Service Engine Engine Model: General Motors 5.0 L Powertrain General Motors 5.7 L Powertrain Generator Models: 50 kW (5.0 L) 50/60 kW (5.
CAUTION Caution: In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow. The service manual of General Motors Powertrain is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others, damage the equipment, or cause the equipment to operate improperly.
Table of Contents Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Cautions and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued Cylinder Head Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Valve Guide Reaming/Valve and Seat Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Valve Rocker Arm Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Valve Rocker Arm Stud Installation . . . . . . . . . . . . . . . . . . . . . .
Introduction This service manual provides the service technician with information to service the General Motors Powertrain engines. This manual has been reprinted by the generator set manufacturer with the permission of General Motors Powertrain. In general, this manual covers the service of the engine and associated standard equipment. In some cases the engine is supplied with accessories and equipment that are unique to the application.
Notes ii Introduction TP-6104 11/01
Cautions and Notices Definition of Caution, Notice, and Important The diagnosis and repair procedures in the GM Powertrain Service Manual contain both general and specific Cautions, Notices, and Importants. GM Powertrain is dedicated to the presentation of service information that helps the technician diagnose and repair the systems necessary for the proper operation of the equipment; however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner.
Moving Parts and Hot Surfaces Caution Fastener Notice Caution: Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury. Notice: Use the correct fastener in the correct location. Replacement fastener must be the correct part number for that application. The service procedure identifies fasteners requiring replacement or fasteners requiring the use of thread-locking compound or sealant.
Engine Engine Mechanical - 5.0L and 5.7L Engine Mechanical - 5.0L and 5.
6-2 Engine Mechanical - 5.0L and 5.
Engine Engine Mechanical - 5.0L and 5.
6-4 Engine Mechanical - 5.0L and 5.7L Engine Engine Mechanical Specifications (5.0 L) (cont’d) Specification Application Metric English 0.018–0.053 mm 0.0007–0.0021 in Crankshaft Crankshaft Bearing Clearance – Journal #1 – Production Crankshaft Bearing Clearance – Journal #2, #3, and #4 – Production 0.030–0.068 mm 0.0012–0.0027 in Crankshaft Bearing Clearance – Journal #5 – Production 0.020–0.060 mm 0.0008–0.0024 in Crankshaft Bearing Clearance – Journal #1 – Service 0.025–0.051 mm 0.0010–0.
Engine Engine Mechanical - 5.0L and 5.7L 6-5 Engine Mechanical Specifications (5.0 L) (cont’d) Specification Application Metric English Piston Compression Ring Groove Clearance – Service Limit – Top Groove 0.030–0.090 mm 0.0012–0.0035 in Piston Compression Ring Groove Clearance – Service Limit – 2nd Groove 0.030–0.090 mm 0.0012–0.0040 in Piston Oil Ring Gap – Production 0.25–0.76 mm 0.010–0.030 in Piston Oil Ring Gap – Service 0.25–0.89 mm 0.010–0.
6-6 Engine Mechanical - 5.0L and 5.7L Engine Engine Mechanical Specifications (5.7 L) (cont’d) Specification Application Metric English 0.05–0.30 mm 0.002–0.012 in Camshaft End Play Journal Diameter Journal Diameter Out-of-Round 47.440–47.490 mm 1.8677–1.8697 in 0.025 mm – Maximum 0.0010 in – Maximum Lobe Lift – Exhaust 7.20–7.30 mm 0.283–0.287 in Lobe Lift – Intake 6.97–7.07 mm 0.274–0.278 in 0.065 mm – Maximum 0.
Engine Engine Mechanical - 5.0L and 5.7L 6-7 Engine Mechanical Specifications (5.7 L) (cont’d) Specification Application Metric English Piston Bore Clearance – Production 0.018–0.053 mm 0.0007–0.002 in Piston Bore Clearance – Service 0.018–0.061 mm 0.0007–0.0024 in 0.013–0.023 mm 0.0005–0.0009 in Piston Pin Clearance in Piston – Production Clearance in Piston – Service Diameter Interference Fit in Connecting Rod 0.013–0.025 mm 0.0005–0.0010 in 23.545–23.548 mm 0.9270–0.9271 in 0.012–0.
6-8 Engine Mechanical - 5.0L and 5.
Engine Engine Mechanical - 5.0L and 5.
6-10 (22) (23) (24) (25) Engine Mechanical - 5.0L and 5.
Engine Engine Mechanical - 5.0L and 5.
6-12 Engine Mechanical - 5.0L and 5.
Engine Engine Mechanical - 5.0L and 5.
6-14 (32) (33) (34) (35) (36) (37) Engine Mechanical - 5.0L and 5.
Engine Engine Mechanical - 5.0L and 5.
6-16 Engine Mechanical - 5.0L and 5.7L Engine Engine Identification SIE-ID = 650058 The Vehicle Identification Number (VIN) is located on the left side rear of the engine block, near the transmission bellhousing, and typically is a 9 digit number stamped onto the engine at the vehicle assembly plant. • The first digit identifies the division. • The second digit identifies the model year. • The third digit identifies the assembly plant.
Engine Engine Mechanical - 5.0L and 5.7L 6-17 Repair Instructions Draining Fluids and Oil Filter Removal SIE-ID = 194572 1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container. 182850 2. Remove the oil filter and discard.
6-18 Engine Mechanical - 5.0L and 5.7L Engine 3. Remove the engine block coolant drain hole plug and allow the coolant to drain into a suitable container. 316798 4. Remove the knock sensor and allow the coolant to drain into a suitable container. 182837 Engine Flywheel Removal SIE-ID = 527623 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel.
Engine Engine Mechanical - 5.0L and 5.7L 6-19 Exhaust Manifold Removal - Left SIE-ID = 650059 Notice: SIO-ID = 2878 Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 1. Remove the spark plug wires from the spark plugs. 1.1. Rotate the spark plug wire boot one half turn. 1.2. Pull outward on the spark plug wire boot to release from the spark plug. 2.
6-20 Engine Mechanical - 5.0L and 5.7L Engine 3. 4. 5. 6. Remove Remove Remove Remove the exhaust manifold bolts. the spark plug wire shields. the exhaust manifold. and discard the exhaust manifold gasket. 69032 Oil Level Indicator and Tube Removal SIE-ID = 518523 1. Remove the oil level indicator tube bolt. 2. Remove the oil level indicator tube from the engine block. 500691 Water Pump Removal SIE-ID = 69041 Tools Required J 41240 Fan Clutch Remover and Installer 1.
Engine Engine Mechanical - 5.0L and 5.7L 6-21 2. Remove the clamps and the water pump inlet hose. 182853 3. 4. 5. 6. Remove the water pump bolts. Remove the water pump. Remove the water pump gaskets. Discard the water pump gaskets. 69011 Crankshaft Balancer Removal SIE-ID = 66682 Tools Required J 23523-F Balancer Remover and Installer 1. Remove the crankshaft balancer bolt and washer.
