7797451 By Engine Manual

Workshop Manual Engine Components

C 2(0)

“BY” Models

Safety Warning

This Workshop IVlanual will alert you to certain proceduresthat must be done very carefully, if you ignore this information, you could... ® injure yourself or people around you ® Injure the boat operator, boat passengers, or people around the boat ® Damagethe Volvo Penta product or its systems Understand the following symbols before proceeding: Z~ Safety Warning

Alerts you to the possibility of dangerand identifies information that will help prevent injuries. Identifies information that will help prevent damageto machinery. Appearsnext to information that controls correct assembly and operation of the product.

This WorkshopManual is ,written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools. This Workshop Manual tells you how to correctly maintain and service Volvo Penta products and systems. When correctly serviced, the Volvo Penta product ,will be reliable and safe to operate. WhenVolvo Penta special tools are called for, use them. Where mentioned, the tools are required to perform the service procedure. If you use service proceduresor service tools that are not recommendedin this manual, YOU ALONEmust decide if your actions might injure people or damagethe Volvo Penta product.

Contents General information

....................................

General Engine Mechanical-

~ii~

V6 and V8 Models ..........

3.0GS Engine ..........................................

~ /

4.3GL, 4.3GS and 4.3Gi Engines .........................

~

5.0GL, 5.0Gi, 5.7GS and 5.7GSi Engines ..................

~

7.4Gi Engines .........................................

~;~

70.4GSi and 8.2GSi Engines ..............................

~/

Steering

Systems

Throttle

and Shift Control Systems ......................

cooling

Systems

g m aa m~ m ~= w = = m []

s m i=

[]

[]

[]

Eim m m ~ = m []

n m m == ~ []

Engine Removal and Installation

~ ¯ m E []

B = = g m B ~ ~ ~ []

IS

[]

== []

!

m~ B es m B ea m~ m o m

m = m m = R m []

.........................

Safety Section .........................................

© 1998VolvoPentaof the Americas,Inc, All rights reserved. i

:~ m~ =-~ Hi

i

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m n m st

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This workshop manualis oneof a set of four that coversVolvoPentasterndrive "BY" modelso Arl four bookscanbe orderedas a set from VolvoPenta Parts. OrderP/N 7797450-9. Individual workshop manuals coveringthesemodelsare also available. Order the folJowingpart numbers from VolvoPentaParts.

, PIN 7797451=7Engine Components Includesinformation on Engineservice andtroubleshooting;Engineremoval andinstallation; Steeringsystems;Throttle andShift Controlsystems;and Coolingsystems.

, PIN 7797452=5 Electrical & Ignition System Includesservice andtroubleshootinginformationon Crankingsystems; Chargingsystems;Trim/Tilt electrical systems;Ignition systems;andEngine and Instrument wMngdiagrams.

¯ PIN 7797453-3Fuel System Includesserviceandtroubleshootinginformationon all carburetor,MFIand TBI fuel systemsand related components.

¯ PIN 7797454-1EFI Diagnostic ManualGM Containstroubleshootingprocedures for all Electronic Fue[ injected GM modelsand related components.

¯ PIN 7797455-8SX and DP-SSterndrives and Transom Shield Includes information on TransomShield, UpperGearUnit and LowerGear Unit service; DriveUnit removalandinstallation; Propellers;andTrim/Tilt hydraulicoperation.

This VolvoPentaWorkshop Manualis part of a set that coversthe following VolvoPenta"BY"Models Engine

Steering

Model Number

TransomShield

3.0 GS

Manual Manual Manual Manual Power Power Power Power

30GSMBYCCE 30GSMBYCCE 30GSMBYCCE 30GSMBYCCE 30GSPBYCCE 30GSPBYCCE 30GSPBYCCE 30GSPBYCCE

3868844 3868844 3868845 3868845 3868844 3868844 3868845 3868845

3865895 (1.97:1) 3868896 (2.18:1) 3868895 (1.97:1) 3868896 (2.18:1) 3868895 (1.97:1) 3868896 (2.18:1) 3868895 (1.97:1) 3868896 (2.18:1)

SX-M SX-M SX-M SX-M SX-M SX-M SX-M SX-M

4.3 GL

Power Power Power Power Power Power Power Power Power Power

43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC 43GLPBYC

3868844 3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846 3868846

3868892 (1.66:1) 3868893 (1.79:1) 3868894 (1.89:1) 3868913 (1.95:1) 3868914 (2.32:1) 3868892 (1.66:1) 3868893 (1.79:1) 3868894 (1.89:1) 3868913 (1.95:1) 3868914 (2,32:1)

SX-M SX-M SX-M DP-SM DP-SM SX=M SX-M SX-M DP-SM DP-SM

Power Power Power Power Power Power Power Power Power

43GSJBYA 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC 43GSPBYC

3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846

3868694 PJX-C1 3868892 (1.66:1 3868893 (1.79:1 3868913 (1.95:1 3868914 (2.32:1 3868892 {1.66:1 3868893 (1.79:1 3868913 {1.95:1 3868914 (2.32:1

Power

43GIJBYA

Power

43GIPBYCCE

386884,4

Power Power Power Power Power Power Power

43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE 43GIPBYCCE

3868844 386884,4 3868844 3868846 3868846 3868846 3868846

3868694 PJX-C1 3868892 (1.66:1 3868893 (1.79:1 3868913 (1.95:1 3868914 (2.32:1 3868892 (1.66:1 3868893 (1.79:1 3868913 (1.95:1 3868914 (2.32:1

Power Power Power Power Power Power Power Power

50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC 50GLPBYC

3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846

3868891(1 3868890(1 3868912(1 3868913(1 3868891(1 3868890(1 3868912(1 3868913(1

4,3 Gi

5.0 GL

m=

iii

Drive Unit

.60:1 .51:1 .78:1 .95:1 .60:1 .51:1 .78:1 .95:1

SX-M SX-M DP-SM DP-SM SX-M SX-M DP-SM DP-SM SX=M

SX-M DP-SM DP-SM SX-M SX-M DP-SM DP-SM SX-M SX=M DP-SM DP-SM SX-M SX-M DP-SM DP-SM

This VolvoPentaWorkshop Manualis part of a set that covers the foUowingVolvoPenta "BY"Models

Engine

Steering

Model Number

TransomShiend

Drive Unit

5.0 Gi

Power Power Power Power Power Power Power Power

50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GIPBYCCE 50GLPBYCCE 50GIPBYCCE 50GIPBYCCE

3868844 3868844 3868844 3868844 3868848 3888846 3868848 3868846

3868891(1 3868890(1 3868912(1 3868913(1 3868891(1 3868890(1 3868912(1 3868913(1

.60:1 .51:1 .78:1 .95:1 .60:1 .51:1 .78:1 .95:1

SX-M SX-M DP-SM DP-SM SX-M SX-M DP-SM DP-SM

5.7 GS

Power Power Power Power Power Power Power Power

57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC 57GSPBYC

3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846

3868889(1 .43:1 3868890(1 .51:1 3868912(1 .78:1 3868913(1 .95:1 3868889(1 .43:1 3868890(1 .51:1 3868912(1 .78:1 3868913 (1.95:1

SX-M SX-M DP-SM DP-SM SX-M SX-M DP-SM DP-SM

5.7 GSi

Power Power Power Power Power Power

57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE 57GSIPBYCCE

3868844 3868844 3868844 3868846 3868846 3868846

3868889 (1.43:1 3868912 (1.78:1 3868913 (1.95:1 3868889 (1.43:1 3868912 (1.78:1 3868913 (1.95:1

SX-M DP-SM DP-SM SX-M DP-SM DP-SM

7.4 Gi

Power Power Power Power Power Power Power Power

74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE 74GIPBYCCE

3868844 3868844 3868844 3868844 3868846 3868846 3868846 3868846

3868889 (1.43:1) 3868911 (1.68:1) 3868912 (1.78:1) 3868913 (1.95:1) 3868889 (1.43:1) 3868911 (1.68:1) 3868912 (1.78:1) 3868913 (1.95:1)

7.4 GSi

Power Power Power Power

74GSIPBYCCE 74GSiPBYCCE 74GSIPBYCCE 74GSIPBYCCE

3868850 3868850 3868916 3868916

3868911 (1.68:1)DP-SM 3868912 (1.78:t) DP-SM 3868911 (1.68:1) DP-SM 3868912 (1.78:1) DP-SM

8.2 GSi

Power Power Power Power

82GSIPBYCCE 82GSIPBYOCE 82GSIPBYCCE 82GSIPBYCCE

3868850 3868850 3868916 3868916

3868911 (1.68:1) 3888912 (1.78:1) 3868911 (1.68:1) 3868912 (1.78:1)

DPX 385

Xact Xact Xact

DPX385XBYDCE DPX385XBYDCE DPX385XBYDCE

3868289 3868289 3868289

3868637 1.59:1) DPX-S1 3868638 1.68:1) DPX-S1 3868639 1.78:1) DPX-S1

DPX 415

Xact Xact Xact

DPX415XBYDCE DPX415XBYDCE DPX415XBYDCE

3868289 3868289 3868289

3868637 1.59:1) DPX-S1 3868638 1.68:1) DPX-S1 3868639 1.78:1) DPX-S1

iv

SX-M DP-SM DP-SM DP-SM SX-M DP-SM DP-SM DP-SM

DP-SM DP-SM DP-SM DP-SM

EN~All sterndnve systems must be matched for either single or dual engine instatmations. Failure to properly matchengine, transombracket and st erndrive will result irl poor boat performance,and risk or damage to the engineandor drive becauseof incorrect drive gear ratio. The model identificatien is located on the engine valve cover, and MUST correspondwith the transombracket and sterndrive numbersas listed in this document. ¯

Engine Model Number [~ [~

DRl14!

® Transom Bracket Model Number E~ o Sterndrive

Model Number E~

DR4282

DR4944

DR2058

v

DR4957 Englne/eng

NOTES

Section 1 General information Table of Contents Battery Cable Requirements .................................. Belt Adjustments Alternator ................................................ Power Steering Pump...................................... Raw=WaterPump.......................................... Belt Tension .............................................. CompressionPressure Limit Chart .............................. Conversion Charts Drill ..................................................... Metric ................................................... Crankcase Oil ................................................ Engine Break-in .............................................. Engine CompressionTesting .................................... Gasolines Containing Alcohol .................................. Gasoline Requirements ....................................... intake Manifold VacuumTests ................................... introduction ................................................. Volvo Penta Dealer Service = 20-HourCheck...................... Off=SeasonStorage Preparations .............................. Oil Filter ................................................... Periodic Maintenance Chart ................................... PowerSteering Fluid Level .................................... PowerTrim/Tilt Fluid Level .................................... Preparation for Boating After Storage ........................... Steering SystemLubrication .................................. SubmergedEngine .......................................... Symbois ................................................... Torque Specifications, General ................................ Troubleshooting Engine .................................................. SystemIsoration .......................................... Tune-up Specifications ....................................... Tuning the Engine ............................................

1 -3g 1-25 1-25 1-25 1-24 1=7 1=41 1=40 1-11 1-21 1-5 1-10 1-10 1-8 1=2 1-23 1 ~13 1-12 1=43 1-13 1-13 1-20 1-13 1=23 1-42 1-39 1-28 1-27 1-35 1-5

Safety Warning Before working on arty part of any Volvo Penta® engine, read the section called Safety at the end of this manual.

Engine/erlg

1-1

Introduction This service manualcovers Volvo PentaSterndrive models.It is divided into sections concerningvarious systemsand assemblies. Refer to the Contents to locate the section coveringthe systemor assemblyrequiring service. Eachsection title pagehasan additional listing that will describethe section’s contentsin moredetail. Be sure to read the Safety Section at the end of this manual,and payspecial attention to all safety warningsas they appearthroughoutthe text. Since modelsare subject to changeat any time, somephotos maynot depict actual product. GoodService Practice Service required for Volvo PentaSterndrivesis generally one of three ki nds: Normalcare and maintenance - which includes putting a newstern drive into operation, storing engines,lubrication, and care under special operating conditions such as salt water and cold weather. Operating malfunctions - due to improper engine or drive mounting,propeller condition or size, boat condition, or the malfunctionof somepart of the engine. This includes engine servicing proceduresto keep the engine in prime operating condition. Complete disassemblyand overhau| - such as major service or rebuilding a unit. It is importantto determinebefore disassemblyjust what the trouble is and howto correct it quickly, with minimumexpenseto the owner. Whenrepairing an assembly,the most reliabJe wayto ensure a goodjob is to do a completeoverhaul on that assembly,rather than just to replace the bad part. Wearnot readily apparent on other parts could cause malfunction soonafter the repair job. Repairkits andseal kits contain all the parts neededto ensure a completerepair, to eliminate guesswork,and to save time. Repair time can also be minimizedby the use of special tools. Volvo Penta special tools are designedto perform service proceduresuniqueto the product that cannotbe completedusing tools from other sources. TheyaEso speedrepair workto help achieveservice flat rate times. [n somecases,the use of substitute tools can damage the part. ~Do not operate engine out of water even momentarily. If operatedin test tank, use proper test wheel. Failure to do so can damage supply pump,overheat engine, or allow excessive engine RPM.

1-2

Eng[ne/eng

Preparationfor Service Properpreparationis extremelyhelpful for efficient service work. A clean workarea at the start of each job will minimizetools and parts becoming misplaced.Cleanan enginethat is excessivelydirty before workstarts. CleaningwiJl occasionally uncovertrouble sources.Obtain tools, instrumentsand parts neededfor the job before work is started. Interrupting a job to locate special tools or repair kits is a needlessdelay. ~Useproper lifting and handling equipment. Workingon sterndrive~== without proper equipmentcan cause damageand personaUinjury. Alwaysuse clean fresh fuel whentesting engines. Troublescan often be tracedto the useof old or dirty fuel. Service Policy Whetherwithin or following the warranty period, Volvo Pentahas a constant interest in their products. It is an Volvo Pentapolicy to providedealers with service knowledge so they can give professional service demanded by today’s consumer.Volvo Penta .Training Centers,Service Bulletins, Letters and Promotions,Special Tools and this Service Manualrepresent the latest VolvoPentaeffort to assist dealers in giving consumersthe best and most promptservice possible. This Service Manualcovers all phasesof servicing the Volvo PentaSterndrive unit. If a service questiondoesnot appearto be answered in this manual,you are invited to write or call the VolvoPentaService Department for additional help. Alwaysbe sure to havecompleteinformation available, including engine modeJnumberand serial number. Be sure that you are ~amiliar with the Volvo PentaWarranty.If you haveany questions, write the Volvo PentaService Department.If other than genuine Volvo Penta replacementcomponentsor parts are used, Volvo Penta may refuse subsequentwarranty claims involving that engine. Whena brand-name product or specific tool is called for, another item may be used. However,the substitute musthave equivalent characteristics, including type, strength, and material. Youmustdetermineif incorrect substitution could result in product malfunctionand personalinjury to anyone. To avoid hazards, equivalent products which are used must meet all current U.S. Coast GuardSafety Regulations and ABYCstandards.

ReplacementParts /~ Whenreplacement parts are required, always use genuine Volvo Pentaparts, or parts with equivalentcharacteristics, including type, strength, andmaterial. Failure to do so mayresult in productmalfunction andpossible injury to the operator and/or passengers. Parts Catalogs Parts Catalogsare a goodsourceof information for ordering parts. They are NOTa goodsource for disassemblyand reassembfyinformation of the engines, sterndrive, or related systems.Theexplodedviews in the Parts Catalogsare representationsand maynot reflect detatls of the actual assembly.TheWorkshopManualhas detailed information and is the ONLY source of disassemblyand reassebly information. Special Service Tools Volvo Pentahas specially designedtools to simplify someof the disassemblyand assemblyoperations. Thesetools are illustrated in this Service Manual,in manycasesin actual use. All Volvo Pentaspecial tools can be order from Volvo Penta GenuineParts. Individual purchasersof Service Manualsmust order Special Tools through an authorized dealer. ProductReferences,illustrations & Specifications Volvo Pentaof the Americas,Inc. reserves the right to makechangesat anytime, without notice, in specifications and modelsand also to discontinue models.Volvo Pentaalso reserves the right to changeany specifications or parts at any time without incurring any obligation to equip sameon modelsmanufactured prior to date of such change.All information, illustrations and specifications containedin this manualare basedon the latest productinformationavailable at the time of printing. All photographsand illustrations usedin this manualmaynot depict actuat modelsor equipment,but are intended as representative views for reference only. The continuing accuracy of this manualcannot be guaranteed.

//~

Safety Related

1-4

Englne/eng

’Tuning The Engine I he purposeof an engine tune-up is to restore powerand performancethat has beenlost through wear and deterioration of one or morecomponents. tr~ the normaloperation of an engine, these changescan take p~aceg~’adJally at a numberof points. It is seldomadvisable to attempt improvement in performanceby correcting one or two items only. Lasting results will be obtained by following a definite and thorough procedureof analysis and correcting all items affecting powerand performance. Economical,dependableoperation can be ensuredif a completetune up is performedonce every’ boating season,preferably at the beginningof the seasonwhenthe boat is brought out of off seasonstorage. Components that affect powerand performancecan be divided into three. groups: Componentsaffecting

compression

® Components affecting ignition ® Components affecting fuel system Proceduresfor performinga completeengine tune-up will be covered in this manual.

