Login- Download PDF Manual
-
. . . . . . . . . . . . . . . 200
. . . . . . . . . . . . . . . . . . . . . . . . . 201INSPECTION INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 201CRANKSHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 202CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 202
. . . . . . . . . . . . . . . . . . . . . . . . . 203INSPECTION
5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 192
CRANKSHAFT OIL SEAL - FRONT
AIR INTAKE SYSTEM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 194CYLINDER HEAD
OPERATION—CYLINDER HEAD . . . . . . . . . . . 194
DIAGNOSIS AND TESTING—CYLINDER HEADGASKET FAILURE . . . . . . . . . . . . . . . . . . . . 194
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 195
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 195CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 196INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES . . . . . . . . . 197
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 197
STANDARD PROCEDURE - REFACING . . . . . 197
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 203CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 204
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 204CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 205FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 205PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 205
STANDARD PROCEDURE—PISTON FITTING . 205
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 206
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 207DR
ENGINE - 5.7L
9 - 177
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 209INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 218
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 219STRUCTURAL COVER
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 210
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 210
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 210FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 211DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 219
DIAGNOSIS AND TESTING - INTAKEMANIFOLD LEAKAGE
. . . . . . . . . . . . . . . . . 219
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 219
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 219REAR MOUNT
EXHAUST MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 213LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 214
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CHECKING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 220
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 220
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 220
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 220ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 214
TIMING/CHAIN COVER
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 221OIL
TIMING/CHAIN AND SPROCKETS
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 222OIL FILTER
TIMING CHAIN/TENSIONER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 222
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 222OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9 - 178
ENGINE - 5.7L
ENGINE - 5.7L DESCRIPTION
The 5.7L engine (Fig. 1)(345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cyl- inders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.
DR
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful
in determining the causes of malfunctions not detected and remedied by routine maintenance.
These malfunctions may be classified as either per- formance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
Fig.15.7LENGINE
DR ENGINE - 5.7L (Continued)
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING)—PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS AND TESTING) for the fuel system diagnosis.
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following diagnosis:
ENGINE - 5.7L
9 - 179
ENGINE - DIAGNOSIS AND TESTING).
† Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING).† Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO- SIS AND TESTING). † Intake Manifold Leakage Diagnosis (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery
1. Charge or replace as necessary.
2. Corroded or loose battery connections.
3. Faulty starter.
4. Faulty coil or control unit.
5. Incorrect spark plug gap.
6. Dirt or water in fuel system.
7. Faulty fuel pump, relay or wiring.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low.
2. Idle mixture too lean or too rich.
3. Vacuum leak.
4. Faulty coil.
5. Incorrect engine timing.
2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. (Refer to 8 - ELECTRICAL/ STARTING - DIAGNOSIS AND TESTING). 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 6. Clean system and replace fuel filter. 7. Repair or replace as necessary.
1. (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/IDLE AIR CONTROL MOTOR - REMOVAL). 2. Refer to Powertrain Diagnosis Information. 3. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).
ENGINE - 5.7L
9 - 180
ENGINE - 5.7L (Continued)DR
CONDITION
POSSIBLE CAUSE
CORRECTION
1. ENGINE LOSS OF POWER
1. Dirty or incorrectly gapped spark plugs.
2. Dirt or water in fuel system.
3. Faulty fuel pump.
4. Blown cylinder head gasket. 5. Low compression.
6. Burned, warped or pitted valves. 7. Plugged or restricted exhaust system. 8. Faulty coil.
1. ENGINE MISSES ON ACCELERATION
1. Spark plugs dirty or incorrectly gapped.
2. Dirt in fuel system. 3. Burned, warped or pitted valves. 4. Faulty coil.
1. ENGINE MISSES AT HIGH SPEED
1. Spark plugs dirty or incorrectly gapped.
2. Faulty coil.
3. Dirt or water in fuel system.
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean system and replace fuel filter. 3. (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 4. Replace cylinder head gasket. 5. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 6. Replace as necessary. 7. Inspect and replace as necessary. 8. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean fuel system. 3. Replcae as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 3. Clean system and replace fuel filter.
