressing evenly on each side

until the injectors are all seated in their bores.

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

Loctite 24 2 (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 10 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

STUDS TORQUE SPECIFICATION 5 Nm

Figure 6A3-67

Throttle Body

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

the intake m anif old.

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

REINST ALL

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 the cleaned

threads of the 10 intake manifold attaching

bolts (2).

3. Install all intake manifold bolts (2), including the

two at the left han d rear, als o securing t he fuel

rail stop bracket (3).

CAUTION: Do not overlook installing the fuel

stop bracket (3). The stop bracket serves as a

protective shield fo r 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 i ntak e m anifold bo lts in t wo st ages,

in the sequence shown, to the correct torque

specification.

INTAKE MANIFOLD BOLTS

TORQUE SPECIFICATION Stage 1 – 5 Nm

Stage 2 – 10 Nm

NOTE: The f uel stop brac k et 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 det aile d:

a. Attach all cable fittings.

b. W ith the outer cab le adjus ter un lock ed, ap pl y a

tension to t he a dj us ter, un ti l the thro ttl e c am (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 f ollo ws:

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 n uts and tighten to the correct torque

specification.

ENGINE DRESS COVER DOME

TORQUE SPECIFICATION 10 Nm

9. Fill the cooling system. Refer to

Section 6B3 ENGINE COOLING - GEN III V8

ENGINE.

10. Start engine, check for leaks and normal

operation.

2.15 VAPOUR VENT PIPE

LT Section No. – 00-249

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects

certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY

DISCONNECTION PROCEDURES before

disconnecting the battery.

2. Drain the cooling system. Refer to

Section 6B3 ENGI NE COO LING - GEN III V8

ENGINE.

3. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. De-pressurise fuel rail. Refer to

2.13 FUEL SYSTEM PRESSURE RELIEF, in

this Section.

5. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

Figure 6A3-76

6. Remove intake manifold. Refer

2.14 INT AKE M ANIFOLD, in this Section.

7. Remove the wiring harness connector (1) from

the knock sensor patch harness (2).

Figure 6A3-77

8. If required, 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 (bold 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 (1).

Figure 6A3-79

REINST ALL

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 hea ds .

3. Install the vapo ur 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 th e vap our vent hos e to the t hrott le bod y

and install the hos e clamp sec urel y.

Figure 6A3-81

2.16 ENGINE VALLEY COVER

LT Section No. – 02-000

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES befor e disc onn ec tin g the battery.

2. Drain the cooling system. Refer to Section 6B3 ENGINE COOLING - GEN III V8 ENGINE.

3. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. De-pressurise fuel rail. Refer to

2.13 FUEL SYSTEM PRESSURE RELIEF, in

this Section.

5. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

6. Remove intake manifold. Refer

2.14 INT AKE M ANIFOLD.

7. Remove vapour vent pipe. Refer

2.15 VAPOUR VENT PI PE .

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 wirin g har ness

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

REINST ALL

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 ‘1’ in Figure

6A3-86).

2. Fit a NEW gasket to the valley cover and install cover to the engine (refer to Figure 6A3-85).

3. Install valley cover bolts and tighten to the correct torque specification.

ENGINE 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 V ALVE ROCKER ARM COVER

LT Section No. – 00-050

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects

certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY

DISCONNECTION PROCEDURES before

disconnecting the battery.

2. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

Figure 6A3-87

3. For the right hand rocker cover, remove the

fres h air hose f rom the front fitting of the r ock er

cover and from the throttle body.

Figure 6A3-88

4. Remove the PCV hose connection from the

rear f itting at t he end of the rock er cover, be ing

removed.

Figure 6A3-89

5. Using quick connect release Tool No. 7371

(not shown in Figure 6A3-90), install over fuel

line.

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

push on Tool 7371 to release the quick

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

on the quick connect and remove.

7. Disconnect the vapour line connector (2) from

the EVAP purge valve (3).

IMPORTANT: Cap the fuel line fittings and plug the

holes after separating the fuel lines to prevent fuel

leaking and/or dirt and other contaminants from

entering the fuel system.

Figure 6A3-90

8. Remove the spark plug leads.

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

lead. T wist the boo t firs t to break the seal, th en 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 r emoved, then l ift the

ignition coils, wiring and bracket from the

engine.

NOTE: The rear attaching bolt on each coil

assembly (arrow) is a conventional screw and not a

stepped stud. Fitment of this screw in the correct

position on reassembly is important to avoid

possible chaffing.

Figure 6A3-92

11. Remove the 4 valve rocker cover bolts, then

remove the cover and gasket from the c ylinder

head.

NOTE: Do not r em ove the oil f ill tu be from the r ight

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

dam age will occ ur on rem ova l.

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 rocker cover in a suitable solvent and dry off with compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

2. Inspect the ventilation system passages for restriction.

3. Inspect the rocker cover gasket groove for damage.

4. Inspect the ignition coil mounting boss threads for damage.

REINST ALL

Reinstallation of the rocker cover is the reverse to

the removal procedure except for the following

items.

1. If the o il f i ll tub e ( 2) was r e moved f r om the rig ht

hand roc ker cover ( 3), it m ust be rep laced 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 lock ed into the

correct position.

4. Install the o il fill cap ( 1), rotatin g clock wise unti l

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 COVER 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 , left hand c oil brac ket f ast ener is a

plain screw and not a stepped stud as are the

others. Fitm ent 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 V ALVE ROCKER ARMS AND PUSH RODS

LT Section No. – 00-050

NOTE: The following fasteners MUST be replaced ( ! )

when performing this operation:

! Rocker arm retaining bolts.

REMOVE

NOTE: W hile s ome vie ws may show a cylinder head t hat is n ot s p ec if ic to th e o n e r eq uired, unl es s no ted, i t c an b e

assumed that the operation is the same for either cylinder 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

mechanis m com ponents in a su itable rac k to avoid

being mixed. This will ensure that parts reinstalled

will be in the same relationship as on removal.

2. Rem ove all t he rock er arm bolts on the s pec ific

cylinder hea d.

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.

REINST ALL

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 reduce the ef fort require d to turn the eng ine

over by hand, remove the spark plugs, taking

note of the following;

a. The engine coolant is to be 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 m aterial

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 finger into the spark plug hole

will determine if the piston is rising on the

compression stroke, by the compressed air

escaping. Finally, a suitable piece of wire can be

used as shown, to determine when the piston is at

TDC.

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

4, 3 and c ylinder num bers are 1, 3 , 5, 7, on th e left

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

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

tighten the following rocker arm bolts to the

correct torque specification:

ROCKER ARM BOLT 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:

ROCKER ARM BOLT TORQUE SPECIFICATION

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

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

9. Reinstall the rocker cover/s. Refer

2.17 VALVE ROCKER ARM COVER, in this

Section, for the necessary procedure.

Figure 6A3-104

2.19 VALVE SPRING AND/OR VALVE STEM OIL SEAL

LT Section No. – 00-075

REPLACE

1. Remove the spark plugs from the cylinder/s

being serviced, taking note of the following;

a. The engine coolant is to be at 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. Ins tall S par k Plug Por t Ada ptor Tool J 227 94 or

a comm ercial equiv alent to the spark plug hole

of the cylinder being serviced.

5. Using suitable adaptors, attach a compressed

air line to J 22794 and app ly a constant su pply

of compressed air to the cylinder being

serviced.

Figure 6A3-106

6. Compres s one of the valv e s prings , using val ve

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 and spring shim

combination (5) (if being replaced).

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 h ead. No specia l tools are r equired f or

this operation.

Figure 6A3-108

10. Install the valve spring with the smaller wound

coils facing up, then install the spring cap.

11. Compress the spring using Tool No. KD2078

until sufficient space is allowed for the valve

collets to be installed.

12. Install both valve stem collets, using clean

grease or petroleum jelly to retain.

13. Releas e the v al ve spr ing c ompres s or, checking

that both valve stem collets are seated

correctly.

14. Lightly tap the valve stem with a soft faced

hammer to ‘seat’ the valve stem collets.

15. Remove the compressed air supply.

16. Remove the spark plug adaptor, Tool J22794.

17. Install the spark plug, tightening to the correct

torque specification.

SPARK PLUG

TORQUE SPECIFICATION 15 Nm

18. Reverse the removal procedure to complete

this operation.

Figure 6A3-109

2.20 OIL LEVEL INDICATOR AND TUBE

LT Section No. – 00-580

REPLACE

1. Remove the oil level indicator from the tube.

2. Remove the oil level indica tor tube br acket bolt

from the right hand exhaust manifold

3. Remove the tube from the engine, then remove

the O-ring.

NOTE: If the tube is not to be reinstalled

immediately, plug the opening 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 tighte n in two s tages, to th e correct t orque

specification.

OIL LEVEL TUBE RETAINING

BOLT TORQUE SPECIFICATION 25 Nm

7. Install the oil level indicator to the tube.

Figure 6A3-110

2.21 EXHAUST MANIFOLD

LT Section No. – 00-450

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES before disconnecting the battery.

2. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

3. De-pressurise fuel rail. Refer to 2.13 FUEL

SYSTEM PRESSURE RELIEF, in this Section.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

Figure 6A3-111

5. For the right hand side exhaust manifold:

a. Rem ove the eng ine oil l evel ind icator and tube. Ref er to 2. 20 OIL LEVEL INDIC ATOR AND TUBE, in this

Section.

b. Plug the opening in the cylinder block to prevent entry of foreign matter.

6. 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.

7. Raise the front of the vehicle and place on

safety stands. Refer to Section 0A GENERAL

INFORMATION for location of jacking and

support points.

Figure 6A3-112

8. W hile not essential , it is re comm ended 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 ox ygen sensor /s from the ex haust

pipe/s.

Figure 6A3-113

9. Remove the exhaust manifold to exhaust pipe

flange nuts.

10. Lower ve hic l e to the groun d.

11. Remove the spark plugs from the cylinder head

on the exhaust manifold side being removed,

taking note of the following;

a. The engine coolant is to be at 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 m aterial

that may otherwise enter the combustion

chamber.

CAUTION: Wear eye protection to avoid

injury.

e. Continue to remove the spark plugs.

Figure 6A3-114

12. Progressively loosen, then remove exhaust

manifold bolts, working from the outside in to

the centre.

13. Remove ex haust m anifold and gas ket from the

cylinder hea d.

Figure 6A3-115

14. If required, remove the heat shield retaining

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

exhaust manifold (3).

NOTE: While the right hand side exhaust manifold

is shown, the left hand side arrangement is similar.

Figure 6A3-116

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 s tr aig ht e dge and f eel er gau ges, c hec k

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 6A3-117

REINST ALL

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 shie ld was removed , apply an ant i-seize co mpound such as Caltex Kopr -Kote (or equiv alent) to the

cleaned heat shield bolt threads, reinstall the heat shield and bolts to the exhaust manifold and tighten the

retaining bolts to the correct torque specification.

EXHAUST MANIFOLD HEAT SHIELD

BOLT TORQUE SPECIFICATION 9 Nm

2. Apply a 5 mm wide band of Loctite 272 thread sealant (or equivalent), to the threads of the exhaust manifold

mounting bolts.

3. Install a NEW exhaust manifold to cylinder

head gasket, install the manifold and bolts.

4. Tighten the exhaust manifold bolts to the

specified, two stage torque specification,

beginning with the centre two bolts, then

alternate from side to side, to the outside bolts.

EXHAUST MANIFOLD BOLT

TORQUE SPECIFICATION Stage 1 – 15 Nm

Stage 2 – 25 Nm

5. Using a flat punch, bend over the exposed

edge of the exhaust manifold gasket at the

front of the right hand cylinder head and the

rear of the left hand cylinder head.

6. If removed, install t he oxygen sens or/s into t he

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 Service Parts Operations, as Part Number

5613695 and is to be applied to the cleaned

threads of the oxygen sensor.

Figure 6A3-118

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 Caltex

Kopr-Kote (or equivalent) to the cleaned

exhaust pipe flange stud threads.

9. Install and ti ghten the ex haust pipe to m anifold

flange nuts to the correct torque specification.

EXHAUST PIPE FLANGE NUT

TORQUE SPECIFICATION 28 Nm

10. Apply thread sealant such as Loctite 565 (or

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 6A3-119

2.22 CYLINDER HEAD

LT Section No. – 00-075

NOTE: The following fasteners MUST be replaced ( ! )

when performing this operation or have either micro

encapsulation or incorporate a mechanical thread lock ( " )

and should only be used once. If in doubt, replacement is

recommended:

! All M11 cylinder head bolts.

" Threads of the M8 bolts.

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES bef ore dis c onn ectin g the battery.

2. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

3. De-pressurise fuel rail. Refer to

2.13 FUEL SYSTEM PRESSURE RELIEF, in

this Section.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

5. Remove the e ngine acces sory drive belt . Refer

to 2.6 ENGINE DRIVE BELTS, in this Section.

6. Remove intake manifold. Refer to

2.14 INT AKE M ANIFOLD, in this Section.

7. Remove vapour vent pipe. Refer to

2.15 VAPOUR VENT PI PE , in this Section.

8. Remove va lve r oc k er arm cover on t he cylind er

head to be removed. Refer to

2.17 VALVE ROCKER ARM COVER, in this

Section.

9. 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 Secti on.

Figure 6A3-120

10. Remove the spark plugs from the cylinder head

being removed, noting the following:

a. The engine coolant is to be at 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 6A3-121

11. 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.

12. Remove the exhaust manifold on the cylinder

head to be removed. Refer to 2.21 EXHAUST

MANIFOLD, in this Sec ti on .

13. For the right hand cylinder head:

a. Remove the bolt securing the automatic

transmission dipstick tube bracket bolt (if

fitted).from the rear of the cylinder head

Figure 6A3-122

b. Remove the bolt securing the powertrain

harness ground strap from the front of the

right hand cylinder hea d.

Figure 6A3-123

14. For the left hand cylinder head:

a. Place a drain tray beneath power steering

pump assembly.

b. Remove the p ower steer ing f luid 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.

c. Loosen and r emove high pr es sur e li ne f lare 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 tap e th e pu m p and hose fitti ngs

to prevent dirt entry.

Figure 6A3-124

d. Remove both bolts (2) securing the power

steering pump (1) to the front of the left hand

cylinder hea d.

NOTE: Access to the two bolts can be made

through the pulley holes, using a suitable

socket and extension.

e. Secure th e res er voir and pum p to one s ide,

using tie wire or sim ilar .

Figure 6A3-125

c. Remove the powertrain wiring harness strap

(1) from the bracket at the rear of the cylinder

head.

d. Remove the bolt (2) securing the powertrain

harness ground cable at the rear of the cylinder

head.

Figure 6A3-126

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 6A3-127

15. Progressively loosen cylinder head bolts

starting with the M8 bol ts (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.

