Inspection and Service Procedures Part 2
PISTON AND CONNECTING ROD ASSEMBLY
Tools Required
- J 24086-C Piston Pin Remover/Installer
NOTICE: After the J 24086-C installer hub bottoms on the support assembly, DO NOT exceed 35 000 kPa (5,000 psi) or the tool may be damaged.
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. Left bank connecting rods should have the flange face toward the front of the engine block. Right bank connecting rods should have the flange face toward the rear of the engine block. The piston pin has an interference fit into the connecting rod and is full floating in the piston.
1. Install the piston pin and connecting rod assembly.
1.1. Lubricate the piston and connecting rod pin bores with clean engine oil.
1.2. Press the piston pin into the piston and connecting rod assembly using the J 24086-C.
1.3. Inspect for proper installation of the piston and pin.
CAUTION:The piston should move freely on the pin with no binding or interference.
2. Install the piston rings onto the piston.
2.1. Install the oil control ring spacer.
2.2. Install the lower oil control ring.
2.3. Install the upper oil control ring.
2.4. Install the lower compression ring. The mark on the side of the ring should face the top of the piston.
2.5. Install the upper compression ring. The mark on the side of the ring should face the top of the piston.
3. Space the compression ring end gaps 120 degrees apart.
4. Space the oil control ring end gaps a minimum of 90 degrees apart.
CAMSHAFT BEARING REMOVAL (REMOVAL PROCEDURE)
Tools Required
- J 33049 Camshaft Bearing Removal/Installation Set
1. Remove the rear camshaft plug.
IMPORTANT: A loose camshaft bearing may be caused by an enlarged, out-of-round, or damaged engine block bearing bore.
2. Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores.
3. Select the cone (1), handle (10), expanding driver (4-8) and washer (2 or 3) from the J 33049.
4. Assemble the J 33049.
IMPORTANT: Remove the inner bearings #2, #3, #4 first. The outer bearings #1 and #5 serve as a guide for the J 33049.
5. Insent the J 33049 through the front of the engine block and into the inner bearing 2-4.
6. Tighten the expander assembly nut (15) until snug.
7. Push the guide cone (1) into the front camshaft bearing to align the tool.
8. Drive the inner bearings from their block bores.
9. Remove the outer bearings #1 and #5.
9.1. Assemble the tool handle (10), expanding driver (4-8), and washer (2 or 3).
9.2. Insert the J 33049 into the engine block front or rear camshaft bearings #1 or #5.
9.3. Drive the bearings from their bores.
CAMSHAFT BEARING REMOVAL
(Tool Instructions)
Bearing, Expander, and Expander Driver Information
- The tool consists of a guide cone (1), driving washers (2,3), expander bearing drivers (4-8), driver bars (9,10), expander jaws (11), expander sleeve (12), expander cone (13), expander shaft (14), and expander assembly (15).
- Expander bearing driver number one inside diameter is 28.575-37.465 mm (1.125-1.475 in) and is used with the expander assembly and the small washer.
- Expander bearing driver number two inside diameter is 37.465-43.180 mm (1.475-1.700 in) and is used with number one expanding driver and the small washer.
- Expander bearing driver number three inside diameter is 43.180-48.895 mm (1.700-1.925 in) and is used with number two expanding driver and the large washer.
- Expander bearing driver number tour inside diameter is 48.895-54.610 mm (1.925-2.150 in) and is used with number three expanding driver and the large washer.
- Expander bearing driver number five inside diameter is 54.610-60.325 mm (2.150-2.375 in) and is used with number four expanding driver and the large washer.
- Expander bearing driver number six inside diameter is 60.325-68.326 mm (2.375-2.690 in) and is used with number five expanding driver and the large washer.
TOOL ASSEMBLY AND OPERATION
1. Select the proper expanding driver and washer from the expanding driver and washer information.
IMPORTANT: To install or remove the expanding driver; always push on or pull from the ends. Pressure on the outside diameter may cause a bind against the rubber expanding sleeve.