6-22 Engine Mechanical - 5.0L and 5.7L Engine 2. Remove the bolts and the crankshaft pulley. 188055 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Use the J 23523-F in order to remove the crankshaft balancer. 3.1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten Tighten the bolts to 25 N·m (18 lb ft). 3.2. Install the J 23523-F forcing screw into the plate. 3.3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer. 4.
Engine Engine Mechanical - 5.0L and 5.7L 6-23 Valve Rocker Arm Cover Removal - Left SIE-ID = 650061 1. Remove the valve rocker arm cover bolts and washers. 2. Remove the valve rocker arm cover. 3. Remove the valve rocker arm cover gasket. 4. Discard the valve rocker arm cover gasket. 39119 Valve Rocker Arm Cover Removal - Right SIE-ID = 650062 1. Remove the valve rocker arm cover bolts and washers. 2. Remove the valve rocker arm cover. 3. Remove the valve rocker arm cover gasket. 4.
6-24 Engine Mechanical - 5.0L and 5.7L Engine 2. Remove the distributor clamp bolt. 3. Remove the distributor and the distributor clamp. 69303 4. Remove the distributor gasket and discard. 523516 Intake Manifold Removal SIE-ID = 66685 1. Remove the evaporative emission canister purge solenoid valve harness. 1.1. Push the quick disconnect clip and hold in place. 1.2. Pull outward on the harness elbow.
Engine Engine Mechanical - 5.0L and 5.7L 6-25 2. Remove the lower intake manifold bolts. Important: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required. Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required. 3. Remove the intake manifold assembly. 4.
6-26 Engine Mechanical - 5.0L and 5.7L Engine Cylinder Head Removal - Left SIE-ID = 650064 1. Remove the engine coolant temperature gage sensor. 521828 2. Remove and discard the spark plugs. 317307 3. Remove the cylinder head bolts.
Engine Engine Mechanical - 5.0L and 5.7L 6-27 Notice: SIO-ID = 13838 After removal, place the cylinder head on two wood blocks to prevent damage. 4. Remove the cylinder head. 317227 5. Remove and discard the cylinder head gasket. 317233 6. Remove the cylinder head locator dowel pin, if required.
6-28 Engine Mechanical - 5.0L and 5.7L Engine Cylinder Head Removal - Right SIE-ID = 650065 1. Remove and discard the spark plugs. 317307 2. Remove the cylinder head bolts. 317239 Notice: SIO-ID = 13838 After removal, place the cylinder head on two wood blocks to prevent damage. 3. Remove the cylinder head.
Engine Engine Mechanical - 5.0L and 5.7L 6-29 4. Remove and discard the cylinder head gasket. 317255 5. Remove the cylinder head locator dowel pin, if required. 182846 Valve Lifter Removal SIE-ID = 24119 Tools Required J 3049-A Valve Lifter Remover 1. Remove the bolts and valve lifter guide retainer.
6-30 Engine Mechanical - 5.0L and 5.7L Engine Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifter. 2. Remove the valve lifter guides and valve lifters. 3. Place the components in a rack so that the components can be reinstalled to the original location. 11509 Important: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits. 4. Use the J 3049-A in order to remove the stuck valve lifters.
Engine Engine Mechanical - 5.0L and 5.7L 6-31 Oil Pan Removal SIE-ID = 66836 1. 2. 3. 4. Remove Remove Remove Remove the oil pan bolts and nuts. the oil pan reinforcements. the oil pan. and discard the oil pan gasket. 182851 5. Remove the oil pan studs.
6-32 Engine Mechanical - 5.0L and 5.7L Engine Oil Pump, Pump Screen and Deflector Removal SIE-ID = 195387 1. Remove the nuts (6) and the crankshaft oil deflector (2). 2. Remove the oil pump bolt (1). 3. Remove the oil pump (3), the oil pump driveshaft (5), and the oil pump driveshaft retainer (4). 4. Separate the oil pump (3), the oil pump driveshaft (5), and the oil pump driveshaft retainer (4). Important: Always install a NEW oil pump driveshaft retainer during assembly. 5.
Engine Engine Mechanical - 5.0L and 5.7L 6-33 Important: Always install a NEW crankshaft position sensor seal, O-ring, during assembly. 3. Remove the crankshaft position sensor seal, O-ring. 4. Discard the crankshaft position sensor seal, O-ring. 387759 5. Remove the engine front cover bolts. 6. Remove the engine front cover and gasket. Important: DO NOT reuse the composite engine front cover and gasket. Always install a NEW engine front cover. 7. Discard the engine front cover and gasket.
6-34 Engine Mechanical - 5.0L and 5.7L Engine 2. Check the camshaft timing chain free play. If the camshaft timing chain can be moved in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly. 2.1. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2). 2.2. Measure the free play on the slack side (3) of the camshaft timing chain. 341357 3. Remove the camshaft sprocket bolts. 4.
Engine Engine Mechanical - 5.0L and 5.7L 6-35 7. Remove the crankshaft balancer woodruff keys, if required. 182847 Camshaft Removal SIE-ID = 69031 1. Remove the bolts and the camshaft retainer. 182836 Notice: SIO-ID = 13833 All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 2. Remove the engine camshaft. 2.1. Install the three 5/16–18 x 4.0 inch bolts in the engine camshaft front bolt holes. 2.2.
6-36 Engine Mechanical - 5.0L and 5.7L Engine Piston, Connecting Rod, and Bearing Removal SIE-ID = 24200 11497 Tools Required • J 5239 Connecting Rod Bolt Guide Set • J 24270 Cylinder Bore Ridge Reamer Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the ring ridge. 1.1. Turn the crankshaft until the piston is at the bottom of the stroke. 1.2. Place a cloth on the top of the piston. 1.3. Use the J 24270 in order to remove cylinder ring ridge. 1.4.
Engine Engine Mechanical - 5.0L and 5.7L 6-37 4. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block. 31373 Important: Always assemble the connecting rod caps to the matching connecting rods. 5. Remove the connecting rod bearings. • Keep the connecting rod bearings with the original connecting rod and connecting rod cap. • Wipe the oil from the connecting bearings. • Wipe the oil from the crankpins.
6-38 Engine Mechanical - 5.0L and 5.7L Engine 3. Remove the crankshaft rear oil seal housing nut and bolts. 4. Remove the crankshaft rear oil seal housing. 5. Remove the crankshaft rear oil seal housing gasket. 6. Discard the crankshaft rear oil seal housing gasket. 7. Remove the rear oil seal housing retainer stud from the engine block. 11479 Crankshaft and Bearings Removal SIE-ID = 69426 1. Mark or identify the crankshaft bearing cap locations and positions for assembly. 2.
Engine Engine Mechanical - 5.0L and 5.7L 6-39 5. Remove the crankshaft bearings from the crankshaft bearing caps. 317295 6. Remove the crankshaft bearings from the engine block. 317292 Engine Block Plug Removal SIE-ID = 348910 Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the transmission locator pins, if required.