16. 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 6A3-128

17. Remove and discard the cylinder head gasket.

Figure 6A3-129

DISASSEMBLE

NOTE: Do not mix r em ove d c omponents. O r g anise

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 necess ary to tap th e valve spring

end of the com pr essor with a plastic f aced ham m er

to loosen jammed valve collets.

Figure 6A3-130

2. Remove the following components from the

cylinder hea d (1):

a. Valve stem collets (2).

b. Valve spring cap (3).

c. Valve spring (4).

d. Valves (7, 8).

e. Valve stem oil seal and shim assembly (5).

NOTE: Do not remove coolant core plugs (8)

unless servicing is required.

Figure 6A3-131

CLEAN

1. Use a c ommerciall y avai la b le rotary wire brush,

clean all carbon deposits from the combustion

chambers and valve ports, taking care not to

scuff or damage the aluminium cylinder head

surfaces.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Clean carbon deposits from valve stems and

heads on a buffing wheel.

3. Check all bolt threads for dam age and remove

all threadlocking compound from both the

threaded holes and bolts.

Figure 6A3-132

INSPECT

Cylinder Head

1. Check cylinder head deck, inlet and exhaust

manif old mating s urfaces for dis tortion, using a

straight e dge (2) and f eeler gauges ( 1). Check

lengthwise, diagonally and crosswise, as

shown by the alp hab etic a l order, in F ig ure 6A3-

133.

2. Check the cylinder head deck to exhaust

manifold the cylinder head deck to intake

manifold surfaces for flatness.

CYLI NDER HEAD FLAT NESS SPECI FICATION

(Measured Over the Cylinder Head Lengt h)

CYLINDER HEAD, ENGINE BLOCK DECK 0.22 mm

CYLINDER HEAD, EXHAUST MANIFOLD DECK 0.22 mm

CYLINDER HEAD, INTAKE MANIFOLD DECK 0.22 mm

Figure 6A3-133

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 , Too l No. J-4238 5-107 (this tool is par t

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 bl oc k.

5. Use compressed air to clean all residue from

bolt holes.

CAUTION: Wear eye protection to prevent

injury.

Figure 6B3-134

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 around plug sealing surface.

7. Inspect cylinder head for cracks, especially between valve seats or exhaust ports.

8. Inspect cylinder block deck surface for distortion, refer to 3.15 CYLINDER BLOCK.

9. Clean the M8 cylinder head bolt threads, replacing any bolt that has suspect threads, stretched or damaged

heads caused by improper use of tools.

NOTE: Discard all M11 bolts after removal, as these are “torque to yield” bolts.

Valve Springs

1. Check all valve springs for distortion. There

should be no more than 1.6 mm variance

(distance ‘1’) of the s prin g end, whi le t he s pri ng

is being rotated on a flat surface. Replace

springs that exceed this specification.

Figure 6A3-135

2. Use a commercially available valve spring

tester to m easur e each valve s pring f ree heig ht

and tension.

3. Discard any spring that does not conform to

specification.

VALVE SPRING SPECIFI C ATION S

VALVE SPRING FREE HEIGHT

(INTAKE and EXHAUST 52.9 mm

VALVE SPRING TENSION 310 N at 45.75 mm

SPECIFICATION (Closed Valve, Minimum)

VALVE SPRING TENSION 980 N at 33.55 mm

SPECIFICATION (Open Valve, Minimum)

Figure 6A3-136

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,

provide d the stem end is ground at ri ght angl es

to the valve stem.

2. Inspect valve stem collet gr oove ( 3) f or wear or

damage.

Figure 6A3-137

3. Check valve face for the following:

Either no m argin (1) or les s tha n 1 .25 m m after

grinding (4 ).

Excessive pitting (2).

Burnt or corroded areas (3).

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

face can be ground, using a valve refacing

m achine. The va lv e seat an gle is 45°.

The equipment manufacturer’s

recom mendatio ns m us t be c aref ully fo llo wed to

achieve the required standard of finish.

NOTE: If an exhaus t valve face is regr ound, it may

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 6A3-138

Valve Guides

Excessive valve stem to guide clearance may

cause a no isy valve tr ain, prem ature valve stem oil

seal wear, co mponent dam age an d/or ex ces s ive o il

consumption.

Insuff ic ient val ve s t em to guid e cle ar anc e will r es u lt

in nois y or s ticking val ves. Valves that are to o 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 nee dle .

To obtain a correct indication of wear, the

indicator stem must contact the side of the

valve s tem, from 8 - 12 mm above top of valv e

guide.

3. With the valve head dropped approximately 2

mm off its seat, move the stem of the valve

side to s ide aga ins t th e d ial ind ica tor us i ng 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 hea d rep lace d.

Figure 6A3-139

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

5. Clean the valve guide bore of all metal

shavings and debris.

Figure 6A3-140

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

valve guide.

7. T he val ve should s lide f r eel y witho ut r esistance

or drag. The clearance must also not exceed

specification.

Figure 6A3-141

Valve Seats

Reconditioning the valve seats is ver y important because the seating of the valves must be precise f or the engine

to deliver the power and performance built into it.

Another important factor is the cooling of the valve head. Good contac t between each valve and its seat in the head

is imperative to ensure that the heat in the valve head will be transferred efficiently.

Severa l differ ent types of e quipment ar e available f or recondit ioning va lve seats with an oscillat ing type va lve seat

grinder being preferred. The recommendations of the manufacturer of the equipment being used should be

carefully followed to attain proper results.

1. Check valv e seats f or any evide nc e of pitt in g or d amage at va l ve cont ac t s urf ac e. If pitti ng is ev ide nt, t he va l ve

seats will nee d to be recondition ed.

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 shou ld not e xc eed specificati on.

VALVE SEAT W IDTH SPECIFICATION

INTAKE 1.02 mm maximum

EXHAUST 1.78 mm maximum

If valve seats are recond itioned 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 par tial contac t is shown, reinstall th e valve a nd rotate f or one full tur n. If blue now indicat es a

full contact then the valve m ust be refaced or replaced. If the blue contact still onl y shows partial cont act then

regrind the valve seat.

e. Clean all traces of blue from the valves and seats, then clean thoroughly before applying clean engine oil to

both surfaces to protect from rusting.

REASSEMBLE

NOTE: Ensure th at all r e-used par ts are r einstalle d

to their original locations.

1. Lubricate all valve stems, guides and valve

faces with clean engine oil, then install valves

(7, 8) to their correct ports.

2. Install a new valve stem oil seal and shim

assem bly b y hand, unti l the shim seats agai nst

the cylinder hea d. No s peci al to ols are requ ired

for this operation.

IMPORTANT: The valve stem oil seal alignment

and position on the valve stem is critical. An

improperly installed valve stem oil seal will lead to

excessive oil consumption and increased exhaust

emissions.

Figure 6A3-142

3. Inst all th e v al ve spr i ngs an d c aps to e ac h val ve

stem.

4. Use a commercially available valve spring

compressor to compress the valve spring.

5. Install valve stem collets, retaining with

petroleum jelly if required.

6. Ensure that the both collets are correctly

located before releasing the valve spring

compressor.

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

a plastic faced hammer to seat the collets.

Figure 6A3-143

8. Measure the v alve spring i nstalled hei ght using

a ruler or vernier calipers. Measurement is to

be taken from the base of the valve spring to

the top.

9. 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 v alve stem oil seals, o nly

use the later design that c ombines the oil seal and

the valve spring shim.

10. Install the remaining valves, springs and other

components, checking each spring height as it

is assembled.

11. If the cylinder head core plugs were removed,

install with sealant such as Loctite 565 (or

equivalent) before plug installation.

Figure 6A3-144

REINST ALL

Reinstallation of either or both cylinder heads is the

reverse to the removal procedure, except for the

follo wing po ints .

NOTE 1: Do not refit removed M11 cylinder head

bolts. Always use NEW bolts when installing a

cylinder hea d.

NOTE 2: Do not use any sealant on the cylinder

head gas ket, nor thr eadloc k com pound on th e M11

cylinder hea d bolts .

1. Check the cylinder head locating sleeves for

correct installation. Dimension ‘A’ is to be 8.3

mm, when the revised design cylinder head

gasket is used.

NOTE: When the earlier design cylinder head

gaskets were used, this dimension was 6 mm.

Figure 6A3-145

2. Install a NEW cylinder head gasket correctly

over the locating sleeves.

NOTE 1: When correctly installed, the tab (arrow)

on the cylinder head gasket will be located to the

front half point (small arrow). This applies with

either cylinder head gasket.

NOTE 2: The cylinder head gaskets will fit on

either side. The only condition is that the word

‘FRONT’ stamped on the gasket must face the

engine front. The tab should also have “5.7”

imprinted on it.

Figure 6A3-146

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, 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 6A3-147

6. T ighten the c ylinder head bolts in the sequ ence

shown and to the correct torque specification.

NOTE 1: Use a tor que a ngl e meter 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 TORQUE SPECIFICATION

Stage 1 (All M11 and M8 Bolts) 30 Nm

Stage 2 (All M11 Bolts only) 90° turn angle

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

(M11 Bolts 9 and 10 only) 50° turn angle

For the rem ainder of reins tallation proc ess, refer to

the following procedures, in the order listed:

2.18 VALVE ROCKER ARM S AND PUSH RODS.

2.17 VALVE ROCKER ARM COVER.

2.15 VAPOUR VENT PIPE .

2.14 INT AKE M ANIFOLD.

2.21 EXH AUST M ANIFOLD/S.

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

2.20 OIL LEVEL INDICATOR AND TUBE.

Figure 6A3-148

2.23 VALVE LIFTERS

LT Section No. – 00-050

REMOVE

NOTE: Ensure that all valve train components are

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

in their orig ina l loc at ions.

1. Remove the cylinder head on the side requiring

hydraulic lifter removal. Refer 2.22 CYLINDER

HEAD - REMOVE, in this Section.

2. Remove both valve lifter guide retaining bolts.

3. Remove valve lifters and guides.

Figure 6A3-149

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

Figure 6A3-150

Techline

DISASSEMBLE

1. Using a small, f ine bladed scr ewdriver , remove

push rod seat retaining clip (10).

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

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

(3) from lifter body (2).

NOTE: If the plunger is stu ck in the lifter body, turn

lifter body upside down and tap lifter body on a

block of wood. If this is not effective, soak lifter

assembly in a suitable cleaning fluid.

Legend:

1. Roller.

2. Lifter Body.

3. Plunger Spring.

4. Ball Check Retainer.

5. Ball Check Spring.

6. Ball Check.

7. Plunger.

8. Oil Metering Valve.

9. Push Rod Seat.

10. Push Rod Seat Retaining Clip.

Figure 6A3-151

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

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

Figure 6A3-152

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 bod y (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 lif ter mounting bores .

Figure 6A3-153

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 lif ter .

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

plunger (4).

Figure 6A3-154

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 6A3-155

4. Reinstall plunger spring into the lifter body.

5. Install p lunger ass em bly in bod y, tak ing 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 6A3-156

TESTING LIFTER LEAKDOWN RATE

After an hydraulic lifter has been cleaned, inspected and reassembled, it must be tested before being reinstalled.

Lifter tes t f ix ture, Tool No 6A23 has be en d esig ned to test the leakdown rat e of the lifter , to ens ure t hat the lif ter wil l

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

come up to its retainer, then lower arm to rest

on ram.

7. Use a stop watch to m easure the tim e required

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 6A3-157

NOTE 1: A doubtful lifter should be tested several times before being discarded.

NOTE 2: Clean cup and refill with fresh test fluid after several lifters have been tested.

9. Stan d test ed lif ters upright s o that fluid does not dr ai n f r om oil holes.

10. After all lifters have been tested, place a cover over the test fixture to keep dirt and dust from the cup.

REINST ALL

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), 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 6A3-158

2.24 CRANKSHAFT BALANCER

LT Section No. – 00-540

NOTE: The following fasteners MUST be replaced ( ! )

when performing this operation:

! Crankshaft balancer bolt.

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES before dis c onn ectin g the battery.

2. Remove radiator, refer Section 6B3 ENGINE

COOLING – GEN III V8 ENGINE.

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 STARTI NG SYSTEM.

5. Remove the right hand side close-out cover

retaining bolt, then the cover.

Figure 6A3-159

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 6A3-160

7. Remove the crankshaft balancer bolt. Do not

discard bolt as it will be required for the

reinstallation process.

Figure 6A3-161

8. Use crankshaft end protector J 41816-2 and

puller J41816 (or three legged commercial

equivalent), to remove the crankshaft balancer.

Figure 6A3-162

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 balanc er hub s eal surf ace with

excessive scoring, grooves, rust or other

damage must be replaced.

• Minor im per fec tions on th e hub seal surf ace

may be removed with polishing compound

or fine grade emery cloth.

• Dirty or damaged be lt gro o ves.

• The bal ancer belt grooves shoul d be free of

any nicks, gouges, or other damage that

may not allow the belt to track properly.

IMPORTANT: F or the belt to track properl y,

the belt grooves should be free of all dirt or

debris.

• Minor im perf ections m ay be rem oved with a

fine file.

• Worn, chunking or deteriorated rubber

between the hub an d pull e y.

Figure 6A3-163

REINST ALL

IMPORTANT: The crankshaft balancer

reinstallation and bolt tightening involves a multi-

stage tightening process. The first pass ensures

that the balancer is installed completely onto the

crankshaft. The remaining passes tighten the new

bolt to the proper torque.

The us ed cr ankshaf t balan c er bolt wil l b e us ed on l y

during the first pass of the balancer installation

procedure. Only inst all a NEW crank shaft balancer

bolt and tighten as described in the remaining

passes of the balancer bolt tightening procedure.

1. Ensure that the teeth of the ring gear locking

Tool No. J 42386-A are correctly engaged.

2. Appl y a sm ear of c lean engine oil onto t he se al

surface of the balancer, then install the

balancer onto the end of the crankshaft.

IMPORTANT: The balancer should be positioned

onto the end of the crankshaft as straight as

possible, before to tool installation.

Figure 6A3-164

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 revers e it, so t hat the l arger 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 inst a llation tool.

Figure 6A3-165

4. Install the used crankshaft balancer bolt and

tighten to the specified torque.

CRANKSHAFT BALANCER

INSTALLATION

TORQUE SPECIFICATION 330 Nm

5. Remove the used balanc er bolt and discar d.

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 6A3-166

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 SPECIFICATION Stage 1: 50 Nm

Stage 2: 140°

Turn angle

10. Rem ove the r i ng g ear l oc king tool N o. J 423 86-

11. Reinstall the close-out cover and tighten the

bolt to the correct torque specification.

