Crusader MP 5.0L Wartungshandbuch

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Inhaltsverzeichnis

Seite 1 - 50/60 kW (5.7 L)

EngineEngine Model:General Motors 5.0 L PowertrainGeneral Motors 5.7 L PowertrainGenerator Models:50 kW (5.0 L)50/60 kW (5.7 L)TP-6104 11/01aService

Seite 2

Fastener Tightening Specifications (cont’d)ApplicationSpecificationMetric EnglishEngine Block Coolant Drain Hole Plug 20 N·m 15 lb ftEngine Block Oil Ga

Seite 3 - Table of Contents

Notice:SIO-ID = 5005 The Linear EGR valve is anelectrical component. DO NOT soak in any liquidcleaner or solvent because damage may result.10. Remove

Seite 4 - Table of Contents, continued

14. Remove the manifold absolute pressure (MAP)sensor from the upper intake manifold.15. Remove the MAP sensor seal from the MAPsensor.16. Discard the

Seite 5 - Introduction

26. Remove the upper intake manifold studs (1).27. Remove the upper intake manifold (2).28. Remove the upper intake manifold to lower intakemanifold g

Seite 6 - TP-6104 11/01ii Introduction

3. Clean the lower intake manifold in cleaningsolvent.4. Dry the lower intake manifold with compressed air.5. Inspect the upper intake manifold for th

Seite 7

Intake Manifold AssembleSIE-ID = 1945131. Install the fuel meter body (5) into the lower intakemanifold (6).2. Install the 8 poppet nozzles into the l

Seite 8

12. Install the NEW fuel seals (8), black O-rings, intothe fuel meter body.13. Install the NEW spacer rings (7), flat washers, intothe fuel meter body.

Seite 9

23. Install the ignition coil and studs.TightenTighten the ignition coil studs to12 N·m (106 lb in).24. If reusing the engine coolant temperature (ECT

Seite 10

27. Install the EGR valve bolts.Tighten27.1. Tighten the EGR valve bolts on thefirst pass to 10 N·m (88 lb in).27.2. Tighten the EGR valve bolts on the

Seite 11 - SIE-ID = 784228

35. Install the accelerator control bracket, the bolt,and the nut.TightenTighten the accelerator control bracket bolt andthe nut to 12 N·m (106 lb in)

Seite 12

Water Pump Cleaning and InspectionSIE-ID = 194965Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Remove the old gasket material fro

Seite 13 - SIE-ID = 784231

Fastener Tightening Specifications (cont’d)ApplicationSpecificationMetric EnglishSpark PlugInitial Installation – NEW Cylinder Head 30 N·m 22 lb ftAll S

Seite 14

8. Screw the thread insert onto the mandrel of thethread insert installer. Engage the tang of thethread insert onto the end of the mandrel.Important:

Seite 15 - SIE-ID = 378556

Service Prior to AssemblySIE-ID = 43122• Dirt will cause premature wear of the rebuiltengine. Clean all the components.• Use the proper tools to measu

Seite 16

Engine Block Plug InstallationSIE-ID = 348917Tools RequiredJ 41712Oil Pressure Switch SocketCaution: Refer to Safety Glasses Caution inCautions and No

Seite 17 - Component Locator

5. Apply sealant GM P/N United States 12346004,GM P/N Canada 10953480, or equivalent, to thethreads of the left side rear and left rear topengine oil

Seite 18

11. Apply threadlock GM P/N United States 12345382,GM P/N Canada 10953489, or equivalent, to theoutside diameter of the NEW engine blockcore hole plug

Seite 19 - SIO-ID = 197523

18. Apply sealant GM P/N United States 12346004,GM P/N Canada 10953480, or equivalent, to thethreads of the engine oil pressure gage sensor.19. Instal

Seite 20 - SIO-ID = 197712

3. Apply clean engine oil to the crankshaft bearingjournals.4. Install the crankshaft.5. Install the crankshaft bearings into the crankshaftbearing ca

Seite 21 - SIO-ID = 348439

11. Ensure that the crankshaft bearing caps are fullyseated in the engine block crankshaft bearing capchannel, and that the crankshaft bearing capsare

Seite 22

Crankshaft Rear Oil Seal and HousingInstallationSIE-ID = 348923Tools RequiredJ 35621-BRear Main Seal InstallerNotice:Refer toFastener Noticein Caution