6-40 Engine Mechanical - 5.0L and 5.7L Engine 2. Remove the S type pin, and the crankshaft rear oil seal housing, if required. 521820 3. Remove the expansion cup plug from the camshaft rear bearing hole. 182854 4. Remove the engine oil pressure gage sensor using the J 41712.
Engine Engine Mechanical - 5.0L and 5.7L 6-41 5. Remove the engine oil pressure sensor gage sensor fitting. 333652 6. Remove the engine block oil gallery plugs from the rear of the engine block and discard. 69847 7. Remove the left side rear and left rear top engine block oil gallery plugs.
6-42 Engine Mechanical - 5.0L and 5.7L Engine 8. Remove the engine block oil gallery plugs from the front of the engine block and discard. Insert a 3/8 x 26 inch rod into the rear oil gallery holes in order to drive out the front engine block oil gallery plugs. 182838 9. Remove the engine block core hole plugs. 9.1. Use a suitable tool in order to drive the engine block core hole plug into the coolant jacket. 9.2.
Engine Engine Mechanical - 5.0L and 5.7L 6-43 Engine Block Cleaning and Inspection SIE-ID = 784233 Tools Required J 8087 Cylinder Bore Gage Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean all the remaining sealing or gasket material from the sealing surfaces. 2. Clean the engine block in cleaning solvent. 3. Flush the engine block with clean water or steam. 4. Clean the cylinder bores. 5. Clean the oil galleries and the oil passages. 6.
6-44 Engine Mechanical - 5.0L and 5.7L Engine 9. Measure the cylinder bores for taper and out-of-round. 9.1. Depress the plunger on the J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. 9.2. Center the J 8087 in the cylinder bore and turn the indicator dial to 0. 9.3. Move the J 8087 up and down the cylinder bore to determine the taper. Refer to Engine Mechanical Specifications (5.0 L) or Engine Mechanical Specifications (5.7 L). 9.4.
Engine 4. 5. 6. 7. 8. • The finish marks should be free from imbedded particles or torn or folded metal. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. 5.1. Scrub the cylinder bores with a stiff bristle brush. 5.2. Rinse the cylinder bores thoroughly with clean hot water. 5.3.
6-46 Engine Mechanical - 5.0L and 5.7L Engine Piston and Connecting Rod Disassemble SIE-ID = 195087 Tools Required J 24086-C Piston Pin Remover/Installer Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the piston rings from the pistons. 4967 2. Press the piston pin from the connecting rod using the J 24086-C. The piston pin has an interference fit into the connecting rod, and is full floating in the piston. 4965 3. Mark, separate, and organize the parts for assembly.
Engine Engine Mechanical - 5.0L and 5.7L 6-47 Piston, Connecting Rod, and Bearings Cleaning and Inspection SIE-ID = 784237 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Measurement of all the components should be taken with the components at room temperature. Do not use a wire brush in order to clean any part of the piston. 1. Clean the piston and connecting rod in cleaning solvent. 2. Dry the components with compressed air. 34671 3.
6-48 Engine Mechanical - 5.0L and 5.7L Engine 7. Measure the piston ring-to-piston ring groove side clearance. 7.1. Insert the edge of the piston ring into the piston ring groove. 7.2. Roll the piston ring completely around the piston. • If binding is caused by a distorted piston ring groove, MINOR imperfections may be removed with a fine file. • If binding is caused by a distorted piston ring, then replace the piston ring. 4969 8. Measure the piston ring side clearance with a feeler gage.
Engine Engine Mechanical - 5.0L and 5.7L 6-49 11. Inspect the connecting rod for twisting. 12. Inspect the connecting rod for damage to the connecting rod bolt threads. 156169 13. Measure the piston compression ring end gap. Important: Fit each piston compression ring to the cylinder in which it will be used. 13.1. Place the piston compression ring into the cylinder bore. 13.2. Push the piston compression ring into the cylinder bore to approximately 6.5 mm (0.25 in) above the piston ring travel.
6-50 Engine Mechanical - 5.0L and 5.7L Engine Important: When assembling the piston and connecting rod, the mark on the top of the piston must point to the front of the engine block. The left bank connecting rods should have the flange face toward the front of the engine block. The right bank connecting rods should have the flange face toward the rear of the engine block. The new piston pin has an interference fit into the connecting rod and is full floating in the piston. 1.
Engine Engine Mechanical - 5.0L and 5.7L 6-51 3. Space the compression piston ring end gaps 120 degrees apart. 4. Space the oil control piston ring end gaps a minimum of 90 degrees apart. 4967 Crankshaft and Bearings Cleaning and Inspection SIE-ID = 69074 Tools Required • J 7872 Magnetic Base Dial Indicator • J 36660-A Torque Angle Meter • J 43690 Rod Bearing Clearance Checking Tool Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Use care when handling the crankshaft.
6-52 Engine Mechanical - 5.0L and 5.7L Engine 5. Inspect the crankshaft for the following: • Crankshaft journals (1) should be smooth with no evidence of scoring or damage. • Deep grooves (2) • Scratches or uneven wear (3) • Pitted surfaces (4) • Wear or damage to the thrust journal surfaces • Scoring or damage to the rear seal surface • Restrictions to the oil passages • Damage to the threaded bolt holes 156170 6.
Engine Engine Mechanical - 5.0L and 5.7L 6-53 8. Using wooden V-blocks, support the crankshaft on the front and rear journals. 9. Use the J 7872 in order to measure crankshaft journal runout. Refer to Engine Mechanical Specifications (5.0 L) or Engine Mechanical Specifications (5.7 L). 35210 10. Measure the crankshaft end play.
6-54 Engine Mechanical - 5.0L and 5.7L Engine 11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue. 52051 12. Inspect the crankshaft bearings for excessive scoring or discoloration. 13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material. 52053 14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings.
Engine Engine Mechanical - 5.0L and 5.7L 6-55 Measuring Crankshaft Bearing Clearances Notice: SIO-ID = 5016 Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface. • The crankshaft bearings are precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required.
6-56 Engine Mechanical - 5.0L and 5.7L Engine 3. Install the bearings into the engine block. 317292 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the bearing cap bolts and tighten to specifications. Refer to Fastener Tightening Specifications. 5. Measure the bearing inside diameter (ID) at the top and bottom. 6. In order to determine the bearing clearance, subtract the average journal diameter from the bearing inside diameter. 7. Compare the readings to specifications.
Engine Engine Mechanical - 5.0L and 5.7L 6-57 4. Insert a piece of paper card stock onto the crankshaft journal. Install the bearing half, bearing cap, and bolts. Refer to Fastener Tightening Specifications. 5. Install the foot (1) and bolt (2) to the pivot arm assembly (3). 6. Tighten the bolt until snug. 627102 7. Install the screw (1 or 3) to the pivot arm assembly (2).