RIGHT HAND CLOSE-OUT C OVER

SCREW TORQUE SPECIFICATION 10 Nm

12. Install the starter motor. Refer to

Section 6D3-2 STARTING SYSTEM and

tighten the m ounting bolts t o the correct torque

specification.

STARTER MOTOR MOUNTING

BOLT TORQUE SPECIFICATION 50 Nm

13. Reinstall the radiator, refer Section 6B3

ENGINE COOLING – GEN III V8 ENGINE.

Figure 6A3-167

2.25 COOLANT PUMP

LT Section No. – 00-325

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 5 0°C), then slow ly 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 the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects

certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. Battery

Disconnection Procedures before disconnecting

the battery.

3. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

5. Loosen coolant pump drive pulley bolts.

Figure 6A3-168

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

a 15 mm ring spanner, refer to 2.6 ENGINE

DRIVE BELTS - REPLACE, in this Section.

Figure 6A3-169

7. Drain engine coolant. Refer to 2.3 DRAINING

AND FILLING COOLING SYSTEM, in Section

6B3 ENGINE COOLING.

IMPORTANT: The information in 2.1 SERVICE

NOTES (Environmental Issues), Section 6B3

ENGINE COOLING is to be read and acted upon.

8. Disconnect both heater hoses, the outlet and

inlet hoses from the coolant pump.

CAUTION: Always wear protective safety

glasses when working with spring type hose

clamps. Failure to do so could result in eye

injury.

Figure 6A3-170

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-171

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

the coolant pump (2) to the cylinder block.

11. If nec es s ar y, use a sof t faced ham mer to lig htly

tap coolant pump housing (2) to dislodge it

from the cylinder block.

12. Rem ove coolant pum p, carr ier type gask ets (3)

and discard.

Figure 6A-172

DISMANTLE

NOTE: Apart from the service operations

described here, there are no other serviceable

parts in the coolant pump assembly and if required,

then the as s embly m us t be repl ac ed as a complet e

unit.

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

the rear cover (3) to the coolant pump (2). Tap

with a sof t faced h amm er to dislodge the cover

from the pump body.

2. Rem ove the sea ling O-r ing (1) from the c oolant

pump body (2).

3. For thermostat remove, test and reinstall

procedures, refer to 2.9 THERMOSTAT, in

Section 6B3 ENGINE COOLING.

Figure 6A-173

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.

• Evidenc e of c oolant leak age at th e coolant o utlet h ous ing or re ar cover gask et ( if these parts h ave 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 14 Nm

REINST ALL

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, install NEW gaskets over them and

install the coolant pump to the cylinder block.

3. Install remaining bolts and tighten to the correct torque specification, in two stages.

COOLANT PUMP BOLT

TORQUE SPECIFICATION Stage 1: 15 Nm

Stage 2: 30 Nm

4. Install the engine accessory 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 t his Secti on.

7. Refill cooling system, refer to 2.3 DRAINING AND FILLING COOLING SYSTEM in Section 6B3 ENGINE

COOLING.

8. Check for cooling system leaks, refer to 2.8 PRESSURE TEST ING in Section 6B3 ENGINE COOLING.

2.26 CRANKSHAFT FRONT OIL SEAL

LT Section No. – 00-325

REPLACE

1. Remove the crankshaft balancer. Refer

2.24 CRANKSHAFT BALANCER in this

Section.

2. Using Tool No. Eb

308 (or commercial equivalent) remove seal from

the front cover.

Figure 6A3-174

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. Refer CRANKSHAFT OIL SEALS, in

1.4 ENGINE LUBRICATION SYSTEM, in this

Section.

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

guide of Tool No. J 41478.

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

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

end of the crankshaft.

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

installer bolt, then rotate the installer nut

clockwise, using a second set spanner, until

the seal bottoms in the cover bore.

7. Remove the tool from the crankshaft.

8. 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 6A3-175

2.27 ENGINE MOUNTS

LT Section No. – 00-475

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. Then, ch eck that the m ounting rubber has not deteriorated, split or separated from its

metal plates.

3. Replace mount if found to be defective.

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. BATTERY DISCONNECTION PROCEDURES befor e disc onn ec tin g the battery.

2. Drain the cooling system. Refer to Section 6B3 ENGINE COOLING - GEN III V8 ENGINE.

IMPORTANT: The inf ormation i n 2. 1 SERVIC E NOT ES (Enviro nment al Issue s), Section 6B3 ENGINE COOLING

is to be read and acted upon.

3. Remove the four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

5. Raise front of vehicle and place on safety

stands. For location of jacking and support

points, refer to Section 0A GENERAL

INFORMATION.

6. Remove the exhaust pipe to manifold flange

nuts on the engine mount side to be removed.

7. From under the vehicle, remove the lower

mounting to crossmember nut for both mounts.

NOTE: A commercially available, 18 mm deep

socket will be required for this operation.

8. Lower the vehicle to the ground, then remove

the exhaust manifold on the engine mounting

side to be removed. Refer to 2.21 EXHAUST

MANIFOLD - REMOVE, in this Section.

9. Use suitable engine lifting equipment to raise

the engine, removing the weight from the engine

mounts.

Figure 6A3-176

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 6A3-177

REINST ALL

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.

ENGI N E MOUNT TO BRACKET NU T

TORQUE SPECIFICATION 80 Nm

2. Install the engine mount stud into the crossm ember, then install th e bracket to cylinder block bolts and tighten

to the correct torque specification.

ENGINE MOUNTING BRACKET BOL T

TORQUE SPECIFICATION 50 Nm

3. Lower the e ngine allo wing the weight to se ttle on the crossm ember , install bot h engine m ount nuts and tighten

to the correct torque specification.

ENGINE MOUNT TO CROSSMEMBER

TORQUE SPECIFICATION 80 Nm

4. Install exhaust manifold. Refer to 2.21 EXHAUST MANIFOLD - REINSTALL in this Section.

3. MAJOR SERVICE OPERATIONS

3.1 ENGINE ASSEMBLY

LT Section No. – 00-500

REMOVE

1. Disconnect the ground cable from the battery.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. Battery Disconnection Procedures before disconnecting 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 four engine dress cover

decorative nuts (1), then remove the dress

cover (2) from the engine.

4. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake duct (4) to the MAF sensor

and the throttle body. Remove the duct (4)

from the engine.

5. De-pressurise fuel rail. Refer to

2.13 FUEL SYSTEM PRESSURE RELIEF, in

this Section.

Figure 6A3-178

IMPORTANT: Before draining coolant, the

information in 2.1 SERVICE NOTES

(Environmental Issues), Section 6B3 ENGINE

COOLING is to be read and acted upon.

6. Place a suit able drain tr ay 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.

7. Loosen the second worm drive hose clamp

securing 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 acces s to the transfer 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.

8. Loosen top radiator worm drive hose clamp at

the engine and a spring type clamp at the

radiator (2), then rem ove the top hose f rom the

engine.

9. Remove the engine cooling fans and radiator.

Refer to Section 6B3 ENGINE COOLING –

GEN III V8 ENGINE.

Figure 6A3-179

10. Recover refrigerant charge, refer to

Section 2C AIR CONDITIONING –

SERVICI NG AND DIAGNOSIS.

Figure 6A3-180

12. After removing the four oil pan under-tray

bolts, rem ove the tra y from the vehicle.

13. Rem ove oil pan dr ain plu g and drain eng ine oil

into a suitable container. Reinstall drain plug

once oil has drained sufficiently.

14. Disconnect windshield washer hose (1) at the

in-line connector located at the rear, left hand

side of the engine hood.

Figure 6A3-181

15. 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.

16. 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 6A3-182

17. Remove both heater hose clamps at the

engine water pump, taking note of the hose

layout. Plug open ends to prevent dirt entry.

Figure 6A3-183

18. Remove the screw (1) securing the ground

lead to the engine cylinder block and from the

left hand engine mount (2).

19. Remove the nut (3) securing the battery

harness ground terminals to the ABS/TCS

control module bracket stud (4).

20. Rem ove the ground terminal (5) at the batter y,

followed by the positive lead (6). Lay the

harness on the engine.

Figure 6A3-184

21. Disconnect the wiring harness connectors

from:

1. Mass Air Flow Sensor.

2. Intake Air Temperature Sensor.

3. Air Cond iti on ing Pres s ure Sens or .

4. Main to Powertrain Wiring Harness.

Figure 6A3-185

22. Disconnect powertrain wiring harness clips (6)

from the engine compartment dash panel

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

6A3-186.

23. Referring to Figure 6A3-186, disconnect

powertrain wiring harness connectors from the

surge ta nk, lo w cool ant s witch ( ‘1’, v iew A) and

the theft deterrent horn (‘4’, view C).

Figure 6A3-186

24. 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.

25. Rem ove the cover from the Powertrain Control

Module (PCM).

26. Rem ove both PCM c onnectors (see ‘3’, view B

in Figure 6A3-186) in the engine bay, after

removing the retaining screw (bold arrows)

from each connector.

27. Remove the PCM wiring harness retaining clip

from the PCM container, to free the harness.

28. Remove the engine wiring harness retaining

clip fr om the power ste erin g pipe br ack et at the

engine front.

Figure 6A3-187

29. From ins ide the passenger compartment of the

vehicle, remove the left hand shroud panel

trim , and glo ve box ass embl y. For det ails , ref er

Section 1A3 INSTRUMENT PANEL AND

CONSOLE.

30. Remove the PIM ( 1), e ither by usin g f ingers (or

a flat bladed screwdriver) to push on and

dislodge the retaining hook, then remove the

PIM and Throttle Relaxer Module (TRM) (if

fitted), as an assembly.

31. Remove the (TRM) connector (2) (if fitted), as

follows:

– Lift the lock ing lev er on the T RM connector (2),

pivot do wn and rem ove the connec tor from the

lower hook .

32. Remove the wiring harness connector (3) from

the Powertrain Interface Module (PIM).

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

34. Disconnect the Powertrain to Main wiring

harness connector, X206 (5).

35. Release the harness to dash panel grommet

(6) and feed the harness and connectors out

into the engine bay.

36. La y the po wertrai n wiring har ness on t op of th e

engine.

Figure 6A3-188

37. Disconnect the cruise control cable (1) (if fitted) (refer Figure 6A3-189) from the stud (2) on the throttle body

valve lever (3), then remove the outer cable (8) from the retainer bracket (4).

38. Lift the throttle cable (5) from the clip (6) at the fuel rail crossover pipe, then lift the cable (5)

from the retainer bracket (4).

39. Remove the inner throttle cable (7) from the throttle body valve lever (3).

40. Set the cable/s to one side.

Figure 6A3-189

41. Using quick connect release Tool No. 7371,

open tool and install over fuel rail line.

42. Close 7371 and pull into fuel rail line quick

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

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

Remove the quick connect release tool from

the fuel rail line.

43. Disconnect the vapour line (2) connection to

the EVAP purge control valve (3) and set to

one side.

IMPORTANT: Plug all openings to prevent fuel

leaking an d dir t/co ntaminan ts from enter ing the f uel

system.

Figure 6A3-190

44. Loosen the hose clamp on the return hose at

the power steering reservoir end.

45. After placing a suitable container under the

reservoir, remove the hose and drain the

reservoir fluid.

IMPORTANT: Plug both openings to prevent dirt

entry.

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

one side.

Figure 6A3-191

47. Loosen an d r emove the hi g h pr ess ur e l ine f lar e

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

fitting at the rear of the power steering pump.

Use a back-up spanner on the outlet fitting

when loosening the flare nut.

IMPORTANT: Plug both openings to prevent fluid

loss and/or dirt entry.

Figure 6A3-192

48. Disconnect the brake booster and heater

control, vacuum hoses from the rear of the

intake manifold.

Figure 6A3-193

49. Remove number 3 spark plug lead and plug

from the left bank, then remove the upper left

engine mount to engine bracket nut, using a

socket, universal joint, long extension and

ratchet.

50. For the right hand engine mount, repeat the

above process by removing the second spark

plug lead and plug (or cylinder No. 4 spark

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

engine mount nut. To improve the removal

process, also remove the lower mount

retaining nut.

NOTE: To improve access to these two nuts, an

alternative method is to remove both exhaust

manifolds. Refer to 2.21 EXH AU ST MANIFOLD, in

this Section, for the necessary procedure, if

required.

Figure 6A3-194

51. Remove the ignition coil and module for cylinder number 8 for right hand drive vehicles or number 7 for left

hand drive vehicles. Refer to Section 6C3-3 SERVICE OPERATIONS.

NOTE: This step is necessary to gain additional clearance around the brake vacuum booster, when the engine is

lifted during the removal process.

52. With manual transmission equipped vehicles, remove the bolt securing the clutch master cylinder reservoir

bracket to the end of the master cylinder. Refer to Section 7A2 CLUTCH for further information.

NOTE: This step is necessary to reduce the possibility of damage to the reservoir, during the engine removal

procedure.

53. Raise vehicle front and rear and support on safety stands. For location of jacking and support points, refer to

Section 0A GENERAL INFORM ATION.

54. Remove the three bolts and nuts securing the propeller shaft, front coupling. Refer to

Section 4C PRO PELLER SH AFT AND UNIVER SAL JOINT S. To discon nect t he pr opel ler sh aft f rom the front

spigot. It m ay be nec essar y to rem ove the t wo centr e b earin g to u nderbod y bol ts a nd lo wer the pr ope ller shaft.

Use tie wire to secure the sliding yoke to the rear of the transmission.

55. Disconnect the gear shift control from the transmission. Refer to Section 7B2 MANUAL TRANSMISSION -

GEN III V8 ENGINE, or Section 7C4 AUTOMATIC TRANSMISSION - ON-VEHICLE SERVICING.

56. F rom under the fr ont of the vehicle , rem ove the

four bolts securing the oil pan under-tray.

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

steering, high pressure line (1) brackets to the

oil pan.

Figure 6A3-195

58. W hile not ess ential, it is rec ommended th at the

oxygen sensors (1) are removed from the

exhaust pipes, to avoid accidental damage.

a. Disconnect the wirin g harn ess connector s from

each oxygen sensor.

b. Remove both oxygen sensors from the exhaust

pipes.

c. Plug openings in exhaust pipes.

59. Remove both exhaust pipe to manifold flange

nuts.

Figure 6A3-196

60. Rem ove the t wo bolts (2) s ecuring the ca talytic

converter bracket (1).

IMPORTANT: Take note of any spacers that may

be included between the bracket and the catalytic

converter, as these must be reinstalled when the

engine is fitted back into the vehicle.

NOTE: While Figure 6A3-197 shows an automatic

transm iss ion equipped vehi cle, th is oper ation is the

same for manual transmission vehicles.

61. Lower the ve hic l e to the ground.

Figure 6A3-197

62. 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.

63. Using a suitable lifting crane, raise the engine

slightly to take the weight off the engine

mounts.