Seite 23 - SIO-ID = 197524

11. Apply a small amount, approximately 2–3 drops,of clean engine oil GM P/N UnitedStates 12345610, GM P/N Canada 993193, orequivalent, to the outside

Seite 24 - Engine Identification

Engine Mechanical Specifications (5.0 L) (cont’d)ApplicationSpecificationMetric EnglishCrankshaftCrankshaft Bearing Clearance – Journal #1 – Production

Seite 25 - Repair Instructions

3. Install theJ 8037onto the piston and compressthe piston rings.Important: The mark on the top of the piston mustface the front of the engine block.W

Seite 26 - Engine Flywheel Removal

7. Remove theJ 5239from the connecting rod bolts.Notice:Refer toFastener Noticein Cautions andNotices.8. Install the connecting rod bearing, cap, and

Seite 27 - SIE-ID = 650060

Camshaft InstallationSIE-ID = 66855Notice:SIO-ID = 13833 All camshaft journals are thesame diameter, so care must be used in removingor installing the

Seite 28 - Water Pump Removal

Timing Chain and Sprockets InstallationSIE-ID = 69464Tools RequiredJ 5590Installer1. Install the crankshaft balancer woodruff keys intothe crankshaft

Seite 29

Notice:SIO-ID = 788777 Do not use tools to force thecamshaft sprocket onto the camshaft. The camshaftsprocket is a slip fit onto the camshaft and doesn

Seite 30

Engine Front Cover InstallationSIE-ID = 194773Notice:Refer toFastener Noticein Cautions andNotices.Important: Do not reuse the composite type enginefr

Seite 31 - Distributor Removal

Oil Pump, Pump Screen and DeflectorInstallationSIE-ID = 194869Tools RequiredJ 36660-ATorque Angle Meter1. Inspect for properly installed oil pump locat

Seite 32 - Intake Manifold Removal

Oil Pan InstallationSIE-ID = 66859Notice:Refer toFastener Noticein Cautions andNotices.1. Install the oil pan studs into the engine block.TightenTight

Seite 33 - SIE-ID = 66690

Important: Always install a NEW oil pan gasket.The oil pan gasket and oil pan must be installed andthe fasteners tightened while the adhesive is still

Seite 34 - Cylinder Head Removal - Left

Oil Filter Adapter InstallationSIE-ID = 695081. Apply clean engine oil GM P/N UnitedStates 12345610, GM P/N Canada 993193, orequivalent, to the NEW oi

Seite 35

Engine Mechanical Specifications (5.0 L) (cont’d)ApplicationSpecificationMetric EnglishPiston Compression Ring Groove Clearance – Service Limit – TopGro

Seite 36 - Cylinder Head Removal - Right

Notice:Refer toFastener Noticein Cautions andNotices.5. Use theJ 23523-Fin order to press the crankshaftbalancer onto the crankshaft.5.1. Install theJ

Seite 37 - J 3049-A

9. Install the crankshaft balancer washer andthe bolt.TightenTighten the crankshaft balancer bolt to95 N·m (70 lb ft).Valve Lifter InstallationSIE-ID

Seite 38

Cylinder Head Installation - LeftSIE-ID = 650067Tools RequiredJ 36660-ATorque Angle Meter1. Clean the cylinder gasket surfaces on theengine block.2. I

Seite 39 - Oil Pan Removal

6. Apply sealant GM P/N United States 12346004,GM P/N Canada 10953480, or equivalent, to thethreads of the cylinder head bolts.Notice:Refer toFastener

Seite 40 - Engine Front Cover Removal

11. If reusing the engine coolant temperature (ECT)gage sensor, apply sealant GM P/N UnitedStates 12346004, GM P/N Canada 10953480 tothe threads of th

Seite 41 - J 5825-A

5. Install the cylinder head to the engine block.Guide the cylinder head carefully into place overthe dowel pins and the head gasket.6. Apply sealant

Seite 42

9. Measure the NEW spark plugs for the proper gap.Adjust the spark plug gap, if necessary.SpecificationsSpark plug gap to 1.52 mm (0.060 in).10. Instal

Seite 43 - Camshaft Removal

Valve Lash AdjustmentSIE-ID = 1947341. Turn the valve rocker arm nuts clockwise until allof the valve lash is removed.2. Turn the crankshaft clockwise