DR ENGINE - 5.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE - 5.7L
9 - 181
CONDITION
POSSIBLE CAUSES
CORRECTIONS
NOISY VALVES
1. High or low oil level in crankcase.
2. Thin or diluted oil. 3. Low oil pressure.
4. Dirt in lash adjusters. 5. Worn rocker arms. 6. Worn lash adjusters 7. Worn valve guides.
8. Excessive runout of valve seats on valve faces.
CONNECTING ROD NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-of-round. 6. Misaligned connecting rods.
MAIN BEARING NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of round. 7. Loose flywheel or torque converter.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Change oil and filter. 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. 4. Replace as necessary. 5. Replace as necessary. 6. Replace as necessary. 7. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE) 8. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE)
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Service or replace crankshaft.
6. Replace bent connecting rods.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS) 2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Check thrust washers for wear. 6. Service or replace crankshaft. 7. Tighten to correct torque
ENGINE - 5.7L
9 - 182
ENGINE - 5.7L (Continued) DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSUREThe results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs. (3) Secure the throttle in the wide-open position. (4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI- CAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(7) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylin- ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect:
DR
† Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss. (1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
(3) Remove the spark plugs. (4) Remove the oil filler cap. (5) Remove the air cleaner hose. (6) Calibrate the tester according to the manufac- turer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.(7) Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. Set piston of cylinder to be tested at TDC compres- sion,While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
AIR ESCAPES THROUGH THROTTLE BODY
POSSIBLE CAUSE
Intake valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH TAILPIPE
Exhaust valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
CORRECTION
Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
DR ENGINE - 5.7L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATION
ENGINE - 5.7L
9 - 183
CONDITION
OIL LEAKS
POSSIBLE CAUSES
CORRECTION
1. Gaskets and O-Rings.
1.
(a) Misaligned or damaged. (b) Loose fasteners, broken or porous metal parts. 2. Crankshaft rear seal 3. Crankshaft seal flange. Scratched, nicked or grooved. 4. Oil pan flange cracked. 5.Front cover seal, damaged or misaligned. 6. Scratched or damaged vibration damper hub.
(a) Replace as necessary. (b) Tighten fasteners, Repair or replace metal parts. 2. Replace as necessary. 3. Polish or replace crankshaft.
4. Replace oil pan. 5. Replace seal.
6. Polish or replace damper.
OIL PRESSURE DROP
1. Low oil level.
1. Check and correct oil level.
2. Faulty oil pressure sending unit. 3. Low oil pressure.
4. Clogged oil filter. 5. Worn oil pump. 6. Thin or diluted oil. 7. Excessive bearing clearance. 8. Oil pump relief valve stuck. 9. Oil pickup tube loose or damaged.
2. Replace sending unit. 3. Check pump and bearing clearance. 4. Replace oil filter. 5. Replace as necessary. 6. Change oil and filter. 7. Replace as necessary. 8. Replace oil pump. 9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
1. Worn or damaged rings.
PLUGS FOULING
2. Carbon in oil ring slots. 3. Incorrect ring size installed. 4. Worn valve guides. 5. Leaking intake gasket. 6. Leaking valve guide seals.
1. Hone cylinder bores and replace rings. 2. Replace rings. 3. Replace rings. 4. Ream guides and replace valves. 5. Replace intake gaskets. 6. Replace valve guide seals.
ENGINE - 5.7L
9 - 184
ENGINE - 5.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICALENGINE MECHANICAL DIAGNOSIS CHART
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISY VALVES/LIFTERS
1. High or low oil level in crankcase
2. Thin or diluted oil
3. Low oil pressure
4. Dirt in tappets/lash adjusters
5. Bent push rod(s) 6. Worn rocker arms
7. Worn tappets/lash adjusters
8. Worn valve guides
9. Excessive runout of valve seats or valve faces
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
4. Excessive connecting rod bearing clearance
5. Connecting rod journal out of round 6. Misaligned connecting rods
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
CONNECTING ROD NOISE
MAIN BEARING NOISE
1. Check for correct oil level. Adjust oil level by draining or adding as needed 2. Change oil. (Refer to 9 - ENGINE/ LUBRICATION/OIL - STANDARD PROCEDURE) 3. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) for engine oil pressure test/specifications 4. Clean/replace hydraulic tappets/ lash adjusters 5. Install new push rods 6. Inspect oil supply to rocker arms and replace worn arms as needed 7. Install new hydraulic tappets/lash adjusters 8. Inspect all valve guides and replace as necessary 9. Grind valves and seats
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) engine oil pressure test/specifications 3. Change oil to correct viscosity. (Refer to 9 - ENGINE/LUBRICATION/ OIL - STANDARD PROCEDURE) for correct procedure/engine oil specifications 4. Measure bearings for correct clearance with plasti-gage. Repair as necessary 5. Replace crankshaft or grind journals 6. Replace bent connecting rods
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) 3. Change oil to correct viscosity.