Engine CompressionTesting 1. CompressionCheck: Proper compressionis essential for good engine performance. An engine with low or unevencompressioncannot be properly tuned. ~Use extreme care around engine while running or cranking. Remove; loose clothing and jewelry to prevent entanglementwith rotating pulleys anddrive belts. a. Runengine up to normal operating temperature. I~ Engine must NOTbe started and run without water for cooling.

b. Removeany foreign matter from around spark pUugsby blowing out with compressedair. c. Remove and inspect all spark plugs. Install thread-type compression gauge in spark plug hole. d. To Prevent Sparking: ¯ All Models Except 5.7 GL, GS and 7.4 GL: Remove (grey) 2-wire connector, with purple and grey wires, at ignition coil. ¯ 5.7 GL and GSModels Only: Removeboth distributor primary wires from the ignition coil Tape wire terminals to prevent accidental grounding. ¯ 7.4 GL Models Only: Remove14-wire connector at ignition module. e. With choke and/or throttle plates wide open, crank engine through at least four compressionstrokes. Test Conclusion The indicated compression pressures are considered normal if the lowest reading cylinder is within 75%of the highest. Example: ff the highest pressure reading was 140 PSI, 75%of 140 is 105. Therefore, any cylinder reading tess than 105 PSi indicates an improperly seated vaBve, worn valve guides, piston, cylinder, or worn or broken piston rings. Any cylinder reading 105 PSi or greater is within specifications, and compressionis considered normal. if one or more cylinders read low, squirt approximately one tablespoonof engine oil on top of the pistons in the low reading cylinders. Repeat compressionpressure check on the cylinders. 1. if compressionimproves considerably, the piston rings are at fault. 2. if compressiondoesnot improve, valves are sticking or seating poorly, or valve guides are worn. 3. If two adjacent cylinders indicate low compressionpressures and squirting oil on the pistons does not increase the compression, the cause maybe a cylinder head gasket neak betweenthe cylinders. This problem could allow engine oil and/or coolant to enter the cylinders.

Safety Related

1-8

Engme/eng

It is recommended the following quick reference chart be used whenchecking cylinder compressionpressures. Thechart has beencalculated so that the lowest reading numberis 75%of the highest reading.

CompressionPressure Limit Chart Max 134 136 138 140 142 144 146 148 150 152

Min 101 102 104 105 107 108 110 111 113 114

Max 154 156 158 160 162 164 166 168 t 70 172

Min 115 117 118 120 121 123 124 126 127 129

Max 174 176 178 180 182 184 186 188 190 192

Min 131 132 133 135 13G 138 140 141 142 144

Max 194 196 198 200 202 2 04 206 208 210 212

Min 145 147 148 1 50 151 153 154 156 157 158

After checking cylinder compression,repairs should be madeas necessary. Subsequentadjustments to an engine that does not have proper compressionwill not measurablyimprove performanceor correct operational problems.After verifying compression,checkignition and fuel systemcomponents.

¯ ¯ ¯ ° ,, o ¯ ¯ Q

¯ ¯ Q Q ® ¯ ¯ ¯ * ¯

SparkPlugs SparkPlug Leads Distributor Cap Rotor IgritionCoil High TensionLeads Igr~itionSwitch Circuit WiringandConnectors Electronic ControlModule

FueITankPickup and Screen FueITankVent Anti-SiphonValve (if equipped) Fuel OctaneandQuality Boat Fuel Lines andValves ExternalEngineFuel Filter or Screen Fuel Pumpsand Lines CarburetorFuelFilter or Screen CarburetorAdjustments Engine PCVValve FlameArrestor ® PressureRegulatorand Injectors

All of the these components are not necessarily part of an engine tuneup, but must be consideredwhenattempting to correct engine/boat performanceproblems. Repair or replace componentsonly as required. L~Do not substitute automotive parts. Volvo Penta marine components meetU.S. Coast GuardRegulationsfor external ignition proof operation and marine use. The use of automotiveparts mayresult irk fire andexplosion.

~,oe~

~ Safety

Related

1-7

intake ManifoldVacuum Tests 1. Install a vacuum gaugeto a goodintake manifold source, following the gauge manufacturer’sinstructions. Start and warmup the engine. 2. Observethe vacuumgaugewhile operation the engine over a range of engine speeds. 3. A steady vacuumreading between18 and 22 in. Hg. (60,7- 74,3 kPa) at idle indicates an engine in goodmechanicalcondition. 4. A vacuum reading below18 in. Hg. (60,7 kPa) at idle, indicates an enginethat is not developing enoughvacuum.Further testing for mechanicalproblemsis required. Test Resu|ts 1. A steady vacuumreading between17 and 21 in. Hg. (60,7 -- 74,3 kPa) at idle indicates normal engine vacuum. 2. A vacuumreading below18 in Hg. (60,7 -- 74,3 kPa) at idle indicates an enginethat is not developing enoughvacuum.Further testing for mechanicalproblemsis needed. 3. Possible causesof low vacuum are late ignition timing, low compression,poor engine sealing, leaks at vacuumline connections, or a bad MAPsensor. 5. Vacuumgaugefluctuates at idle but smoothsout as the engine RPMincreases, poorly seating valves, worncamshaft,or a sticking hydraulic lifter. 6. Vacuumgaugefluctuates morewith increases in engine RPM,check for weakor brokenvalve springs, poorly seatedvalves, ignition miss, or a leaking headgasket. 7. Vacuum gaugefluctuates with each engine cycle check for bad vatve. 8. Vacuum reading drops steadily as RPM is increased, check for exhaustrestriction. E~ NORMAL: Steady reading at 17-21 in. Hg. []LATEIGNITIONTIMING:14-17 in. Hg. at idle. LATEVALVE TIMING:8-15 in. Hg. at idle. [~

INTAKELEAK: Low steady reading.

[~

NORMAL CONDiTiON: Drops to 2, then rises to 25 whenaccelerated rapidly. WORN PISTONRINGS:Drops to 0, then rises to 22 whenaccelerated rapidEy.

[~ STiCKiNGVALVES:Normally steady, intemittently ticks highest reading.

downward4 in. from

1-8

Englne/eng

LEAKING VALVE!:Regular drop approximately2 in. from highest reading. [~ BURNED OR WARPED VALVE:Vacuum gauge fluctuates evenly with a downscale pulse approximately5 in. with eachengine RPM at idle, checkfor a burnedor warpedvalve. [~0"U WORN VALVE GUUDES: Vacuumgaugeoscillates valve guides for excessivewear.

approximately 4 in. Hg. Check

[~1]~]] WEAK VALVE SPRINGS: Vacuumgaugegive violent or sharp oscillations RPM is increased, checkfor weakvalve springs.

as the

r12~ IMPROPER IDLE! MmXTURE: Vacuumgaugesteadily floats between13 - 17 in. Hg., checkand/or adjust the idle mixture. J~3~ EXHAUST RESTRICTION: Vacuumgauge gives a normal reading on engine start but drops to 0 as engine RPMis increased. The vacuummayeventually rise to approximately16 in. Hg. Checkfor restrictions in the exhaustsystem. [~4~ LEAKING HEADGASKET: Vacuumgauge floats leaking headgasket.

between5 - 20 in. Hg., check for

[] SPARKPLUGGAP TO CLOSEOR DEFECTIVEPOINTS: Vacuum gauge gives a slight float between14 - 16 in. Hg. checkfor defective ignition points on ergines equippedwith ignition IDoints or small spark plug gap.

DRC6688

Engme/eng

1-9

Gasoline Requirements Volvo Penta engines are designed for maximum performance using gasoline with the following minimum octane specifications: ¯ Anti-knock Index Number(AKI) o Research Octane Number (RON) 4.3GL, GSAND5.7GL, GSModels:The ignition timing must be retarded if fuels are used with less than 88 AKl (90 RON)octane are used. Refer "Timing and Fuel Requirementsin the TuneUp Section of this manualfor details. When ignition timing is retarded, a slight decreasein performance can be expected. Useof gasoline with lower than 89 AKI (93 RON)octane in 4,3GL, GSand 5.7GL, GSmodels,without retarding ignition timing as specified, will result in serious damage to your engine and will void the engine warranty. All Other Models:Lower octane fuels, lower than 88 AKI (90 RON) octane, can be used. With the use of lower octanefuel, a slight decreasein power can be expected. Every attempt should be madeto use unleadedfuel, however, some marinasonly sell fuel with lead additives. If unmeaded fuel is unavailable, the substitution of leadedfuel for temporaryuse will not harmthe fuel system. Premiumgrade fuels contain injector cleaners and other additives that protect the fuel system and provide optimumperformance.The use of premiumgrade fuels is strongly recommended. Do not use leaded fuel in Certified Emissionengines. Leadedfuel will void the certification of emissions. CarburetedModels:Useof lead-free or leaded gasoline is acceptable. i

Note j Engine damageresulting from the use of gasominewith octane lower than 87 AKI (91 RON)is consideredmisuseof the engine and will void the engine warranty. Volvo Penta suggeststhe use of 89 AKI or higher fuels. Thesefuels have additives that are beneficial to maximum engine performanceand long life of service components.To prevent gumformation TM Marine Fuel Cleaner P/N and corrosion in the fuel system, use DuraPlus 3855830-0in the gasoline. DuraPlusTM Marine Fuel Cleaner P/N 38558300 is available throughyour VolvoPentadealer. Z~ Gasoline is extremely flammable and highly explosive under certain conditions. Alwaysstop engine and do not smokeor allow open flames near the boat whenrefueling. Whenfueling, always groundthe tank to the fuel sourceby holding the hosenozzle firmSy against the side of the deckfiller plate, or groundit by someother means.This action prevents static electricity buildup whichcould cause sparksand ignite fuel vapors.

Gasolines Containing Alcohol Manygasolines being sold today contain alcohol. Twocommonlyused alcohol additives are Ethanol (ethyl alcohol) and Methanol(methyl alcohol).

Z~ Safety

Related

1-10

Engme/eng

Seethe Operator’s Manualto determineif the boat’s fuel systemis compatible with a}coholblendedfuels. If it is, your enginemayuse gasolines blendedwith no more; than 10%Ethanol (ethyl alcohol) meetingthe minimumoctane specification. Do not use any gasoline which contains METHANOL (methyl alcohol). [~ Continued use of METHANOL (methyl alcohol) fuel will serious damage to the fuel system.

cause

If you use gasoline containing alcohol, be awareof the following: The engine will operate leaner. This maycause engine problemssuch as vapor lock, low speedstalling, or hard starting. Alcohol blendedfuels attract and hold moisture. Moisture cancausefuel tank corrosion. Inspect fuel tanks at least annually. Replacecorrodedor leaking fuel tanks. ® Frequently inspect non-metallic parts of fuel systemand replaceif excessivelystiff, deterioratedor leaking. FueOleakagecan contribute to a fire and/or explosion.

CrankcaseOil [~ Initial factory fial is a high quality motoroil for API ServiceSG/CD. During the break-in period (20 hours), frequently checkthe oil level. Some° what higher oil consumption is normaluntil the piston rings are seated. The oil level should be maintainedin the safe range betweenthe Addand Full markson the dipstick. This range representsapproximately1 litre (1 quart). If it is necessary to addor changethe motoroil, usea quality oil with API service category SG/CDthat meets General Motors Standard GM60g4-M. At the end of the break-in period (20 hours), changethe crankcaseoil and replace the oil filter. Refer to Lubrication and Inspection Chart for recommended oil changeintervals. E~ The use of multi-viscosity not recommended.

oits,

such as lOW-30 or lOW40, is

Draining and Filling the Engine Crankcase Drain and refill crankcaseevery 50 hours of operation or 6 months,whicheveroccursfirst. L~To prevent fire ,and explosion, always make sure engine compartment is free of gasoline fumes before using any sparkproducingtools such as the electric drill motor used with oil withdrawal pumpkit.

Engme/eng

Z~ Safety Related

1-11

[~] "~[~ Checkthe motor oil frequently. Whenoil is to be changed,removedipstick and drawoil from crankcasethrough dipstick tube with a suction pump.Thedipstick tube is intendedto be usedfor drainageof the engineoil so it will not haveto be drained into the bilge. Fill the crankcaseto recommended capacity with a quality motoroil labeled for SAEservice category SGwhich meet General Motors Standard GM-6094-M. Oils conforming to this standard contain detergent andanti-wear additives that will prolongengineJife. Volvo Penta Dura PlusTMSynthetic Motor Off P/N 3851230-7exceedsthis standard.

37904

Whenchangingmotor oil, select the viscosity that matchesthe temperature range in which the boat will be operated. Use the sameviscosity whenaddingmotoroil, do not mix different viscosity oils. Lowest Anticipated Temperature 32°F(0°C)andabove 0°F(-18°C) to 32°F(0°C) Below 0°F(-18°C)

SAE Viscosity Oil Recommended SAE30 SAE20W-20 SAE10W 34101

,~CAUTION: DOnot fill abovefull mark. Overfilling results in high operatingtemperatures,foamingthe oil (mixing air in the oil), loss power,and reducedenginelife. Crankcase Capacities

LessFilter

WithFilter

3.0GS

3.5qts.(3,3liters)

4.0qts.(3,8liters)

14.3GL,GS,Gi

4.0qts. (3,8liters)

4.5qts.(4,3liters)

5.7GL,GSGJand GSi

5.0qts. (4,7liters)

6.0qts. (5,7liters)

7.4GL,Gi, GSi

8.0qts. (7,5liters)

9.0qts.(8,5liters)

8.2GSi

8.0qts. (7,5liters)

9.0qts. (8,5liters)

DPX300

5.0qts. (4,7liters)

6.0qts.(5,7liters)

DPX385,DPX415, DPX500

8.0qts. (7,5liters)

9.0qts.(8,5liters)

Model

37210

DR2497

Oil Filter [~ Replace the oil filter whenever the motoroil is changed. Thisfilter is a self contained,screw-on type. Toremove, unscrew filter canister couterclockwise, remove anddrain residualoil into a suitablecontainer. Dispose of the oil andfilter properly.When attachinga newfiltwer, be sure the gasketis lightly lubricatedwith freshmotoroil. handtightenonly, run engineto checkfor leaks. Donot run enginewithoutsupplyingcooling water. SeeTune-Up Specifications for modelandfilter requirements. 1-12

Eng~ne/eng

PowerSteering Fluid Leve [5~] [~ Maintain the level with DuraPlusTM PowerTrim/Tilt & Steering Fluid. Approved powersteering fluids suchas GMpowersteering fluid or DexronII automatictransmission fluid canalso be used.Donot overfill the pumpreservoir.

Steering SystemLubrication ~] Every60 days, greasethe steering ram(~) with Volvo Penta Grease.

GR980726

Power Trirn/Tilt-Fluid Level L’~Atthe beginning of eachboatingseason,checkthe fluid level in the ~’eservoir asfollows: ~Thetrim/tilt hydraulicsare pressurizedwhenthe drive unit is in the down position.Thedrive unit mustbe tilted full up to retieve hydraulicpressure beforeremoving level/fill plug(~. Failureto tilt the drive unit to the full up positionbeforeremoving level/fill plugwould result in a hazardous sprayof hydraulicoil= Cautionshouldalwaysbe takenwhenremoving level/fill plugbyplacinga rag overthe level/fill pmug to preventresidual pressurefromsprayingoil. 1. Withthe driveunit lilted full up, slowlyandcarefullyremove the level/fill plug. 2. Check the fluid level. Thefluid shouldbelevel with the bottomof the ’ill TM Power holewhenthe drive unit is at full tilt. If necessary, addDuraPius Trim/Tilt & SteeringFluid. Replace the level/fill plugandtighten securely.

Off-SeasonStoragePreparations Step 1. Condition Fuel System: TM MarineFuelStabilizer to fuel system.Followinstructions AddDuraPlus for addingconditionerandrunningengineas statedonthe container.This will stabilizethe fuel andpreventformationof varnishandgumin entire fuel system.Dothis beforecontinuingwith the followingprocedures.

I~N~Modelsequi~opedwith 4 BBLcarburetors should be run under a loadat a highenough throttle setting to circulate conditionerthroughthe secondary float bowl.

GR980723 En~line/eng

1-13

Step 2. ChangeMotorOil andOil Fi|ter: Engineshouldfirst be operatedunderload until oil is thoroughly warmed up. If oil is allowed to warmup before draining, a morecompaetedraining will be accomplished.In addition, accumulated impurities wilt be held in suspension by the oil and be removedduring draining operation. Remove motor oil by siphoningit out of oil withdrawaltube. Follow the procedureunder Draining and Filling the Engine Crankcase. ® Install a newoil filter oil.

and fill

crankcasewith recommended

Notel Vertical drive must be submerged in water or an accessoryflushing adaptor must be used while operating engine. When using a flushing adaptor, removepropeller before starting engineto preventaccidental contact with rotating propeller. ¯

With vertical drive in full downposition, run engineat a fast idle for a few minutesto distribute clean oil throughengine. Shutoff engineand checkoil level. Checkoil filter gasket for leaks. Addoil if necessary to bring oil level up to, but not over, the full mark.