Seite 44

6. With the engine in the number 6 firing position,adjust the exhaust valves for cylindersnumber 2, 5, 6, and 7 and the intake valves forcylinders numb

Seite 45 - SIE-ID = 24222

Notice:SIO-ID = 41431 Apply the proper amount of thesealant when assembling this component. Excessiveuse of the sealant can prohibit the componentfrom

Seite 46 - SIE-ID = 69426

Engine Mechanical Specifications (5.7 L) (cont’d)ApplicationSpecificationMetric EnglishCamshaftEnd Play 0.05–0.30 mm 0.002–0.012 inJournal Diameter 47.4

Seite 47 - Engine Block Plug Removal

Notice:SIO-ID = 382467 Proper lower intake manifoldfastener tightening sequence and torque is critical.Always follow the tightening sequence, and torq

Seite 48

2. Remove the distributor cap bolts and discard.3. Remove the distributor cap.4. Install a NEW distributor gasket onto thedistributor.5. Align the ind

Seite 49

7. Align the slotted tang in the oil pump driveshaftwith the distributor driveshaft. Rotate the oil pumpdriveshaft with a screwdriver if necessary.8.

Seite 50

13. Install the distributor cap onto the distributor.14. Install the NEW distributor cap bolts.Do not overtighten the NEW distributor cap bolts.Tighte

Seite 51

Valve Rocker Arm CoverInstallation - RightSIE-ID = 650070Important: Always install a NEW valve rocker armcover gasket.1. Install the NEW valve rocker

Seite 52 - Cylinder Boring and Honing

6. Install the fan and water pump pulley and boltsusing theJ 41240.TightenTighten the fan and water pump pulley bolts to25 N·m (18 lb ft).Oil Level In

Seite 53

6. Install the spark plug wire supports and bolts.TightenTighten the bolts to 12 N·m (106 lb in).7. Install the spark plug wires onto the spark plugs.

Seite 54 - J 24086-C

Engine Flywheel InstallationSIE-ID = 7842411. Install the engine flywheel (1 or 2) to thecrankshaft.Align the engine flywheel locator hole to theflywheel

Seite 55

Description and OperationEngine Component DescriptionSIE-ID = 69042Cylinder BlockThe engine block is made of cast iron and haseight cylinders arranged

Seite 56

5.0L and 5.7L engines have two bolts per crankshaftbearing cap. The heavy duty 5.7L engines havefour bolts per crankshaft bearing cap, on bearing caps

Seite 57 - SIO-ID = 71607

Engine Mechanical Specifications (5.7 L) (cont’d)ApplicationSpecificationMetric EnglishPiston Bore Clearance – Production 0.018–0.053 mm 0.0007–0.002 in

Seite 58

Lubrication DescriptionSIE-ID = 650073The gear-type oil pump is driven through an extensiondriveshaft. The extension driveshaft is driven by thedistri

Seite 59 - Inspection

Cleanliness and CareSIE-ID = 19007• Throughout this section, it should be understoodthat proper cleaning and protection of machinedsurfaces and fricti

Seite 60

− Abrasive pads also produce a fine grit thatthe oil filter cannot remove from theengine oil.This fine grit is an abrasive and can causeinternal engine d

Seite 61

• Do not overtighten the fasteners.− Apply the gasket eliminator sealant evenly toget a uniform thickness of the gasketeliminator sealant on the seali

Seite 62

Special Tools and EquipmentSIE-ID = 690690Illustration Tool Number/ Description14487J 3049-AValve Lifter Remover3404J 5239Connecting Rod BoltGuide Set

Seite 63 - Micrometer Method

Illustration Tool Number/ Description2014J 8001Dial Indicator Set3403J 8037Ring Compressor3414J 8062Valve Spring Compressor5110J 8087Cylinder Bore Gag

Seite 64 - Clearances – J 43690 Method

Illustration Tool Number/ Description5118J 33049Camshaft BearingService Set350498J 35621-BRear Main Seal Installer3413J 36660-AElectronic TorqueAngle

Seite 65 - Specifications

CCamshaft and Bearings Cleaning andInspectionEngine Mechanical - 5.0L and 5.7L ... 6-67Camshaft Bearing InstallationEngine Mechanical - 5

Seite 66

OOil Filter Adapter InstallationEngine Mechanical - 5.0L and 5.7L ... 6-121Oil Filter Adapter RemovalEngine Mechanical - 5.0L and 5.7L ...