DR ENGINE - 5.7L (Continued)
ENGINE - 5.7L
9 - 185
CONDITION
POSSIBLE CAUSES
CORRECTION
LOW OIL PRESSURE
OIL LEAKS
4. Excessive main bearing clearance
5. Excessive end play
6. Crankshaft main journal out of round or worn 7. Loose flywheel or torque converter
1. Low oil level 2. Faulty oil pressure sending unit 3. Clogged oil filter 4. Worn oil pump 5. Thin or diluted oil 6. Excessive bearing clearance
7. Oil pump relief valve stuck
8. Oil pickup tube loose, broken, bent or clogged 9. Oil pump cover warped or cracked
1. Misaligned or deteriorated gaskets 2. Loose fastener, broken or porous metal part 3. Front or rear crankshaft oil seal leaking 4. Leaking oil gallery plug or cup plug
EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED
1. CCV System malfunction
2. Defective valve stem seal(s) 3. Worn or broken piston rings
4. Scuffed pistons/cylinder walls
5. Carbon in oil control ring groove 6. Worn valve guides
7. Piston rings fitted too tightly in grooves
4. Measure bearings for correct clearance. Repair as necessary 5. Check crankshaft thrust bearing for excessive wear on flanges 6. Grind journals or replace crankshaft
7. Inspect crankshaft, flexplate/ flywheel and bolts for damage. Tighten to correct torque
1. Check oil level and fill if necessary 2. Install new sending unit 3. Install new oil filter 4. Replace oil pump assembly. 5. Change oil to correct viscosity. 6. Measure bearings for correct clearance 7. Remove valve to inspect, clean and reinstall 8. Inspect oil pickup tube and pump, and clean or replace if necessary 9. Install new oil pump
1. Replace gasket 2. Tighten, repair or replace the part
3. Replace seal
4. Remove and reseal threaded plug. Replace cup style plug
1. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS - DESCRIPTION) for correct operation 2. Repair or replace seal(s) 3. Hone cylinder bores. Install new rings 4. Hone cylinder bores and replace pistons as required 5. Remove rings and de-carbon piston 6. Inspect/replace valve guides as necessary 7. Remove rings and check ring end gap and side clearance. Replace if necessary
ENGINE - 5.7L
9 - 186
ENGINE - 5.7L (Continued) STANDARD PROCEDURESTANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essen- tially, this repair consists of: † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or equivalent. † Installing an insert into the tapped hole to bring the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
(1) Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N·m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter.
DR
(14) Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery. (16) Start the engine and check for any leaks.
REMOVAL
(1) Disconnect the battery negative cable. (2) Remove the air cleaner resonator and duct
work as an assembly.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(5) Remove the viscous fan/drive (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (6) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(7) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for engine removal.
(8) Remove the A/C compressor with the lines
attached. Secure compressor out of the way. (9) Remove generator assembly (Refer
to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOV- AL).
(10) Perform the Fuel System Pressure Release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(11) Remove the intake manifold and IAFM as an assembly(Refer to 9 - ENGINE/MANIFOLDS/IN- TAKE MANIFOLD - REMOVAL).
(12) Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
aside.
(14) Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(15) Raise and support the vehicle on a hoist and
drain the engine oil.
(16) Remove engine front mount thru-bolt nuts. (17) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(18) Disconnect exhaust pipe at manifolds. (19) Disconnect the starter wires. Remove starter to 8 - ELECTRICAL/STARTING/
motor STARTER MOTOR - REMOVAL).