Step 3. ChangeVertical Drive Lubricant: TMGL-5Synthetic GearLubricant. Refer Drain and refiJl with fresh DuraPlus to Vertical Drive Service Manual. Step 4. Fog Engine: o ®

- -®

V =0*

o Warmup engine to ensure fuel conditioner is throughout fuel system.UseV2pint (0,24 iitre) of Volvo PentaFogging Oil P/N 4414651°810 oz. (355 ml) spray can to fog engine. Remove flame arrestor from carburetor. Following instructions on container, bring engineup to a fast idle and slowly spray 2/3 of the foggingoil into carburetor. Keep enginerunning while spraying fogging oil into carburetor throat. Reduce throttle to idle andlet enginedie. Turnoff ignition and replaceflame arrestor. Closefuel shutoff valve (if so equipped).

~1 Safety

Related

1-14

Engme/eng

Preparean engine"storagemixture"in an outboardsix gallonfuie tank. il mustconsistof 5 gallonsof fuel; 4 pints (84 oz.) Fogging Oil; and1/3 cup TM Marine (2.5 oz.) DuraPlus Fuel Stabilizer. Mixtheseingredientsthoroughly. -

Disconnectboat fuel line at the enginefuel pump.Connect the "storagemixture"to the fuel pump fitting. Runthe enine on the "storagemixture"for approximately 5 minutesat t500 RPM. This will ensurethat all fuel systemandinternal enginecomponenets are thoroughlyprotected. Shut off the enginebeforethe "storagemixture"is usedup.

E~Donot run the engineout of fuel. Theelectric fuel pumpswill be damaged if allowedto run dry. Step 5. Drain CoolingSystem: ~No~When draining the enginecooling system,raise or lower the bos of the boatto positionthe enginein a horozonta[ plane.Thiswill providefor completedrainageof the engineblock andexhaustmanifolds,if the bowof the boat is higheror lowerthan the stern, sore watermaybe trappedin the engineblock or exhaustmanifolds. Improperor incompletedraining may relult in freeze damage to the engine,manifolds, sterndrive or other cemponenets. Freeze damage is not coveredunder the Volvo Penta limited warranty,

Starboard O Disconnectand drain large hoseat circulating pump.

@)Remove exhaustmanifolddrain plug. Clear hole with a small wire to ensurecompletedraiqage. O Remove cylinder block drain plug. Clear hole with a small wire to ensurecompletedrainage.

Er~gine/eng

1-15

Front ~) Disconnectthe small waterby-passhoseat the top of the thermostat housing. Rear Disconnect the waterdischargehose.Lowerto the rear of the block. Blow out waterby applyingair to the by-passhose. 42859"a"

[~ Front (.~ Disconnectanddrain large hoseat circulating pump. Starboard Remove exhaustmanifolddrain plug. Clearhole with a small wire to ensurecompletedrainage. @Remove cylinder block petcockstem.Clear hole with a small wire to ensurecompletedrainage.

44195

Port ® Remove exhaustmanifolddrain plug. Clear hole with a small wire to ensurecompletedrainage. Remove cylinder blockdrain plug. Clearhole with a small wire to ensure completedrainage.

34102

1-18

Englne/eng

[1-’] Front O Disconnectthe small water by-passhoseat the top of the thermostat housing. [~ Rear (~) Disconnectthe w~terdischargehose.Lowerthe hosebelowthe level the engine. Blowout waterby applyingcompressed air to the by-pass hose.

["6-~ Front C3>Disconnect the large hoseat the circulation pump. r=~ Starboard ~ Remove the exhaustmanifold drain plug. (~> Remove the cylinder blockdrain plug. Clearhole with a small wire to ensure completedrainage. ES~ Port C_6>Remove the exhaustmanifolddrain plug. ~>Remove the cylinder block drain plug. Clear the drain hole with a small wire to ensurecompletedrainage.

En~ine/eng

1-17

42859b

[~

Front

(~ Disconnectthe water bypasshose at large diameter of check valve. ® Drain or blow out valve and short hose to thermostat housing. = Drain or blow out Eonghoseto fuel resovoir.

[33

Front

®

Disconnectand drain the large hoseat the circulation pump.

[Z]

Starboard

®

Loosen clamp and remove rubber hose.

®

Remove cylinder block drain plug. Clear hole with small wire to ensure complete drainage.

[33

Port

®

Loosenclamp and reove rubber hose.

®

Remove cylinder block drain plug. Cleanhole with a small wire to ensure complete drainage.

42863

28283

28284

1 - 18

Engme/eng

L~ Remove lowest water hosefrom cooler (A) from oil cooler to drain.

~ Remove one waler hose(B) from oil cooler, loosen mountingbolt (C,), andtip oil coolerdownward to drain.

Remove lowestwaterhosefrom cooler (D) fromoil cooler to drain. 21122

E~’="~Loosenandslide hoseclampsback. Remove hosesfrom the rear of the raw-waterpumpand drain. Crankthe engineno morethan 2 seconds (DONOTSTART) to expel any water trapped in the raw-waterpump. Reinstall raw-waterpumphoses.

Step6. DrainPivot Housing:

Todraincavityin pivot housing, tilt driveunit to the full tilt (up) position andremove the waterdrain plug (E) fromthe port side of the pivot housing. Tilt the drive unit to the full down position.Allowunit to drain. After unit hascompletelydrained,replacepivot housingplug. Inspect drive unit waterintake screenfor obstructions.

Thedrain plug (E) is deletedon later modelSX-Mpivot hosings.Todrain thesemodels,lower the sterndnveto its lowestposition. ~ Failure to completly drain the cooling systemwill result in serious damage to the engine, exhaustmanifolds, andsterndrive whentemperature go belowfreezing. If complete drainageis in doubt, checkdrain opening with a smallpieceof wire. Step 7. Inspect sterndrive water pick-upfor obstructions. Step 8. Disconnectthe Battery andplace in storage.Whenstorage will be for a considerable lengthof time, periodically rechargethe battery following the manufacturer’srecommendations. Step 9. SprayEntire EngineandDrive Unit WithVolvoPenteDuraTM Corrosion PhJs Shield. Followdirections on the container.

Engine/eng

1-19

Preparationfor BoatingAfter Storage 1. Install stemsand close atl drain petcocks.Install cooling hosesand clamps. Checkcondition of hoses, manifold end caps and clamps. Connect hosesto engineand tighten clampssecurely, install boat drain plug, if removed. 2. Remove the distributor cap and rotor. Wipethe inside of the distributor TMCorrosion Shield P/N cap dry with a clean cbth and spray with DuraPlus 362002-8or equivalent. Replacethe rotor and cap. 3. Cleanthe battery terminals. With the ignition switch in the "OFF"position, install the battery and attach the battery cables. Sprayterminals with DuraPlusTM Corrosion Shield P/N 362002-8. ~4. Openthe fuel shut-off valve (if so equipped)and checkall fuel line connectionsfor leaks. ~5. Checkthe flame arrestor and clean if necessary. Reinstall, make sure all parts are in place andtighten nut securely. 6. Makea thorough checkof the boat and enginefor loose or missing nuts and screws. Pumpthe bilge dry and air out the engine compartment. ~SafetyWarning To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting engine, if the boat is not equippedwith a bilge blower, openengine cover or hatch prior to starting andleave openuntiP, after engineis running. ® if operatingboat in water, tie boat securelyto dockto prevent forward or backwardmovement. Whenusing a flushing adaptor, removethe propeller before starting engineto prevent accidental contact with rotating propeller. 7. Test run engine: Launchboat or use a flushing adaptorinstalled on vertical drive. ~] Do not start engine out of water unless using a flushing adaptor. Atwaysturn water on before starting engine. Control water pressureas full water pressure maycause dam~_geto supply pumpand engine. ~8. With engine compartmentopen, start the engine. Monitor the voltmeter, oil pressureand water temperaturegaugesfrequently to be sure all systemsare operating properly. Checkfor fuel, oil, andwaterleaks,

Safety Related

1-20

Englne/eng

EngineBreak=in All VolvoPentaSterndrive engineshavebeenrun for a short period of time: as a final test at the factory. Youmustfollow the EngineBreak-Inprocedure during the first 20 hours of operation to ensure maximum performanceand Ioiflgest enginehfe. E~-JO-~To ensureproper lubrication during the break-in period, do not removefactory break-in oil until after the 20-hourbreak-in is completed.

For the first five to ten minutesof operation,operateengineat a fast idle (above 1500 RPM).After engine has reachedoperating temperature, momentarilyreduce engine speed,then increase engine speed, .to assist br0~ak=inof rings andbearings. Duringthe remainingfirst two hoursof operation, accelerateto bring boat onto plane quickly andbring throttle backto maintaina planing attitude. During this period, vary the enginespeedfrequently by accelerating to approximatelythree-fourths throttle for two to three minutes,then backto n’finimumplaning speed.Maintainplaning attitude to avoid excessiveengine load. DO NOT RUN ENGINE! AT A CONSTANTRPM FOR PROLONGED PERIODS OFTIME DURING THE BREAKqNPERnOD.

During next eight hours, continue to operate at approximately three-fourths throttle or less (minimumplaning speed). Occasionally reduce throttle to idle speedfor a cooling period. Duringthis eight hoursof operationit is permissible to operateat full throttle for periodsof less than two minutes. DO NOT RUN ENGINE: AT A CONSTANTRPM FOR PROLONGED PERIODS OF TIME DURINGTHE BREAK-IN PERIOD.

During the final ten hoursof break°in, after warmingengineto operating temperature,it is permissibleto operateat full throttle for five to ten minutes al a time. Momentarilyreducethen increase enginespeedto assist break-in ot rings and bearings. Occasionallyreduceenginespeedto idle to provide cooling periods.

Eng,ne/eqg

1-21

DO NOT RUN ENGINE AT A CONSTANTRPlVl FOR PROLONGED PERIODSOF TIME DURINGTHE BREAK-INPERIOD. During break-in period, be particularly running of engine, as follows:

observant during initial

1. Checkcrankcaseoil levek frequently. Maintain oil level in safe range, between "add" and "full" marks on dipstick. If you have a problemgetting a good oil level reading on dipstick, rotate dipstick 180° in tube. 2. Watchoil pressure gauge. If indicator fluctuates wheneverboat attitude (i.e. turning, climbing on plane, etc.) is changed,it may be the oil pickup screen is not covered with oil. Checkcrankcase dipstick, and add oil to crankcaseif required. DONOTOVERFILL. If oil level is correct and condition still exists, checkfor possibne gauge or oil pumpmalfunction. Oil pressure will rise as RPMincreases, and fall as RPM decreases. In addition, cold oil will generally showhigher oil pressure for any specific RPMthan hot oil. Both of these conditions reflect normal engine operation. 3. Watchengine temperature indicator to be sure there is proper water circulation. Failure to follow the break-in procedure will engine warranty.

void the

At end of break-in period (20 hours), removemotor oil and replace oil filter. Fill crankcasewith recommended 4-cycle motor oil. OperationAfter Break-In After break-in, the engine can be operated at any RPMfrom idle to full throttle. However,cruising at 3600 RPMor less saves fuel, reduces noise, and prolongs engine life. Whenstarting a cold engine, aBwaysallow engine to warm up gradually. Never run engine at full throttle until engine is thoroughly warmedup. Be sure to check oil level frequently during the first 50 hours of operation, since oil consumptionwill be high until piston rings are properly seated.

1-22

Engme/eng

SubmergedEngine Remove engine from water as quickly as possible. Bt is imperative that your dealer removeall water from the engineand immediatelyrelubricate all internal parts. All electrical devicesmustalso be dried and inspected for water damage.Delay in completing these actions mayallow extensive engine damage. Frequently check engine compartmentfor gasoline fumes and excessive water accumulation;water depth in bilge should be kept well belowflywheel housing.

Volvo Penta Dealer Service = 20-Hour Check 1. Change engineoil and oil filter. 2. Checkfuel filter/water separator. 3 Checkpowertrim/tilt

reservoir for properfluid level.

4 3.0 GSOnly: Cleanand inspect the ceramicfilter pump.

rocated under the fuel’

5. All ModelsExcept 3.0 GS: Change fuel filter/water

separator.

~/~6. Checkflame arrestor for proper mounting. ~=~W~ 7, Start engineandcheckcompletefuel systemfor aeaks. ~8. Lubricate steering cable ram with Volvo Penta GreaseP/N 8282501. On modelsequipped with powersteering, check power steering pump reservoir for correct fluid level. FaiRureto properly nubricatethe steering system could lead to Hossof steering control L’~._~ 9. Checkshift system for proper adjustmentand operation. ~. 10. Inspect exhaust system. Tighten all hose clamps, and check for leaks. 1 ~. Checktensionon all drive belts~ 12, Checkall enginemountscrewsfor tightness. 13. Checkbaseignition timing. 14. CarburetedModels:Checkand adjust carburetor for correct idle m;,xture and idle RPM. 15, Checkfor defencies, malfunctions, signs of abuse,etc. TM GL16.Checkoil level in sterndrive and add as necessarywith DuraPlus 5 Synthetic GearLubricant.

17. Checkengine can achieve maximum rated RPM.See engine specifications.

E,~,,~,o,~ //~ Safety Related

1-23

Belt Tension

o 3.0 GS Models E~ o 4.3, 5.0, 5.7, 7.4, and 8.2 ModelsE~ e 3.0 GSNon power steering Models [~ ® 4.3 PJX Models [~ (~) PowerSteering PumpBeLt (~) AlternatorBelt (~) Raw-waterPumpBelt [~m,~,,[~ With engine stopped, belts should be tight

enough so

that it will deflect 1/4" to 1/£, (6 - 13 mm)whenpressedwith a finger the point indicated. Alternate method,use Volvo Pentaspecial tool 1159660=8 and tighten beets to 20 - 25 kg (44 - 55 Ibs.). If belts are too tight, excessivebelt and bearing wearcan occur. If they are too loose, slippage can occur, resulting in excessivebeat wear, poor circulation pump, raw-water pump,and or power steering performance. Tensionof a newbelt should be checkedafter 10 hours of service and every 50 hours thereafter. 4

O

1-24

Engine/eng

Alternator Belt Adjustment ® 3.0 GS Models [~ ¯

3.0 GS NPSModels E~]

o 4.3, 5.0, 5.7 GL, GS, and Gi Models[~ ® 4.3 PJX Models DE] o 7.4, 8.2 GL, Gi and GSi ModelsE~] 10 CrankshaftPulley Pulley (~) Circulating Pump Alternator Pulley ~ (4~1/4" to 1/2"(6- 13ram)Deflection (~, Raw-waterPumpPulley [~="==~[~ Checkalternator belt tension (~) midwaybetweenthe circulating pump pulley (~) andthe alternator pulley 1. Loosenalternator mountingscrewsand nuts, pivot alternator awayfrom engineto increasebelt tension.

DRC43344

2. Whilemaintainingtensionon alternator belt, tighten top screw,bottom screwandnut. Recheck belt tension. [~ot~ Thebelts usedfor the alternator, circulating pump,and power steering pumpare heavy-duty. DONOTreplace with automotivebelts.

Raw-WaterPumpBelt Adjustment EJ~~ Check raw-water pump belt tension midway between the circulating pumppulley (~ andthe raw-waterpumpputley ®. 21815

Loosenmountingbracket to raw-waterpumpscrews, pry raw-waterpump awayfromengineto increasebelt tension. Whilemaintainingpressureon raw-waterpump,retighten top andbottomscrews.Recheck belt tension.

©

Engirie/eng

1 -

25

®

DR4933

DRC4334,4

16067

PowerSteering Pump8eit Adjustment

® 3.0 GS Models [~ ® 4.3, 5.0, 5.7, 7.4 and 8.2 Liter Models[~ (~ PowerSteering PumpPulley Pulley (~ Circulating Pump (~ V4"to 1/£, (6 - 13ram)Deflection

23910

~-] Improperpowersteering belt adjustmentwilt causea loss of power steeringassist, resulting in hardsteering. [~=~[~] Checkpower steering belt tension (~) midwaybetweenthe circulating pumppulley (~ andthe powersteering pumppulley O.

[~ [~ To increase belt tension: Loosennut on lower pivot bolt, and loosenscrewon bracebehindpulley. Placea Y2" breakerbar into the squarehole in the pumpmountingbracket, and pivot pumpawayfrom engineas shown.Whilemaintainingpressureon pump,retighten all mountingscrews. Recheckbelt tension. Neverpry against the pump reservoiror pull ~ier neck.

24278

[~ To increase belt tension: Loosenpumpmountingbracket screws,insert a I/2 in. breakerbar into squarehole in the pump mounting bracket, and pivot pumpawayfrom engineas shown.White maintaining pressureon pump,retighten all mountingscrews.Recheck belt tension. Neverpry againstthe pump reservoiror pu|mfiller neck.

[~ To increase belt tension: Loosenpumpmountingbracket screws.Witha long pry-bar, pry againstcornerof timing chain coverand tab on pumpmountingbracket. While maintainingpressureon bracket, tighten screwclosest to tab. Tightenthe remainingscrews.Recheck belt tension.

1-26

Ertgine/eng

¯ roubieshooting

- System Isolation

The following is to help you isolate a maffunction of one or possibRyseveral systems. After determining which systemsare related to the malfunction, refer to the individual systemtroubleshooting charts to isolate the specific cause.