6-58 Engine Mechanical - 5.0L and 5.7L Engine 8. Install the pivot arm assembly (1) onto the connecting rod. 627108 9. Position the foot of the pivot arm assembly over the large end of the connecting rod bolt. 10. Position the screw (1) onto the small end of the connecting rod bolt and tighten securely. 627107 11. Install the base (1) and bolt (2) to the oil pan rail.
Engine Engine Mechanical - 5.0L and 5.7L 6-59 12. Align the center of the base (1) with the screw (3) of the pivot arm assembly. 13. Tighten the bolt (2) until snug. 627115 14. Align the link (1) of the pivot arm assembly on a plane (3) equal to that of the connecting rod beam (2). 627113 15. With the link of the pivot arm assembly aligned to the beam of the connecting rod, position the pivot arm to the base and insert the pin (1).
6-60 Engine Mechanical - 5.0L and 5.7L Engine 16. Insert the handle (1) to the pivot arm assembly. 627116 17. Select the adapter (2), as required, and install to the swivel base (1). 18. Tighten until snug. 627118 Important: The clamp of the swivel base and the shaft of the indicator should be free of oil or other debris. A loose or improperly clamped indicator may indicate incorrect readings. 19. Install the indicator (2) to the swivel base (1). 20. Tighten the clamp of the base until snug.
Engine Engine Mechanical - 5.0L and 5.7L 6-61 21. Install the swivel base (1) to the oil pan rail of the engine block. 22. Tighten until snug. 627124 23. Adjust the swivel base as required, and position the indicator tip slightly above the connecting rod cap. Lock the swivel base in position by rotating the locking lever (1). Do not allow the tip of the indicator to contact the connecting rod at this time. 627126 24.
6-62 Engine Mechanical - 5.0L and 5.7L Engine 25. Rotate the fine adjustment knobs, on the dial indicator end of the swivel base, to position the tip of the indicator in contact with the connecting rod. 627132 26. Lightly actuate the handle of the pivot arm assembly, multiple times in both directions, to ensure the oil film is removed from the journal. 627141 27. Load the handle in the forward position and zero the dial indicator.
Engine Engine Mechanical - 5.0L and 5.7L 6-63 Measuring Crankshaft Bearing Clearances – Plastic Gage Method 1. Install the crankshaft bearings into the engine block. 317292 2. Install the crankshaft. 317351 3. Install the gaging plastic the full width of the journal.
6-64 Engine Mechanical - 5.0L and 5.7L Engine 4. Install the crankshaft bearings into the crankshaft bearing caps. 317295 5. Install the crankshaft bearing caps in the original positions, and the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the crankshaft bearing cap bolts and the crankshaft bearing cap studs. Refer to Fastener Tightening Specifications. 7.
Engine Engine Mechanical - 5.0L and 5.7L 6-65 Measuring Connecting Rod Bearing Side Clearance 1. Insert a feeler gage between the connecting rod caps and measure the connecting rod side clearance. Refer to Engine Mechanical Specifications (5.0 L) or Engine Mechanical Specifications (5.7 L). 2. The connecting rod side clearances may also be measured with a dial indicator set.
6-66 Engine Mechanical - 5.0L and 5.7L Engine Engine Flywheel Cleaning and Inspection SIE-ID = 195065 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the engine flywheel (1 or 2) in cleaning solvent. 2. Dry the engine flywheel with compressed air. 188129 3.
Engine Engine Mechanical - 5.0L and 5.7L 6-67 5. Inspect the engine flywheel, manual transmission, if equipped, for the following: • Pitted friction surface (1) • Scoring or grooves (2) • Rust or other surface damage (3) • Damaged ring gear teeth (4) • Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel.
6-68 Engine Mechanical - 5.0L and 5.7L Engine 6. Inspect the engine camshaft for the following: • Worn, scored, or damaged bearing journals (1) • Worn engine camshaft lobes (2) • Damaged bolt hole threads (3) • Damaged camshaft sprocket locator pin (4) 188095 7. Measure the engine camshaft journals with a micrometer. If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft. 188014 8.
Engine Engine Mechanical - 5.0L and 5.7L 6-69 Camshaft Bearing Removal SIE-ID = 195130 Tools Required J 33049 Camshaft Bearing Service Kit 1. Select the cone (1), the handle (10), the expanding driver (4–8), the washer (2 or 3), and the expander assembly (15) from the J 33049. 2. Assemble the J 33049. 66100 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: A loose camshaft bearing may be caused by an enlarged, out-of-round, or damaged engine block camshaft bearing bore.
6-70 Engine Mechanical - 5.0L and 5.7L Engine 3.14. Tighten the J 33049 expander assembly nut until snug. 3.15. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049. 3.16. Drive the camshaft inner bearing #4 from the camshaft inner bearing bore #4. 3.17. Loosen the J 33049 expander assembly nut. 3.18. Remove the camshaft inner bearing #4 from the J 33049 expander assembly. 4. Remove the J 33049 from the engine block. 63219 5.
Engine Engine Mechanical - 5.0L and 5.7L 6-71 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: The camshaft bearing lubrication holes must align with the oil gallery holes in the engine block. After installation of the camshaft bearings, always inspect the camshaft bearing lubrication holes for proper alignment with the oil gallery holes.
6-72 Engine Mechanical - 5.0L and 5.7L 4985 Engine Important: The camshaft bearing lubrication holes must align with the oil gallery holes in the engine block. After installation of the camshaft bearings, always inspect the camshaft bearing lubrication holes for proper alignment with the oil gallery holes. An improperly aligned camshaft bearing lubrication hole and oil gallery hole will restrict oil flow to the camshaft bearing and the camshaft journal. 3.
Engine Engine Mechanical - 5.0L and 5.7L 6-73 3.19. Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2. 3.20. Loosen the J 33049 expander assembly nut. 4. Carefully remove the J 33049 from the engine block. Timing Chain and Sprockets Cleaning and Inspection SIE-ID = 195154 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the components in cleaning solvent. 2. Dry the components with compressed air. 3.
6-74 Engine Mechanical - 5.0L and 5.7L Engine Valve Rocker Arm and Push Rods Cleaning and Inspection SIE-ID = 195201 182835 Important: Parts that are to be reused must be marked, sorted and organized for assembly. 1. Mark, sort, and organize the components for assembly. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the components with cleaning solvent. 3. Dry the components with compressed air. 4.
Engine Engine Mechanical - 5.0L and 5.7L 6-75 Valve Lifters and Guides Cleaning and Inspection SIE-ID = 195248 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Components that are to be reused must be marked, sorted, and organized for assembly. 1. Mark, sort, and organize the components for assembly. 2. Clean the components in cleaning solvent. 3. Dry the components with compressed air. 4.
6-76 Engine Mechanical - 5.0L and 5.7L Engine Cylinder Head Disassemble SIE-ID = 195340 Tools Required J 8062 Valve Spring Compressor Caution: SIO-ID = 411464 Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force.