(Refer
(7) Be sure all fluid has been removed from the
(13) Remove the power steering pump and set
DR ENGINE - 5.7L (Continued)
ENGINE - 5.7L
9 - 187
(20) Remove the structural dust cover and trans- mission inspection cover,(Refer to 9 - ENGINE/EN- GINE BLOCK/STRUCTURAL COVER - REMOVAL). (21) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(22) Remove transmission bell housing to engine
block bolts.
(23) Lower the vehicle. (24) Install engine lift fixture, special tool # 8984. (25) Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
(1) Install engine lift fixture Special tool # 8984. (2) Position the engine in the engine compartment. (3) Lower engine into compartment and align engine with transmission: † Manual Transmission: Align clutch disc assem- bly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmis- sion surfaces. Install two transmission to engine block mounting bolts finger tight. † Automatic Transmission: Mate engine and trans- mission and install two transmission to engine block mounting bolts finger tight.
(4) Position the thru-bolt into the support cushion
brackets.
(12) Lower the vehicle. (13) Remove engine lift fixture, special tool # 8984. (14) Connect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(15) Reinstall the power steering pump. (16) Connect the heater hoses. (17) Install the intake manifold. (18) Using a new gasket,
install
throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ THROTTLE BODY - INSTALLATION).
(19) Install the generator and wire connections (Refer to 8 - ELECTRICAL/CHARGING/GENERA- TOR - INSTALLATION).
(20) Install a/c compressor and lines (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
(21) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(22) Install upper radiator support crossmember. (23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the radiator lower hose. (25) Connect the transmission oil cooler lines to
the radiator.
(26) Install the fan shroud. (27) Install the fan (Refer to 7 - COOLING/EN-
(5) Lower engine assembly until engine mount
GINE/RADIATOR FAN - INSTALLATION).
through bolts rest in mount perches.
(6) Install remaining transmission to engine block
mounting bolts and tighten.
(7) Tighten engine mount through bolts. (8) Install drive plate to torque converter bolts.
work..
(28) Connect the radiator upper hose. (29) Install the washer bottle. (30) Connect the transmission cooler lines. (31) Install the air cleaner resonator and duct
(Automatic transmission models)
(9) Install the structural dust cover and transmis- sion dust cover,(Refer to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) . (10) Install the starter and connect the starter to 8 - ELECTRICAL/STARTING/
wires STARTER MOTOR - INSTALLATION). (11) Install exhaust pipe to manifold.
(Refer
(32) Add engine oil to crankcase (Refer to LUBRI- CATION & MAINTENANCE/FLUID TYPES - SPEC- IFICATIONS).
(33) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(34) Connect battery negative cable. (35) Start engine and inspect for leaks. (36) Road test vehicle.
ENGINE - 5.7L
9 - 188
ENGINE - 5.7L (Continued) SPECIFICATIONS5.7L ENGINE
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type
Bore and Stroke
90° V-8 OHV
99.5 x 90.9 mm (3.91 x 3.58 in.)
Displacement
5.7L (345 c.i.)
Compression Ratio
9.6:1
Firing Order
Lubrication
1–8–4–3–6–5–7–2
Pressure Feed – Full
Flow
Filtration
DR
DESCRIPTION
SPECIFICATION
Bearing to Journal Clearance Standard
No. 1
No. 2
No. 3
No. 4
No. 5
Camshaft End Play
0.040 – 0.080 mm (.0015 – .003 in.) 0.050 – 0.090 mm (0.0019 – .0035 in.) 0.040 – 0.080 mm (.0015 – .003 in.) 0.050 – 0.090 mm (0.0019 – .0035 in.) 0.040 – 0.080 mm (.0015 – .003 in.)
0.080 - 0.290 mm (0.0031 - 0.0114 in.)
CONNECTING RODS
Cooling System
Liquid Cooled – Forced
Piston Pin bore Diameter
Cylinder Block
Cylinder Head
Crankshaft
Camshaft
Circulation
Cast Iron
Aluminum
Nodular Iron
Hollow assembled
camshaft
Pistons
Aluminum Alloy w/strut
Connecting Rods
Powdered metal
CAMSHAFT
Bearing Journal Diameter No. 1
No. 2
No. 3
No. 4
No. 5
58.2 mm (2.29 in.) 57.8 mm (2.27 in.) 57.4 mm (2.26 in.) 57.0 mm (2.24 in.) 43.633 mm (1.72 in.)