Engine should (:rank at specified RPM.If not, check for: Cranking System

1. Discharged or dead battery 2. Loose or corroded connections 3. Cranking System Troubleshooting Chart in the Electrical Service Manual Must have good spark at spark plugs, ff not, check the:

Engine Does Not Run

ignition System

1. Distributor cap and rotor 2. Coil and spark plug leads 3. ignition timing 4. Automatic spark advance 5. Appropriate ignition Troubleshooting Chart in the ignition Service Manual 6. EFi Modelsrefer to Diagnostic Service Manual EFi Models: Refer to Diagnostic Service Manual Non-EF! Models: Carburetor accelerator pumpshould squirt fuel into venturi whenthrottle is advanced.If not, check the:

Fuel System

1. Fuel tank, valves, and lines 2. Fuel pumpand fiater 3. Carburetor and filter =

Check the following:

Engine Runs Improperly

1. Compression 2. Ignition system 3. Fuel and carburetor/injector system 4. Lubrication system 5. Cooling system 6. Vertical drive and propeller 7. Vertical drive gear ratio and installation 8. Engine Troubleshooting Guides

Engine Troubleshooting Guides EFi EnginesOnly: Refer to EFI Diagnostic Service Manual. These guides were written to help you trace the symptomsof the trouble to the source, without having to read through and prove every possibility. Muchof the information here will be familiar to well informed mechanics. Also, manyfactors will seeminsignificant but whenyou think of it, usually the toughest problemto troubleshoot is causedby the smallest error. The greatest aid to solving a service problemis information. Start gathering information from the boat operator and write it on his job card or workticket. Find out pertinent facts, such as: ¯ Whendid this trouble start? ¯ Howwas the boat loaded? ¯ Did the trouble occur suddenly, or start gradually? Analyzethis information and try to matchit to siminar situations you have experienced in the past. Keepin mind the fundamental rules: 1. COMPRESSION - Mixture inducted into pressed.

cylinder

and com-

2. SPARK - Proper intensity at the proper time. 3. FUEL-Proper mixture of air and fuel. Theseare very oUdrules, but necessaryfor the engine to run. Use these charts and the service information they refer to. Do not try to remembertonerances, settings, measurements,etc., as they are written in the service manual.Leaveyour mind free to analyze the probiem. Following is a list of the troubleshooting guides which maybe found on the pages indicated. Title 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

..........................................

Engine Will Not Crank .......................... Engine Cranks, But Will Not Start ................. Hard Starting - CoDdEngine ...................... Hard Starting - Hot Engine ...................... Engine Runs Rough ............................ Engine Noises and Vibrations .................... Engine Overheats ............................. Engine Dies Out ............................... Engine Won’t Reach Operating RPM............... Defective Engine Lubricating System .............. Low Battery Voltage After Short Storage ...........

1-28

Page 1-29 1-29 1-30 1-30 1-31 1-31 1-32 1-33 1-33 1-34 1-34

Engine Will Not Crank

¯ ¯ e e ¯ ¯ ¯ ¯

Battery condition: weak, dead, sulfated, bad cells Battery cables for loose or corroded connections Shorted or open ignition switch Starter motor and solenoid for shorts, grounds or open circuits Starter assist solenoid/starter relay Circuit breakers Wiring from battery to ignition switch See Electrical/Ignition Service Manual

EngineCranks, But Will Not Start

e Primary circuit wiring from ignition switch to ignition coil/ignition module ¯ Secondarycircuit wiring from coil to spark plug e Spark plugs for proper gap, fouling, burned electrodes, cracked or dirty insulator ¯ See Electrical/Ignition Service Manual ¯ Ignition circuit breaker ¯ Low battery voltage

¯ ¯ e e e e ¯ ¯ ¯ ¯ ¯

Quantity and condition of fuel in boat tank Operation and flow capacity of boat anti-siphon valve Fuel tank vent is unrestricted Fuel tank pick-up screen is clean Correct diameter/unrestricted boat fuel lines Fuel shutoff and multiple tank valves Fuel pump/relay/circuit breaker operation Fuel filter canister and carburetor filter Carburetor accelerator pump Vaporseparator~fuel reservoir (EFI) See Fuel SystemService Manual 0_’__

~

0 "

0

"~

¯ Conduct test following procedure in this section, and compare readings to CompressionLimit Chart

Eng,ne/eng

1-29

Hard Starting - Cold Engine Ask these questions first: m

e

" ’ __,

" __

eo ° _---

¯ ¯ e e

Carburetor choke operation and adjustment Fuel lines for obstructions For debris inside fuel tank See Fuel System Service Manual

¯ ® ¯ ® ¯

For clean external canister and carburetor fuel filters Emptycarburetor float bowl due to evaporation Water in fuel due to condensation Fuel quality deterioration See Fuel System Service Manual

I

¯ ® ¯ ¯ ¯

A

=

oe®

¯

Carburetor choke operation and adjustment Carburetor accelerator pump Fuel systemfor leaks, dirt, or obstructions Engine timing and ignition system See Electrical/Ignition and Fuel System Service Manuares

Hard Starting - Hot Engine Ask these questions first: --I

_

e

= A

=

D 0 _"

-

_ "

e Carburetor choke operation and adjustment ¯ See Fuel System Service Manual A

a

e 0

e

°

¯ e e ¯ ¯

Brand, type or octane of fuel Spark plugs Water in fuel Condition of battery and cables Starter motor for overheat damage

e ¯ ¯ ¯ ¯

Ignition systemprimary circuit ignition coil/ignition module Engine timing Carburetor choke operation and adjustment See ElectricaUIgnition and Fuel SystemService Manuels

1-30

Engme/eng

Engine Runs Rough

® Idle speed and idle mixture ¯ Engine timing and spark plugs ® Fuel pump pressure ® Water or contaminants in fuel ¯ Carburetor or manifold vacuumleak ¯ nnternal carburetor fuel leak ® See Fuel SystemService Manual &

® ® ® ® ® ¯ ® ® ® ¯

e

O= ° e

"

Air leak on suction side of fuel system Too low octane fuel Ignition systemsecondarycircuit Engine timing Wrongmodel or size carburetor, improper main jets or powervalve, defective secondaryfuel circuit, secondary vacuum diaphragm failure External canister and carburetor fuel filters Fuel pump pressure Engine compression Water or contaminantsin fuel, water in cylinders See General information section and Electrical/Ignition and FuemSystemService Manuals

Engine Noises and Vibrations

¯ RappingonJy whenstarting (oil too heavy for prevailing weather, varnish on lifter, oil needsto be changed) ¯ Untermittent rapping (Deakageat lifter checkball) ¯ Idle noise (excessive leak downrate, faulty check ball seat) ® Generally =noisy (excessive oil in crankcase,stuck lifter plunger) ® Loudnoise at operating temperature(scored lifter plunger, fast leak downrate, oil viscosity too light for prevailing weather or operating temperatures) ® See appropriate Engine section

~-~,,j,o~,/eog

1-31

EngineNoises and Vibrations, Cont,

¯ ® ¯ ®

Improper tuning Incorrect spark plug wire routing Use higher octane fuel See Electrical/Ognition Service ManuaB

e Supply pump e Loosebelts, pulleys e See Cooling System section

¯ Loose, broken or worn engine mounts ® Loose lag screws hotding mounts to stringer ¯

.

~.

¯

"

e

°#]

e Loosebolt(s)

Loose pulley, worn bearings Loose mounting bolts

Failed U-joints or gimbal bearing Damagedinternal drive components Worn, bent or broken propeller hub or blades e Loose, worn or damagedengine coupler

EngineOverheats- Check" ¯ Actual engine temperature by verifying with an accurate thermometer ¯ Gaugeoperation and wiring circuit ¯ Sending unit operation and wiring circuit ¯ Supply pump, circulating pumpand belts ® Water intake screens for blockage ¯ Thermostat ¯ Water supply hoses ¯ Engine timing ¯ Water leaks on pressure side of supply pump o Air leaks on suction side of supply pump e Engine compression

1-32

Englne/eng

Engine

Dies

, ® -0 e e

-

Out

.............

-___

¯ ¯ ¯ ¯ e e ¯ e ¯

Fuel gauge operation and wiring Fuel level in tank ’Water or debris in fuel Fuel pickup tube and screen blockage Fuel tank vent blockage Pluggedexternal canister or carburetor fuel filters Air leak on suction side of fuel system Fuel leak on pressure side of fuel system Inoperative, restricted or incorrectly sized anti-siphon valve ® Boat fuel lines too small in diameter o Fuel pumppressure and suction ¯ Carburetor cleanliness and operation ¯ See Fuel System Service Manual

¯ ® ¯ ¯ ® ®

Primary and secondaryignition circuits Ignition switch Circuit breakers Wiring between engine and dash Main engine harness wiring See ElectricaN/|gnition Service Manual

¯ ¯ ¯ ¯

Vertical drive for internal damage Oil pressure gauge and crankcase oil level Temperature gauge and cooling system operation Internal engine componentsas required

Engine

Won’t

Reach

Operating

FIPNi

e Fuel type or octane o Propeller pitch or diameter, damagedblades, slipping hub o Crankcase oil volume e Marine growth on hull and drive e Wrongvertical drive gear ratio ¯ Operating at high altitude ® Restricted carburetor air intake ® Restricted e×haust outlets in engine, transombracket or drive ® Poor cylinder compression ® Carburetor size and type correct for engine ® Fuel pump pressure and vacuum ® Boat overloaded, or load improperly placed ¯ Engine overheating ® Engine timiing and ignition system operation ¯ Remotecontrol cables and linkage for proper attachment and travel

Engme/eng

1-33

-

Check:

,,,=,,,~

Defective EngineLubricating System

¯ Cloggedor incorrect oil filter ® Worn oil pumpgears, cover or shaft ¯ Wornor collapsed oil pumprelief valve spring, or foreign material caught on valve seat ® Oil pumprelief valve plunger loose in cover ¯ Damagedfilter bypass grommet ® Cloggedoil pickup screen, broken tube or housing ® Pluggedcrankshaft or blocked oil galneys ® Dirty or defective hydraulic lifters, clogged push rod passages ® Poor quality, incorrect viscosity or quantity of oil ¯ Incorrect hose routing on remote filter systems ¯ Water in crankcase oil from condensation, defective head gasket, oil cooler, or cracked manifold/block water passages

o Oil gauge/warning horn operation and wiring o Engine temperature o Oil pressure gauge and warning horn sender operation and wiring

LowBattery Voltage After Short Storage

¯ All electrical accessoriesincluding ignition circuit off ¯ Disconnect main battery negative cable from battery ¯ Connect ammeteror voltmeter in series between negative battery cable and negative battery post 1. Meter reading of "0’" indicates no draw, test battery and charging system 2. Meter movementno matter how slight indicates draw from battery ® Disconnect main engine harness 10-Pin Connector 1. Meter drops back to "0", problem caused by boat system, continue to isolate each boat electrical accessory until problem is found 2. Meter does not drop back to "0", problem caused by engine electrical system, continue to isolate each engine electrical accessory until problem is found ® Repair or replace componentsas necessary

1-34

Engine/eng

Tune-upSpecifications

EngineFiring Order 3.0 liter ................................................... 4..3 alter ............................................... 5.0 and 5.7 liter ..................................... 7.4 and 8.2 liter .....................................

1-3-4-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2 1-8=4=3-6-5-7-2

Fuel PumpPressure Carbureted Models ..................................... Fuel Injecected Models ..................

5.75- 7 psi (40- 48 kPa) at idle RPM See GMEFI Diagnostic Service Manual

CrankcaseCapacities Model 3.0GS 4.3GL, GS,Gi 5.0GLand Gi 5.7GSand GSi 7.4GL,Gi, GSi 8.2GSi DPX300 DPX385, DPX415,DPX500

LessFilter 3.5qts. (3,3liters) 4.0qts. (3,8liters) 5.0qts. (4,7liters) 5.0qts.(4,7liter.,;) 8.0qts.(7,5liter.,;) 8.0qts. (7,5liters) 5.0qts.(4,7liter.,;) 8.0qts.(7,5liters.)

WithFiater 4.0qts. (3,8liters) 4.5qts. (4,3liters) 8.0qts. (5,7liters) 8.0qts. (5,7liters) 9.0 qts. (8,5liters) 9.0 qts. (8,5liters) 6.0 qts. (5,7liters) 9.0 qts. (8,5liters)

Tune=up Specifications Idle* and OperatingRPM 3.0 GS Idle ....................................... WOT.................................... 4.3 GL Idle ....................................... WOT.................................... 4.3 GS Idle ....................................... WOT.................................... 4.3 Gi Idle ............................. WOT.................................... 5.0 GL Idle ....................................... WOT.................................... 5.0 Gi Idle ............................. WOT.................................... 5.7 GS Idle ....................................... WOT.................................... 5.7 GS~ Idle ............................. WOT.................................... 7.4 Gi Idle ............................. WOT........................................ 7.4 GSi Idle ............................. WOT........................................ 8.2 GSi Idte ............................. WOT................................... DPX385 Idle ............................. WOT........................................ DPX415 Idle ............................. WOT...................................

650-750 RPM 4200-4600 RPM 550-650 RPM 4200-4600 RPM 550-650 RPM 4400-4800 RPM 600 RPM- Not Adjustable 4400-4800 RPIVI 550-650 RPM 4400-4800 RPM 600 RPM- Not Adjustable 4600-5000 RPM 550-650 RPM 4400-4800 RPM 600 RPM- Not Adjustable 4600-5000 RPM 600 RPM- Not Adjustable 4200-4600 600 RPM- Not Adjustable 4800-5200 600 RPM- Not Adjustable 4600 - 5000 RPM 600 RPM- Not Adjustable 4800-5200 600 RPM- Not Adjustable 4600 - 5000 RPM

* In Forward Gear WOT= Wide Open Throttle

1-36

Engine/eng

Tune-up Specifications Oil Pressure-All IViodels 103-207 kPa (15-30 psi)[

800RPM .............................. 2000RPM ............................

.276-414 kea(40-60 psi) I’ Timing and Fuel Requirements

3.0GS .........................

2° ATDC - w/87AKI or higher Volvo Penta885163=6 shunt required

4.3GL, GS ....................

6° BTDC - w/89AKI or higher 1 o BTDC - w/87AKI VolvoPenta885163-6shunt required

4.3Gi ........................

8° 6TDC - w/87AKBor higher Service Moderequired

5.0GL .......................

10° BTDC - w/86 AKI or higher

5.0Gi ........................

8° BTDC - w/87 AKI or higher Service Moderequired

5.7GS ........................

8° BTDC - w/86 AKI or higher

5.7GSi .......................

8° BTDC - w/87 AKI or higher Service Moderequired

7.4 Gi .......................

10° BTDC - w/87 AKI or higher Service Moderequired

7.4 GSi ......................

10° BTDC - w/87 AKt or higher Service Moderequired

8.2 GSi ......................

10° BTDC - vv/87AKI or higher Service Moderequired

DPX385, DPX415.............

10° BTDC - w/87 AKI or higher Service Moderequired

NI timingset at idle RPM

Englne/eng

1 -37

Tune-upSpecifications

= Spark Plugs

3.G GS Spark Plug ..................... VP-3851857-7, AC-MR43LTS, CH-RS12YC Gap ............................................. 0.045" (1,143ram) Torque .............................................. 20ft. Ib. (27Nm) 4.3 GL, GS, Gi Spark Plugs .................... VP-3856756-0, AC-MR43LTS, CH-RS12YC Gap ............................................. 0.045" (1,143ram) Torque .............................................. 20ft. lb. (27Nm) 5.0 GL Spark Plugs ..................... VP-3851859-3, AC-MR43T,CH-RV15YC4 Gap ............................................... 0.035" (0.89ram) Torque .............................................. 20ft. lb. (27Nm)

t5.0 Gi Spark Plugs ................................ Gap ............................................. Torque ..............................................

VP-3854399-7, CH-RS12YC 0.045"(1,143 ram) 20ft. lb. (27Nm)

5.7 GS Spark Plugs ..................... VP-3851859-3, AC-MR43T,CH-RV15YC4 Gap ............................................... 0.035" (0.89ram) Torque .............................................. 20ft. lb. (27Nm) 5.7GSi Spark Plugs .................... VP-3856756-0, AC-MR43LTS, CH=RS12YC Gap ............................................. 0.045" (1,143 mm) Torque .............................................. 20ft. lb. (27Nm) 7.4 GL Spark Plugs ..................... VP=3851861-9,AC-MR43T,CH-RVl5YC4 Gap ............................................. 0.045" (1,t43 mm) Torque .............................................. 20ft. lb. (27Nm) 7.4 Gi Spark Plugs ..................... VP-3851862-1, AC-R43TS,CH-RV15YC4 Gap ............................................. 0.045" (1,143 mm) Torque .............................................. 20 ft. lb. (27Nm) 7.4 GSi Spark Plugs ..................... VP-3851861-9, AC-MR43T,CH-RV15YC4 Gap ............................................. 0.045" (1,143 mm) Torque .............................................. 20 ft. lb. (27Nm)

8.2 GSi VP=3851861-9,AC-MR43T,CH-RV15YC4 Spark Plugs ..................... Gap ............................................. 0.045" (1,143 mm) Torque .............................................. 20ft. lb. (27Nm) VP = Volvo Penta

CH= Champion

AC= ACDelco ,~CAUTIONWhenreplacing spark plugs, use only VP# 3854399-7 or ChampionRS12YC.Failure to use the correct spark plug mayresult in engine failure and is not coverdunder ’volvo Penta’s Limited warranty.

1-38

Englne/eng

GeneralTorqueSpecifications T,hefollowing specificationsare for nut andscrewsizes not havingspecific torquerecommendations. Screw Size

Ft. Lb.

in. Lb.