2. Place the expanding driver onto the expander assembly.
3. Check to insure that the separation lines between the segments of the expanding driver align with the separation lines of the expander assembly.
4. Place the guide cone over the driving bar (with the small end of the cone facing the driver assembly).
5. Place the driving washer over the threaded portion of the expander assembly.
6. Screw the expander assembly (with driving washer) onto the driving bar.
NOTE:It may be necessary to install the driver bar extension for removal of the inner bearings.
7. Insert the tool into a inner camshaft bearing and tighten until snug.
NOTE:Operate the tool from the front or rear of the engine block. On some engine blocks the nut on the expander assembly is inaccessible except from either end. In this case you must use a socket and extension to enlarge and reduce the expander assembly.
8. Slide the nylon cone into the front or rear camshaft bearing (this will properly align the tool).
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner bearings.
11. For the two end bearings (front and rear), remove the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.
CAMSHAFT AND BEARINGS CLEAN AND INSPECT
Tools Required
- J 7872 Magnetic Base Dial Indicator
1. Clean the camshaft in solvent.
CAUTION: Wear safety glasses In order to avoid eye damage.
2. Dry the camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
4. Inspect the camshaft for the following:
- Worn, scored, or damaged bearing journals (1)
- Worn camshaft lobes (2)
- Damaged bolt threads (3) Damaged sprocket pin (4)
5. Measure the camshaft journals with a micrometer.
NOTE: If journals are more than 0.025 mm (0.0010 in) out-of-round, replace the camshaft.
6. Measure for a bent camshaft or excessive camshaft runout using the J 7872.
6.1. Mount the camshaft in V-blocks between centers.
6.2. Use the J 7872 in order to check the intermediate camshaft journals.
7. If the runout exceeds 0.065 mm (0.0026 in), the camshaft is bent and should be replaced.
8. Measure the camshaft lobe lift using 6 the J 7872.
8.1. Lubricate the camshaft using lubricant GM P/N 12345501 or equivalent.
8.2. Place the camshaft on the V-blocks.
8.3. Use the J 7872 in order to measure the camshaft lobe lift.
9. Replace the camshaft if the camshaft lobe lift is not within specifications.
CAMSHAFT BEARING INSTALLATION
Tool Required
- J 33049 Camshaft Bearing Remover/Installer
IMPORTANT:
- The outer camshaft bearings #1 and #5 must be installed first. These bearings serve as guides for the tool and help center the inner bearings during the installation process. Ensure the correct camshaft bearing fits into the proper bore. The cam bearing bores may vary in size.
- Ensure that the camshaft bearing lubrication hole or holes align with the oil gallery hole or holes in the block. On some engines, the oil holes may be difficult to see. Verify that the holes are aligned.
1. Assemble the J 33049 handle (10), expanding driver (4-8), and washer (2 or 3).
2. Insert the J 33049 into the engine block end camshaft bearings #1 or #5.
IMPORTANT:
- The camshaft bearing oil holes must align with the oil galleries in the engine block.
- After installation of the camshaft bearings, inspect the camshaft bearing oil holes for proper alignment with the oil galleries. An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the bearing and the camshaft journal.
3. Drive the end bearings #1 and #5 into their bores.
4. Select the tool handle (10), cone (1), expanding driver (4-8), and washer (2 or 3) from the J 33049.
5. Assemble the J 33049.
6. Insert the J 33049 through the front of the engine block and to the inner bearing bores #2, #3, and #4.
7. Install the bearing onto the expanding driver (4-8).
8. Tighten the expander assembly nut (15) until the J 33049 is snug in the bearing.
IMPORTANT:
- The camshaft bearing oil holes must align with the oil galleries in the engine block.
- After installation of the camshaft bearings, inspect the camshaft bearing oil holes for proper alignment with the oil galleries. An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to the bearing and the camshaft journal.