Side Clearance
23.955 – 23.975 mm (0.9431 – 0.9438 in.)
0.10 - 0.35mm
( 0.003 - 0.0137 in.)
CRANKSHAFT
Rod Journal
Diameter
Out of Round (Max.) Taper (Max.) Bearing Clearance
53.992 – 54.008 mm (2.125 – 2.126 in.)
0.005 mm (0.0002 in.) 0.003 mm ( 0.0001 in.)
0.020 – 0.060 mm
(0.0007 – 0.0023 in.)
Main Bearing Journal
Diameter
64.988 – 65.012 mm (2.5585 – 2.5595 in.)
Out of Round (Max.)
0.005 mm (0.0002 in.)
Taper (Max.)
0.003 mm (0.0001 in.)
Bearing Clearance
Crankshaft End Play
0.023 – 0.051mm (0.0009 – 0.002 in.)
0.052 – 0.282 mm (0.002 – 0.011 in.)
Service Limit
0.282 mm ( 0.011 in.)
DR ENGINE - 5.7L (Continued)
ENGINE - 5.7L
9 - 189
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
CYLINDER BLOCK
Exhaust
Cylinder Bore
Diameter
Out of Round (Max.)
Taper (Max.)
Lifter Bore
Diameter
99.50 – mm (3.917 – in.) 0.00762 – mm
.0003 ( in.) 0.0127 – mm
0005 ( in.)
21.45 – 21.425 mm (0.8444 – 0.8435 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle
44.50° – 45.00°
Runout (Max.)
0.05 mm (0.0019 in.)
Width (Finish)
Intake
1.018 – 1.62 mm
(0.0464 – 0.0637 in.)
Exhaust
1.48 – 1.92 mm
(0.0582 – 0.0755 in.)
Valves
Face Angle
Head Diameter
45.0° – 45.5°
Intake
Exhaust
50.67 mm – 50.93 mm (1.99 in.) – (2.00 in.) 39.27mm – 39.53mm (1.54 in.) – (1.55 in.)
Length (Overall)
Intake
Exhaust
123.38 – 123.76 mm (4.857 in. – 4.872 in.) 120.475 – 120.855 mm (4.743 in. – 4.758 in.)
Guide Bore
Stem to Guide Clearance Intake
7.905 - 7.925 mm (0.311 - 0.312 in.)
7.975 - 8.000 mm (0.313 - 0.314 on.)
0.022 - 0.065 mm
(0.0008 - 0.0025 in.)
Exhaust
0.050 - 0.095 mm
(0.0019 - 0.0037 in.)
Valve Springs Spring Tension
Valve closed
422 N @ 46.0 mm (95 lbs. @ 1.81 in.)
Valve open
@ 33.5 mm
Number of Coils
7.4
Installed Height
46.0 mm (1.81 in.)
Wire Diameter
5.39 x 4.52mm
(0.212 – 0.177in.)
HYDRAULIC TAPPETS
Body Diameter
Clearance (to bore)
21.387 - 21.405 mm (0.8420 - 0.8427 in.)
0.020 - 0.063 mm
(0.0007 - 0.0024 in.)
Dry Lash
3.0 mm (at the valve)
(0.1181 in.)
OIL PRESSURE
Curb Idle (Min.*)
25 kPa ( 4 psi)
@ 3000 rpm
170-758 kPa ( 25-110
psi)
* If oil pressure is zero at curb idle, DO NOT RUN ENGINE.
Valve Lift (@ zero lash) Intake Exhaust
Stem Diameter
12 mm (0.472 in.) 11.7 mm (0.460 in.)
OIL PUMP
Clearance over Rotors
.095 mm ( 0.0038 in.)
Intake
7.935 - 7.953 mm (0.312 - 0.313 in.)
(Max.)
Outer Rotor to pump
body
ENGINE - 5.7L
9 - 190
ENGINE - 5.7L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Clearance (Max.)
0.235 mm ( 0.009 in.)
Compression Ring (2nd)
0.35 - 0.60 mm
Tip Clearance between
(0.0137 - 0.0236 in.)