Figure 6A3-198

Vehicles with Manual Transmission

64. Mark the relationship of the engine rear

crossmember (2) to the frame, to assist with

alignment on reassembly.

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

crossm em ber ( 2) to the f ram e, r emove th e rear

mounting to crossmember nuts (4), then

remove the crossmember from the vehicle.

66. Remove the catalytic converter bracket to

transm ission extension bolts (7) and nuts, then

remove the bracket (6) from the vehicle and set

to one side.

Figure 6A3-199

Vehicles with Automatic Transmission

67. Us ing a scr iber or s im ilar, m ark the relations hip

of the engine rear crossmember (2) to the

frame, to assist with alignment on reassembly.

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

crossm em ber ( 2) to the f ram e, r emove th e rear

support to crossmember nuts (4), then remove

the crossmember from the vehicle.

69. Remove the rear mount to transmission

extension housing bolts (5) and nuts, then

remove the mount (1) and the catalytic

converter bracket (6).

Figure 6A3-200

70. Raise engine and transmission assembly with

front tilted upward and a floor jack supporting

the rear of the transmission assembly.

IMPORTANT: Take care when removing engine and transmission assembly, that no part of the assembly is

allowed to rest on the power steering rack.

NOTE: Do not allow the engine to swing forward and damage the air conditioning condenser (if fitted).

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

DISASSEMBLE

1. Rem ove the wiri ng har ness connector s an d earth c onn ections f rom the engi ne an d transm is sion assem bl y 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 eng in e is to be dism antled a nd in par ticu lar, the c am shaf t is t o be r em oved, the n the c am shaft

lobe lift check should be carried out, prior to the removal of the cylinder heads. Refer to 3.2 CAMSHAFT LOBE

LIFT MEASURE 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 2.3 ENGINE OIL FILTER & ADAPTOR REPLACE in this section.

b. Engine drive belts, refer to 2.6 ENGINE DRIVE BELTS – REPLACE ENGINE ACCESSORY BELT AIR

CONDITIONG COMPRESSOR BELT in this section.

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

d. Engine accessory drive belt idler and tension pulley assemblies, refer to 2.7 ACCESSORY BELT IDLER

PULLEY REPLACE and 2.9 ACCESSORY BELT TENSIONER REPLACE in this section.

e. Air conditioning drive belt idler and tension pulley assemblies, refer to 2.8 A/C BELT IDLER PULLEY

REPLACE and 2.10 A/C BELT TENSIONER in this section.

f. Generator and mounting brackets, refer Section 6D3-1 CHARGING SYSTEM - GEN III V8 ENGINE.

g. Intake manifold, refer to 2.14 INTAKE MANIFOLD in this section.

h. Vapour vent pipe, refer to 2.15 VAPOUR VENT PIPE in this section.

i. Engine valley cover, refer to 2.16 ENGINE VALLEY COVER in this sect ion.

j. Valve rocker arm covers, refer to 2.17 VALVE ROCKER ARMS & PUSH RODS in this section.

k. Valve rock er arm s and pus h rods, r efer to 2 .18 V ALVE ST EM OIL SE AL AND.OR V ALVE SPRING in t his

section.

l. Oil level indicator and exhaust manifolds (if not already removed), refer to 2.20 OIL LEVEL INDICATOR

AND TUBE and 2.21 EXHAUST MANIFOLD in this section. Plug the oil level indicator hole in the oil pan to

avoid dirt entry.

m. Cylinder heads and valve lifters, refer to 2.22 CYLINDER HEAD and 2.23 VALVE LIFTERS in this section.

n. Starter motor, refer Section 6D3-2 STARTING SYSTEM - GEN III V8 ENGINE.

o. Crankshaft balancer, refer to 2.24 CRANKSHAFT BALANCER in this section.

p. Coolant pump assembly, refer to 2.25 COOL ANT PUM P in this section.

REASSEMBLE

Reassembly of the components listed in step 4. of the DISASSEMBLE description above, is the reverse of the

disassembly procedures, except for specific points stated in each description for that component.

For other engine components that are detailed in this Section, the reassembly process is also detailed.

REINSTALL, SET UP AND T ESTING

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 SPECIFICA TIONS, at the end of this Section.

2. Use onl y the specif ied eng ine lu bricant t ype and qu antit y. It is rec omm ended that a f luoresc ent oil d ye, such as

that contained in J 28481-B, be added to assist in any future oil leak diagnosis.

3. Fill the c ooling s ystem with the prop er quant ity and grade of coolant. Refer S ection 6B3 ENGINE COO LING -

GEN III V8 ENGINE.

4. Check transmission fluid level, topping up as requir ed, using the specified lubric ant for the transm ission fitted.

Refer Section 7C4 AUTOMATIC TRANSMISSION - ON-VEHICLE SERVICING.

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

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

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

8. Check the vehic le oil pres s ure gauge or warn ing lam p and conf irm that the eng ine has ac ceptab le oil pres sur e.

If necessary, install an oil pressure gauge and measure the engine oil pressure. Refer to 2.4 ENGINE OIL

PRESSURE - CHECK, in this Section.

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

10. Listen for sticking lifters and other unusual noises.

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

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

13. Check engine hood alignment.

3.2 CAMSHAFT LOBE LIFT

MEASURE

IMPORTANT: Measuring camshaft lobe lift is a

procedure used to determine if the camshaft lobes

have worn. This test is to be performed prior to

engine disassembly and with the camshaft, push

rods and valve lifters installed in the engine.

1. To measure the camshaft lobe lift, proceed as

follows:

a. Remove the valve rocker arms and bolts.

Refer 2.18 VALVE STEM OIL SEAL

AND.OR VALVE SPRING, 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 6A3-201

3.3 OIL PAN

LT Section No. – 00-275

REMOVE

IMPORTANT: Bec aus e of c ritical alignm ent pr ocedur es require d for oil pa n instal latio n, it is stron gl y recom mende d

that the engine assembly is removed from the vehicle, before oil pan removal.

1. Remove the starter motor. Refer Section 6D3-1 STARTING MOTOR – GEN III V8 ENGINE.

2. Remove the right close-out cover screw and cover (View ‘A’).

3. Remove the left close-out cover screw and cover (View ‘B’).

Figure 6A3-202

4. Invert the engine assembly.

5. Remove the oil pan bolts, loosening gradually

from the ends and working inwards toward the

centre.

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

hand or a rubber hammer, to dislodge the seal.

Figure 6A3-203

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 al lo w m etal s hav ings 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 s har p t wist dr ill ( 3) to dril l o ut e a ch 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 6A3-204

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 6A3-205

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 recomm ended that the front studs are

left attached to the transfer tube assem bly and the

whole assembly withdrawn from inside the oil pan.

Figure 6A3-206

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

and baff le.

Figure 6A3-207

CLEAN AND INSPECT

1. Clean the oil pan in a suitable solvent. Ensure that all oil passages and recesses are thoroughly cleaned.

2. Clean the oil pan gasket surfaces, using a plastic scraper to avoid scratching or damaging the machined

surfaces.

3. Dry the oil pan with compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

4. Inspect the oil pan for the following:

a. Gasket sealing surfaces for excessive scratches or gouging.

b. Oil pan dr ain p lug an d thr e aded dr a in hol e f or damaged threa ds . The dra in plu g O-ring s ea l may be reus e d

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 pr oper op er at ion Lig htly push the

bypass valve into the bore. The valve

spring should reseat the valve to the

proper position.

5. Inspect the oil transfer tube for damage or

restrictions.

Figure 6A3-208

REASSEMBLE

1. Install the oil pa n baffle and r etaining bolts an d

tighten to the correct torque specification.

OIL PAN BAFFLE BOLT

TORQUE SPECIFICATION 12 Nm

Figure 6A3-209

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 PLUG

TORQUE SPECIFICATION 25 Nm

4. Apply thread lock compound such as Loctite

242 (or equivalent) to the cleaned threads of

the oil transfer tube bolts (3)

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

transfer tubes (1).

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

correct torque specification.

OIL FILTER TRANSFER TUBE

TORQUE SPECIFICATION 12 Nm

Figure 6A3-210

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 requir ed, insta ll a NEW oil f ilter bypas s valve ,

using a suitable size socket and hammer to

fully seat in the oil filter flange.

Figure 6A3-211

REINST ALL

IMPORTANT: The alignment of the structural oil

pan is critic al. The r ear bolt hole locations of the oil

pan provide mounting points for the transmission

bell housing. To ensure the rigidity of the

powertra in and correc t transm ission alignm ent, it is

important that the rear of the engine block and the

rear of the oil pan are flus h. 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 6A3-212

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 6A3-213

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

IMPORTANT: Be sure to align the oil gallery

passages in the oil pan and engine block properly

with the oil pan gasket.

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

the gask et. Install the oil pan, gasket and bo lts

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 6A3-214

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

and rear of oil pan are flush or even.

7. Inst all the oil pan t o f r ont c over bo lts and t he o il

pan to rear cover bol ts , tigh tening to the corr ec t

torque specifications.

OIL PAN TO FRONT COVER

TORQUE SPECIFICATION 25 Nm

OIL PAN TO REAR COVER BOLT

TORQUE SPECIFICATION 12 Nm

NOTE: This pr elim inar y step is requir ed to a void oil

pan ‘creep’ and create a misalignment condition.

8. Place a straight edge across the rear of the

engine block and rear of oil pan at the

transmission bell housing mounting surfaces.

9. Insert a feeler gauge between the straight edge

and the oil pan 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: T he rear of the oil pan m ust NEVER

protrude beyond the en gi ne bloc k and trans mission

bell housing mounting surfaces.

10. Install remaining oil pan to cylinder block bolts

and tighten to the correct torque specification.

Figure 6A3-215

OIL PAN TO CYLINDER BLOCK

TORQUE SPECIFICATION 25 Nm

If the oil pan alignment is not within specification,

remove the oil pan and repeat the above

procedure.

3.4 ENGINE FRONT COVER

LT Section No. – 00-375

REMOVE

IMPORTANT: Because of critical alignment

procedures required for the reinstallation of the

front c over and oil pan, i t is strongl y recomm ended

that the engine assembly is removed from the

vehicle, before oil pan removal.

1. Remove the crankshaft balancer. Refer

2.24 CRANKSHAFT BALANCER - REMOVE,

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 6A3-216

CLEAN AND INSPECT

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

2. Clean the front cover in a suitable solvent and blow dry.

CAUTION: Wear safety glasses to avoid eye injury.

3. Inspect the front cover sealing surfaces for excessive scratches and/or gouges.

4. Inspect the front cover gasket for damage to the membrane or distortion to the aluminium carrier.

5. Inspect the front cover to oil pan threaded holes for damaged threads or debris. Refer to

3.16 THREAD REPAIR, in this Section, if rectification is required.

6. Inspect the cover crankshaft oil seal bore for damage.

REINST ALL

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 of sealant to the front cover gasket.

NOTE 3: The special tools in this procedure must be used to properly align the engine front cover at the oil pan

surface and to centre the crankshaft front oil seal.

NOTE 4: All gasket surfaces should be free of oil or other foreign material during assembly.

NOTE 5: T he crank shaf t front oil s eal MU ST be c entr ed in re lation to the c rank shaf t. The oi l pan s ealing s urf ace at

the front cover and engine block MUST also be aligned within specifications.

NOTE 6: An improperly aligned front cover may cause premature front oil seal wear and/or engine assembly oil

leaks.

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

onto the engine.

2. T ighten th e c o ver bo lts f ing er tigh t on ly. Do not

tighten.

Figure 6A3-217

3. Assem ble alig nm ent tool J 4148 0 to f ront cover

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

the locations sho wn but do not tigh ten.

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

J 41480) t o the engine blo ck and tighten to the

specified torque.

FRONT COVER ALIGNMENT TOOL

BOLT TO ENGINE BLOCK

TORQUE SPECIFICATION 25 Nm

Figure 6A3-218

5. Install centralising Tool J 41476 as shown and

hold in position by hand.

IMPORTANT: DO NOT install the crankshaft

balancer bo lt to reta in the ali gnment too l. 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 t wo bolts (1) secur ing Tool 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 COVER BOLT

TORQUE SPECIFICATION 25 Nm

8. Remove the alignment tools.

Figure 6A3-219

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 straight edge tool. The cover must be

flush with the oil pan surface or no more than

0.25 mm below flush (dimension ‘A’).

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

surface alignment is not within specifications,

repeat the cover alignment procedure.

10. If the correct front cover to engine block

alignm ent c ann ot b e o bta in ed, r e plac e the f r ont

cover.

Figure 6A3-220

CRANKSHAFT FRONT OIL SEAL – INSTALL

IMPORTANT: Do not lubricate the oil seal sealing

surface.

1. Lubricate the o uter edge of the oil sea l (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 seal) 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 6A3-221

3.5 ENGINE FLYWHEEL/FLEXPLATE

LT Section No. – 00-400

NOTE: The following fasteners MUST be replaced ( ! )

when performing this operation:

! Flywheel/Flexplate retaining bolts.

REMOVE

IMPORTANT: Note the position and direction of

the engine flywheel before removal. The flywheel

does not use a locating pin for alignment. Mark or

scribe the end of the crankshaft and the flywheel

before component removal. The engine flywheel

must be reinstalled to the original position and

direction. The engine flywheel will not initially seat

against the crankshaft flange, but will be pulled

onto the crankshaft by the engine flywheel bolts.

This procedure requires a three stage tightening

process.

If replacing a flywheel, note the location of any

existing balance weight pins (relative to the

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 remove the pins from the old flywheel

and then reinstall them in the same relative

location in the repl ac ement part.

NOTE 1: Balance weight pins will only be fitted to

some engines that may have been dynamically

balanced at manufacture, where balance weight

pins are required to balance the

crankshaft/flywheel assembly. Hence the need to

reinstall them to a new flywheel, in the same

position.

NOTE 2: A correctly installed balance weight pin

will be either flush or below flush with the machined

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 :

Section 7B2 MANUAL TRANSMISSION -

GEN III V8 ENGINE,

Section 7A2 CLUTCH - GEN III V8 ENGINE

Section 7C4 AUTOMATIC TRANSMISSION.

2. Mark the end of the crankshaft and the

flywheel/ flexplate, using a felt tipped pen or

similar. Remove the engine flywheel/ flexplate

bolts.

3. Remove the engine flywheel/flexplate.

Figure 6A3-222

CLEAN AND INSPECT

Flywheel

1. Clean the flywheel in a suitable solvent and

blow dry with compressed air.

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 inter ference f it onto t he

flywheel and should be positioned

completely against the flange of the

flywheel.

f. Missing, bent or damaged pressure plate

locating pins. The two locating pins are

pressed into the flywheel and are spaced

170° apart.