9. Align the oil lubrication hole in the bearing with the oil galleries in the engine block.
10. Push the guide cone (1) into the front camshaft bearing bore to align the J 33049.
11. Drive the bearing into the bore.
BALANCE SHAFT BEARING AND/OR BUSHING REMOVAL
Tools Required
- J 38834 Balance Shaft Bearing Service kit
IMPORTANT: The balance shaft and the front bearing are serviced only as an assembly. Do not remove the front bearing from the balance shaft.
1. Use a soft-faced hammer in order to remove the balance shaft and the front bearing.
2. Use the J 38834 in order to remove the rear bearing.
2.1. Insent the J38834 shaft through the front of the engine block.
2.2. Rotate the tool shaft clockwise until the legs of the puller end engage behind the rear bearing.
2.3. Use a wrench in order to rotate the tool nut clockwise until the bearing has left the bore.
NOTE: Use a second wrench and hold the tool shaft. Do not allow the shaft to rotate.
BALANCE SHAFT CLEAN AND INSPECT
IMPORTANT: The balance shaft and the front bearing are serviced only as an assembly. Do not remove the front bearing from the balance shaft.
1. Inspect the balance shaft bearings for the following:
- Front roller bearing for damage or wear
- Front roller bearing for smoothness of operation
- Rear sleeve bearing for wear, scoring, or other damage
2. Inspect the balance shaft (4) for the following:
- Wear or scoring on the rear sleeve bearing end
- Damaged bolt thread
- Damaged to the driven gear locating pin
3. Inspect the balance shaft retainer plate (3) for wear or damage.
4. Inspect the driven gear (2) for wear, damage to the teeth or excessive backlash.
5. Inspect the drive gear retaining bolt (1) for damaged threads.
6. Inspect the drive gear for wear and damage to the teeth or excessive backlash.
BALANCE SHAFT BEARING AND/OR BUSHING
Installation
Tool Required
- J 8O92Handle
- J 38834 Balance Shaft Bearing Service Kit
- J 36996 Balance Shaft Installer
1. Use the J 38834 and the J 36996 in order to install the rear bearing.
1.1. Insert the J 38834 into the engine block. Position the J 38834 bushing into the engine block front bearing bore.
1.2. Install the J 36996 onto the J 38834 shaft.
1.3. Lubricate the NEW bearing with clean engine oil.
1.4. Install the NEW bearing onto the J3699&
1.5. Use a wrench and rotate the tool nut until the bearing is properly and completely pushed into the block bore. Use a second wrench and hold the tool shaft. Do not allow the shaft to rotate.
IMPORTANT: The balance shaft and the front bearing are serviced only as an assembly. Do not remove the front bearing from the balance shaft.
2. Use the J 36996 and the J 8092 in order to install the balance shaft and front bearing.
TIMING CHAIN AND SPROCKETS CLEAN AND INSPECT
1. Clean the components with cleaning solvent.
CAUTION: Wear safety glasses in order to avoid eye damage.
2. Dry the components with compressed air.
3. Inspect the timing chain for binding or wear.
4. Inspect the camshaft and crankshaft sprockets for:
- Worn teeth (1)
- Damaged teeth (2)
- Chipped teeth (3)
- Worn valleys between the sprocket teeth Crankshaft sprocket keyway for wear
VALVE ROCKER ARM AND PUSH RODS CLEAN AND INSPECT
IMPORTANT: Parts that are to be reused must be marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for assembly.
2. Clean the components with cleaning solvent.
CAUTION: Wear safety glasses in order to avoid eye damage.
3. Dry the components with compressed air.
4. Inspect the valve rocker arms for wear or scoring in the ball area.
5. Inspect the valve rocker arm pushrod sockets and valve stem mating surfaces. These surfaces should be smooth with no scoring or exceptional wear.
6. Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
7. Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
8. Inspect the pushrod oil passages for restrictions.
9. Inspect the valve rocker arm studs for unusual wear or damage to the threads.
VALVE LIFTERS AND GUIDES CLEAN AND INSPECT
IMPORTANT: Components that are to be reused must be marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for assembly.
