Service manual

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. The crankshaft position
sensor reluctor ring has four lugs used for crankshaft
timing and it is constructed of powdered metal.
The reluctor ring has an interference fit onto the
crankshaft and an internal keyway for correct
positioning.
Pistons and Connecting Rods
The pistons are made of cast aluminum that use
two compression rings and one oil control ring
assembly. The piston is a low-friction, lightweight
design with a flat top and barrel-shaped skirt.
The piston pins are chromium steel. The piston pins
have a floating fit in the piston and are retained
by a press fit in the connecting rod assembly. The
connecting rods are made out of either forged
powdered metal or forged steel. The connecting rods
are machined with the connecting rod cap installed
for proper clearances and alignment.
Valve Train
The valve train is a ball pivot type. Motion is
transmitted from the camshaft through the hydraulic
roller valve lifters and tubular valve pushrods to
the valve rocker arms. The valve rocker arm pivots on
a ball in order to open the valve. The hydraulic
roller valve lifters keep all parts of the valve train in
constant contact. The valve rocker arm ball is retained
on the valve rocker arm ball stud with a locking nut.
The valve rocker arm ball studs are pressed into
the cylinder head.
Intake Manifold
The intake manifold is a two piece design. The upper
intake manifold portion is made from a composite
material and the lower intake manifold portion
is cast-aluminum. The throttle body mounts to the
upper intake manifold. The lower intake manifold has
an exhaust gas recirculation (EGR) port cast into
the manifold for mixture of exhaust gases with the fuel
and air mixture. The EGR valve mounts to the
lower intake manifold.
The Central Sequential Multiport Fuel Injection,
Central (SFI) system uses multiple injectors to meter
and distribute fuel to each engine cylinder. The
Central (SFI) unit is retained by a bracket bolted to the
lower intake manifold. The TBI fuel meter also
houses the pressure regulator. Metal inlet and outlet
fuel lines and nylon delivery tubes independently
distribute fuel to each cylinder through nozzles located
at the port entrance of each manifold runner where
the fuel is atomized.
New Product Information
SIE-ID = 512775
The purpose of New Product Information is to highlight
or indicate important product changes from the
previous model year.
Changes may include one or more of the
following items:
• Torque values and/or fastener tightening strategies
• Changed engine specifications
• New sealants and/or adhesives
• Disassembly and assembly procedure revisions
• Engine mechanical diagnostic procedure revisions
• New special tools required
• A component comparison from the previous year
Torque Values and/or Fastener Tightening
Strategies
• Cylinder head bolts, crankshaft bearing cap bolts,
and connecting rod bolts apply a torque angle
strategy.
In an on-vehicle situation where a torque angle
meter may not fit into the vehicle packaging,
a three step tightening process may be used with
a torque wrench.
• Certain fasteners should not be reused. Bolts,
studs, or other fasteners that must be replaced will
be called out in the specific service procedure.
Changed Engine Specifications
Engine specifications remain the same as the 1999
products.
Disassembly and Assembly Procedure
Revisions and Additions
No revisions or additions.
Engine Mechanical Diagnostic Procedure
Revisions
• Valve Train diagnostic information is now provided
in table form. Potential or probable causes are
supplied for each specific concern.
• Engine Noise diagnostic information is now
provided in table form. Potential or probable
causes are supplied for each specific concern.
New Special Tools Required
No new special tools are required.
Engine Engine Mechanical - 5.0L and 5.7L 6-141
2002 - Unit Repair (May 25, 2001)