IMPORTANT: In order to maintain the correct

component balance, contact surface taper and

heat transfer, should any flywheel damage be

observe d, t hen t he f lywheel is NO T to be mac hined

and must be replaced.

Figure 6A3-223

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 atte mpt to repair any welded

areas that retain the ring gear to the flexplate.

Replace the flexplate assembly if welds are

cracked.

Figure 6A3-224

REINST ALL

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

cranks haft and f lywhe el we re ba lanced 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

flywheel.

2. Install the flywheel/flexplate, aligning the

scribed marks on the crankshaft and

flywheel/flexplate.

Figure 6A3-225

3. Loosely install NEW flywheel/flexplate bolts,

tightening in the sequence shown in Figure

6A3-227, 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 6A3-226

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: 100 Nm

6. Reinstall clutch and transmission, as required.

Refer Section 7A2 CLUTCH - GEN III V8

ENGINE, Section 7B2 MANUAL

TRANSMISSION - GEN III V8 ENGINE or

Section 7C4 AUTOMATIC TRANSMISSION.

Figure 6A3-227

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 FLY W HEEL /F L EXPLATE, in this Section.

Manual Transmission:

W hile previousl y, the ring gear was welde d to the flywhee l, the flywhee l/ring gear c om bination is no w a on e-piece,

pressed as sem bl y and, as s uch, is no longer serv icea ble. Sh ould a ny dam age be evident to the r ing gear, t h en the

flywheel must be replaced. Refer to 3.5 ENGINE FLYWHEEL/FLEXPLATE, in this Section.

3.7 CRANKSHAFT SPIGOT BEARING

REPLACE

1. Disc onnec t batt er y grou nd lead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00 CAUTIONS, 5. Battery Disconnection Procedures before disconnecting the battery.

2. Remove manual transmission and the clutch

assembly, refer to Section 7B2, MANUAL

TRANSMISSION - GEN III V8 ENGINE and

Section 7A2 CLUTCH - GEN III V8 ENGINE.

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

6A22-2 and s l ide ham mer 7A28) or c ommercial

equivalent, rem ove the spigot bearing from the

rear of the crankshaft. Discard the removed

bearing.

Figure 6A3-228

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 6A3-229

Techline

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

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

install a repl acem ent bush ( 1) to t he rear of the

crankshaft, until flush with the crankshaft

counter-bore, as shown.

7. Lubricate the bearing with a small amount of

SAE 90 gear oil.

8. Reinstall clutch assembly and manual

transmission, refer to Section 7A2 CLUTCH -

GEN III V8 ENGINE and

Section 7B2 MANUAL TRANSMISSION -

GEN III V8 ENGINE.

9. Reinstall the s tarter m otor. Refer Section 6D3-

2 STARTING SYSTEM - GEN III V8 ENGINE.

10. Reconn ec t batter y ground l ead.

11. Check starter motor operation and road test

vehicle to check transmission and clutch

operation.

Figure 6A3-230

3.8 ENGINE REAR COVER

LT Section No. – 00-200

REMOVE

IMPORTANT: Because of critical alignment

procedures required for the reinstallation 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 6A3-231

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.

REINST ALL

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: T he special tools in t his proce dure ar e used to pr operl y align the engine rear cover at the oi l pan s urface

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: T he c r anks haf t r ear main oil se al MUST be c entr ed in re lat io n to the cra nkshaft and is to be ins ta lled 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.

Techline

1. If removed, inspect the rear main oil gallery

plug and ensure that it is of the later design

(‘A’). If of the ear l ier d es ign ( ‘B ’) th en it must be

replaced.

NOTE: Visually, the later plug has a thicker end

boss (‘X’) that the earlier design (‘Y’).

Figure 6A3-232

2. Lubricate the O-ring with clean engine oil and

install the plug into the rear of the cylinder

block . Caref ull y install u ntil the plu g com es to a

stop agains t the steppe d bore of the oil galler y.

At this point, the plug should be protruding by

approximately 1.2 mm (distance ‘A’).

NOTE: When the rear cover and gasket are

installed, the plug protrusion will rest against the

rear cover machined internal surface.

Figure 6A3-233

3. Install the rear cover gasket, the rear cover and

bolts.

NOTE: If undamaged, the original cover gasket

can be re-used.

4. Only tighten the rear cover bolts finger tight.

Do not overtighten.

Figure 6A3-234

5. Assemble the alignment tool J 41480 to rear

cover and install bolts (1) (part of Tool J 41480)

in the locations shown but do not tighten.

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

engine block and tighten to the specified

torque.

REAR COVER ALIGNMENT TOOL

BOLT TO ENGINE BLOCK

TORQUE SPECIFICATION 25 Nm

Figure 6A3-235

7. Rotate the crankshaft until two opposing

flywheel/ flexplate mounting bolt holes are

parallel to the oil pan surface of the engine

block (arrows).

8. Inst all al ig nment Tool J 41476 to th e rear of the

crankshaft.

NOTE: The tapered le gs of the alignm ent too l m ust

enter the rear cover oil seal bore.

9. Install the two screws supplied with Tool J

41476 and tighten with a screwdriver until

snug. Do not over-tighten.

Figure 6A3-236

10. T ighten the alignm ent T ool J 4148 0 bolts (1) to

the rear cover to the specified torque.

REAR COVER ALIGNMENT TOOL

BOLT TO REAR COVER

TORQUE SPECIFICATION 12 Nm

11. Tighten the engine rear cover bolts to the

correct torque specification.

ENGINE REAR COVER BOLT

TORQUE SPECIFICATION 25 Nm

12. Remove the alignment tools.

Figure 6A3-237

13. 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 an d the st raight e dge tool . T he cover

must be f lush with the oil p an sur fac e or no

mo re than 0.25 m m 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.

14. If the correct rear cover to engine block

alignm ent cannot be obtained, replac e the rear

cover.

Figure 6A3-238

CRANKSHAFT REAR OIL SEAL - INSTALL

IMPORTANT: Do not lubricate the oil seal inside

diameter (ID) nor the crankshaft seal surface

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

with clean engine oil.

DO NOT allow oil or other lubricants to come

into contact with the seal surface.

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

clean engin e 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.

Figure 6A3-239

8. Reinstall flywheel. Refer to 3.5 ENGINE FLY W HEEL/FLEX PLATE, in this Section.

9. Reinstall clutch and transmission, as required. Refer Section 7A2 CLUTCH - GEN III V8 ENGINE,

Section 7B2 MANUAL TRANSMISSION - GEN III V8 ENGINE or Section 7C4 AUTOMATIC

TRANSMISSION.

3.9 OIL PUMP, PUMP SCREEN, AND DEFLECTOR

LT Section No. – 00-251

REMOVE

IMPORTANT: Because of critical alignment

procedures required for the reinstallation of the

front c over and oil pan, i t is strongl y recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove oil pan, refer 3.3 OIL PAN –

REMOVE, in this Section.

2. If the harmonic balancer and front cover have

not already been removed, refer to

2.24 H ARMONIC B ALANCER - REM OVE 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 6A3-240

5. Remove the remaining crankshaft oil deflector

nuts.

6. Remove the c r ank s haf t oil deflector, noting that

the cover orientation is stamped ‘REAR’ to

assist in correct installation.

Figure 6A3-241

7. Remove the four bo lts sec uring the o il 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 6A3-242

OIL PUMP DISASSEMBLE

1. Remove oil pum p cover bolts , then remove th e

cover.

Figure 6A3-243

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 6A3-244

3. Unscrew the oil pressure relief valve plug and

remove spring and valve from the oil pump

body.

Figure 6A3-245

CLEAN AND INSPECT

NOTE: Apart from the oil pr ess ur e relief valve spr i ng, t her e are no oth er 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.

Apart from thread reclam ation and the correction of minor conditions, replace the oil pump assembly if any of the

following conditions are observed.

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 requir ed.

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 splines for excessive wear.

Replace the oil pump pick-up screen and pipe assembly if either of the following conditions are observed.

1. Inspect the oil pump pick-up screen for clogging with debris or restriction.

2. Inspect the screen mesh for broken or loose strands.

OIL PUMP REASSEMBLE

Reassembly is the reverse of the disassembly process, except for the following items:

1. Liberally coat all oil pump components with clean engine oil before assembly.

2. Take note of the relationship of the inner to the outer oil pump gears when assembling.

3. Tighten the oil pump cover screws to the correct torque specification.

OIL PUMP COVER TO BODY SCREW

TORQUE SPECIFICATION 12 Nm

4. Install a NEW pressure relief valve spring.

5. Tighten the pressure relief valve plug to the correct torque specification.

OIL PUMP PRESSURE RELIEF PLUG

TORQUE SPECIFICATION 12 Nm

6. Rotate the assembled pump, checking for smoothness of operation by rotating the inner drive gear.

REINST ALL

1. Chec k the oil pump and e n g in e bloc k oil ga llery

passages to ensure that any debris is

removed.

2. Align the splined surfaces of the crankshaft

sprocket and the oil pump drive gear and install

the oil 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 6A3-246

4. Install the crankshaft oil deflector, noting that

the ‘REAR ’ s tamping o n th e def lec tor is loc a ted

at the rear of the engine.

5. Install a ll the c rank shaf t oil deflec tor nu ts to t he

main bearing cap studs and tighten to the

correct torque specification.

CRANKCASE OIL DEFLECTOR

NUT TORQUE SPECIFICATION 25 Nm

NOTE: Do not install a nut to the stud used to

secure the oil p ick- up bracket, at this time. Refer to

Figure 6A3-248 for the location.

Figure 6A3-247

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

(1) with clean engine oil a nd install onto the oil

pump pick-up tube (2).

7. Fully install the pick-up tube (2) into the oil

pump housing, aligning the support bracket (3)

with the main bearing cap stud.

8. Reinstall the remaining nut (4) to the main

bearing cap stud and tighten to the correct

torque specification.

CRANKCASE OIL DEFLECTOR

NUT TORQUE SPECIFICATION 25 Nm

9. Install the pic k-up tube sc rew (5) and tighte n 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.

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

REINSTALL, in this Section.

11. Reinstall the front cover, refer to 3.4 ENGINE

FRONT COVER – REINSTALL and

2.24 HARMONIC BALANCER - REINSTALL,

in this Section.

Figure 6A3-248

3.10 TIMING CHAIN AND SPROCKETS

LT Section No. – 00-225

REMOVE

IMPORTANT: Because of critical alignment

procedures required for the reinstallation of the

front c over and oil pan, i t is strongl y recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove oil pan, refer 3.3 OIL PAN -

REMOVE, in this Section.

2. If the harmonic balancer and front cover have

not already been removed, refer to

2.24 HARMONIC BALANCER – REMOVE

and 3. 4 ENGINE FRON T COVER – REM OVE,

in this Section.

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

PUMP SCREEN AND DEFLECTOR, in this

Section.

NOTE: If the c ylinder head s and v alve tr ain 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 Figure 6A3-257. Remove the harmonic

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 6A3-249

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 r ankshaf t s procket drive key from

the crankshaft nose, if required.

Figure 6A3-250

CLEAN AND INSPECT

1. Clean the sprockets and timing chain in

suitable solvent and blow dr y with com pressed

air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the timing chain for binding or wear.

Figure 6A3-251

3. Inspect the camshaft and crankshaft sprockets

for:

a. Worn teeth (1 ).

b. Damaged teeth (2).

c. Chipped teeth (3).

d. Worn valleys between the sprocket teeth.

Figure 6A3-252

4. Inspect the crankshaft sprocket keyway (1) for

wear.

5. Inspect the crankshaft sprocket oil pump drive

splines (2) for wear.

Figure 6A3-253

REINST ALL

1. If r em oved, ins ta ll th e c r an k shaf t s pr ocket drive

key into the crankshaft.

T he key should be ta pped into place un til each

end bottoms on the crankshaft.

Figure 6A3-254

2. Install the crankshaft sprocket onto the

crankshaft nose, aligning the keyway with the

key.

3. Use installer J 41665 to install the crankshaft

sprocket, as follows:

a. Install the threaded bolt, nut and flat washer

from Tool J 41478) through the end plate and

stepped sleeve of Tool J 41665.

b. Screw threaded bolt into the crankshaft, using

set spanner (1).

c. While holding the threaded bolt with set

spanner (1), turn the nut on the threaded bolt

with a sec ond set sp anner ( 2), moving ins taller

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 bo lt and r otate the crank shaf t until the

timing alignment mark is at the 12 o’clock

position. Refer Figure 6A3-263.

Figure 6A3-255

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

peg on the camshaft with the sprocket hole.

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

position. Refer Figure 6A3-263.

6. If required, temporarily install the camshaft

sprocket bolts and use a suitable lever to rotate

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. Inst all the camshaf t s pr ock et o ver t he c amshaft

peg.

Figure 6A3-256

9. Before installing the camshaft sprocket bolts

(‘1’ in Figure 6A3-262), 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 BOL T

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 6A3-257

3.11 CAMSHAFT

LT Section No. – 00-175

REMOVE

IMPORTANT: Because of critical alignment

procedures required for the reinstallation of the

front c over and oil pan, i t is strongl y recomm ended

that the engine assembly is removed from the

vehicle, before this service operation is carried out.

1. Remove the intake manifold assembly, if this

operation has not already been carried out.

Refer 2.14 INTAKE MANIFOLD – REMOVE,

in this Section.

2. Remove the camshaft sensor bolt and sensor

from the engine block.

Figure 6A3-258

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 H ARMONIC B ALANCER - REM OVE 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 TIM ING CHAIN AND SPROCKETS

- REMOVE in this Section.

7. Remove the camshaft retainer bolts then

remove the retainer and gasket.

Figure 6A3-259

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

rem oved coolant pump bo lts) in th e 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 6A3-260

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 6A3-261

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 Jour nal Out- of-R ou n d 0.025 mm Max.

Camshaft Bearing Journal Diameter 54.99 mm Min.

Figure 6A3-262

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 6A3-263

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.

Replac e th e c amshaf t if the r unout exc eeds th e

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 6A3-264

REINST ALL

NOTE: If camshaft replacement 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 mm bolts into the

camshaft front journal.

3. Using the b olts as a han dle, c aref ully instal l the

camshaft into the engine block.

NOTE: As all the cam shaf t bearing jour nals are the

same size, care must be taken to avoid bearing

damage during camshaft installation.

4. Remove the three bolts after camshaft

installation.

Figure 6A3-265

5. Ensure that the engine block surface is clean

and free of debris, then install the camshaft

retainer pl ate with th e seali ng gask et f acing the

engine bloc k.

6. Install the camshaft retainer bolts and tighten

to the correct torque specification.

CAMSHAFT RETAINER BOLT

TORQUE SPECIFICATION 25 Nm

Figure 6A3-266

7. Inspect the camshaft position sensor O-ring,

renewing if it is cut or damaged.

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

install to the sensor.