Engine Engine Mechanical - 5.0L and 5.7L 6-77 3. Dry the components with compressed air. 4. Use the J 8089 to clean the carbon from the cylinder head combustion chambers. Be careful not to scuff the combustion chambers. 5.
6-78 Engine Mechanical - 5.0L and 5.7L Engine 7. Use the J 9666 in order to measure the valve spring. Replace the valve spring if the valve spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in). 4960 8. Inspect the valve springs for squareness. 40075 9. Valve stems (1) with excessive guide (2) clearance must be repaired or replaced.
Engine 10. Measure the valve stem-to-guide clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness. 10.1. Clamp the J 8001 on the exhaust port side of the cylinder head. 10.2.
6-80 Engine Mechanical - 5.0L and 5.7L Engine 2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption. 156172 Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Exhaust valves with excessive valve stem-to-guide clearance must be replaced with the available service valve that has an 0.774 mm (0.0305 in) oversize valve stem. The intake valves are NOT available with oversize valve stems.
Engine 6. Inspect the valve contact surface for the following: • Undersized margin (1) • Pitted surface (2) • Burnt or eroded areas (3) • Acceptable edge (margin) (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired. 7. Reconditioning of the valves and valve seats: • The valves must seat perfectly for the engine to deliver optimum power and performance. • Cooling the valve heads is another important factor.
6-82 Engine Mechanical - 5.0L and 5.7L Engine 3. Rotate the nut clockwise to remove the valve rocker arm ball stud. Valve Rocker Arm Stud Installation SIE-ID = 195354 Tools Required • J 5715 Reamer (0.0762 mm (0.003 in) • J 6036 Reamer (0.03302 mm (0.013 in) • J 6880 Rocker Arm Stud Installer Caution: Refer to Safety Glasses Caution in Cautions and Notices. 66509 Important: Valve rocker arm ball studs that have damaged threads or are loose in cylinder heads should be replaced.
Engine Engine Mechanical - 5.0L and 5.7L 6-83 Cylinder Head Assemble SIE-ID = 195342 Tools Required • J 8062 Valve Spring Compressor • J 42073 Valve Stem Seal Installer Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal.
6-84 Engine Mechanical - 5.0L and 5.7L Engine 6. Install the valve spring (3). 7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. 334505 Caution: SIO-ID = 411464 Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force.
Engine Engine Mechanical - 5.0L and 5.7L 6-85 Oil Pump Disassemble SIE-ID = 195049 1. Remove the oil pump driveshaft and oil pump driveshaft retainer. 5274 Important: Do not remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly. 2. Remove the oil pump screen, if necessary. The oil pump screen has a press fit into the oil pump cover. 5275 3. Remove the oil pump cover bolts.
6-86 Engine Mechanical - 5.0L and 5.7L Engine 4. Remove the oil pump cover. 5277 5. Remove the oil pump drive gear and the oil pump driven gear. 6. Matchmark the gear teeth for assembly. 5278 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 7. Remove the following items: 7.1. The oil pump pressure relief valve spring straight pin 7.2. The oil pump pressure relief spring 7.3.
Engine Engine Mechanical - 5.0L and 5.7L 6-87 Oil Pump Cleaning and Inspection SIE-ID = 35473 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the oil pump components in cleaning solvent. 2. Dry the components with compressed air. 3.
6-88 Engine Mechanical - 5.0L and 5.7L Engine 3. Apply clean engine oil GM P/N United States 12345610, GM P/N Canada 993193, or equivalent, to the oil pump drive gear, the oil pump driven gear, and the oil pump body internal surfaces. 4. Install the oil pump drive gear and the oil pump driven gear into the oil pump body. 4.1. Align the matchmarks on the oil pump drive and driven gears. 4.2. Install the smooth side of the oil pump drive and driven gears toward the oil pump cover. 5278 5.
Engine Engine Mechanical - 5.0L and 5.7L 6-89 8. Install the oil pump screen. 8.1. If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body. 8.2. Mount the oil pump in a soft jawed vise. 8.3. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the end of the oil pump screen pipe. 8.4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body.
6-90 Engine Mechanical - 5.0L and 5.7L Engine • Damage to the bolt holes (4) • Restrictions to the ventilation system passages Oil Pan Cleaning and Inspection SIE-ID = 194998 521835 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the oil pan in cleaning solvent. 2. Dry the oil pan with compressed air. 3.
Engine Engine Mechanical - 5.0L and 5.7L 6-91 2. Remove the throttle body attaching studs. 3. Remove the throttle body. 4. Remove the throttle body to upper intake manifold gasket. 5. Discard the throttle body to upper intake manifold gasket. 500667 6. Remove the water outlet studs. 7. Remove the water outlet. 8. Remove the engine coolant thermostat. 500671 Important: Note the position and direction of the exhaust gas recirculation (EGR) valve before removal.
6-92 Engine Mechanical - 5.0L and 5.7L Engine Notice: SIO-ID = 5005 The Linear EGR valve is an electrical component. DO NOT soak in any liquid cleaner or solvent because damage may result. 10. Remove the EGR valve and EGR valve gasket from the lower intake manifold. 11. Discard the EGR valve gasket. 480565 12. Remove the engine coolant temperature (ECT) sensor from the lower intake manifold. 10932 13. Remove the studs and the ignition coil.
Engine Engine Mechanical - 5.0L and 5.7L 6-93 14. Remove the manifold absolute pressure (MAP) sensor from the upper intake manifold. 15. Remove the MAP sensor seal from the MAP sensor. 16. Discard the MAP sensor seal. 500677 17. 18. 19. 20. 21. Remove the fuel pipe bolt (4). Remove the nuts (2) and the fuel pipe retainer (1). Remove the fuel pipe (3). Remove and discard the fuel seal retainers (5). Remove and discard the fuel seals (6) (yellow O-rings). 22.
6-94 Engine Mechanical - 5.0L and 5.7L Engine 26. Remove the upper intake manifold studs (1). 27. Remove the upper intake manifold (2). 28. Remove the upper intake manifold to lower intake manifold gasket (3). 29. Discard the upper intake manifold to lower intake manifold gasket (3). 30. Remove the fuel meter body seal (4). 31. Discard the fuel meter body seal (4). 32. Remove the 8 poppet nozzles from the lower intake manifold bores. 33. Remove the fuel meter body (5) from the lower intake manifold (6).
Engine Engine Mechanical - 5.0L and 5.7L 6-95 3. Clean the lower intake manifold in cleaning solvent. 4. Dry the lower intake manifold with compressed air. 500684 5. Inspect the upper intake manifold for the following: • Cracks or other damage to the exterior (1) • Cracking or damage in the gasket grooves (2 and 3) • Damage to the throttle body mounting surface (4) • Loose or damaged bolt hole thread inserts (5) 500685 6.