Nm

Screw Size

Ft. Lb.

In. lb.

Nm

No. 6

9.7 - 14

1,1- 1,6

M-6

72-108

8-12

No=8

19.4- 24.7

2,2- 2,8

M-8

6-9 14-21

168-252

19-28

No. 10

2- 3

25 - 35

3-4

M-10

2840

336-480

38-54

No. 12

3- 4

35 - 45

4- 5

M-12

50-71

600-852

68-98

1/4-20

5- 7

60 - 80

6,8 - 9,5

M-14

80-114

960-1368

108-155

5/16-18

12 - 14

144- 168

14- 16

3/8-16

20 - 25

240 - 300

24 - 27

7/16-14

3240

384480

43 - 54

Pound-inchesx 0.11298= NewtonMeters (N*m) Pound-feetx 1.3558== NewtonMeters(N.m)

Battery Cable Requirements Thebattery shouldbe mounted as closeto the engineas practical to cut downon battery cabaelengths. Followthe recommendations below. 0-10 feet 1AWG 10-15feet 2.0 AWG 15-20 feet 4/0AWG LNo-~Thesespecifications do not apply to aluminum battery cabtes. Volvo Pentadoesnot recommend the useof aluminum battery cables. L/~Toprevent the possibility of fire or explosion, do not substitute automotiveparts for the foJJowingmarine components: o Alternator Carburetorand related parts Distributorandrelatedignition parts Fuel pump Fuelfilter canister ,, Solenoids Spark plug leads * Starter Tilese components Ilave beenspecifically designedto meetU.S. CoastGuardregulationsnot to emit fuel vaporsor to causeignition of fuel vaporsin the bilge. E,,~,.~/~.g ~ Safety Related

1-39

METRIC CONVERSIONCHART

inches feet yards miles inches

X X X X X

25.4 0.3048 0.9144 1.6093 2.54

= = = = =

2 inches 2 inches 2 feet 2 yards acres

X X X X X

645.16 6.452 0.0929 0.8361 0.4047

2 miles

X 2.590

= millimetres 2 2) (mm = centimetres 2 2) (cm = metres2 s) (m = metres2 2) (m = hectares (104 s) (ha) = kilometres 2 2) (km

3 inches 3 inches 3 inches quarts gallons 3 feet 3 feet fluid oz 3 yards

ounces (av) pounds (av) tons (2000 Ib) tons (2000 Ib)

millimetres (mm) metres (m) metres (m) kilometres (km) centimetres (cm)

X X X X X X X X X

16387 16.387 0.01639 0.94635 3.7854 28.317 0.02832 29.57 0.7646

= millimetres 3 3) (ram = centimetres3 3) (cm = litres (I) = litres (I) = litres (I) = litres (I) = metres3 3) (m = millilitres (ml) 3) = metres3 (m

X X X X

28.35 0.4536 907.18 0.90718

= grams (g) = kilograms (kg) = kilograms (kg) = metric tons (t)

ounces- f (av) X 0.278 pounds- f (av) X 4.448 kilograms - f X 9.807

= newtons (N) = newtons (N) = newtons (N)

2 feet/sec 2 inches/sec

= metres/sec2 2) (m/S 2) = metres/sec2 {m/S

X 0.3048 X 0.0254

foot-pounds calories Btu watt-hours kilowatt - hrs

mines/gal

X X X X X

1.3558 4.187 1055 3500 3.600

= joules (j) = joules (j) = joules (j) = joules (j) = megajoules (M J)

X 0.42514 = kilometres/litre

(km/I)

N ore: 235.2/(mi/gal) = litres/100 235.2/(litres/100 kin) = mi/gal

footcandles

X 10.76 = lumens/metre 2 2) (Im/m

= kilopascals (kPa) = kilopasca~s (kPa) = kilopascals (kPa) = kilopascals (kPa) = pascals (Pa)

inches HG(60°F) pounds/sq in inches H20 (60°F) bars pounds/sq ft

X 3.377 X 6.895 X 0.2488 X 100 X 47.88

horsepower ft-lbf/min

X 0.746 = kilowatts (kW) X 0.0226 = watts (W)

°Celsius = 0.556 X (°F -32) °Fahrenheit = (1.8 X °C) +32

pound-inches pound-feet

X 0.11299 = newton-metres (N.m) X 1.3558 = newton-metres (N.m)

miles/hour feet/sec kilometres/hr miles/hour

X 1.6093 X 0.3048 X 0.27778 X 0.4470

1-40

= = = =

kilometres/hour (km/h) metres/sec (m/s) metres/sec (m/s) metres/sec (m/s)

Engine/eng

Drill Size ConversionChart SHOWINGMILLIMETER SIZES, FRACTIONALAND DECIMALINCH SIZES AND NUMBERDRILL SIZES Milh- Dec. Frac- Num- MilliDec. Frac= Num- Mdh- Dec. Frac- Num- MILE== Dec. Frac- Num- MilliDec. FracMeter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equw tionai .1 .15 ,2 .25 .3 .... .35 .... .39 .4 .4; .5’ .. .5i .... .6 .... .... .65 .... .... .7 .... .75 .... .79 .8 .... .... .85 .... .9 .... .... .95 .. 1.0 .. 1’.05 .... .... 1.1 1.15 .... 1.19 1.2 1.25 1,3 .... 1.35 .... 1.4 1.45 1.5 .... 1.55 1.59 1.6 .... 1.65 1.7 ....

.0039 1.75 .0689 .0059 .... 0700 .0079 1.8 .0709 .0098 1.85 .0728 .0t18 .... 073O 0135 80 1.9 .0748 .... 0760 .0138 0415 79 1.95 .0767 .0156 1/s4 ... 1,98 .0781 %4 .0157 .... 0785 .0160 78 2.0 .0787 .0177 2.05 .0807 .0180 77 .... 0810 .0197 .... 0820 .0200 76 2.1 .0827 .0210 75 2.15 .0846 .0217 .... 0860 0225 74 2.2 .0866 2.25 .0855 .0236 0240 73 .... 0890 0250 72 2.3 .0905 2.35 .0925 .0256 71 .... 0935 0260 0280 70 2.38 .0937 %2 .0276 2,4 .0945 0292 69 .... 0960 .0295 2.45 .0964 0310 68 .... 0980 .0312 1~2 . . 2.5 .0984 .0315 .... 0£95 0320 67 .... 1015 0330 66 2.6 .1024 .... 1040 .0335 2.7 .1063 0350 65 .0354 .... 1065 0360 64 2.75 .1082 0370 63 2.78 .1094 %4 .... 1100 .0374 62 2.8 .1102 .0380 .039o 61 .. .1110 .0394 .... 1130 ,0400 60 2.9 .1141 .0410 59 .... 1160 .0413 3.0 .1181 0420 58 .... 1200 0430 57 3.1 .1220 .0433 3.18 .1250 ~ .0452 3.2 .1260 0465 56 3.25 .1279 .0469 %4 ........ 1285 .0472 3.3 .1299 .O492 3.4 .1338 .0512 .... 1360 0520 3.5 ,1378 55 ,0513 .... 1405 0550 54 3.57 .1406 %4 .0551 3.6 .1417 .0570 .... 1440 .0591 3.7 ,1457 0595 53 .... 1470 .0610 3.75 .1476 .0625 .... 1495 ½6 ... ,0629 3.8 .1496 0635 52 .... 1520 .0649 3.9 .1535 .... 1540 .0669 067O 51 3.97 .1562 ~/32

Engme/eng

1570 .1575 1590 .1610 49 4.1 .1614 4.2 .1654 48 .... 1660 4.25 .1673 ... 4.3 .1693 47 .... 1695 4,37 .1719 1~4 .... 1730 46 4.4 .1732 45 .1770 4.5’ .1771 .1800 44 4.6’ .1811 .... 1820 4.7 .1850 43 4.75 .1870 4,76 .1875 ¾6 4.8 .1890 42 .... 1910 ... 4.9 .1929 .... 1935 41 ... 1960 5.0 .1968 40 .... 1990 5.1 .2008 .... 2010 39 38 5.16 .2031 13/e4 .... 2040 37 5.2 .2047 .... 2055 36 5.25 .2067 5.3 .2086 ........ 2090 35 5.4 .2126 .... 2130 34 5.5 .2165 33 5.56 .2187 7/32 56 .2205 32 .... 2210 5.7 .2244 31 5.75 .2263 .... 2280 ... 5.8 .2283 5.9 .2323 .... 2340 3O 5.95 .2344 15/64 6.0 .2362 .... 2380 29 6.1 .2401 .... 2420 28 6.2 .2441 ... 6.25 .2460 6.3 .2480 27 6.35 .2500 ¼ 6.4 .2520 26 .2559 6.5 .... 2570 25 6.6 .2598 .... 2610 24 6.7 .2638 6,75 .2657 1%4 23 6.75 .2657 ... .... 2660 50

.... 4.0 ....

1-41

22 2I 20 19 18 1"7’ 16 15 14 13

12 11 10 9 8 7

i 5 4 3

2 1 A B C D E F G

H

6.8 .2677 6.9 .2716 .... 2720 7.0 .2756 .... 2770 7.1 .2795 .... 2811 7.14 2812 %2 7.2 .2835 7.25 .2854 7.3 .2874 .... 2900 7,4 .2913 .... 2950 7,5 .2953 7.54 .2968 19/64 7.6 .2992 .... 3020 7.7 .3031 7.75 .305I 7.8 .3071 7.9 3110 7.94 .3125 ~5/16 8.0 .3150 .... 3160 8.1 .3189 8.2 .3228 .... 3230 8.25 .3248 8.3 .3268 8.33 .3281 ~J/64 8.4 .3307 .... 3320 8.5 .3346 8.6 .3386 .... 3390 8.7 .3425 8.73 .3437 W32 8.75 .3445 8.8 .3465 .... 3480 8.9 .3504 9.0 .3543 .... 3580 9.1 .3583 9.13 .3594 23/64 9.2 .3622 9.25 .3641 9,3 .3661 .... 3680 9.4 .3701 9.5 .3740 9.53 .3750 3/8 .... 3770 9.6 3780 9.7 .3819 9.75 .3838 9.8 .3858 .... 3860 9.9 .3839 9.92 .3906 2~/64 10.0 .3937 .... 3970 .... 4040 10.32 .4062 13/32 .... 4130 10.5 4134

I J K ..

L M .. N

.. 0 P .. Q R .. S T ..

U

’V

W .. X Y "Z

10.72 11.0 11.11 11.5 11.51 11.91 12.0 12.30 12,5 12.7 13.0 13.10 13.49 13.5 13.89 14.0 14.29 14.5 14.68 15.0 15.08 15.48 15.5 15.88 16.0 16.27 16.5 16.67 17.0 17.06 17.46 17.5 17.86 18.0 i18.26 ;18.5 18.65 19.0 19.05 19.45 19.5 19.84 20.0 20.24 20.5 20.64 21.0 21.04 21.43 21.5 21.83 22.0 22.23 22.5 22.62 23.0 23.02 23.42 23.5 23.81 24.0 24.21 24.5 24.61 25.0 25,03 25,4

.4219 .4330 .4375 .4528 .4531 .4687 ,4724 .4843 .4921 .5000 .5118 .5156 .5312 .5315 ,5469 .5512 .5624 .5709 .5781 .5906 .5937 .6094 ,6102 .6250 .6299 .6406 .6498 .6562 .6893 .6719 .6875 .6890 .7031 .7087 .7187 .7283 .7344 .7480 .7500 .7656 .7677 .7812 .7874 .7969 .8071 .8125 .8268 .8218 3437 .8465 ,8594 .8661 .8750 .8858 ,8906 .9055 ,9062 ,9219 .9252 ,9375 .9449 .9531 ,9646 .9687 .9843 .9844 1,0000

2%4 ¾6 2%4 1%2 3~4 1~ 3%4 1%2 3%4 ~6 3%4 ~%2 3%4 % 41/~ 21A2 4%4 u48 4~4 2¾2 4~4 ¾ 49/64 2~2 5~4 1¾6 s~4 2%2 ~%4

s%4 2%2 6%4 1~6 6~4 3½2 6~4 1

DR2949-ENG

Symbols Certainsymbolsor combinations of symbolsmayappearon your VolvoPentaSterndriveor on their accessories.It is very importantthat youunderstand the!r meaning or purpose.If anysymbolis not clearly understood, seeyour Dealer.

"Safety Warning" Symbols

~,

~

A " Risk of serious injury

o,soooo

Contents Under Pressure

"Position indicator" Symbois Shift Positions NEUTRAL Raise

-4’-

Lower

FORWARD

"Condition"

(~

Hour Meter

~ Vo,tmeter Water Temperature

Symbols

Tachometer

® Ammeter f o Voltmeter ~ OH Fi,ter

~

REVERSE

@ FuelFilter

Emergency Stop ~1~(~ Oil

Pressure

instructional Symbols

1-42

Engme/eng

Periodic MaintenanceChart Items marked//~Safety Warningare safety related service points to preventmechanicalfailures, fire and explosion. Makesure the safety related service is performed at thesepointsandat the intervals specified.

[ServicePoint

Every25 Hours or AsSpecified Every50 Hours or AsSpecified

IAIternator Belt, !PowerSteeringPump Belt

Check belt for tensionand deterioration,

Recommendations Adjustto specifications. Replace deteriorated belts. Keep spareon board.

FlameArrestor

Checkfor damage to grill area. Must be firmly attached.

Seasonallyclean and inspect. If damaged,replace with specified Damaged unit mayallow backfire VolvoPentaparts, tf dirty, cleanin flame to enter engine compartment, solvent, air dry beforeinstallation.

Crankcase

Checkoil level daily.

Drain and refill every 50 hours or every 6 months, whichever occurs first.

SeeSpecifications.

Engine Alignment

Seasonally.

Checkengine alignment.

Oil Filter

Replace.

SeeSpecifications.

Every 50 Hoursor As Specified

Recommendations

Power Steering Pump

Checkresovoir fluEd level.

Use DuraPlus SteeringFluid.

Steering Cable Ram

Lubricate every 50 hours or every 60 days, whichever comesfirst

Use Volvo Penta Grease P/N 828250-1.

Service Point

Every 25 Hoursor As Specified

PowerTrirrVTilt &

Service Point

Every 25 Hoursor As Specified

Every 50 Hours or As Specified

Recommendations

Engine

Checkfor leaks. CPleckbelts for correct tension,

Seasonally check for hose deterioration, Checksupply pump operat=on.Repair as requ=red,

Drain after operation in freezing temperatures, or during seasonal lay-up. -Rghtenconnections. Replace supply pumpevery 2 years.

Seasonally check for hose deterioration.

Drain after operation in freezJng temperatures, or during seasonal lay=up.

TransomShietd

Sterndrive

Check water pickup screens for obstructions.

Drain after operation m free;ang temperatures, or during seasonal lay- up.

Periodic MaintenanceChart - Continued

ServicePoint

Every25 Hoursor As Specified

Every 50 Hoursor As Specified

ControlLinkage

Checkoperation.Check adjustment andlubricate

Shift System

Check for smooth shifting into and out of gear.

Replace shift cableif necessary. Seasonally or every100hours, checkcablefor properrouting and operation.

r ServicePoint

Every25 Hoursor AsSpecified

Every50 Hoursor As Specified

Bilge Area

Checkfor gas fumesandleaks.

Repairor replacedefective components.

Hull

Checkfor marinegrowth.

Cleanboat bottom.

Adjustas required. UseVolvoPenta GreaseP/N 828250-1.

Trailer(if applicable)

Recommendations

SeePreparationfor Boating.

Preparationfor boating season Safety Equipment

Recommendations

Checkremotecontrol and emergency stopswitch, if installed, for properoperation,

All boat safety equipment shouldbe Besure U.S.C.G.required checked for conditionandproper equipmentaboard(check Coast operation. Guardregulations). Seasonallyrepackwheelbearings. UseMarine E/P wheel bearing grease.

1-44

Engine/eng

NOTES

1-45

NOTES

1-46

Section 2 General Engine Mechanical V6 and V8 iVlodels Table of Contents, AssemblingPiston and ConnectingRod...... 2=10 Camshaft Bearings ....................................................... 2-13 Bearing installation ..................................... 2-14 Bearing Removal ......................................... 2-13 Cleaning andinspection ............................. 2-13 Measurements ............................................. 2=14 Cleanliness andCrate ........................................ 2-2 Crankshaft and ConnectingRodBearings ... 2=18 Cleaning andinspection ............................. 24 8 Connecting RodSideClearance ................ 2-21 Crankshaft End Play.................................... 2-21 Crankshaft Runout ...................................... 2-21 Measuring BearingClearance .................... 2=19 Cylinder Bores ................................................... 2-4 Boring ............................................................. 2=6 Honing ............................................................ 2-7 Measuring TaperandOut-of-Round ............ 2=4 Reconditioning .............................................. 2-5 Removing Ridge ............................................ 2-5

Cylinder Head ................................................... 2=15 Assembly ...................................................... 2=18 Cleaning andInspection ............................. 24 5 Disassembly ................................................. 2-15 Reaming Valve Guides ................................ 2-17 Repair ............................................................2=17 Valve Grinding ............................................. 2-17 Valve SeatGrinding ..................................... 2=17 Engine Gaskets, Replacing ............................... 2-4 General Description ........................................... 2-2 PistonandConnecting Rod.............................. 2=8 Measuring Pistonto Pin Clearance ................. 2=9 Piston Rings Assembly ...................................................... 2-12 inspecting ..................................................... 2-12 installing ....................................................... 2=11 Piston Selection ............................................... 240 RTVSealer / AnaerobicGasketEliminator ..... 2-2 Special Tools .................................................... 2=23 Thread Repair ................................................... 2=22

Z~ Safety Warnings Beforeworkingon any part of the engine,readthe section called Safety at the endof this manual. Alwaysuse the correct fastener in the properlocation. When you replace a fastener, useONLY the exactpart number for that application. Thetext will call out thosefastenersthat requrereplacement after removal.The text will also call out the fastenersthat requirethreadlockersor thread sealant. UNLESS OTHERWISE SPECIFIED,do not use supplement coatings (paint, grease,or other corrosioninhibitors) on threadedfasteners fastenerjoint interfaces. Generally,suchcoatingsadverselyaffect the fastener torque andthe joint clampingforce, andmaydamage the fastener. When you install fasteners, use the correct tightening sequence and tighteningspecifications. Followingtheseinstructionswill help youavoid damage to parts and systems.