9. Install the camshaft position sensor and the

retaining bolt and tighten to the correct torque

specification.

CAMSHAFT POSITION SENSOR

BOLT TORQUE SPECIFICATION 25 Nm

10. Reinstall the camshaft chain and sprocket.

Refer 3.10 TIMING CHAIN AND

SPROCKETS, in this Section.

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

PUMP SCREEN AND DEFLECTOR, in this

Section.

12. Reinstall the front cover and harmonic

balancer. R efer 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 6A3-267

3.12 PISTON, CONNECTING ROD AND BEARING

LT Section No. – 00-550

NOTE: The following fasteners MUST be replaced ( ! )

when performing this operation:

! Connecting rod bolts and nuts.

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, PUM P SCREEN AND CO VER

– 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 ro tate the cr anks haft unt il the p iston is at

the top of its stroke (TDC).

e. Rem ove the clot h and an y m etal shavin gs f rom

the piston crown.

Figure 6A3-268

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 stam ping mark 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 6A3-269

8. Install guide pins Tool J 41556 to the

connecting rod to be removed.

Figure 6A3-270

9. Use a ham mer handle to tap lightl y 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 6A3-271

DISASSEMBLE

1. Remove the piston rings from the piston.

Figure 6A3-272

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 reas sem bly if original p arts are to

be re-used.

Figure 6A3-273

CLEAN AND INSPECT

Piston and Pin

1. Clean a ny var nish f rom the pis ton an d 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

comm er c ially availab le too l.

4. Clean the oil lubrication holes and slots in the

ring grooves.

Figure 6A3-274

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 6A3-275

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 groov e, MINOR rin g groove im perf ections m ay

be removed with a fine file.

NOTE 2: If binding is caused by a distorted piston

ring, replace the ring.

Figure 6A3-276

NOTE: For each of the following measurements,

ensure that the micrometer zeroing has been

carried out and the measurements are all taken

with components at room temperature.

7. Again using a new piston ring in the correct

location, check the side clearance using a

feeler gauge. If side clearance exceeds

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 ic atio n, t he pis to n a n d pi n ass embl y m us t

be replaced.

Figure 6A3-277

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

measure the pin with a micrometer.

Piston Pin Specification

Piston Pin Diameter 23.997 - 24.000 mm

Figure 6A3-278

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 6A3-279

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

a. With a suitable sized micrometer at right

angles to the piston pin bore, measure the

piston skirt dimension, 11 mm above the

bottom of the skirt.

b. Measure the piston at two different points

and compare the readings

c. If the difference exceeds specification, then

replace the pist on a nd pin ass em bl y.

Piston Skirt Out-of Round Specification

Piston skirt dimension variation 0.018 mm Maximum

Figure 6A3-280

Connecting Rods and Bearings

NOTE: The powdered metal connecting rod and

cap are machined for the correct clearances. The

connecting rod and the cap must be used as an

assembly, with no repairs or modifications carried

out to either mating surface.

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 leng th with s uitable m easuring

equipment.

c. Nicks or gouging in the bearing bore.

d. Damage to the bearing locating slots in the

bearing bore.

e. Correct fit of the connecting rod and cap

mating surfaces.

Connecting Rod Specification

Centre to Centre Length 154.90 ± 0.02 mm

Width 24.00 ± 0.05 mm

Twist 0.010 mm Maximum

Bend 0.02 mm Maximum

Figure 6A3-281

5. Reinstall the connecting rod big end cap and

bolts. Tighten bolts to the correct torque

specification.

CONNECTING ROD CAP BOL T

TORQUE SPECIFICATION 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 6A3-282

7. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves als o ind ic at e fatigu e.

Figure 6A3-283

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 6A3-284

10. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-285

Measuring Piston Ring End Gap

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

to be fitted and push it down the bore, using

the piston, invert ed 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 6A3-286

REASSEMBLE

Piston Selection

NOTE 1: All measurements should be taken at

normal room temperature.

NOTE 2: A used piston and pin set may be

reinstalled if, after cleaning and inspection, they

are both within specification.

1. With a 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 6A3-287

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 ind ic ator.

Figure 6A3-288

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 clearance. If the correct clearance

cannot be obtai ned us ing t his m ethod, then t he

cylinder bore may require honing for an

oversize piston fitment, or the cylinder block

will need to be replaced.

9. When the correct piston to bore clearance is

obtained, mark the piston crown for correct

installation.

NOTE: The cylinder bore must be checked for

ovalit y and taper bef or e th i s operatio n is attempted.

Refer 3.15 CYLINDER BLOCK - CYLINDER

BLOCK CLEAN, INSPECT AND MEASURE, in

this Section.

Figure 6A3-289

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 6A3-290

3. With the connecting rod inserted with the

correct orientation into the piston, insert the

Black piston p in 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-

Figure 6A3-291

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

as shown. Lock this position with the knurled

ring.

Figure 6A3-292

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 h ave equal s pacing on each sid e of the

piston pin boss.

Figure 6A3-293

PISTON RINGS

NOTE: Use commercially available piston rings

pliers and on ly expand th e piston r ing suf f iciently to

slide over the piston. Excessive expansion will

permanently distort the piston ring.

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

following manner:

a. Install the oil control spacer to the lower ring

groove. Ensure that the ends do not

overlap.

b. Install the lower oil control ring segment.

There are no identifying 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 en ds of the three oil c on tr ol ri ng

components b y 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 6A3-294

REINST ALL

NOTE 1: Before installation, check that the piston

ring end gaps are staggered correctly and that the

piston has been assembled to the connecting rod

in the correct manner.

NOTE 2: Before honing the cylinders, refer to

3.15 CYLINDER BLOCK, BORING AND

HONING, in this Section for important information,

relating to this task.

1. Lightly lubricate the piston, cylinder bore,

piston rings and bearing surfaces with clean

engine oil.

2. Remove the connecting rod cap and bearing

shell from the connecting rod being installed

and install the connecting rod guide pins, Tool

J 41556.

3. Install a commercially available piston ring

compressor over the piston rings and

compress.

4. Install the piston and connecting rod assembly

into the cor rect c ylinder bor e, 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.

Figure 6A3-295

7. Remove connecting rod guides, Tool J 41556

and check that the upper bearing shell is

correctly installed in the connecting rod. Apply

clean engine oil to the upper bearing shell.

8. Install lower connecting rod bearing into the

cap, lubricate with clean engine oil and install,

ensuring that the cap orientation is correct.

Refer Figure 6A3-296.

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 6A3-296

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 determ ined 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 different

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

replacement connecting rod bolts, MUST be of the

same 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 BOL T

TORQUE SPECIFICATION Stage 1: 20 Nm

Stage 2: 60° turn angle

DESIGNS ‘B’ and ‘C’

CONNECTING ROD CAP BOL T

TORQUE SPECIFICATION Stage 1: 20 Nm

Stage 2: 75° turn angle

NOTE: Use torque angle meter Tool E7115 to

achieve the second reading.

Figure 6A3-297

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 6A3-298

3.13 CRANKSHAFT AND BEARINGS

LT Section No. – 00-200

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 Section 6D3-2 STARTING SYSTEM - GEN III V8 ENGINE.

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

c. Crankshaft balancer, refer 2.24 CRANKSH AFT B ALANCER, in this Sec t ion.

d. Front cover, refer 3.4 FRONT COVER, in this Section.

e. Oil pump, screen and deflector, refer 3.9 OIL PUMP, PUMP SCREEN AND DEFLECTOR, in this Section.

f. Timing chain, refer 3.10 TIMING CHAIN AND SPROCKETS, in this Section.

g. Flywheel/Flex plate, refer 3.5 FLYWHEEL/ FLEXPLATE, in this Section.

h. Rear cover, refer 3.8 ENGINE REAR COVER, in this Section.

3. Remove the crankshaft position sensor

retainin g bolt, the n rem ove the sensor from the

cylinder bl oc k.

Figure 6A3-299

4. Remove the crankshaft main bearing cap M8

side bolts (1). While these bolts must be

renewed o n final assem bly, place the removed

bolts to one side, as they will be requir ed when

checking the main bearing oil clearance.

5. Remove the main bearing cap M10 bolts and

studs, loosening each pair gradually. Take note

of the stud positions for reassembly.

Figure 6A3-300

6. Loosen the bolts of m ain bearing rem oval Tool

J 41818 to separate the chamfered collets.

Then install the chamfered sections into each

ma in bearing cap bolt h ole, aligni ng 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 6A3-301

9. Remove the remaining main bearing caps in

the same way. Check that the lower main

bearing shells are also removed with each cap.

Figure 6A3-302

10. Rem ove the c rank shaf t fr om the cylind er block ,

lifting evenly to avoid jamming against the main

thrust bearing.

Figure 6A3-303

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 6A3-304

11. Rem ove the crank shaft m ain bearings from the

cylinder block and the main bearing caps.

NOTE: Take par ticu lar car e to organ ise al l par ts s o

they can be reinstalled in their original positions.

Figure 6A3-305

CLEAN AND INSPECT

IMPORTANT: Take care not to damage the

reluctor ring on the crankshaft, as this part is non-

serviceable.

1. Clean the crankshaft with a suitable solvent.

2. Thoroughly clean all oil passages and inspect

for restrictions or burrs.

3. Blow dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

4. Carry out a visual inspection of the crankshaft

for damage.

5. Inspect the crankshaft reluctor ring lobes for

damage. The reluctor ring teeth should not

have imperfections on either the rising or falling

edges.

Figure 6A3-306

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 scratches or

wear (3).

9. Inspect the crankshaft journals for pitting or

embedded bearing material (4).

Figure 6A3-307

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

threaded hole (3) for damage.

Figure 6A3-308

11. Measure all crankshaft journals for wear and

out-of-round.

Crankshaft Journal Specific ations

Connecting Rod Journal Diameter 53.308 mm Min.

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

Connecting Rod Journal Taper 0.010 mm Max.

Main Bearing Journal Diameter 64.993 mm Min.

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

Main Bearing Journal Taper 0.020 mm Max.

Figure 6A3-309

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 dim ens ions:

Crankshaft runout at the front and rear,

intermediate main bearing journals.

Crankshaft rear flange.

Reluctor ring (measured 1.00 mm below the

minimum tooth diameter), at the rear surface.

Crankshaft thrust wall at the centre main

bearing.

Main Bearing Journal Runout Specifications

Reluctor Ring Lateral Runout 0.250 mm Maximum

Crankshaft Thrust Wall Runout 0.025 mm Maximum

Crankshaft Rear Flange Runout 0.050 mm Maximum

Figure 6A3-310

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

BEARI NG – R EP LACE, in this Sec tio n.

Figure 6A3-311

Main Bearings - Inspect

1. Inspect connecting rod bearing halves for

craters or pockets. Flattened sections on the

bearing halves als o ind ic at e fatigu e.

Figure 6A3-312

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 6A3-313

4. Inspect connecting rod bearing halves for

improper seating, indicated by bright, polished

section/s on the bearing material.

Figure 6A3-314

Main Bearing Oil Clearance - Check

1. After thoroughly cleaning all relevant parts,

install bearing halves into the cylinder block

and main bearing caps.

Figure 6A3-315

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 p lace the gaugin g material acr oss

an oil feed hole.

NOTE 2: Ensure that the crankshaft does not

rotate during this process.

Figure 6A3-316

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

the same order as removal.

Figure 6A3-317

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 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.

6. Tighten the side ca p bolts to the cor rect torque

specification, first on one side, then on the

other.

MAIN BEARING CAP SIDE BOLTS

TORQUE SPECIFICATION 25 Nm

Figure 6A3-318

7. Remove the main bearing cap M8 side bolts

(1) and discard, as new bolts m ust be used on

final assembly.

Figure 6A3-319

8. Loosen the bolts of m ain bearing rem oval Tool

J 41818 to separate the chamfered collets,

then install the chamfered sections into each

ma in bearing cap bolt h ole, aligni ng 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 6A3-320

11. Remove the remaining main bearing caps in

the same way.

Figure 6A3-321

12. Using the scale supplied with the gauging

plastic, measure the deformed plastic at its

widest part.

• If the def ormed st rip shows a width var i ation

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 6A3-322

REINST ALL

1. Apply clean engine oil to the bearing halves

and crankshaft journals.

Figure 6A3-323

2. Install crankshaft to cylinder block, ensuring

that the crankshaft is held square to avoid

jamming/ damaging the centre main thrust

bearing.

Figure 6A3-324

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

the correct order.

Figure 6A3-325

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 6A3-326

6. Thrust the crankshaft rearward then forward,

using a suitab le le ver .

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. Mi nor imperfections 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 wil l lessen bearing shoc k when the

engine is started and the clutch is first released.

Figure 6A3-327

8. Inspect the crankshaft position sensor O-ring

for nick s, cuts or other dam age. If undamaged,

the O-ring may be re-used.

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

10. Instal l th e s ens or, al ig ni ng t he r et ain in g br ac ket

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 Sectio n 6D3-2 ST ARTI NG

SYSTEM - GEN III V8 ENGINE.

13. Reinst all engin e into veh icle, ref er 3.1 ENGIN E

ASSEMBLY – REINSTALL in this Section.

Figure 6A3-328

3.14 ENGINE BLOCK PLUGS

LT Section No. – 00-248

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 6A3-329

2. Rem ove the three plugs from the lef t hand s ide

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’.

Figure 6A3-330

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 6A3-331

Techline

NOTE: Only remove the plug from the front of the

engine block, if replacement is required.

4. Rem ove the e ngine b lock , front o il g allery p lug.

A suggested method is to:

a. Drill a small pilot hole through the plug.

b. Install a self tapping screw into the plug.

c. Using a slide ham mer with a suitable

fitting, remove the plug.

d. Discard the removed plug.

Figure 6A3-332

5. To remove the rear oil gallery plug, either one

of two methods can be used:

a. With the fr ont plug r em oved, use a suit able

length of MS rod (e.g. 5 mm ) inserted from

the front of the eng in e bloc k and a h am mer

to tap the rear oil gallery plug free.

b. With the cylinder b loc k plug r emoved (#3 i n

Figure 6A3-330 and position ‘1’), use a

small screwdriver inserted in the plug

aperture to prise the oil galley plug free.

CAUTION: Take care not to slip during this

latter operation, as the machined edges of

aluminium components are extremely sharp.

6. Inspect the O-ring seal on the rem oved gallery

plug and if undamaged, it may be re-used

during assembly.

Figure 6A3-333

7. If removed, inspect the rear main oil gallery

plug and ensure that it is of the later design

(‘A’). If of the ear l ier d es ign ( ‘B ’) th en it must be

replaced.

NOTE: Visually, the later plug has a thicker end

boss (‘X’) that the earlier design (‘Y’).