Rotors (Max.)
.150 mm (0.006 in.)
Oil Control (Steel Rails)
0.15 - 0.66 mm
Ring Side Clearance
Compression Rings Top
(0.0059 - 0.0259 in.)
0.02 - 0.068 mm
(0.0007 - 0.0026 in.)
2nd
0.02 - 0.058 mm
(0.0007 - 0.0022 in.)
Ring Width Compression rings
Oil Ring (Steel Rails) & Max.
1.472 - 1.490 mm
(0.05795 - 0.0586 in.)
0.447 - 0.473 mm
(0.0175 - 0.0186 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) Opens (BTDC)
Intake Valve
Closes (ATDC) Opens (BTDC)
Valve Overlap
27° 233°
253° 7°
34°
PISTONS
Clearance at Top of Skirt
0.0215 - 0.0485 mm
measured at 45.0 mm (1.77 in.) below deck
Land Clearance (Diam.) Groove #1
(0.0008 - 0.0019 in.)
0.6715 - 0.7105 mm (0.0264 - 0.0279 in.)
Groove #2
.5455 - .6245
(0.0214 - 0.0245 in.)
54.70 – 55.30mm (2.153 – 2.177 in.)
Piston Length
Piston Ring Groove
Width
Groove #1
1.51 - 1.54 mm
(0.0594 - 0.0606 in.)
Groove #2
1.51 - 1.53 mm
(0.0594 - 0.0602 in.)
Groove #3
3.030 - 3.055 mm (0.1192 - 0.1202 in.)
Weight
413 grams (14.56 oz.)
PISTON PINS
Clearance in Piston
0.009 - 0.018 mm
(0.00035 - 0.00070 in.)
24.0 - 24.003 mm
(0.9448 - 0.9449 in.)
69.75 - 70.25 mm (2.74 - 2.76 in.)
PISTON RINGS
Diameter
Length
Ring Gap
Compression Ring (Top)
0.23 - 0.38 mm
(0.0090 - 0.0149 in.)
DR ENGINE - 5.7L (Continued) TORQUE
TORQUE CHART 5.7L ENGINE
DESCRIPTION
N·m
Ft. Lbs. —
— 90
——
In. Lbs. 177
240
— 250250
40 — 15
plus 90° Turn ——
—
20
27
122
2828
55
21
plus 90° Turn 27
plus 90° Turn 28 —Block Pipe Plugs (1/4 NPT)
(3/8 NPT)
Camshaft Sprocket—Bolt Camshaft Tensioner Plate—Bolts Timing Chain Case Cover— Bolts
Lifting Stud
Connecting Rod Cap—Bolts
Main Bearing Cap—Bolts M-12
Crossbolts M-8
Cylinder Head—Bolts M-12 Bolts—
— —
—
— —
— — —
Step 1
Step 2
Step 334
54
Turn 90°25
40
Turn 90°M-8 Bolts Step 1
Step 2Cylinder Head Cover—Bolts Exhaust Manifold to Cylinder Head Flywheel—Bolts Front Insulator—Through bolt/nut Front Insulator to Support Bracket
—Stud Nut (4WD) —Through Bolt/Nut (4WD)
Front Insulator to Block— Bolts (2WD) Generator—Mounting Bolt Intake Manifold—Bolts
— 15 — 25 — —
70
22020
34
2595
9541
102
95—
70
7030
75
7040
— 55
Refer to ProcedureENGINE - 5.7L
9 - 191
DESCRIPTION
Oil Pan—Bolts Oil Dipstick Tube Oil Pan—Drain Plug Oil Pump—Attaching Bolts Oil Pump Pickup Tube – Bolt and Nut Rear Seal Retainer Attaching Bolts Rear Insulator to Bracket— Through-Bolt (2WD) Rear Insulator to Crossmember Support Bracket—Nut (2WD) Rear Insulator to Crossmember— Nuts (4WD) Rear Insulator to Transmission— Bolts (4WD) Rear Insulator Bracket—Bolts (4WD Automatic) Rear Support Bracket to Crossmember Flange—Nuts Rear Support Plate to Transfer Case—Bolts Rocker Arm—Bolts Spark Plugs Thermostat Housing—Bolts Throttle Body—Bolts Transfer Case to Insulator Mounting Plate—Nuts Transmission Support Bracket— Bolts (2WD) Vibration Damper—Bolt Water Pump to Timing Chain Case Cover—Bolts
N·m 12
12
34
28
2815
68
41
Ft. — — 25
— ——
50
30
In. 105
105
— 250
250132
—
—
68
50
—
68
50
—
68
41
41
22
— 28
12
20450
30
30
— — — — 105
—
—
—
195
— 250
105
—68
50
—
176
28129
—— 250
ENGINE - 5.7L
9 - 192
ENGINE - 5.7L (Continued) SPECIAL TOOLS5.7L ENGINE
DR
Bloc–Chek–KitC-3685–A
DialIndicatorC-3339
BoreSizeIndicatorC-119
Puller8454
CrankshaftDamperInstaller8512
CrankshaftDamperRemovalInsert8513-A
HandleC-4171
OilPressureGaugeC-3292
PistonRingCompressorC-385
DR ENGINE - 5.7L (Continued)
ENGINE - 5.7L
9 - 193
PressureTesterKit7700
RearCrankshaftSealInstaller8349
RearCrankshaftSealRemover8506