6-96 Engine Mechanical - 5.0L and 5.7L Engine Intake Manifold Assemble SIE-ID = 194513 500681 1. Install the fuel meter body (5) into the lower intake manifold (6). 2. Install the 8 poppet nozzles into the lower intake manifold (6). 3. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores. 4. Install the NEW fuel meter body seal (4) into the groove on the fuel meter body (5). 5.
Engine 12. Install the NEW fuel seals (8), black O-rings, into the fuel meter body. 13. Install the NEW spacer rings (7), flat washers, into the fuel meter body. 14. Install the NEW fuel seals (6), yellow O-rings, into the fuel meter body. 15. Install the NEW fuel seal retainers (5) into the fuel meter body. 16. Install the fuel pipe (3) into the fuel meter body. 17. Install the fuel pipe retainer (1) and the nuts (2). 18.
6-98 Engine Mechanical - 5.0L and 5.7L Engine 23. Install the ignition coil and studs. Tighten Tighten the ignition coil studs to 12 N·m (106 lb in). 500674 24. If reusing the engine coolant temperature (ECT) sensor, apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the ECT sensor. 25. Install the ECT sensor into the front of the lower intake manifold. Tighten Tighten the ECT sensor to 20 N·m (15 lb ft).
Engine Engine Mechanical - 5.0L and 5.7L 6-99 27. Install the EGR valve bolts. Tighten 27.1. Tighten the EGR valve bolts on the first pass to 10 N·m (88 lb in). 27.2. Tighten the EGR valve bolts on the final pass to 30 N·m (22 lb ft). 480563 28. Install the engine coolant thermostat. 29. Install the water outlet. 30. Install the water outlet studs. Tighten Tighten the water outlet studs to 25 N·m (18 lb ft). 500671 31. Install a NEW throttle body gasket into the groove in the upper intake manifold.
6-100 Engine Mechanical - 5.0L and 5.7L Engine 35. Install the accelerator control bracket, the bolt, and the nut. Tighten Tighten the accelerator control bracket bolt and the nut to 12 N·m (106 lb in). 500661 Exhaust Manifold Cleaning and Inspection SIE-ID = 784240 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the exhaust manifolds in cleaning solvent. 2. Dry the components with compressed air. 3.
Engine Engine Mechanical - 5.0L and 5.7L 6-101 Water Pump Cleaning and Inspection SIE-ID = 194965 Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the old gasket material from the water pump sealing surfaces. 2. Clean all the dirt and any debris from the water pump. 3.
6-102 Engine Mechanical - 5.0L and 5.7L Engine 8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel. Important: The thread insert should be flush to 1 turn below the surface. 9. Lubricate the thread insert with clean engine oil (except when installing in aluminum) and install the thread insert. 10.
Engine Service Prior to Assembly SIE-ID = 43122 • Dirt will cause premature wear of the rebuilt engine. Clean all the components. • Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer’s specification must be repaired or replaced. 2002 - Unit Repair (May 25, 2001) Engine Mechanical - 5.0L and 5.7L 6-103 • When the components are re-installed into an engine, return the components to the original location, position, and direction.
6-104 Engine Mechanical - 5.0L and 5.7L Engine Engine Block Plug Installation SIE-ID = 348917 Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Install the transmission locator pins, if required. A properly installed transmission locator pin will protrude 12.7 mm (0.5 in) from the rear face of the engine block. 182855 2.
Engine Engine Mechanical - 5.0L and 5.7L 6-105 5. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the left side rear and left rear top engine oil gallery plugs. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the left side rear and left rear top oil engine gallery plugs. Tighten Tighten the left side rear and left rear top engine oil gallery plugs to 20 N·m (15 lb ft). 182841 7.
6-106 Engine Mechanical - 5.0L and 5.7L Engine 11. Apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489, or equivalent, to the outside diameter of the NEW engine block core hole plugs. 12. Install the NEW engine block core hole plugs. A properly installed engine block core hole plug must be installed flush or below the bottom of the chamfer (1) of the engine block core hole. 500653 13.
Engine Engine Mechanical - 5.0L and 5.7L 6-107 18. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the engine oil pressure gage sensor. 19. Install the engine oil pressure gage sensor using the J 41712. Tighten Tighten the engine oil pressure gage sensor to 30 N·m (22 lb ft). 333649 20. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the knock sensor. 21. Install the knock sensor.
6-108 Engine Mechanical - 5.0L and 5.7L Engine 3. Apply clean engine oil to the crankshaft bearing journals. 4. Install the crankshaft. 317351 5. Install the crankshaft bearings into the crankshaft bearing caps. 6. Apply clean engine oil to the crankshaft bearings. 317295 Important: Ensure that the crankshaft bearing cap directional arrow points toward the front of the engine block, and the crankshaft bearing cap is in the original location and position. 7.
Engine Engine Mechanical - 5.0L and 5.7L 6-109 11. Ensure that the crankshaft bearing caps are fully seated in the engine block crankshaft bearing cap channel, and that the crankshaft bearing caps are centered on the engine block bulkheads. 12. Measure the crankshaft end play. 12.1. Tighten the crankshaft bearing cap bolts and the crankshaft bearing cap studs finger tight. 12.2. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces. 12.3.
6-110 Engine Mechanical - 5.0L and 5.7L Engine Crankshaft Rear Oil Seal and Housing Installation SIE-ID = 348923 Tools Required J 35621-B Rear Main Seal Installer Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the crankshaft rear oil seal housing retainer stud. Tighten Tighten the crankshaft rear oil seal housing retainer stud to 6 N·m (53 lb in).
Engine Engine Mechanical - 5.0L and 5.7L 6-111 11. Apply a small amount, approximately 2–3 drops, of clean engine oil GM P/N United States 12345610, GM P/N Canada 993193, or equivalent, to the outside diameter of the NEW crankshaft rear oil seal. 12. Install the NEW crankshaft rear oil seal onto the J 35621-B. 13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Notice: SIO-ID = 348112 Proper alignment of the crankshaft rear oil seal is critical.
6-112 Engine Mechanical - 5.0L and 5.7L Engine 3. Install the J 8037 onto the piston and compress the piston rings. 480573 Important: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and connecting rod cap should point to the front of the engine block on the left bank and point to the rear of the engine block on the right bank. 4. Install the connecting rod bearing. 5.
Engine Engine Mechanical - 5.0L and 5.7L 6-113 7. Remove the J 5239 from the connecting rod bolts. 31373 Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the connecting rod bearing, cap, and nuts. Tighten 8.1. Tighten the nuts on the first pass evenly to 27 N·m (20 lb ft). 8.2. Tighten the nuts on the final pass to 55 degrees using the J 36660-A. 480549 9.
6-114 Engine Mechanical - 5.0L and 5.7L Engine Camshaft Installation SIE-ID = 66855 69013 Notice: SIO-ID = 13833 All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 1.