Seite 68

Sealers, Adhesives, and LubricantsApplication Type of MaterialGM Part NumberUnited States CanadaCamshaft Retainer Bolt Threadlock 12345382 10953489Cra

Seite 69

TP-6104 11/01a

Seite 70

Component LocatorDisassembled ViewsSIE-ID = 348556Legend(1) Fuel Pipe Retainer Bracket(2) Fuel Pipe Retainer Bracket Nuts(3) Fuel Pipe(4) Fuel Pipe At

Seite 71 - Plastic Gage Method

(22) Engine Coolant Thermostat(23) Water Outlet(24) Water Outlet Stud(25) Upper Intake Manifold Stud(26) Throttle Body Gasket(27) Throttle Body(28) Th

Seite 72 - Tightening Specifications

Legend(1) Engine Front Cover(2) Camshaft Timing Chain(3) Camshaft Sprocket(4) Camshaft Sprocket Bolt(5) Valve Lifter Guide Retainer Bolt(6) Valve Lift

Seite 73

CAUTIONCaution: In order to reduce the chance of personal injury and/or property damage, carefully observe the instructionsthat follow.The service man

Seite 74

Legend(1) Valve Rocker Arm Cover Bolt(2) Valve Rocker Arm Cover Bolt Washer(3) Valve Rocker Arm Cover(4) Valve Rocker Arm Cover Gasket(5) Valve Stem K

Seite 75

Legend(1) Piston Ring Kit(2) Piston(3) Connecting Rod(4) Connecting Rod Bolt(5) Connecting Rod Bearings(6) Connecting Rod Cap(7) Hex Nut (Connecting R

Seite 76

(32) Crankshaft Sprocket(33) Crankshaft Position Sensor Reluctor Ring(34) Woodruff Keys (Crankshaft Balancer)(35) Crankshaft Bearing(36) Crankshaft Be

Seite 77 - Camshaft Bearing Removal

Legend(1) Engine Block(2) Oil Pump Driveshaft(3) Oil Pump Driveshaft Retainer(4) Pin (Oil Pump Locator)(5) Oil Pump(6) Oil Pan Gasket(7) Oil Pan(8) Oi

Seite 78 - Camshaft Bearing Installation

Engine IdentificationSIE-ID = 650058The Vehicle Identification Number (VIN) is located onthe left side rear of the engine block, near thetransmission be

Seite 79

Repair InstructionsDraining Fluids and Oil Filter RemovalSIE-ID = 1945721. Remove the oil pan drain plug and allow theengine oil to drain into a suita

Seite 80

3. Remove the engine block coolant drain hole plugand allow the coolant to drain into a suitablecontainer.4. Remove the knock sensor and allow the coo

Seite 81

Exhaust Manifold Removal - LeftSIE-ID = 650059Notice:SIO-ID = 2878 Twist the spark plug bootone-half turn in order to release the boot. Pull on thespa

Seite 82

3. Remove the exhaust manifold bolts.4. Remove the spark plug wire shields.5. Remove the exhaust manifold.6. Remove and discard the exhaust manifold g

Seite 83

2. Remove the clamps and the water pumpinlet hose.3. Remove the water pump bolts.4. Remove the water pump.5. Remove the water pump gaskets.6. Discard

Seite 84 - Cylinder Head Disassemble

Table of ContentsTP-6104 11/01 Table of ContentsCaution Inside Front Cover...Introdu

Seite 85

2. Remove the bolts and the crankshaft pulley.Notice:Refer toFastener Noticein Cautions andNotices.3. Use theJ 23523-Fin order to remove thecrankshaft

Seite 86

Valve Rocker Arm Cover Removal - LeftSIE-ID = 6500611. Remove the valve rocker arm cover bolts andwashers.2. Remove the valve rocker arm cover.3. Remo

Seite 87 - Grinding

2. Remove the distributor clamp bolt.3. Remove the distributor and the distributor clamp.4. Remove the distributor gasket and discard.Intake Manifold

Seite 88

2. Remove the lower intake manifold bolts.Important: The intake manifold may be removed asan assembly. Do not remove the specific intakemanifold compon