Figure 6A3-334

REINST ALL

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. Inst all th e pl ug a nd t igh ten t o the c or rec t torq ue

specification, using an 8 mm Allen key socket.

COOLANT DRAIN PLUG

TORQUE SPECIFICATION 60 Nm

Figure 6A3-335

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

565 or equivalent, to the sealing washer on

each of the left hand side engine block plugs.

4. Install each plug and tighten to the correct

torque specification, using an 8 mm Allen key

socket for plugs ‘1’ and ‘3’ and a 17 mm Allen

key socket for plug ‘2’.

COOLANT DRAIN PLUG – ALL

TORQUE SPECIFICATION 60 Nm

Figure 6A3-336

5. Lubricate the O-ring with clean engine oil and

install the plug into the rear of the cylinder

block . Caref ull y install u ntil the plu g com es to a

stop agains t the steppe d bore of the oil galler y.

At this point, the plug should be protruding by

approximately 1.2 mm (distance ‘A’).

NOTE: When the rear cover and gasket are

installed, the plug protrusion will rest against the

rear cover machined internal surface.

Figure 6A3-337

6. Apply a sealant such as Loctite 242 or

equivale nt to the s ide of a NEW front oil gallery

plug.

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

engine bloc k to the specif ie d dep th, to clear t he

engine bloc k chamfer .

Front Oil Gallery Plug Installation Specification

Below Flush 2.2 - 2.8 mm

Figure 6A3-338

8. App l y seal ant s uch as Loc t i te 56 5 or e qui va le nt

to the cleaned threads of the oil pressure

sensor (1) and reinstall, using Tool No. J

41712 and suitable 3/8” drive socket

equipment. Tighten to the correct torque

specification.

OIL PRESSURE SENSOR

TORQUE SPECIFICATION 20 Nm

Figure 6A3-339

3.15 CYLINDER BLOCK

LT Section No. – 00-248

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

first remove the cylinder heads and hydraulic

lifters . By removi ng the push r ods and inver ting the

engine, the hydraulic lifters will drop sufficient to

clear the camshaft journals.

1. Prior to bearing removal, inspect all camshaft

bearings for a loose fit in the engine block

bearing bores .

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

have been caused by an enlarged, out of round or

damaged engine block bearing bore.

Figure 6A3-340

2. The universal camshaft bearing

rem over/installer, Tool J 3 3049, consis ts 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).

Figure 6A3-341

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 6A3-342

5. Once installed, ensure that the separations in

the expander assembly segments, are aligned

with those of the expanding driver as shown

(‘A’).

Figure 6A3-343

6. Manoeuvre the assembly into the cylinder

block, in front of the bearing to be removed,

then install the large driving washer (3) over

the threaded end of the expander assembly

(5).

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

with the smaller diameter toward the cylinder

block.

NOTE: The components shown in Figure 6A3-349

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 6A3-344

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 on e

hand, drive the bearing from the cylinder block.

12. Repeat this process with the remaining

bearings being removed.

Figure 6A3-345

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 6A3-346

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

way to bearing removal, except for the

follo wing items :

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

must be aligned with the top of the engine

block. To assist with alignment, use a felt tip

pen to mark the back of the bearing, 180°

from the join, as this will be visible when

install ing the bear ing .

b. While the o il 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 care when installing the

driver bar through the newly installed bearings

to avoid damage.

Figure 6A3-347

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.

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

2. Dry the block with compressed air.

CAUTION: Wear safety glasses to avoid eye injury.

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

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

passages and oil galleries.

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

6. Clean a ny res idue of c ylinder hea d bo lt thre ad se alant fr om the c ylinder b lock threads , us ing ins taller, 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 compressed air to clean all residue from bolt holes.

CAUTION: Wear eye protection to prevent injury.

Inspect

Inspect the following areas:

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

2. The coolant jacket for cracks.

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

4. The crankshaft bearing webs for cracks.

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

6. The oil galleries for restrictions.

7. All threaded bolt holes for damage.

Measure Cyli nder 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 6A3-348

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 6A3-349

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 . Chec k for bore 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 0.18 mm out-of-

round must be honed and fitted with an

oversi ze piston.

Figure 6B3-350

Measure En gine Bl oc k 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 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 Proc edure

1. Oversize service piston and piston ring sets

are available in 0.25 mm.

IMPORTANT: GEN III V8 cylinder boring is not

permitted.

2. It is recommended to hone the cylinder to

achieve proper f it for the o vers ize pisto n. Refer

to the CYLINDER HONING PROCEDURE for

the proper honing information.

Honing Proced ur e

1. When honing the cylinders, follow the

manufacturer's recommendations for

equipment use, cleaning, and lubrication. Use

only clean, sharp stones of the proper grade

for the amount of material you remove. Dull,

dirty stones cut unevenly and generate

excessive heat. Do not hone to final clearance

with a coarse or medium-grade stone. Leave

sufficient metal so that a ll stone marks m ay be

removed with fine-grade stones. Perform final

honing with a fine-grade stone, honing the

cylinder to the proper clearance.

2. During the honing operation, thoroughly clean

the cylinder bore. Repeatedly check the

cylinder bore for f it with the s elected pis ton. All

measurements of the piston or the cylinder

bore should be made with the components at

normal room temperature.

3. When honing a cylinder for fit to an oversize

piston, f irst perform the preliminar y ho ning with

a 100 grit stone.

Figure 6A3-351

4. Perform final cylinder honing with a 240 grit stone and obtain a 45 degree cross hatch pattern.

5. A 240 grit stone is preferred for final honing. If a 240 grit stone is not available, a 220 grit stone may be used as

a substitute.

6. When honing to eliminate taper in the cylinder, make full strokes for the complete bore length. Repeatedly

check the measurement at the top, the middle, and the bottom of the bore.

7. The finis h marks should be clean b ut not sharp. T he finish m ark s should also b e free fr om embedded p articles

and torn or folded metal.

8. By measurin g the select ed piston at the sizi ng point a nd by addin g the aver age of the c learance spec ificati on,

the final cylinder honing dimension required, can be determined.

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

taper requirements.

10. After f inal ho nin g a nd bef or e th e p ist on is c hec ked for fit, c lean th e cylinder bor es with hot water an d d eter g e nt.

Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any

abrasive m ater ial to rem ain in the c ylinder b ores . This abrasive m aterial m a y cause prem ature we ar of the ne w

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 grit s tone is preferred f or final honing. If a 240 grit stone is not av ailable, a 220 grit s tone ma y be us ed as a

substitute.

3.16 THRE AD REPAIR

GENERAL INFORMATION

With the extensive use of aluminium alloy in the

construction 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.

Detailed descriptions of all thread specifications

used in this engine are listed in 3.17 THREAD

REPAIR SPECIFICATIONS in this Section,

contains .

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 installe d to the proper de pth, the flang e

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,

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 wr enc h or dri ll motor.

Figure 6A3-352

GENERAL THREAD REPAIR

1. Drill out the t hreads 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 inser ts requir e a minimum dr ill de pth of

23.5 mm.

2. Using compressed air, clean out any chips.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-353

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 6A3-354

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 requ ire a m inim um 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 n ot use any cleani ng agents tha t

contain Trichloralethane, as this is harmful to

aluminium.

8. Using compressed air, clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-355

9. Lubricate the threads of the installer tool (2)

with the driver oil ( 1).

IMPORTANT: Do not allow oil or other foreign

material to contact the outside diameter (OD) of the

insert.

Figure 6A3-356

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

Figure 6A3-357

11. Apply threadlock Loctite 272 (1) or equivalent

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

(2).

Figure 6A3-358

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 counter-bored 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 6A3-359

16. Ins pect t he ins ert f or pr oper ins tallati on int o the

hole.

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

or slightly below flush with the surface of the

base material (2).

Figure 6A3-360

CYLINDER HEAD BOLT HOLE THREAD REPAIR

The cylinder head bolt hole thread repair kit

consists of the following items:

1. Drill

2. Tap

3. Installer

4. Sleeve

5. Alignment Pin

6. Bushing

7. Bolts

8. Fixture Plate

Figure 6A3-361

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 wr enc h or dri ll 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 6A3-362

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 6A3-363

6. Cylinder head bolt holes 1-8 are the deep

holes and will be dr illed without the dr il l slee ve.

7. C ylinder h ead b olt ho les 9 and 10 ar e the more

shallow holes, so drilling MUST be done with

the drill sleeve in place

Figure 6A3-364

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

required).

Figure 6A3-365

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 6A3-366

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

drilled hole.

Figure 6A3-367

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 t ap unt il th e u pper mark on the

tap (4) aligns with the top of the drill

bushing.

• For the shallower cylinder head bolt holes

(9 and 10), rotate the tap until the lower

mark on the tap (1) aligns with the top of the

drill bushing.

14. Remove the fixture plate (2), bushing (3), and

bolts.

15. Using compressed air, clean out any chips.

16. Spray a suitable cleaner such as GM P/N

12346139, P/N 12377981 or equivalent, into

the hole.

IMPORTANT: Do n ot use any cleani ng agents tha t

contain Trichloralethane, as this is harmful to

aluminium.

17. Using compressed air, clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-368

18. Lubricate the threads of the installer tool (2)

with the driver oil ( 1).

IMPORTANT: Do not allow oil or other foreign

material to contact the outside diameter (OD) of the

insert.

Figure 6A3-369

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

Figure 6A3-370

20. Apply threadlock Loctite 272 (1) or equivalent

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

(2).

Figure 6A3-371

21. Install the insert and driver (1) into the hole.

22. Continue to install the insert until the flange of

the insert contacts the counter-bored 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 6A3-372

MAIN CAP BOLT HOLE THREAD REPAIR

The m ain cap bolt hole thr ead repair k it 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 6A3-373

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 wr enc h or dri ll 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 6A3-374

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 6A3-375

5. In order to tap the new threads to the proper

depth, rotate the tap into the hole until the

marks (1 or 4) on the tap align with the top of

the drill bushing (3), as follows:

• For the deeper main cap holes (1-10),

rotate the tap until the upper mark (4) on

the tap aligns with the top of the bushing

(3).

• For the shallower main cap holes (11-20),

rotate the tap until the lower mark (1) on

the tap aligns with top of the bushing (3).

6. Remove the fixture plate (2), bushing (3), and

bolts.

7. Using compressed air, clean out any chips.

8. Spray a suitable cleaner such as GM P/N

12346139, P/N 12377981 or equivalent, into

the hole.

IMPORTANT: Do n ot use any cleani ng agents tha t

contain Trichloralethane, as this is harmful to

aluminium.

9. Using compressed air, clean any cutting oil and

chips out of the hole.

CAUTION: Wear safety glasses to avoid eye

injury.

Figure 6A3-376

10. Lubricate the threads of the installer tool (2)

with the driver oil ( 1).

IMPORTANT: Do not allow oil or other foreign

material to contact the outside diameter (OD) of the

insert.

Figure 6A3-377

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

Figure 6A3-378

12. Apply threadlock Loctite 272 (1) or equivalent

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

(2).

Figure 6A3-379

IMPORTANT: T he fixture plate ( 1) and bushin g (2)

remains installed onto the engine block during the

insert installation procedure.

13. Install the insert and driver (3) through the

fixtur e plate and bushi ng a nd into the ho le.

14. Rotate t he driver too l until the m ark 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 6A3-380

3.17 THREAD REPAIR SPECIFICATIONS

ENGINE BLOCK - FRONT VIEW

Figure 6A3-381

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

1-6 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17.5

7 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 25.0 19.5

8 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 32.5 25.0

9 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

10 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 Through Through

11-13 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

14 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Through 18.0

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

16 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Through 18.0

17-27 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

ENGINE BLOCK - REAR VIEW

Figure 6A3-382

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

1 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 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 6A3-383

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

1 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

2-3 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

4 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 16.0

6-7 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

8 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

9 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 69.0 60. 0

10 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

11        

12-17 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 23. 0

18 M28 x 1.25       

19-20 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 16. 0

21 M16 x 1.5       

22 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27. 0 21.5

23 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

24 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 69.0 60.0

25 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

26-27 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

28 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22. 5 16.0

29 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

• Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm counterbore included in the 124.0 mm drill depth.

• Bolt holes 9 and 24 have a 30 mm counterbore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the drill and tap.

ENGINE BLOCK - RIGHT SIDE VIEW

Figure 6A3-384

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

1 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

2-3 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

4 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 15.0

6-7 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

8 M8 x 1. 25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19. 0

9 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 69.0 60. 0

10 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

11-14 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 21. 5

15-19 M10 x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 23. 0

20 M16 x 1.5       

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

22 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

23 M11 x 2 J 42385-108 J 42385-105  J 42385-106 J 42385-107 69.0 60. 0

24 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

25-26 M11 x 2.0 J 42385-108 J 42385-105  J 42385-106 J 42385-107 124.0 115.0

27 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22. 5 15.0

28 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 19.0

• Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have a 85 mm counterbore included in the 124.0 mm drill depth.

• Bolt holes 9 and 23 have a 30 mm counterbore included in the 69.0 mm drill depth. Use sleeve J 42385-315 with the drill and tap.

ENGINE BLOCK - BOTTOM VIEW

Figure 6A3-385

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

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

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

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

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

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

6 M16 x 1.5       

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

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

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Depth

Maximum

Tap Depth

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

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

28-29 M10 x 2.0 J 42385-104 J 42385-101  J 42385-102 J 42385-103 53.5 44. 0

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

31 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

32 M28 x 1.25       

33 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

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

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

36 M8 x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 17. 5

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

• Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm counterbore included in the 31.0 mm drill depth. Use sleeve J 42385-

316 with the drill and tap..

• Bolt holes 13 and 14 have a 11.5 mm counterbore included in the 42.5 mm drill depth. Use sleeve J 42385-311 wi t h t he drill and tap.

ENGINE BLOCK - TOP VIEW

Figure 6A3-386

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dept h

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 6A3-387

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dept h

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 6A3-388

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dept h

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 6A3-389

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dept h

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 6A3-390

Hole Thread Size Insert Drill Counterbore

Tool Tap Driver

Maximum

Drill Dept h

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 performance diagnosis procedures are covered in Section 6C3 POWERTRAIN MANAGEMENT GEN

III V8 ENGINE and should be referred to for diagnosis of any Driveability, Emissions, or Check Powertrain

Lamp concerns.

2. The following diagnosis covers common concerns and possible causes.

3. When the proper diagnosis is made, the co ncern shou ld be corrected by adjustm ent, repair or r eplacement as

required.

4. Refer to the appropriate section of the service manual for each specific procedure.

5. This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty

camshaft, worn or damaged bearings or bent pushrod.

6. This table will not isolate a crossed injector wire, fault y injector or any other driveability component f ailure 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, DIA GNOSTIC CHARTS.

8. When 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 inspectio n 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 cylin der head sea lin g surfa ce.