Engine Engine Mechanical - 5.0L and 5.7L 6-115 Timing Chain and Sprockets Installation SIE-ID = 69464 Tools Required J 5590 Installer 1. Install the crankshaft balancer woodruff keys into the crankshaft keyway. 182847 2. Align the keyway of the crankshaft sprocket with the crankshaft balancer woodruff key. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 3. Use the J 5590 in order to install the crankshaft sprocket. 4.
6-116 Engine Mechanical - 5.0L and 5.7L Engine Notice: SIO-ID = 788777 Do not use tools to force the camshaft sprocket onto the camshaft. The camshaft sprocket is a slip fit onto the camshaft and does not require tools to install. Using force against the camshaft can cause component damage and cause the expansion plug at the rear of the block to move out of position. The expansion plug out of position can leak engine oil or fall out.
Engine Engine Mechanical - 5.0L and 5.7L 6-117 Engine Front Cover Installation SIE-ID = 194773 Notice: Refer to Fastener Notice in Cautions and Notices. Important: Do not reuse the composite type engine front cover and seal. Always install a NEW engine cover, which includes a new seal. 1. Install the NEW engine front cover and bolts. Tighten Tighten the engine front cover bolts to 12 N·m (106 lb in). 69010 Important: DO NOT reuse the original crankshaft position sensor seal, O-ring.
6-118 Engine Mechanical - 5.0L and 5.7L Engine Oil Pump, Pump Screen and Deflector Installation SIE-ID = 194869 Tools Required J 36660-A Torque Angle Meter 1. Inspect for properly installed oil pump locator pins. 182852 Important: Do not reuse the oil pump driveshaft retainer (4). During assembly, install a NEW oil pump driveshaft retainer. 2. Assemble the oil pump (3), the oil pump driveshaft (5), and a NEW oil pump driveshaft retainer (4). 3. Install the oil pump (3).
Engine Engine Mechanical - 5.0L and 5.7L 6-119 Oil Pan Installation SIE-ID = 66859 Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the oil pan studs into the engine block. Tighten Tighten the oil pan studs to 6 N·m (53 lb in). 521817 2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N United States 12346141, GM P/N Canada 10953433, or equivalent, to the engine front cover to engine block junction at the oil pan sealing surfaces. 317310 3.
6-120 Engine Mechanical - 5.0L and 5.7L Engine Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. 4. Install the NEW oil pan gasket. 5. Install the oil pan. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. 6. Install the oil pan reinforcements. 7. Install the nuts and the bolts. Tighten 7.1.
Engine Engine Mechanical - 5.0L and 5.7L 6-121 Oil Filter Adapter Installation SIE-ID = 69508 1. Apply clean engine oil GM P/N United States 12345610, GM P/N Canada 993193, or equivalent, to the NEW oil filter adapter seal, O-ring, if applicable. 2. Install the NEW oil filter adapter seal into the groove in the oil filter adapter, if applicable. 3. Install the NEW oil filter adapter gasket, if applicable, and the oil filter adapter. Notice: Refer to Fastener Notice in Cautions and Notices. 4.
6-122 Engine Mechanical - 5.0L and 5.7L Engine Notice: Refer to Fastener Notice in Cautions and Notices. 4065 5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. 5.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten Tighten the J 23523-F plate bolts to 25 N·m (18 lb ft). 5.2. Install the J 23523-F screw into the end for the crankshaft. 5.3. Install the J 23523-F bearing, the washer, and the nut onto the J 23523-F screw. 5.4.
Engine Engine Mechanical - 5.0L and 5.7L 6-123 9. Install the crankshaft balancer washer and the bolt. Tighten Tighten the crankshaft balancer bolt to 95 N·m (70 lb ft). 173172 Valve Lifter Installation SIE-ID = 69825 1. Apply lubricant GM P/N United States 12345501, GM P/N Canada 992704, or equivalent, to the valve lifter rollers. Important: If reusing the valve lifters, install the valve lifters in the original positions. 2. Install the valve lifters. 11509 3. Install the valve lifter guides. 4.
6-124 Engine Mechanical - 5.0L and 5.7L Engine Cylinder Head Installation - Left SIE-ID = 650067 Tools Required J 36660-A Torque Angle Meter 1. Clean the cylinder gasket surfaces on the engine block. 2. Inspect the cylinder head locator dowel pins for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head. 182846 Important: Do not use any type sealer on the cylinder head gasket, unless specified. 4.
Engine Engine Mechanical - 5.0L and 5.7L 6-125 6. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the cylinder head bolts. Tighten Tighten the bolts in sequence on the first pass to 30 N·m (22 lb ft). 317217 8. Use the J 36660-A in order to tighten the cylinder head bolts in sequence on the final pass.
6-126 Engine Mechanical - 5.0L and 5.7L Engine 11. If reusing the engine coolant temperature (ECT) gage sensor, apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the threads of the ECT gage sensor. 12. Install the ECT gage sensor. Tighten Tighten the ECT gage sensor to 20 N·m (15 lb ft). 521828 Cylinder Head Installation - Right SIE-ID = 650068 Tools Required J 36660-A Torque Angle Meter 1. Clean the cylinder gasket surfaces on the engine block. 2.
Engine Engine Mechanical - 5.0L and 5.7L 6-127 5. Install the cylinder head to the engine block. Guide the cylinder head carefully into place over the dowel pins and the head gasket. 317246 6. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the threads of the cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the cylinder head bolts. Tighten Tighten the bolts in sequence on the first pass to 30 N·m (22 lb ft). 317239 8.
6-128 Engine Mechanical - 5.0L and 5.7L Engine 9. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap, if necessary. Specifications Spark plug gap to 1.52 mm (0.060 in). 10. Install the NEW spark plugs. Tighten • Tighten the spark plugs for a USED cylinder head to 15 N·m (11 lb ft). • Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N·m (22 lb ft).
Engine Engine Mechanical - 5.0L and 5.7L 6-129 Valve Lash Adjustment SIE-ID = 194734 1. Turn the valve rocker arm nuts clockwise until all of the valve lash is removed. 2. Turn the crankshaft clockwise until the alignment mark on the crankshaft balancer is aligned with the notch in the engine front cover tab. 3. Look at the number 1 cylinder valves as the crankshaft balancer alignment mark approaches the notch in the engine front cover tab.
6-130 Engine Mechanical - 5.0L and 5.7L Engine 6. With the engine in the number 6 firing position, adjust the exhaust valves for cylinders number 2, 5, 6, and 7 and the intake valves for cylinders number 3, 4, 6, and 8. 6.1. Turn the valve rocker arm nut counter clockwise until the valve lash is felt in the valve pushrod. 6.2. Turn the valve rocker arm nut clockwise until all the valve lash is removed.
Engine Engine Mechanical - 5.0L and 5.7L 6-131 Notice: SIO-ID = 41431 Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage. Important: All sealing surfaces must be clean, free of oil, dirt, or any other foreign material. 3. Apply a 5 mm (0.
6-132 Engine Mechanical - 5.0L and 5.7L Engine Notice: SIO-ID = 382467 Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. 9. Install the lower intake manifold bolts. Tighten 9.1. Tighten the bolts on the first pass in sequence (1–8) to 3 N·m (27 lb in). 9.2.