Seite 89 - J 5802-01

Cylinder Head Removal - LeftSIE-ID = 6500641. Remove the engine coolant temperature gagesensor.2. Remove and discard the spark plugs.3. Remove the cyl

Seite 90 - SIE-ID = 195354

Notice:SIO-ID = 13838 After removal, place thecylinder head on two wood blocks to prevent damage.4. Remove the cylinder head.5. Remove and discard the

Seite 91 - Cylinder Head Assemble

Cylinder Head Removal - RightSIE-ID = 6500651. Remove and discard the spark plugs.2. Remove the cylinder head bolts.Notice:SIO-ID = 13838 After remova

Seite 92 - SIO-ID = 411464

4. Remove and discard the cylinder head gasket.5. Remove the cylinder head locator dowel pin, ifrequired.Valve Lifter RemovalSIE-ID = 24119Tools Requi

Seite 93 - Oil Pump Disassemble

Important: Place the valve lifters in the rack in theupright position in order to maintain the oil inside thevalve lifter.2. Remove the valve lifter g

Seite 94

Oil Pan RemovalSIE-ID = 668361. Remove the oil pan bolts and nuts.2. Remove the oil pan reinforcements.3. Remove the oil pan.4. Remove and discard the

Seite 95 - Oil Pump Assemble

Table of Contents, continuedTP-6104 11/01Table of ContentsCylinder Head Cleaning and Inspection 6-76...Val

Seite 96

Oil Pump, Pump Screen and DeflectorRemovalSIE-ID = 1953871. Remove the nuts (6) and the crankshaft oildeflector (2).2. Remove the oil pump bolt (1).3. R

Seite 97

Important: Always install a NEW crankshaft positionsensor seal, O-ring, during assembly.3. Remove the crankshaft position sensor seal,O-ring.4. Discar

Seite 98

2. Check the camshaft timing chain free play.If the camshaft timing chain can be moved inexcess of 11 mm (0.43 in), replacement ofthe camshaft timing

Seite 99

7. Remove the crankshaft balancer woodruff keys, ifrequired.Camshaft RemovalSIE-ID = 690311. Remove the bolts and the camshaft retainer.Notice:SIO-ID

Seite 100

Piston, Connecting Rod, and BearingRemovalSIE-ID = 24200Tools Required•J 5239Connecting Rod Bolt Guide Set•J 24270Cylinder Bore Ridge ReamerCaution: R

Seite 101

4. Use theJ 5239in order to protect the crankshaftjournals and remove the connecting rod and thepiston out of the top of the engine block.Important: A

Seite 102 - Cautions and Notices

3. Remove the crankshaft rear oil seal housing nutand bolts.4. Remove the crankshaft rear oil seal housing.5. Remove the crankshaft rear oil seal hous

Seite 103

5. Remove the crankshaft bearings from thecrankshaft bearing caps.6. Remove the crankshaft bearings from theengine block.Engine Block Plug RemovalSIE-

Seite 104 - Fastener Notice

2. Remove the S type pin, and the crankshaft rearoil seal housing, if required.3. Remove the expansion cup plug from thecamshaft rear bearing hole.4.

Seite 105

5. Remove the engine oil pressure sensor gagesensor fitting.6. Remove the engine block oil gallery plugs fromthe rear of the engine block and discard.7

Seite 106

TP-6104 11/01 iIntroductionIntroductionThis service manual provides the service technicianwith information to service the General MotorsPowertrain eng

Seite 107

8. Remove the engine block oil gallery plugs fromthe front of the engine block and discard.Insert a 3/8 x 26 inch rod into the rear oil galleryholes i

Seite 108 - SIE-ID = 784240

Engine Block Cleaning and InspectionSIE-ID = 784233Tools RequiredJ 8087Cylinder Bore GageCaution: Refer to Safety Glasses Caution inCautions and Notic

Seite 109 - Thread Repair

9. Measure the cylinder bores for taper andout-of-round.9.1. Depress the plunger on theJ 80877mm(0.275 in) or until theJ 8087enters thecylinder bore.9

Seite 110

• The finish marks should be free from imbeddedparticles or torn or folded metal.4. When finished, the reconditioned cylinder boresshould have less than

Seite 111 - Service Prior to Assembly

Piston and Connecting Rod DisassembleSIE-ID = 195087Tools RequiredJ 24086-CPiston Pin Remover/InstallerCaution: Refer to Safety Glasses Caution inCaut