Coolant Cons umption 1. Coolant consumption may or may not cause the engine to overheat. Inspect for

the following:

• External coolant lea ks.

• Faulty cylinder head gasket.

• Warped 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.

• Pist on damage.

Abnormal Internal Engine Noises 1. With the engine running, try and determine if the noise is timed to camshaft

speed or crankshaft spe ed.

NOTE: Using a timing light, two knocks per flash is crankshaft speed and one knock

per flash is camshaft spe ed.

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 which the noise exists. Note factors such as the ambient temperature, 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

components) or one-half engine speed (valve train noise such as rocker arms, valve lif ters, and tim ing chain). Try

to determine the rate at which the noise is occurring.

Compare the engine sounds to other engines. This is required to make sure you are not trying to correct a

normal condition.

Checks Action

Noise on Start-Up but Only Lasts a

Few Seconds 1. This noise condition may be cause d by:

• Improper oil viscosity. Install the recommended oil viscosity for the expected

temperatures.

• Incorrect oil filter without the a nti-dra inb ac k 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 1. Common causes for a cold start knock, are:

• Loose or broken crankshaft ba lanc er or acces sory driv e com ponen ts.

• 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

1. Intermittent noises at idle can be caused by:

• 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.

Checks Action

Valve Train Noise (Rattle/Tapping) 1. The following conditions may cause valve train noise:

• Lower than specified oil pressure.

• Worn or faulty oil pump.

• Loose oil pump-to-engine block bolts.

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

• Loose valve rocker arm attachments.

• Worn valve rocker arm bearings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticki ng 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.

Knocks at Idle Hot

(Rumble/Knocking) 1. The following conditions may cause a knocking noise:

• Malfunctioning accessory drive system components.

• Loose or broken crankshaft ba lanc er.

• 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.

• 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 compo nen ts.

• 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.

Thes e tapping nois es will t ypic ally increase with eng ine speed.

• Before attempting to diagnose valve train noise, check for the proper oil level and thoroughly warm up the

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

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

• Whenever Valve Lifter Diagnosis is necessary, always use a listening device such as a stethoscope. Tools

such as this will help to isolate any lifter noise and identify noises that could be mis-diagnosed as lifter noise.

DIAGNOSTIC PROCEDURE

Checks Action

A light tapping noise similar to valve

train noise.

1. This light type of noise may be caused by the following:

• Fuel injectors.

• Evaporative emission (EVAP) purge solenoid.

• Detonation.

• Loose heat shields.

Causes of Valve Train Noise

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

• Poor oil quality caused by water contamination, aeration, or fuel dilution.

• Low engine oil pressure.

• Worn or faulty oil pump.

• A loose or plugged oil pump screen.

• Loose or damaged oil transfer tube.

• Loose valve rocker arm attachments (causing excessive valve lash).

• Worn or damaged valve rocker arm bearings.

• Worn valve rocker arm and/or pushrod.

• Broken valve spring.

• Sticki ng 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.

Techline

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: Excess ive oil c onsumption ( not due to lea ks) is the use of 0.95 l itres or m ore of engine oi l within 2,500

kilometres.

Checks Action

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

• External oil leaks. Refer to 4.6 OIL LEAK DIAGNOSIS in this Section.

• Incorrect oil level or improper reading of the oil level indicator. W ith 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 eng ine oil lev el.

• 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.

4.5 OIL PRESSURE DIAGNOSIS

Conduct an oil pressure check, as detailed in 2.4 ENGINE OIL PRESSURE - CHECK, in this Sec ti on

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

the leak.

Can you identify the type of fluid and the approximate location

of the leak?

− Go to Step 10 Go to Step 3

3. 1. Visually inspec t 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 inspec t 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 powder surface discolouration.

Can you identify the type of fluid and the approximate location

of the leak?

− Go to Step 10 Go to Step 7

7. 1. Visually inspec t 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

Step Action Value(s) Yes No

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 inspec t 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 compon ents.

• Improper sealant s or gasket s w here required.

• Improper sealant or gasket ins talla tion .

• Damaged or worn gaskets or seals.

• Damaged or worn sealing surfaces.

Is there mechanical damage to the engine?

− Go to Step 11 −

11. Repair or replace all damaged components. − Go to Step 1 −

5. SPECIFICA T IONS

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

LUBRIC ATION SYSTEM

Oil Capacity (without Oil Filter Change)............................. 5.2 litres

Oil Capacity (with Oil Filter Change).................................. 5.7 litres

Oil Pressure (Minimum-Hot) .............................................. 90 kPa @ 1,000 rpm

125 kPa @ 2,000 rpm

165 kPa @ 4,000 rpm

Oil Type.............................................................................. 10W - 30 SJ GF2 (Service Refill)

CAMSH AFT

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 Manif old Dec k Flatness........................................ 0.22 0 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

INTA KE 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 Surf ace) ...................... 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 SYST EM

Valve Lifter ............................................................................ Hydraulic Roller

Valve Rocker Arm Ratio........................................................ 1.70:1

Valve Lash............................................................................. Net Lash-No Adjustment

Valve Margin ......................................................................... 1.25 Minimum

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

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

Valve Seat Runout ................................................................ 0.050 mm (Maximum)

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

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

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

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

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

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

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

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

Valve Spring Free Length ..................................................... 52.9 mm

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

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

Installed Height (Intake)..................................................... 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

SEALAN T S AND ADH E S I V E S

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

NOTE

Fasteners must be replaced after loosening.

•

••

•

Vehicle must be at curb height before final tightening.

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

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

Air Conditioning Compressor Drive Belt Idler Pulley Bolt ................................. 50

Air Conditioning Compressor Mounting Bracket to Cylinder Block Bolts.......... 50

Air Conditioning Compressor to Mounting Bracket Bolts.................................. 50

Accelerator Control Cab le Brac k et Bolts........................................................... 10

Accessor y Drive Belt Idler Pul ley Bolt............................................................... 50

Accessory Drive Belt Tensioner Bolt................................................................. 50

Alternator Bracket to Cylinder Block Bolts ........................................................ 50

Alternator Support Bracket to Cylinder Block Bolts .......................................... 30

Catalytic Converter Bracket Bolts to Catalytic Converters................................ 25

Catalytic Converter Bracket Bolts/Nuts to Manual Transmission Extension .... 50

Camshaft Retainer Bolts................................................................................... 25

Camshaft Position Se ns or Bol t ......................................................................... 25

Camshaft Sprocket Bolts................................................................................... 35

Close-out Cover Retaining Bolt (Each Side)..................................................... 12

Clutch Housing to Engine Block Bolt (Manual Transmission)........................... 50

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

Stage 2 (‘A’ design only)........................ 60° turn angle

Stage 2 (‘B’ and ‘C’ designs).................. 75° turn angle

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

Coolant Inlet Housing Bol ts............................................................................... 15

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

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

Crankshaft Balancer Bolt: .................Stage 1 with new Bolt............................. 50

Stage 2 with new Bolt............................. 140° turn angle

Crankshaft Main Bearing Cap Bolts..(Inner – Stage 1 in Sequence)............... 20

(Inner – Stage 2 in Sequence)............... 80° turn angle

Crankshaft Main Bearing Cap Studs.(Outer – Stage 1 in Sequence) .............. 20

(Outer – Stage 2 in Sequence) .............. 53° turn angle

! "

Crankshaft Main Bearing Cap Side Bolts ........................................................ 25

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° turn angle

Stage 3 – only Longer M11 Bolts........... 90° turn angle

Stage 3 – only Medium Length Bolts..... 50° 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...................................................................... 6

Engine Dress Cover Retaining Nut................................................................... 10

Engine Front Cover Bolts.................................................................................. 25

Engine Mount to Bracket or Crossmember Nut................................................ 80

Engine Mount Bracket to Cylinder Block Bolt ................................................... 50

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

" Ex haus t Man ifold Bo lts...........................Stage 1.............................................. 15

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

Exhaust Manifold Heat Shi eld Bo lt.................................................................... 9

! Flywheel/Flexplate Bolts (in Sequence) Stage 1.............................................. 20

Stage 2.............................................. 50

Stage 3.............................................. 100

" Fuel Rail Bolts................................................................................................... 10

" 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 Sc re w Plug ............................................................................ 25

Oil Pan Baffle Bolts ........................................................................................... 12

Oil Pan Closeout Cover Bolt (Either Sid e) ........................................................ 10

Oil Pan Drain Plug............................................................................................. 25

" O il Pan Gal ler y 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-Tra y Bolt.................................................................................... 30

" Oil Pressure Sensor.......................................................................................... 20

Oil Pump-to-Eng ine Bloc k 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.............................................................................................. 48

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

Torque Converter Housing to Engine Block Bolts (Automatic Transmission) .. 50

" Torque Converter to Flexplate Attaching Bolts (Automatic Transmission)....... 65

Transmission Crossmember to Side Frame Bolts ............................................ 25

Transmission Support to Crossmember Nuts................................................... 60

Transmission Support to Transmission Extension Housing Bolts .................... 25

Valve Lifter Guide Bolts..................................................................................... 12

! Valve Rocker Arm Bolts.................................................................................... 30

Vapour Vent Pipe Bolts and Studs.................................................................... 12

7. SPECIAL TOOLS

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

E308

SEAL REMOVER

Previously released.

Also num ber ed, 5675 0

Desirable

49 U012 006

T6A3114b

HYDRAULIC VALVE LIFTER

TESTER

Previously released.

Used in conjunction with testing

fluid SPx No. E1151

Also num ber ed 6A23.

Unique

E1152

VALVE LIFTER ASSEMBLY

TOOLS

Used to assist in assembly of the

hy draulic valve lifters.

Previously released, as 6A24.

Unique

J6125-1B SLIDE HAMMER

Used in conjunction with J 41818

to remove main bearing caps.

Previously released.

Unique

7371

QUICK CONNECT RELEASE

TOOL

Previously released for releasing

fuel line quick connects on V6 S/C

engine after fuel system has been

de-pressurised.

Used on GEN III V8 engine for the

same purpose

Mandatory

E 7115

TORQUE ANGLE WRENCH

Used to accuratel y tighten

fasteners when an angle torque is

required.

Previously released.

Unique

J 8087 CYLINDER BORE CHECKING

GAUGE

Also as a commercial equivalent.

Previously released.

Unique

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

J 8433-1

PULLEY PULLER

Used to remove GEN III V8

engine crankshaft timing gear

sprocket, in conjunction with J

41558 and J 41816 –2.

Previously released.

Unique

J 21427-01 PULLER AD APT O R

Used in conjunction with J 8433-1,

J 41558 and J 41816-2 to remove

crankshaft timing gear sprocket.

Previously released to remove

automatic transmission speed

sensor ring.

Unique

J 22794

T6A3256a

ADAPTOR

Used to facilitate the application of

air pressure to a cylinder when

replac ing a val ve sprin g or va lv e

stem oil seal with the cylinder

head installed.

Previously released.

Desirable

J 23907

SLIDE HAMMER

Also released as remover, 6A22-2

and slide hammer 7A28.

Previously released.

Unique

J 24086-C

PISTON PIN

REMOVER/INSTALLER

Universal tool containing selective

components to suit multiple

engine applicati ons.

Previously released.

Unique

J 28431-B

FLUID DYE

Used in conjunction with black

light, leak detection lamp J 42220

to locate various types of vehicle

fluid leak s .

Supplied in packs of 24, 1 ounce

bottles.

Previously released.

Desirable

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

J 33049

CAMSHAFT BEARING

REMOVER/ INSTALLER

Universal tool containing selective

components to suit multiple

engine applicati ons.

Previously released.

Unique

J 37378-1

VALVE GUIDE REAMER

Used to ream worn valve guides

to su it oversize valve stem.

Previously released.

Unique

J 38836

T6A3 189b

PILOTED DRIVER

Used to install the spigot bush in

the crankshaft.

Previously released.

Unique

J 41476

T6A3257a

FRONT AND REAR COVER

ALIGNMENT TOOL

Used to align both the front and

rear engine covers during

installation.

Previously released.

Desirable

J 41478

T6A3258a

CRANK SHAFT FRONT OIL SEAL

INSTALLER

Threaded bolt, nut and washer are

also used in conjunction with

J 41665 to install the crankshaft

balancer.

Previously released.

Desirable

J 41479

T6A3259

CRANKSHAFT REAR OIL SEAL

INSTALLER

Previously released.

Desirable

J 41480

T6A3260a

FRONT AND REAR COVER

ALIGNMENT TOOL

Used in conjunction with

alignment tool J 41476, to

correctly align the front and rear

engine covers.

Previously released.

Desirable

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

J 41556 CONNECTING ROD GUIDES

Used to assist in piston and

connecting rod installation.

Previously released.

Desirable

J 41558 CRANKSHAFT SPROCKET

REMOVER

Used in conjunction with the bolts

from J 21427-01 and pulley puller

J 8433, to remove the crankshaft

sprocket.

Previously released.

Desirable

J 41665

CRANKSHAFT BALANCER

INSTALLER

Comprises stepped sleeve, J

41665-1 and end plate J 41665-2.

Used in conjunction with Tool J

41478, to install the crankshaft

balancer and crankshaft sprocket.

Previously released.

Desirable

J 41712

OIL PRESSURE SENSOR

SOCKET

Used in conjunction with 3/8” drive

socket equipment to

rem ove/r eins ta ll oi l press ure

sensor.

Previously released.

Desirable

J 41816

THREE LEGGED PULLER

Used in conjunction with J 41816-

2 to remove crankshaft balancer.

Also commercially available.

Previously released.

Desirable

J 41816-2

ADAPTOR

Used in conjunction with puller J

41816 to remove crankshaft

balancer.

Previously released.

Desirable

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

J 41818

CRANKSHAFT BEARING CAP

REMOVER

Used in conjunction with slide

hammer J 6125-1B to remove

main bearing caps.

Previously released.

Desirable

16296 BLACK LIGHT, LEAK

DETECTION LAMP

Used with dye, Tool J 28431-B to

locate the source of various

ve hicle fluid leaks.

Previously released.

Desirable

J 42385

THREAD REPAIR KIT

Comprises;

Cylinder Head/Rear Main

Bearing Cap K it J 42385-

100

General Kit J 42385-200

Fixtures /Hard war e Kit J 42385-

300

Previously released.

Unique

J 42386

FLYWHEEL HOLDING TOOL

Previously released.

Desirable

J 42907

OIL PRESSURE ADAPTOR

Fitted to the oil filter adaptor and

used in conjunction with a

comm er c ially avai lab le oi l

pressure gauge and hose.

Previously released.

Desirable

J38606

VALVE SPRING COMPRESSOR

Used in conjunction with spark

plug adaptor J 22794 to remove

valve springs with cylinder head/s

installed.

Previously released as KD2078,

for the V6 engine.

Desirable