Inspection and Service Procedures Part 5

PISTON SELECTION

Tools Required
- J 8087 Cylinder Bore Checking Gauge A

IMPORTANT:
- Measurements of all components should be taken with the components at normal room temperature.
- For proper piston fit, the engine block cylinder bores should not have excessive wear or taper.
- A used piston and pin set may be reinstalled if, after cleaning and inspection, they are within specifications.

1. Inspect the engine block cylinder bore. Refer to Engine Block Clean and Inspect
2. Inspect the piston and pin. Refer to Piston, Connecting Rod and Bearings Clean/Inspect.
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.





4. Measure the bore gauge with a micrometer and record the reading.





5. With a micrometer or caliper at a right angle to the piston, measure the piston 11 mm (0.433 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. Refer to Engine Mechanical Specifications.
7. If the proper clearance cannot be obtained, select another piston and measure the clearances.

NOTE:If the proper fit cannot be obtained, the cylinder bore may require honing or boring.

8. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top A of the piston for installation into the proper cylinder.





PISTON AND CONNECTING ROD ASSEMBLE

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.