Engine Engine Mechanical - 5.0L and 5.7L 6-133 2. Remove the distributor cap bolts and discard. 3. Remove the distributor cap. 500690 4. Install a NEW distributor gasket onto the distributor. 523516 5. Align the indent hole on the driven gear with the paint mark on the distributor housing. 6. Ensure that the distributor rotor segment points to the cap hold area.
6-134 Engine Mechanical - 5.0L and 5.7L Engine 7. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary. 8. Align the flat (1) in the distributor housing toward the front of the engine. 9. Install the distributor and distributor clamp. 523746 10. Once the distributor is fully seated, align the distributor rotor segment with the number 8 pointer that is cast into the distributor base. 11.
Engine Engine Mechanical - 5.0L and 5.7L 6-135 13. Install the distributor cap onto the distributor. 14. Install the NEW distributor cap bolts. Do not overtighten the NEW distributor cap bolts. Tighten Tighten the distributor cap bolts to 2.4 N·m (21 lb in). 500690 15. Install the ignition coil wire harness. 341359 Valve Rocker Arm Cover Installation - Left SIE-ID = 650069 Important: Always install a NEW valve rocker arm cover gasket. 1. Install the NEW valve rocker arm cover gasket. 2.
6-136 Engine Mechanical - 5.0L and 5.7L Engine Valve Rocker Arm Cover Installation - Right SIE-ID = 650070 Important: Always install a NEW valve rocker arm cover gasket. 1. Install the NEW valve rocker arm cover gasket. 2. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the valve rocker arm cover washers and bolts. Tighten Tighten the bolts to 12 N·m (106 lb in).
Engine Engine Mechanical - 5.0L and 5.7L 6-137 6. Install the fan and water pump pulley and bolts using the J 41240. Tighten Tighten the fan and water pump pulley bolts to 25 N·m (18 lb ft). 317191 Oil Level Indicator and Tube Installation SIE-ID = 349357 1. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, around the oil level indicator tube 13 mm (0.5 in) below the tube bead. 2. Install the oil level indicator tube into the engine block.
6-138 Engine Mechanical - 5.0L and 5.7L Engine 6. Install the spark plug wire supports and bolts. Tighten Tighten the bolts to 12 N·m (106 lb in). 7. Install the spark plug wires onto the spark plugs. 317185 Exhaust Manifold Installation - Right SIE-ID = 650072 1. 2. 3. 4. Install the NEW exhaust manifold gasket. Install the exhaust manifold. Install the spark plug heat shields.
Engine Engine Mechanical - 5.0L and 5.7L 6-139 Engine Flywheel Installation SIE-ID = 784241 1. Install the engine flywheel (1 or 2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin. 188129 Important: If replacing the engine flywheel (manual transmission), note the position and length of the original flywheel weights, if applicable.
6-140 Engine Mechanical - 5.0L and 5.7L Engine Description and Operation Engine Component Description SIE-ID = 69042 182830 Cylinder Block Camshaft The engine block is made of cast iron and has eight cylinders arranged in a V shape with four cylinders in each bank. The cylinder block is a one piece casting with the cylinders encircled by coolant jackets. A steel engine camshaft is supported by five camshaft bearings pressed into the engine block.
Engine 5.0L and 5.7L engines have two bolts per crankshaft bearing cap. The heavy duty 5.7L engines have four bolts per crankshaft bearing cap, on bearing caps 2, 3, and 4. The number 5 crankshaft bearing cap at the rear of the engine is the end thrust bearing cap. The four connecting rod journals (two connecting rods per journal) are spaced 90 degrees apart. The crankshaft position sensor reluctor ring is pushed onto the front of the crankshaft.
6-142 Engine Mechanical - 5.0L and 5.7L Engine Lubrication Description SIE-ID = 650073 Right Side View SIO-ID = 71039 67757 The gear-type oil pump is driven through an extension driveshaft. The extension driveshaft is driven by the distributor which is gear driven by the camshaft. The oil is drawn from the oil pan through a pickup screen and tube.
Engine Engine Mechanical - 5.0L and 5.7L Front View 6-143 SIO-ID = 71037 67753 Cleanliness and Care SIE-ID = 19007 • Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. • When any internal engine parts are serviced, care and cleanliness is important.
6-144 Engine Mechanical - 5.0L and 5.7L − Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil. This fine grit is an abrasive and can cause internal engine damage. Assembling Components • Assemble components using only the sealant (or equivalent) that is specified in the service procedure. • Sealing surfaces must 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.
Engine • Do not overtighten the fasteners. − Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface. − Tighten the fasteners in sequence, if specified, and to the proper torque specifications. − After properly tightening the fasteners, remove the excess gasket eliminator sealant from the outside of the joint. Engine Mechanical - 5.0L and 5.7L 6-145 • Apply the pipe sealant bead to the inside of any bolt hole areas.
6-146 Engine Mechanical - 5.0L and 5.7L Engine Special Tools and Equipment SIE-ID = 690690 Illustration Tool Number/ Description Illustration Tool Number/ Description J 3049-A Valve Lifter Remover 14487 J 5825-A Crankshaft Gear Remover 3406 J 5239 Connecting Rod Bolt Guide Set 3404 J 5830-02 Valve Guide Reamer Set 4999 J 6036 Rocker Stud Hole Reamer 0.33 mm (0.013 in) oversize J 5590 Installer 3407 14492 J 5715 Rocker Stud Hole Reamer 0.0762 mm (0.
Engine Engine Mechanical - 5.0L and 5.
6-148 Engine Mechanical - 5.0L and 5.
INDEX 1 C E Camshaft and Bearings Cleaning and Inspection Engine Mechanical - 5.0L and 5.7L ................ 6-67 Camshaft Bearing Installation Engine Mechanical - 5.0L and 5.7L ................ 6-70 Camshaft Bearing Removal Engine Mechanical - 5.0L and 5.7L ................ 6-69 Camshaft Installation Engine Mechanical - 5.0L and 5.7L .............. 6-114 Camshaft Removal Engine Mechanical - 5.0L and 5.7L ................ 6-35 Cleanliness and Care Description Engine Mechanical - 5.0L and 5.7L ..........
2 INDEX O Oil Filter Adapter Installation Engine Mechanical - 5.0L and 5.7L .............. 6-121 Oil Filter Adapter Removal Engine Mechanical - 5.0L and 5.7L ................ 6-30 Oil Level Indicator and Tube Installation Engine Mechanical - 5.0L and 5.7L .............. 6-137 Oil Level Indicator and Tube Removal Engine Mechanical - 5.0L and 5.7L ................ 6-20 Oil Pan Cleaning and Inspection Engine Mechanical - 5.0L and 5.7L ................ 6-90 Oil Pan Installation Engine Mechanical - 5.0L and 5.
TP-6104 11/01a