Enc.lne/eng

2-1

Generai Description The engine repair information described in this section explains how to clean, inspect, and measurecertain engine components. Use this section along with the proper engine repair section for the correct disassembly and assembly procedures. Engine specifications are found in the back of each engine repair section and wild be referred to often in this section.

Cleanliness and Care An engine is a combination of manymachined, honed, polished, and lapped surfaces with very close tolerances. Whenevervalve train, cylinder head, crankshaft, piston, and connecting rod componentsare removedfor service, they should be installed in their original location. Anytime the flame arrestor is removed, the intake opening must be covered. This will protect against the entrance of foreign materiaD which could follow the intake passageinto the cylinder and cause extensive damagewhenthe engine is started. Whenany internal engine parts are serviced, care and cleanliness are important. Apply a liberal coating of engine oil to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machinedsurfaces and friction areas is part of the repair procedure. This is considered standard shop practice evenif not specifically stated.

Use of RTVSealer and Anaerobic Gasket Eliminator Twotypes of sealants are commonlyused in the engines covered by this manual. These are RTVsealer and anaerobic "gasket eliminator" sealer. It is important that these sealers be applied properly and in the proper place to prevent oil leaks. THETWOTYPESOF SEALER ARE NOT INTERCHANGEABLE. Use the sealer recommended in the procedure. ®

RTV (Room Temperature Vulcanizing) sealer is used where a non-rigid part is assembled to a rigid part. Commonexamples are oil pans and valve rocker arm covers. Anaerobic gasket eliminator hardens in the absence of air. This sealer is used where two rigid parts (such as castings) are assembledtogether. Whentwo rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using gasket eliminator.

2-2

Engme,’eng

Using RTVSealer 1. Do not use RTV in areas where extreme temperatures are expected, such as exhaust manifold or head gaskets, or where gasket eliminator is specified. 2. Use a rubber mallet to separate componentssealed with RTV. Bumpthe part sideways to shear the RTVsealer. Bumpingshould be done at bends or reinforced areas to prevent distortion of parts. RTVis weaker in shear (lateral) strength than in tensiJe {vertical) strength. [~ Attempting to pry or pull componentsapart may result damageto the part.

in

3. Removeall gasket material from the part using a plastic or wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N 79040, or Permatex brand "Gasket Remover", P/N 4MA, or equivalent. Follow all safety recommendationsand directions that are on the can. Do not use any other methodor technique to removegasket material from a part. [~ Do not use abrasive pads, sand paper or power tools to clean gasket surfaces. These methods of cleaning can damage the part. Abrasivepadsalso producea fine grit that the oil filter cannot removefrom the oil. This grit is abrasive and has been knownto cause internal engine damage. 4. Apply RTVto one of the clean surfaces. Use a bead size as specified in the procedure. Runthe bead to the inside of any bolt holes. Do not allow the seaner in any blind threaded holes, as it may prevent the bolt from seating properly or cause damage whenthe bolt is tightened. 5. Assemblecomponentswhile RTVis still Do not wait for RTVto skin over.

wet (within 3 minutes).

6. Torquebolts to specifications. Do not overtighten. Using AnaerobicGasket Eliminator 1. Removeall gasket material from the part using a pJastic or wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N 79040, or Permatex brand "Gasket Remover", P/N 4MA, or equivalent. Follow all safety recommendationsand directions that are on the can. Do not use any other methodor technique to removegasket material from a part. r~ Do not use abrasive pads, sand paper or power tools to c, lean gasket surfaces. These methods of cleaning can damage the part. Abrasivepadsalso producea fine grit that the oil filter cannot removefrom the oil. This grit is abrasive and has been knownto cause internal engine damage.

Engme/eng

2-3

2. Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be cmeanand dry. 3. Spread the bead evenly with your finger to get a uniform coating on the complete flange. 4. Assembleparts in the normal mannerand torque immediately ecifications.

~

important: Anaerobic sealed joints that are partially torqued and allowed to cure morethan five minutes mayresult in incorrect shimmingof the joint.

~C6507

Replacing Engine Gaskets Composite-type head gaskets and intake manifold gaskets are used in the engine assembly. The head gaskets have a thin metal core. Someengine applications use a thin metal core for intake manifold gaskets. Use caution whenremovingor handling gasketsto help avoid personalinjury.

Cylinder Bores MeasuringCylinder Bore Taper and Out-of-Round [~ Took Required: J 8087 Cylinder Bore Gauge If one or more cylinder bores are rough, scored or worn beyondlimits, it will be necessaryto smoothor true up such bores to fit newpistons. No attempt should be madeto cut downoversize pistons to fit cylinder bores as this wiia destroy the surface treatment and affect the weight. The smallest possible oversize service pistons should be used and the cylinder bores shouUdbe honed to size for proper cmearances. 1. Refer to EngineSpecifications in the proper engine repair section for cylinder bore tolerances. [~] 2. Depressplunger on tool 0.03 in. (0,76 ram) or until tool enters cylinder bore. [~ 3. Center the gaugein the cylinder and turn the dial to "0".

Safety Related

2-4

Engme/eng

~-~ 4. Carefully work the gauge up and down the cylinder to determinetaper and turn it to different points aroundthe cylinder wall to determine the out-of-round condition. Measurethe bore both paralleD to and at right angles to the engine centerline. Measureat the top, middle, and bottom of the bore and note the readings. 5. Recondition the cylinder bore as necessary. Refer to Cylinder BoreReconditioningin this section.

-®®__l---

Cylinder Bore Reconditioning DRC6508

Measure: 1. Cylinder bore for out-of-round and taper. ~=~ 2. Wearat the top of the bore ~ and the bottom (~. Refer to Engine Specifications in the proper engine repair section for cylinder bore tolerances. F~D Cylinder bores can be measured by setting the cylinder gaugedial at zero in the cylinder at the point of desired measurement. Lock the dial indicator at zero before removingit from the cylinder, and measureacross the gauge contact points with an outside micrometer, with the gauge at the same zero setting when removed from the cylinder. If cylinder bore taper or wearexceedspecification, the cylinder,,; must be bored and honed to the smallest oversize. Refer to Engine Specifications in the proper repair section. Fh~evertical scratches madeby ring endswill not, by themselves, cause excessive oil consumption; therefore, honing to remove them is unnecessary. If the bore is glazed but otherwise serviceable, break the glaze lightly with a honeand replace the piston rings. Refer to Honingin this section. if honing is not required, the cylinder bores should be cleaned with a hot water and detergent wash.Apply clean engine oil to the. bore after cleaning.

Engme/eng

2=5

DRC6509

RemovingCylinder Bore Ridge E! Tool Required: J 24270 Ridge Reamer [~ important: Do NOT remove excessive material from the cylinder bore. Excessive removal of material mayrequire cylinder boring to the next oversize. 1. Rotate the crankshaft unti~ the piston is at BDC. 2. Place a cloth on top of the piston. [~] 3. Performthe cutting operation with a J 24270ridge reamer. Refer to the manufacturer’s instructions before using J 24270.

DRC6510

4. Remove J 24270and rotate the crankshaft until the piston is at -rDC. 5. Remove the cloth and cuttings. 6. Repeatthis procedure for each piston. Boring [~ important: Refer to Engine Specifications in the proper enginerepair section for additional information. 1. Before the honing or reboring operation is started, measureall new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline. Somepistons must be measuredat a specified distance from the piston crown. Refer to the proper section for additional instructions. Then select the smallest piston for the first fitting. Theslight variation usually found betweenpistons in a set mayprovide for correction in case the first piston is fitted too loose. 2. Before using any type of boring bar, the top of the cylinder baock should be filed to removeany dirt or burrs. This is very important. If not checked, the boring bar maybe tilted which wouldresult in the rebored cylinder wall not being at right angles to the crankshaft. 3. The instructions furnished by the manufacturer of the equipment being used should be carefully followed. 4. Whenreboring cylinders, all crankshaft bearing caps mustbe in place and tightened to the proper torque to avoid distortion of bores in the final assembly.

2-6

Eng=neJeng

5. Whentaking the final cut with a boring bar, leave 0.001 in. (0,025 ram) on the diameter for finish honing to give the required position to the cylinder clearance specifications. (The honing or boring operation must be done carefully so the specified clearance betweenpistons, rings, and cylinder bores is maintained). Honing 1. Whenhoning the, = cylinders, follow the hone manufacturer’,,; recommendationsfor use, cleaning, and lubrication during honing. Use only clean, sharp stones of the proper grade for the; amountof material to be removed.Dull, dirty stones cut unevenly and generate excessive heat. Whenusing coarse or medium grade stones, use care to leave sufficient metal so that all stone marks maybe removedwith the fine stones used for finishing to provide proper clearance. 2. Occasionally, during the honing operation, the cylinder bore should be thoroughly cleaned, and the piston selected for the individual cylinder checkedfor correct fit. 3. Whenhoning to eliminate taper in the cylinder, makefull strokes of the hone in the cylinder. Also check measurementat the top, middle, and bottom of the bore repeatedly. Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been honed to the correct size. The piston can be easily distorted through careless handling. 4. Whenfinish honing a cylinder bore to fit a piston, movethe hone up and down at a sufficient speed to obtain very fine uniform surface finish marks in a cross-hatch pattern at the specified angle (45 to 65 degrees). 5. The finish marks should be clean but not sharp, free from embeddedparticles and torn or folded metal. 6. By measuring the piston to be installed at the sizing point specified in the proper section, and adding the average of the clearance specification, the finish hone cylinder measurement can be determined. IL is important that both the block and piston be measuredat normal room temperature. 7. Refer to Engine Specifications section.

in the proper engine repair

8o It is of the greatest importancethat refinished cylinder bores are trued up to haveless than the specified out-of-round or taper. Eachbore must be final honedto removeall stone or cutter marks and provide a smooth surface.

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2-7

9. After final honingand before the piston is checkedfor fit, clean the bores with hot water and detergent. Scrubwith a stiff bristle brush and rinse thoroughly with hot water. It is essentian that a good cleaning operation be performed. If any of the abrasive material is allowed to remainin the cylinder bores, it will wearthe newrings, cyJinder bores, and bearings bubricated by the contaminated oil. After washing, the dry bore should be brushed clean with a power-driven fiber brush. 10. Refer to Engine Specifications in the proper engine repair section. 11. Permanentlymark the piston for the cylinder to which it has beenfitted.

DRC6511

J 24086-C

12. Apply clean engine oil to each bore to prevent rusting.

Piston and ConnectingRod Tools Required: J 24086-CPiston Pin Removaland Installation

Set

E~ Disassemble: [~ 1. Piston rings. In most cases the rings should be discarded and replaced with new rings at assembly. 2. Connectingrod bearings. If the bearings are to be reused, place them in a rack so they may be reinstalled with the original connecting rod and cap. 3. Piston pin. a. Place the piston/connecting rod on support fixture J 24086-C. Makesure the connecting rod is fully supported. b. Place removerJ 24086-Con the support fixture.

DRC65~5

c. Pressout the piston pin.

2-8

Engine/eng

Cleaning and Inspection [~ C|ean: Piston o Removeall varnish and carbon deposits. DO NOTUSEA WIRE BRUSH. ¯ Use an approved cleaning solution to remove carbon build-up. ¯ Removethe carbon from the ring grooves. Use a ring groove cleaning tool. e Oil-control ring groove holes. EL~ Inspect: t. Piston pin bore and connectingrod bore for scuffing and burr,,;. 2. Connecting rod for cracks, nicks, etc. If a suitable jig is available, check the connecting rod for a bent or twisted condition. 3. Connectingrod bearings for scratches or deep pitting~ 4. Piston for: ¯ ¯ ¯ ® ¯

Scratches, scuffing, and burrs Ring land for cracking and wear Ring grooves for burrs and nicks Skirts and loin bossesfor cracking Skirts for scuffing

MeasuringPiston Pin to Piston Clearance E~

Measure:

[~] 1. Piston pin diameter. Checkagainst Engine Specifications in the proper engine, repair section.

DRC6512

2u Piston pin to piston clearance. a. Measurethe piston pin hole diameter. b. Subtract the piston pin diameter from the piston pin hole diameter to obtain the clearance. c. Replacethe pL,;ton and piston pin if the clearance exceeds specifications. Thepiston and piston pin are a matchedset and not available separately.

Engme/eng

2-9

i

DRC6513

Piston Selection Checkthe used piston to cylinder bore clearance. r~

Measure:

1. Cylinder bore diameter. Use a telescoping bore gauge, located 2.56 in. (65 mm)below the top of the cylinder bore. [~ 2. Piston diameter= Measurethe piston skirt at a right angle to the piston pin, at the centerline of the piston pin. DRC6507

3. Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance. 4. Refer to Engine Specifications in the proper engine repair section to determine if piston clearance is within the acceptable range. If the usedpiston is not acceptable, determineif a newpiston will fit the cylinder bore. If a newpiston doesnot bring the cJearance within tolerances, the cylinder bore must be reconditioned. Mark the piston to identify the cylinder for whichit wasfitted.

Assemblingthe Piston and ConnectingRod Tool Required: J 24086-CPiston Pin Removaland Installation Set

DRC6514

J 24086-C

Assemble: 1. Piston and connecting rod. a. The alignment mark on the top of the piston must face the front of engine block. Connectingrod must be installed in the correct orientation. Refer to the proper engine repair section for piston and connecting rod installation. b. Lubricate the piston pin holes in the piston and connecting rod with engine oil.

DRC65!5

2-10

Engme/eng

c. Install the pin guide. Hold the piston and connecting rod together. Be sure to use the proper pin guide. Refer to the instructions supplied with the tool. 2. Piston pin: a. Insert the piston pin into the piston pin hole. ~] b. Place the assembly on the support fixture. ~] c. Adjust the piston pin installer (J 24086-C)to the correct length, using the letter-number scale on the installer adjuster. This is necessaryto ensure the piston pin is pressed into the piston to the correct depth. Refer to the instructions supplied with the tool for the proper setting. d. Lock the adjuster in place with the lock ring. ~ot~ After the installer hub bottoms on the support assembly, do not exceed5000PSI (35,000 kPa} pressure, as this could cause damageto the tool. e. Place the adjuster in the supportfixture. Pressthe piston pin into place (until the adjustable installer bottomsin the support fixture). f. Removethe piston and connecting rod assembly from the tool and check the piston for freedom of movementon the piston pin.

installing the Piston Rings Measure: ~’~ Ring end gap as follows: 1. Select rings comparablein size to the piston being used. 2. Slip compressionring into the cylinder bore. 3. Use piston to square ring in cylinder wall. ~’~ Insert piston without rings upside down and guide the compressionring into the cylinder bore until ring is downabout 1.499 in. (38,1 mm)below ring travel. [~’~ 4. Spaceor gap betweenthe ends of the ring with a feeler gauge.

Engme/eng

2-11

DRC6516

5. Refer to EngineSpecificatiens in the proper engine repair section for correct gap. 6. if the gap betweenthe ends of the ring is not as specified, removethe ring and try another for fit. mnspect: Ring fit as follows: 1. Fit each compressionring to the piston on which it is going to be used.