Seite 112

Piston, Connecting Rod, and BearingsCleaning and InspectionSIE-ID = 784237Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: M

Seite 113

7. Measure the piston ring-to-piston ring groove sideclearance.7.1. Insert the edge of the piston ring into thepiston ring groove.7.2. Roll the piston

Seite 114

11. Inspect the connecting rod for twisting.12. Inspect the connecting rod for damage to theconnecting rod bolt threads.13. Measure the piston compres

Seite 115 - J 36660-A

Important: When assembling the piston andconnecting rod, the mark on the top of the piston mustpoint to the front of the engine block. The left bankco

Seite 116

3. Space the compression piston ring end gaps120 degrees apart.4. Space the oil control piston ring end gaps aminimum of 90 degrees apart.Crankshaft a

Seite 117

TP-6104 11/01ii IntroductionNotes

Seite 118 - Installation

5. Inspect the crankshaft for the following:• Crankshaft journals (1) should be smooth withno evidence of scoring or damage.• Deep grooves (2)• Scratc

Seite 119

8. Using wooden V-blocks, support the crankshaft onthe front and rear journals.9. Use theJ 7872in order to measure crankshaftjournal runout.Refer toEn

Seite 120

11. Inspect the crankshaft bearings for craters orpockets. Flattened sections on the crankshaftbearing halves also indicate fatigue.12. Inspect the cr

Seite 121

Measuring Crankshaft Bearing ClearancesNotice:SIO-ID = 5016 Do not shim, scrape, or filebearing inserts. Do not touch the bearing surface of theinsert

Seite 122

3. Install the bearings into the engine block.Notice:Refer toFastener Noticein Cautions andNotices.4. Install the bearing cap bolts and tighten tospec

Seite 123

4. Insert a piece of paper card stock onto thecrankshaft journal. Install the bearing half, bearingcap, and bolts. Refer toFastener TighteningSpecifica

Seite 124

8. Install the pivot arm assembly (1) onto theconnecting rod.9. Position the foot of the pivot arm assembly overthe large end of the connecting rod bo

Seite 125

12. Align the center of the base (1) with the screw (3)of the pivot arm assembly.13. Tighten the bolt (2) until snug.14. Align the link (1) of the piv

Seite 126

16. Insert the handle (1) to the pivot arm assembly.17. Select the adapter (2), as required, and install tothe swivel base (1).18. Tighten until snug.

Seite 127

21. Install the swivel base (1) to the oil pan rail of theengine block.22. Tighten until snug.23. Adjust the swivel base as required, and positionthe

Seite 128

TP-6104 11/01 ICautions and NoticesCautions and NoticesDefinition of Caution, Notice, andImportantThe diagnosis and repair procedures in the GMPowertr

Seite 129 - J 23523-F

25. Rotate the fine adjustment knobs, on the dialindicator end of the swivel base, to position the tipof the indicator in contact with the connecting r

Seite 130

Measuring Crankshaft Bearing Clearances –Plastic Gage Method1. Install the crankshaft bearings into theengine block.2. Install the crankshaft.3. Insta

Seite 131

4. Install the crankshaft bearings into the crankshaftbearing caps.5. Install the crankshaft bearing caps in the originalpositions, and the arrow on t

Seite 132

Measuring Connecting Rod Bearing SideClearance1. Insert a feeler gage between the connecting rodcaps and measure the connecting rod sideclearance. Ref

Seite 133

Engine Flywheel Cleaning and InspectionSIE-ID = 195065Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean the engine flywheel (1 o

Seite 134

5. Inspect the engine flywheel, manual transmission,if equipped, for the following:• Pitted friction surface (1)• Scoring or grooves (2)• Rust or other

Seite 135

6. Inspect the engine camshaft for the following:• Worn, scored, or damaged bearing journals (1)• Worn engine camshaft lobes (2)• Damaged bolt hole th

Seite 136 - Valve Rocker Arm and Push Rod

Camshaft Bearing RemovalSIE-ID = 195130Tools RequiredJ 33049Camshaft Bearing Service Kit1. Select the cone (1), the handle (10), theexpanding driver (

Seite 137 - Valve Lash Adjustment

3.14. Tighten theJ 33049expander assembly nutuntil snug.3.15. Push theJ 33049guide cone into thecamshaft front bearing in order to aligntheJ 33049.3.1