Adapter,ValveSpringCompressorOff-vehicle8464
ENGINESUPPORTFIXTURE8534
ValveSpringCompressorC-3422-B
ENGINELIFTFIXTURE8984
ValveSpringTesterC-647
REARCAMPLUGINSTALLER9048
9 - 194
ENGINE - 5.7L
AIR INTAKE SYSTEM REMOVAL
Filter Element Only
DR
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 2) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 2) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 2) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
Fig.3AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
(3) Pry up 4 spring clips (Fig. 2) and lock cover to
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
CYLINDER HEAD OPERATION—CYLINDER HEAD
The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. † Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
Fig.2AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 2) and disconnect air duct
at air cleaner cover.
pins (Fig. 3).
(2) Lift entire housing assembly from 4 locating
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
tabs (Fig. 2).
DR CYLINDER HEAD (Continued)
ENGINE - 5.7L
9 - 195
− Loss of engine power − Engine misfiring − Poor fuel economy † Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
− Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from
exhaust
− Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the proce- dures in Cylinder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders will result in approxi- mately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.
REMOVAL
work.
(1) Disconnect the battery negative cable. (2) Drain cooling system. (3) Remove the air cleaner resonator and duct
(4) Remove the generator. (5) Remove closed crankcase ventilation system. (6) Disconnect the evaporation control system. (7) Perform the Fuel System Pressure Release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect heater hoses. (9) Remove cylinder head covers and gaskets. (10) Remove intake manifold and throttle body as
an assembly.
(11) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(12) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylin- der head gasket.
Clean all surfaces of cylinder block and cylinder
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
CLEANING
heads.
INSPECTION
(1) Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylin- der head.
(4) Inspect pushrods. Replace worn or bent push-
rods.
INSTALLATION
der heads.
(1) Clean all surfaces of cylinder block and cylin-
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
CAUTION: The head gaskets are not interchange- able between left and right sides. They are marked “L” and “R” to indicate left and right sides.
(3) Position new cylinder head gaskets onto the
cylinder block.
ENGINE - 5.7L
9 - 196
CYLINDER HEAD (Continued)CAUTION: The head gaskets are marked “TOP” to indicate which side goes up.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Tighten the cylinder head bolts in three steps (Fig. 4): † Step 1— Snug tighten M12 cylinder head bolts, in sequence, to 34 N·m (25 ft. lbs.) and M8 bolts to 20 N·m (15 ft. lbs.) torque. † Step 2— Tighten M12 cylinder head bolts, in sequence, to 54 N·m (40 ft. lbs.) and verify M8 bolts to 20 N·m (15 ft. lbs.) torque.. † Step 3— Turn M12 cylinder head bolts, in sequence, 90 degrees and tighten M8 bolts to 34 N·m (25 ft. lbs.) torque.
Fig.4CYLINDERHEADTIGHTENINGSEQUENCE (6) Install push rods and rocker arm assemblies in
their original position.
(7) Install the intake manifold and throttle body