10755

[~ 2. Slip the outer surface of the top and second compression ring into the respective piston ring groove, to makesure the ring is free. Lf binding occurs at any point, the cause should be determined. If binding is causedby the ring groove, correct it by dressing the groovewith a fine cut file. If the binding is causedby a distorted ring, try a newring. ~]

Assemble:

Refer to Piston Assemblyin the proper engine repair section. ARI compressionrings are markedon the upper side of the ring. Wheninstalling the compression rings, make sure the MARKED SiDE IS TOWARD THE TOP OF THE PISTON. The oil control rings are 3-piece assemblies, consisting of two rails and an expander. ¯ ¯ ¯ ¯ ¯

Expander Lowerrail Upperrail Lower compression ring Upper compression ring

F}ex all rings to makesure they are free. If binding occurs at any point the cause should be determined. If binding is causedby the ring groove,correct it by dressingthe groovewith a fine cut file. If binding is causedby a distorted ring, try a newring. ¯ Ring gaps must be 180 degrees apart ¯ Rail gaps must be 180 degrees apart

2-12

Engine/eng

L==~ Measure: E2-~ 1. Ring clearance. Use a feeler gauge. 2 Compare with Engine Specifications repair section.

in the proper engine

CamshaftBearings Camshaft Bearing Removal E-~ Disassemble,:

DRC6517

~3~ Tool Required: J 33049 Camshaft Bearing Removal and installation Set

J33049

1. Rear camshaft plug. D~ 2. All camshaft bearings. Use J 33049. a. hsert the tool with the correct collet bearing you want to replace.

into the camshaft

b. Turn the tool until the collet has tightened in the bearing. c. Push the center cone against the block and into the first bearing bore to center the tool. d. Drive the bearing from the block. e. Repeat this procedure to remove the remaining inneF camshaft bearings. Note that the rear bearing must be re.movedfrom the front of the block and the front bearing should be removed from the rear. This allows the tool to remain centered. CJeaningand inspection Clean: ¯ Camshaftbearing bores in the block. ~o~ Inspect: ® Camshaftbearingsfor scratches, pits, or loose fit in their bores. Replace the camshaft bearings if necessary. ¯ Camshaftlobes and journals for scratches, pitting, scoring, and wear. Minor irregurarities maybe cleaned up with emery cloth.

Engme/eng

2-13

DRC6518

Camshaft Measurements

m new

Tool Required: J 7872 Dial Indicator or Equivalent Important: Wheneverthe camshaft needs to be replaced, a set of valve roller lifters mustalso be installed. Measure:

m

1. Camshaftjournal diameters using a micrometer. Compare with EngineSpecificatiens in the proper engine repair section. DRC651g

[~ 2. Camshaft runout. Mount the camshaft in V-blocks or between centers. Using J 7872, check the intermediate camshaft journal. Comparecamshaft runout specifications in the proper engine repair section. If the camshaftis excessively bent, replace the camshaft and camshaft bearings.

CamshaftBearing Installation Tool Required: Installation Set

J 33049 Camshaft Bearing Removal and

The outer camshaft bearings must be installed first. Thesebearings serve as guides for the tool, and help center the inner bearings during the installation process.

DRC6520

333049

Makesure to fit the correct cambearing into the bore. The cam bearing bores mayvary in size. [~

Assemble:

[~ 1. Rear camshaft bearings. Drive the bearings into place using J 33049 from front of engine. E~ Important: Make sure the camshaft bearing lubrication hole (or holes) align with the oil gallery hole (or holes) in block. On someengines, the oil holes maybe difficult to see. Verify the holes are lined up.

DRC6518

2. Front camshaft bearing using tool J 33049. [~ important: Make sure the camshaft bearing lubrication hole (or holes) align with the oil hole (or holes) in the block.

2=14

Eqgmeleng

[-3~ 3. Inner camshaft bearings using J 33049. Reverseof remova~ procedure. 4. Camshaftrear plug. a. Coat a newcamshaft plug with GMSealer, P/N 12345493,or equivalent. b. Install the plug. The plug must be installed deepenoughin camshaft bore. Refer to the proper engine repair section for camshaftplug installation.

Cylinder Head E~]

Disassemble:

Valves and components.Refer to the proper engine repair section. Cleaning and Inspection E4~] Tools Required" J 8089 Wire Brush Clean: E4~ 1. Carbon from the combustion chambers, using J 8089.

DR3123

2. Valve stems and heads on a wire wheel. 3. Carbonand old gasket from the cylinder head gasket surface. ~-~ 4. Valve guides using a valve guide cleaner. [~ inspect: 1. Cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the coolant chamber. Gasket surfaces should be free of damage. 2. Valves for burning, pitting, or warpage. Grind or replace as needed. Refer to Valve Grinding in this section. Checkthe valve stems for scoring or excessive wear. Stemsmust not be bent. 3. Valve rocker arm studs for wear, damage,or improper fit. 4.. Valve seats for pitting Peeded.

or other damage.Grind or reface as

5. Rotators (if used). The rotators should rotate smoothly without binding.

Engrne/eng

2-15

DR3124

[~ 6. Cylinder head for surface flatness. [~

Measure:

~]’~[~ Tools Required: J 8001 Dial Indicator or equivalent J 9668 Valve Spring Tester 1. VaBvestem to guide bore ckearance. Excessive valve stem to guide bore clearance will cause excessive oil consumption and may damagecomponents.Insufficient clearance wiII result in noisy and sticky functioning of the valve and interfere with engine smoothness.

DRC6521

a. Clampa dial indicator J 8001or equivalent on one side of the cylinder headvalve rocker armcover gasket rail. [~ b. Observe dial indicator movementwhile moving valve from side to side (crosswise to the head). The dial indicator measurementmust be taken just above the valve guide bore. c. Drop the valve head about 0°063 in. (1,8 mm)off the valve seat. d. Movethe stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream the valve guide bores for oversize valves as outlined later.

DR2101

2. Valve spring tension, using J 9666or equivalent. E~ a. Compressthe valve springs to the specified height. Check valve spring height in Engine Specifications in the proper engine repair section. Valve springs should be replaced if not within specification. [~ b. Valve spring length. Replace the valve spring if valve spring length exceedsspecifications. Refer to Engine Specifications in the proper engine repair section.

DR3122

DRCb’522

2-16

Eng,ne/eng

Repair Valve Grinding ~ E~-5~] Pitted valves must be refaced to the proper angle. Valw. stems that show excessive wear, or valves that are warped = excessiveb/must be replaced. Whenan excessively warpedvalw. head is refaced, a sharp or thin valve margin mayresult because of the amount of metal that must be removed. Undersize valve margins lead to breakage, burning, or preignition due to heat localizing on this edge. Refer to Engine Specifications in the proper engine repair section. Several different types of equipmentare available for refacing valves. The manufacturer’s instructions for howto use the equipment should be carefully followed to achieve proper results. Refer to Engine Specifications in the proper engine repair section for vaUveface angle specifications.

NEWVALVE 2(}4 VALVETIP 2(}5 KEY GROOVE 2(}6 STEM=LEASTWORN SECTION

WORNVALVE 207 STEM-MOSTWORN SECTION 208 FACE 209 MARGIN

Valve Seat Grinding Reconditioning the valve seats is very important, because the seating of the valve.,; mustbe perfect for the engineto deliver the power and performance it was designed to produce.

DRC6523

Another important factor is the cooling of the valve head. Good contact betweeneach valve and its seat ensuresthat heat will be carried awayproperly. Several different types of equipmentare available for resurfacing valve seats. Carefullly follow the recommendationsof the manufacturer of the equipmentbeing used to attain proper results. Regardlessof what type of equipmentis used, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the pilot in the guide. Refer to EngineSpecification.,} in the proper engine repair section for valve seat angle specifications. Reaming Valve Guides The valve guides used in engines covered by this manual are simply holes bored into the cylinder head. The valve guides are not replaceable. If the valve stem-to-bore clearance as previously measuredis excessive, the valve guides should be reamedand a valve with an oversize stem installed. Oversize valves are available. Refer to Engine Specifications in the proper engine repair section. E~ Select a reamer that will provide a straight, through the entire length of the valve guide.

Eng~ne/eng

2-17

clean bore

DRC8524

Assembly Valves and components.Refer to the proper engine repair section. ~]

®

Measure:

Valve spring installed height of each valve spring as follows: [~] 1. Valve installed height using a narrowthin scale. A cutaway scabe ~ may be helpful [~ 2. Spring seat in the cylinder head to the top of the valve spring cap. E~ 3. Certain engine applications use valve spring shims to adjust valve spring installed height. If measurement® exceeds the amountshownin EngineSpecifications in the proper engine repair section, install valve spring seat shimsof sufficient thickness (between the spring and cylinder head) to obtain desired measurement.NEVER shim the spring so as to give an installed height under the specified amount.

Crankshaftand ConnectingRodBearings

DRC6667

@ DRC6668

Cleaning and inspection [~ Clean: 1. Crankshaft with solvent. ¯ Do not scratch the bearing journals ¯ Removeall sludge from the oil passages with compressed air 2. Crankshaft bearings. e Wipefree of oil with a soft cloth. [~ inspect: Crankshaft for cracks. ¯ Use the magnaflux methodif available. e Crankshaft, crankshaft bearing journals, and thrust surfaces for scoring, nicks, or damagecaused by lack of lubrication.

2-18

Engtne/eng

Crankshaft: bearings for scoring or other damage.Jn general, the lower crankshaft bearings (except the #1 bearing) showthe greatest wear and distress from fatigue. Uponinspection, if a lower crankshaft bearing is suitable for reuse, it can be assumedthat the upper crankshaft bearing is also satisfactory. If a lower crankshaft bearing shows evidence of wear or damage,both the upper and lower crankshaft bearings must be replaced. MeasuringBearing Clearance Crankshaft bearings are of the precision insert type and do not use shims for adjustment. If clearances are excessive, newupper and lower bearings with be required. Service bearings are avaiF able in standard size and undersize. Refer to Crankshaft arid Bearing Installation in the proper engine repair section. Selective fitting of crankshaft bearings are necessaryin productk~n to obtain close tolerances. For example, you may find one-half of a standard crankshaft bearing with one-half of an undersize crankshaft bearing. To determine the correct replacement bearing size, the bearing clearance must be measuredaccurately. Either of the following two methods may be used, however, the micrometer method £~ives morereliable results and is preferred. Micrometer

Method

~ 1. Measurethe crankshaft journal diameter with a micrometer in several places, approximately 90 degreesapart, and average the measurements. 2. Computetaper and runout. Refer to Engine Specifications in the proper engine repair section for allowable limits. 3. Install crankshaft bearings into the crankshaft cap and engine block. 4. Install crankshaft caps and bolts. Tighten bolts to the Torque Specifications in the proper engine repair section. 5. Bearing inside diameter (I.D.) using an inside micrometer. 6. Comparecrankshaft bearing clearance specifications using Engine Specifications in the proper engine repair section. 7. If bearing clearancesexceedsspecifications, install newcrankshaft bearings. a. Measureinside diameter with an inside micrometer. Place the micrometerat 90 degreesto the split line of the crankshaft bearing.

Englne/eng

2-19

DRC6525

b. Subtract journal diameter from bearing inside diameter to obtain bearing clearance. Refer to EngineSpecifications in the proper engine repair section for bearing inside clearance. Replaceor repair the crankshaft if clearanceexceedsspecifications. Plastic GaugeMethod [~ 1. Install

/

all crankshaft bearings and crankshaft into block.

[~ Install the crankshaft bearing caps and torque them to specifications. Removethe bearing caps and check the amount the gauging plastic has been compressed. Gauging plastic may adhere to either the crankshaft bearing or crankshaft journal. 2. On the edge of the gauging plastic envelope there is a graduated scale. Without removing the gauging plastic, measure its compressedwidth (at the widest point).

DRC6526

t

3. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearanceindicating taper, nowspot or other irregularity of the bearing or journal. 4. Normally crankshaft bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround 0.001 in. (0,0254 mm)maximum journal, be sure to fit the maximum diameterof the journal. If the bearing is fitted to the minimumdiameter and the journal is excessively out-of-round, interference betweenthe bearing and the journaB will result in rapid bearing failure.

DRC6527

5. If the bearing clearanceis within specifications, the bearing is satisfactory, if the clearanceis not within specifications, replace the bearing. Always replace both upper and lower bearings as a unit. 6. A standard or undersize bearing combination mayresult in the proper clearance. If the proper bearing clearance cannot be achieved using standard or undersize bearings, it will be necessary to replace the crankshaft. Crankshaft bearings must not be shimmed, scraped or filed. Do not touch the bearing surface with bare fingers. Skin oil and acids wild etch the bearing surface. 7. Remove the flattened gaging plastic. 8. Measureremaining journals.

2-20

Englne/eng

Crankshaft Runout Tools Required: J 7872 Magnetic Base Dial Indicator MeasureCrankshaft: E3~] 1. Mountthe crankshaft in V-blocks at crankshaft journals 1 and 5. 2. Position a dial indicator pointer on the center mainbearing and rotate crankshaft. DRC6528

3, Refer to Engine, Specifications in the proper engine repair section for crankshaft runout specifications,

C, onnectingRodSide Clearance ~-~ Measure: E’$-’=] Connectingrod side clearance. Refer to Engine Specifications in the proper engine repair section for clearances

Crankshaft End Play L~

DRC652

Measure:

Crankshaft end play, as follows: I. Firmly thrust the end of the crankshaft first rearward then forward. This will line up the rear crankshaft bearing and crankshaft thrust surfaces. ES~2. With crankshaft wedgedforward, measureat the front end of the crankshaft bearing(thrust side) with a feeter gauge.Refer Engine Specifications in the proper engine repair section for crankshaft end play clearance. 3 If correct end play cannot be obtained, be certain that the correct size crankshaft bearing has been installed. Someproduction engines mayuse crankshaft bearings that are wider across the thrust faces than standard size bearings. Refer to Engine Specifications in the proper engine repair section for available bearing sizes.

Engme/eng

2-21

DRC6530

[~ Inspect: Crankshaftfor binding. Turn crankshaft to checkfor binding. If the crankshaft does not turn freely, loosen the crankshaft bearing bolts, onepair at a time, until the tight bearingis located. Burrs on the bearing cap, foreign matter between the bearing and the block or the bearing cap, or a faulty bearing could causea lack of clearance at the bearing.

Thread Repair Damaged threads may be reconditioned by drilling rethreading, and installing a suitable thread insert.

out,

DRC6572

Z~ Wearsafety gUassesto avoid eye damage. 1. Determinesize, pitch, and depth of damaged thread. If neces, adjust stop collars on cutting too[ and tap to required depth.

~

Important: Refer to the kit manufacturer’s instructions regarding the size of drill and tap to be used.

IT] 2. Drill

out damagedthread. Clean out chips.

[~] 3. Lubricate tap with light engine oil. Tap hole. Clean the thread. [-~ Important: Avoid buildup of chips. Sack out the tap every

DRC6573

few turns and removechips. 4. Threadthe thread insert onto the mandrelof the instalBer. Engagethe tang of the insert onto the end of the mandrel. [~ 5. Lubricate the insert with light installing in aluminum)and install. ~’~ Important: Whencorrectly

engine oil (except when

installed,

the insert should be

DRC6574

flush to one turn below the surface. 6. If the tang of the insert doesnot break off whenbackingout the installer, breakthe tang off with a drift.

DRC6575

2-22

Engme/eng

1

J 8087

J 24086-C DRC6576

DRC6577

DRC6579

Special Tools E~ Cylinder Bore Gauge E~ Piston Pin Replacer Set J 8089

E~==1 CamshaftBearing Remover / Installer DRC6580

E~ Wire Brush [==9~Dial indicator ~ Valve Spring Tester

[~ Ridge Reamer DRC6578

DRC6581

J 24270 2-23

DRC6582

NOTES

2-24

Eng,ne/eng

Section 3 3.0 GSEngines Table of Contents Camshaft .......................... Camshaft Bearings .................. Circulating Pump.................... Connecting Rod Bearings ............. Crankshaft ......................... Crankshaft Bearings ................. Cylinder Block ...................... Cylinder Head Assembly .............. Distributor Lower Bearing ............. Engine Coupler Replacement ........... Engine Specifications ................. Exhaust (Flapperl Valve Replacement.... Exhaust Hose Replacement ............ Front Engine MmJnt .................. Height Adjustment .................

3-14 3-16 3-32 3-19 3-18 3-20 3-27 3-6 3-31 3=40 3-42 3-39 3-38 3-35 3-37

General Motors Tools ................. High-Rise Exhaust Elbow RepJacernent... Hydraulic Valve Lifter ................. Intake~Exhaust Manifold .............. OU Fi0ter Bypass Valve ................ Oil Pan Replacement ................. Oil Pump .......................... Oil Seal Replacement, Rear Main Bearing Oil Seal Retainer Replacement ......... Piston Rings ........................ Piston a~d Connecting Rod ............ Timing Gear Cover ................... Torque Specifications ................. Valve Lash Adjustment ............... Valve Spring and Seal Repair ...........

Before removing cooling system hoses, it may be neces= sary to removeboat from water to prevent flooding boat.

Safety Warnings Before working or= any part of the engine, read the section called Safety at the end of this manual. Unless instructed otherwise, always disconnect the battery cables from the battery before working on electrical system to prevent possible sparks or arcing in the engine compartment. Before starting engine after repair or maintenanceprocedures, always makesure engine compartmentis free of fuel vapors to prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the a0ternator, power steering, supply pumpand circulating pumpbelts, pulleys and other moving parts.

Engme/eng

3-1

3-2 3-37 3-4 3-3 3-35 3-32 3-33 3-23 3-23 3-25 3-23 3-12 3-45 3-5 3-5

Genera/Motors Tools Part Number Air Line Adaptor ........................................... Bolt Guide Set ........................................... CamLobe Lift Indicator ....................................... Camshaft Bearing Removerand Installer ...................... Carbon Remover Brush ...................................... Crankshaft Gear Installer ..................................... Cylinder Bore Checker ....................................... Distributor Bearing Installer ................................... Distributor Bearing Remover................................ Piston Pin Tool ............................................. Piston Ring Tool ............................................ Rear Crankshaft Seal Installer ................................ Rocker Arm Stud Hole Reamer(0.003 Oversize) .................. Rocker Arm Stud Hole Reamer(0.013 Oversize) .................. Rocker Arm Stud Installer ..................................... Rocker Arm Stud Remover ................................. Timing Cover Tool .......................................... Valve Guide Cleaner ......................................... Valve Guide ReamerSet ................................... Valve Seal Tester ........................................... Valve Spring Compressor ..................................... Valve Spring Compressor ..................................... Valve Spring Tester .......................................... Vibration Damperand Crankshaft Gear Remover................