2. Clean the components in cleaning solvent.
CAUTION: Wear safety glasses in order to avoid eye damage.
3. Dry the components with compressed air.
4. Inspect the valve lifter guides for excessive wear.
5. Inspect the valve lifter guides for cracks or damage.
6. Inspect the valve lifter body for the following:
- Broken or damaged clip (1)
- Worn pushrod socket (2)
- Scuffed or worn lifter (3)
NOTE: If the valve lifter shows scuffing or wear; inspect the engine block valve lifter bores for wear.
- Worn roller (4)
- Loose or damaged pin (5)
- Plugged oil hole (6)
CYLINDER HEAD DISASSEMBLE
Tools Required
- J 8062 Valve Spring Compressor
1. Use J 8062 in order to compress the valve springs.
IMPORTANT: Mark, sort, or organize the components so that they may be reinstalled to their original location and position.
2. Remove the valve stem keys (1).
3. Remove the cap (3).
4. Remove the valve spring (4).
5. Remove the valve stem oil seal (2).
6. Discard the valve stem oil seal.
7. Remove the valve.
CYLINDER HEAD CLEAN AND INSPECT
Tools Required
- J 8001 Dial Indicator
- J 8089 Carbon Removal Brush
- J 9666 Valve Spring Tester
1. Use the J 8089 in order to clean the carbon from the combustion chambers. Be careful not to scuff the chambers.
CAUTION: Wear safety glasses In order to avoid eye damage.
2. Clean the valve stems and heads of a buffing wheel.
3. Clean the following components in solvent:
- Valve stem keys (1)
- Valve spring cap (3)
- Valve spring (4)
- Cylinder head
CAUTION: Wear safety glasses In order to avoid eye damage.
4. Dry the components with compressed air.
5. Measure the cylinder head for warpage with a straight edge and feeler gauge.
5.1. A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
5.2. A cylinder head exhaust manifold deck with warpage in excess of 0.5 mm (0.002 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
5.3. A cylinder head intake manifold deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
6. Use the J 9666 in order to measure the valve spring.
NOTE: Replace the valve spring if the spring tension is less than 338 N (76 lb) at 43.2 mm (1.70 in).
7. Inspect the valve springs for squareness.
8. Valve stems (1) with excessive guide (2) clearance must be repaired or replaced.
9. Measure the valve stem4o-guide clearance.
- Excessive valve stem-to-guide clearance may cause 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.
- Clamp the J 8001 on the exhaust port side of the cylinder head.
- Locate the indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct movement of the indicator stem.
NOTE: The indicator stem must contact the side of the valve stem just above the valve guide.
- Drop the valve head about 1.6 mm (0.0064 in) off the valve seat.
- Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading.
VALVE GUIDE REAMING/VALVE AND SEAT GRINDING
Tool Required
- J 8001 Dial Indicator Set
1. Use the J 8001 to measure the valve stem-to-guide clearance. Refer to Cylinder Head Clean and Inspect.
2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption.
3. Ream the valve guide as necessary to achieve proper valve stem-to-guide clearance.
3.1. Ream the valve guide oversize to accept a valve guide sleeve.
3.2. Insert the valve guide sleeve into the guide bore.
3.3. Ream the sleeve to achieve proper valve stem-to-guide clearance.
4. Always recondition the valve and valve seat after reaming the valve guide bores or installing new valves.
5. Inspect the valves for the following:
- Burnt or damaged areas (1)
- Undersized valve margin (2)
- Bent stem (3)
- Scoring or other damage to the stem (4)
- Worn key groove (5) Worn stem tip (6)
6. Inspect the valve contact surface for the following:
- Undersized margin (1)
- Pitted surface (2)
- Burnt or eroded areas (3)
- Acceptable edge (margin) (4)
7. Valves with excessive damage must be replaced.
NOTE: Minor imperfections of the valve or valve seat may be repaired.