Seite 138 - Intake Manifold Installation

Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: The camshaft bearing lubrication holesmust align with the oil gallery holes

Seite 139

TP-6104 11/01II Cautions and NoticesMoving Parts and Hot Surfaces CautionCaution: Avoid contact with moving parts and hotsurfaces while working around

Seite 140 - Distributor Installation

Important: The camshaft bearing lubrication holesmust align with the oil gallery holes in the engine block.After installation of the camshaft bearings

Seite 141

3.19. Drive the camshaft inner bearing #2 into thecamshaft inner bearing bore #2.3.20. Loosen theJ 33049expander assembly nut.4. Carefully remove theJ

Seite 142

Valve Rocker Arm and Push RodsCleaning and InspectionSIE-ID = 195201Important: Parts that are to be reused must bemarked, sorted and organized for ass

Seite 143

Valve Lifters and Guides Cleaning andInspectionSIE-ID = 195248Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: Components th

Seite 144 - Water Pump Installation

Cylinder Head DisassembleSIE-ID = 195340Tools RequiredJ 8062Valve Spring CompressorCaution:SIO-ID = 411464Compressed valve springshave high tension ag

Seite 145

3. Dry the components with compressed air.4. Use theJ 8089to clean the carbon from thecylinder head combustion chambers.Be careful not to scuff the co

Seite 146

7. Use theJ 9666in order to measure the valvespring.Replace the valve spring if the valve springtension is less than 338 N (76 lb) at 43.2 mm(1.70 in)

Seite 147

10. Measure the valve stem-to-guide clearance.Excessive valve stem-to-guide clearance maycause an excessive oil consumption and may alsocause a valve

Seite 148 - Description and Operation

2. Improper valve stem (1) to valve guide (2)clearance may cause excessive oil consumption.Caution: Refer to Safety Glasses Caution inCautions and Not

Seite 149 - New Product Information

6. Inspect the valve contact surface for the following:• Undersized margin (1)• Pitted surface (2)• Burnt or eroded areas (3)• Acceptable edge (margin

Seite 150 - Lubrication Description

Engine Mechanical - 5.0L and 5.7LSpecificationsSIE-ID = 784227Fastener Tightening SpecificationsApplicationSpecificationMetric EnglishAccelerator Control

Seite 151 - Replacing Engine Gaskets

3. Rotate the nut clockwise to remove the valverocker arm ball stud.Valve Rocker Arm Stud InstallationSIE-ID = 195354Tools Required•J 5715Reamer (0.07

Seite 152 - Vulcanizing (RTV) Sealant

Cylinder Head AssembleSIE-ID = 195342Tools Required•J 8062Valve Spring Compressor•J 42073Valve Stem Seal InstallerCaution: Refer to Safety Glasses Cau

Seite 153 - Tools and Equipment

6. Install the valve spring (3).7. Install the valve spring cap (2) onto the valvespring (3), over the valve stem.Caution:SIO-ID = 411464Compressed va

Seite 154 - Special Tools and Equipment

Oil Pump DisassembleSIE-ID = 1950491. Remove the oil pump driveshaft and oil pumpdriveshaft retainer.Important: Do not remove the oil pump screen from

Seite 155

4. Remove the oil pump cover.5. Remove the oil pump drive gear and the oil pumpdriven gear.6. Matchmark the gear teeth for assembly.Caution: Refer to

Seite 156

Oil Pump Cleaning and InspectionSIE-ID = 35473Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean the oil pump components in clea

Seite 157 - 2002 - Unit Repair

3. Apply clean engine oil GM P/N UnitedStates 12345610, GM P/N Canada 993193, orequivalent, to the oil pump drive gear, the oil pumpdriven gear, and t

Seite 158

8. Install the oil pump screen.8.1. If removed, replace the oil pump screen.The oil pump screen must have a goodpress fit into the oil pump body.8.2. M

Seite 159

• Damage to the bolt holes (4)• Restrictions to the ventilation system passagesOil Pan Cleaning and InspectionSIE-ID = 194998Caution: Refer to Safety

Seite 160 - TP-6104 11/01a

2. Remove the throttle body attaching studs.3. Remove the throttle body.4. Remove the throttle body to upper intake manifoldgasket.5. Discard the thro

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