8. 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. Good contact between each valve and its seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away.
- Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt to ensure the proper centering of the pilot in the guide. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.
- Reface pitted valves on a valve refacing machine in order to insure the correct relationship between the head and the stem.
- Replace the valve stems that show excessive wear or are warped.
- Replace the valve if the edge of the head is less than 0.79 mm (0.031 in) thick after grinding.
- Several different types of equipment are available for reconditioning valves and valve seats. Follow the manufacturers recommendations for equipment use to attain the proper results.
CYLINDER HEAD ASSEMBLE
Tools Required
- J 8062 Valve Spring Compressor
- J 42073 Valve Stem Oil Seal Installer
IMPORTANT: The exhaust valve oil seal has the letters EX (1) molded into the top of the seal. The seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal.
1. Assemble the valve into the proper guide.
2. Select the proper valve stem oil seal for the specific valve guide.
3. Lubricate the valve stem oil seal and guide with clean engine oil.
NOTE: The exhaust and intake valve seals are not interchangeable.
4. Assemble the valve stem oil seal onto the valve guide using the J 42073.
NOTE: Install the oil seal onto the valve guide until the installation tool bottoms against the valve spring seat.
5. Inspect the oil seal. The seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the seal and the guide.
6. Install the valve spring (4).
7. Install the spring cap (2) onto the spring (4) and over the valve stem (5) or (6).
8. Use the J 8062 in order to compress the valve spring.
9. Install the valve stem keys (1).
9.1. Use grease in order to hold the keys (1) in place while disconnecting the J 8062.
9.2. Ensure that the keys seat properly in the upper groove of the valve stem.
9.3. Tap the end of the stem with a plastic-faced hammer in order to seat the keys, if necessary.
OIL PUMP DISASSEMBLE
1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
2. If necessary, remove the oil pump screen.
- The oil pump screen has a press fit in to the oil pump cover.
- Do not remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
5. Remove the drive gear and the driven gear. Matchmark the gear teeth for assembly.
6. Remove the following items:
- The locator pin
- The oil pressure relief spring The oil pressure relief valve
OIL PUMP CLEAN AND INSPECT
1. Clean the oil pump components in solvent.
CAUTION: Wear safety glasses in order to avoid eye damage.
2. Dry the components with compressed air.
3. Inspect the oil pump for the following:
- Scoring, damage or casting imperfections to the housing (3)
- Damage gears (chipping, galling, or wear) (2)
- Scoring on the top of the gears (1)
- Damaged or scored gear shaft (5)
- Damaged bolt threads
- Worn driveshaft housing bore
- Damaged or sticking pressure relief valve (minor imperfections may be removed with a fine oil stone).
- Collapsed or broken pressure relief valve spring
4. If the oil pump is to be reused, install a NEW pressure relief valve spring.
5. During oil pump installation, install a NEW oil pump driveshaft retainer.
OIL PUMP ASSEMBLE
Tools Required
- J 21882 Oil Pump Screen Installer
1. Lubricate the oil pressure relief valve, spring, and oil pump housing with clean engine oil.
IMPORTANT: Replace the pressure relief valve spring when you reuse the oil pump.
2. Install the following items:
2.1. The oil pressure relief valve
2.2. The oil pressure relief spring
2.3. The locator pin
3. Coat the drive gear, the driven gear and the housing gear surfaces with clean engine oil.
4. Install the drive gear and the driven gear into the pump body.
NOTE: Align the matchmarks on the gears. Install the smooth side of the gear toward the pump cover.
5. Install the oil pump cover.
NOTE: Refer to Fastener Notice in Caution and Notices.
6. Install the oil pump cover bolts.
Tighten
- Tighten the bolts to 12 N.m (106 lb in).
7. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.
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 to the end of the pipe.
8.4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body. The screen must align parallel with the bottom of the oil pan when it is installed.
IMPORTANT: Install a NEW oil pump driveshaft retainer during assembly.
9. Install the oil pump driveshaft and the NEW retainer.