J-23590 J-6305-01 J-8520 J-6098-01 J-8089 J-5590 J-8087 J-9535 J-9534-01 J-24086 J-8037 J-35621 J-5715 J-6036 J-6880 J-5802-01 J-23042 J-8101 J-5830-02 J-23994 J-5892 J-8062 J-8056 J-6978-E

Order Directly from: Kent-MooreTool Division 28635 Mound Road Warren, M148092800-345-2233 Price and ordering information are available from Kent-Moore Tool Division.

Material Required Molykote Lubricant Volvo Penta Gasket Sealing CompoundP/N 1161231-4 Permatex~ No. 2 GMSuperEngine Oil Supplement PlastigageTM(G teen) DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil For additional service information not coveredin this manual,obtain the appropriate ChevroletEngineService Manualfrom: HelmInc. P.O.Box 07130 Detroit, M148207

3-2

Eng[neleng

Intake/E×haust Manifold Removal 1. Disconnect battery cables at battery. Removethrottle cable from anchor block and actuating bracket. 2. Drain water from block and exhaust manifold (see Cooling SystemSection in this manual). 3. Removecarburetor from intake manifold. FolBowthe instruc-. tions in Fuel SystemsService Manual. EI~ 4. Disconnect water hose (~ running between manifold end cap and thermostat housing. E2~ 5. Removealternator

and mounting bracket ®.

E3~] 6. Loosen upper hose clamps © securing exhaust hose to high rise elbow. Loosen and remove screws and lock washers @ securing elbow to manifold and removethe throttle linkage plate and elbow. 7. Removefour bolts, two nuts and lock washers securing manifold to cylinder head, then pull manifold off of head. Discard gasket.

45375

8. Clean all gasket surfaces of cylinder head and manifold and check for cracks on the manifold casting. Installation 1. Position a newgasket over the manifold studs on the head. Use a gasket sealer if leakage has occurred. Carefully install the manifold in posith)n making sure that the gasket is correct,ly placed. 2. Install nuts, bolts and washerswhile holding the manifold iin place. Tighten borers and nuts finger tight, then alternately tighten to 20-25 ft. Ibs. (27-34 N.m) working from the center towards the ends. 3. Apply gasket sealer to a newelbow gasket and place it on the manifold. Pushthe eJbowinto the exhaust hose, then install the elbow, throttle linkage plate, lock washers, and screws. Tighten tlhe screwsto 12-14 ft. Ibs. (16-19 N.m). [~ 4. Install carburetor using a new mounting gasket following the instructions in Fuel SystemsService Manual. Install water hose from thermostat housing to manifold ~.

34727

[~ 5. Install aPternator with mounting bracket ~. Tighten screws ® to 26-30 ft. Ibs= (35-41 N.m).. Reset belt tension following the procedures found in the General mnformationsection of this manual. Tighten the alternator screws© to 26-30 ft. Ibs. (35-41 N.m). 6. Reconnect throttle cable to anchor block and actuating bracket. Securewith cotter pin. Z~ 7. Connectbattery cables. Start engine and check for fuel leaks. 45376

HydraulicValve Lifter RemovaU 1. With air hose and cloths, clean dirt from cylinder head and adjacent parts to avoid getting dirt into engine, it is extremely important that no dirt gets into the valve Bifters. 2. Disconnect ventilation hose, fuel line, and fuel pumpoverflow hose. Removecircuit breaker bracket. Removerocker arm cover. 3. Loosenrocker arm nuts and pivot the rocker arms free of the push rods. 4. Disconnect spark plug wires at plugs. Remove high tension lead from coil. Removeboth connectors from coil. Removecoil and mounting bracket from cylinder head. [~ 5. Removeboth connectors at distributor. Take off cap, note distributor rotor position and removedistributor. (Mark distributor housing and block with chaUkat point of rotor.)

ROTATING - NORMAL, OK- NOTROTATING

6. Fromrear of block, take out screwsthat mountthe shift bracket assembly and move bracket away from push rod cover. 7. Removepush rod cover and gasket. 8. Remove pushrods and lift out vaBvelifters that require service. Place lifters in a woodenblock having numberedholes, or use other suitable meansof identifying them according to original position in the engine. 9. If less than a completeset of lifters is being removed,immediately disassembleand inspect one or two for presence of dirt or varnish. If lifters contain dirt or varnish, it is advisableto replace all lifters. Otherwise,it will be satisfactory to service only those lifters that are not operating properly.

GALLED - SHOULD 8E REPLACED - SOFT,WORN

860000

[~ 10. Examinethe cam contact surface at lower end of lifter body. If this surface is excessively worn, galled or otherwise damaged,discard the lifter assembly. In this case, also examine the mating camshaft lobe for excessive wear or damage.

SafetyRelated

3-4

Englne/eng

I:nstallation ["~ Before installing any new lifters, lifter with Molykoteor its equivalent.

coat the bottom of each

1. Rnstall valve lifters in cylinder block, if anynewlifters or a new camshaft has been installed, an additive containing EPlubricant such as GMEngine Oil Supp/ement must be added to the crankcaseoil for break-in. 2. Install pushrods onto lifters new gasket.

and install pushrod cover with a

3. Install distributor {position rotor to markon housingandblock). install coil and bracket. Connectboth connectorsto coil. Install distributor cap and attach spark plug and coil wires. Connectbol:h connectorsto distributor. 4. Install shift bracket assembly. 5. Pivot rocker arms in place and turn adjusting nuts the amount necessaryto elimh~ate lash.

Valve Lash Adjustment Adjust valve lash whenlifter

is on basecircle of camas follow,J:

1+ Remove distributor cap and crank engine until distributor rotor points to numberone cyninder terminal. In this position the piston in numberone cylinder is at top center on compressionstroke. Both lifters are on base circle of cam and both valves can be adjusted. E3~] 2. Turn adjusting nut until all lash is removedfrom valve train. This can be determined by checking push rod side play by hand while turning nut slowly. At this point, turn adjusting nut one moreturn to place the lifter plunger in center of its travel. 3. Follow steps 1 and 2 for each cylinder following firing order sequenceand adjust remaining valve one cylinder at a time. No further adjustment is necessary. ENo-~Do not attempt to turn the adjusting nut one full turn while the engine is operating. Adjustmentin this mannerwill not allow the lifters to bleed down.This wouldresult in valve train damage, probably bent push rods. For those whoprefer to adjust the valve lash while the engine is running, the preferred methodwould be to find the "zero lash" point as described aboveand then slowly 1urn the adjusting nut V+ turn. Wait for the lifter to bleed down (several engine revolutions) and again turn adjusting nut V+ turn. Continuethis adjust-and-wait cycle until nut is one completeturn down from "zero lash" point. Repeat sequence on remaining V;3[ves.

En ~,ne/eng

3-5

4. Install rocker cover gasket and cover. Connectfuel line and fuel pumpoverflow hose to carburetor. 5. Install hose.

circuit breaker bracket. Connectcrankcaseventilation

Z~ 6. Start engineand checkfor oil or fuel leaks and Jisten for lifter noise. Checkenginetiming.

Valve Spring and Seal Repair Refer to 5.7 GL, GSand Gi EngineSection for procedure.

Cylinder Head Assembly The condition of the cylinder head and va6ve mechanismsignificantly determines the power, performance and economyof the valve-in-head engine. Extreme care should be exercised when conditioning the cylinder head and valves. Maintain correct valve stem to guide clearance, correctly grind valves and valve seats, and properly adjust valves. Removal 1. Removeintake and exhaust manifold as described under heading Intake/E×haust Manifold. 2. Disconnect coolant hoses at thermostat housing. Disconnect spark plug wires and removespark plugs. 3. Disconnect fueN line retaining clips at thermostat housing and cylinder head. Disconnect wire harness from the temperature sending unit, leaving harness clear of clips on rocker arm cover. Removethermostat housing assembly from front of cylinder head. Disconnect fuel line at the fuel pumpand remove. 4. Removethe rocker arm cover. Next, back off the rocker arm nuts and pivot the rocker arms to clear the push rods. Remove the push rods.

860002

5. Remove the ignition coil and bracket. 6. Removethe cylinder head bolts, cyRinder head, and gasket. Place the cylinder head on two blocks of woodto prevent damage to the head. Disassembly E~ 1. Removerocker arms nuts, ball seats and rocker arms. Use tool J-8062, compressthe valve springs and removevalve stem keys. Release the spring compressor tool and remove exhaust valve rotator or intake valve cap, shield, spring and seals.

SafetyRelated

3-6

Engme/eng

2. Removevalves from bottom of cylinder head and place them in a rack in their proper sequenceso they can be assembledin their original positions.

"....

Cleaning [i~ 1. Clean aH carbon from combustion chambers and varv’e ports using tool J-8089. inspect the cylinder headfor cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber. Clean carbon deposits from head gasket mating surfaces. [-3~ 2. Thoroughly clean the valve guides using tool J-810’1. Clean all carbon and sludge from push rods and rocker arms.

N

860003

:3. Clean valve stems and heads on a buffing wheel. Inspect the valve for burned head, worn seat, cracked faces, or damaged stems. 4. Washall parts in cleaning solvent and dry them thoroughly. Checkfit of valve stemsin their respective bores. 5. Measurevalve stem clearance as follows: Clampa dial indicator on one side of the cylinder headrocker armcover gasket rail, locating the indicator so that movementof the valve stem from side to side (crosswise to the head} will cause a direct movementof the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide. With the valve headdroppedabout 1/10 in. offthe valve seat; movethe stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceedsspecifications it will be necessaryto reamvalve guides for oversize valves as outlined.

860004

Excessive valve stem to bore clearance will cause lack of power, oil consumption, rough idling and noisy valves, and may cause valve breakage. Insufficient clearance will result in noisy and sticky functioning of the valves and disturb engine smoothness of operation. Intake and exhaust valve stem to bore clearance should be 0.001-0.0027 in. (0,025-0,007 ram). By using micrometer and a suitable hole gauge, check the diameter of the valve stem in three, places; top, center and bottom. Unsert hole gauge in valve guide bore, measuring at the center. Subtract highest reading of valve stem diameter from valve guide bore center diameter to obtain valve to valve guide clearance. If clearance is not within limits use next oversize valve and ream bore to fit using suitable reamer. []~ 6. Checkvalve spring tension with tool J-8056 spring tester. [~tet~ Onall models, springs should be compressed to 12V32in. at which height it should check 78-86 pounds(35,5-39,0 kg). Weak springs affect power and economyand should be replaced if below 70 pounds. (31,8 kg)

En§jme/eng

3-7

86OOO5

\

86(}O06

7. Checkvalve Jifters for free fit in block. Theendthat contactsthe camshaft should be smooth. If this surface is worn or rough, the lifter should be replaced. If lifter is damaged,check the corresponding camshaft lobe for damage. Repair [~ 1. Valve Guide Bore: Valves with oversize stems are available for inlet and exhaust valves in the following sizes: 0.0003 in., 0.015 in., and 0.030 in. Use the 11/32 in. diameter reamer sizes from reamer tool set J-5830-02 which are: J-4822 standard; J-5830-1,0.003in oversize, J-5830-2, 0.015 in. oversize and J-5830-3, 0.030 in. oversize to ream the bores for the new valves.

f l

2. Rocker Arm Studs Rocker arm studs that have damagedthreads may be replaced with standard studs. If the studs are loose in the head, oversize studs (available in .003 in. or .013 in. oversize) maybe installed after reaming the holes as follows: Do not attempt to install stud hole.

860007

oversize stud without reaming

Remove old stud by placing tool J-5802-01 over the stud. InstaUb nut and flat washer, and removestud by turning nut. b. Reamhole for oversize stud. Use tool J-5715 for 0.003 in. oversize and tool J-6036 for 0.013 in. oversize. E~

C.

Coat press-fit area of stud with a hypoid axle Jubr[cant. Install newstud using tool J-6880. Tool should bottom on head.

3. Valve Seats: Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the powerand performancebuilt into it. Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve headwill be properly carried away.

86OOO8

Several different types of equipmentare available for reseating valve seats; the recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results.

3-8

860009

Engme/eng

Regardless of what type of equipment is used, however, it is essential that valve guides be free from carbon or dirt to ensure proper centering of pilot in the guide. a. lnstall expanding pilot in the valve guide bore and expandpilot by tightening nut on top of pilot. bo

Place roughing stone or forming stone over pilot and just clean up the valve seat. Usea 46° stone for both the inlet and exhaust valve seats. Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smoothfinish.

860010

d. Narrowdownthe valve seats to the proper width for the intake and exhaust. See Engine Specifications. °This operation is doneby grinding the port side with a 30 stone to lower seat: and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. Eh~ ~ Valve seats should be concentric to within 0.002 in. total indicator reading. 4. Valves: Valves that are pitted can be refaced to the proper angle, ensuring correct relation between the head and stem on a valve refacing machine. Valve sterns which showexcessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be groundon part or a[ll of the valve headdue to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this k~[fe edge. If the edgeof the valve headis less than 1/32 in. thick after grinding, replace the valve. a.

If necessary, dress the valve refacing machinegrinding °wheelto makesure it is smoothand true. Set chuck at45 mark for grinding valves.

b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheelby movingthe lever to the left. d.

Er,~;me/eng

Turn the feed screw until the valve head just contacts wheel. Movevalve back and forth across the wheel and regulate the feed screw to provide light valve contact.

3=9

8600~1

e. Continuegrinding until the valve face is true and smooth all around valve. If this makesthe valve thin the valve must be replaced as the valve will overheat and burn.

®

f. Removevalve from chuck and place stem in "V" block. Feedvalve squarely against grinding wheel to grind any pit from rocker arm end of stem. Only the extreme end of the valve stem is hardened to resist wear. Do not grind end of stem excessively. g. After cleaning valve face and cyDinder head valve seat of grinding particles, makepencil marksabout 1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve.

860012

Remove valve and checkface carefully. If all pencil marks have not been removedat the point of contact with the valve seat, it will be necessary to repeat the refacing operation and again recheck for proper seating. i. Grind and check remaining valves in the samemanner. 860013

Assembly [~ 1. Starting with number one cylinder, place the exhaust valve in the port, and place the valve spring (~) and cap ® position. Place spring and cap on exhaust valves. Then, using tool J-8062, compressthe spring and install the oil seal @and valve keys @.Seethat the seal is flat and not twisted in the valve stem groove and that the keys seat properly in the valve stem groove. Place valve springs in position with the closed coil end toward the cylinder head. 2. Assemblethe remaining valve, valve springs, spring caps, oil seals and valve keys in the cylinder headusing tool J-8062. Check seals by placing a vacuumcup over valve stem and cap, squeeze vacuumcup to makesure no oil leaks past oil seal.

860014

[~ 3. Check the installed height of the valve springs using a narrow, thin scale to measurefrom the top of the shim or spring seat in the head, to the top of the valve spring shield. If this is found in excess of 12s/s2 in., install a valve spring seat shim, approximately 1/16 in. thick. At no time should the spring be shimmed to give an installed height of less than 121/32 inch. If springs are to be changedwith cylinder head installed, refer to Valve Spring and Seal Repair, in 5.7 GL, GSand Gi Engine Section.

3-10

860015

Engme/eng

I. Thegasket surface,,; of both the headand the block mustbe clean and free of any foreign matter, andfree of nicks or heavyscratches.

REAR

2. Cylinder headbolt threads in the block mustbe cleanedas well as the threadson the cylinder headbolts. Dirt will affect bolt torque. E3--’] 3. Placea newcylinder headgasketin position over the dowelpins in the cylinder block. Onengineswith a steel gasket coat both sides of a new gasket with a thin, even coat of Volvo Penta Gasket Sealing Compound P/N 1161231-4.Too muchseater will hold the beadsof the gasket awayfrom the block or head. [_No~~The 3.0 Litre engine has a specia, marine head gasket. Do not substitute an automotiveheadgasket. E~ 4. Carefully guide cylinder headinto place over dowel pins and gasket. Coat threads of cylinder headbolts with PermatexNo. 2 P/N 910032.Install the bolts and run themdownto the block. ES-~5. Tighten the cylinder headbolts, with a torque wrench,in three progressive steps following the sequenceshown. ¯

Step 1 -35ft. Ibs. (47 N m)

® Step 2 - 65 ft. Ibs. (88 N.m) ® Step3 - 95 ft. Ibs. (129N.m) 6. Install valve push rods downthrough openingsin the cylinder headand seat themin lifter sockets. E~7. Install rocker arms, balls and nuts and tighten rocker arm nuts until all pushrod play is taken up. 8. Install thermostathousingusing a newgasket. Attach coolant hoses.

FRONT

9. Cleanall spark plugs with abrasive-typecleaner, inspect for damage (replace if necessary)and set the gap at 0.045 in. (1,14 mm)using a gauge.Install the sparkplugs. Tightenspark plugsto 20 ft. Ibs. (27 N.m).

860016

10. Install coil andconnectboth connectorsto coil. Connectwire to terrperature sendingunit. 11. Cleanmanifold gasket surfaces and install newgasket over manifold studs, Position manifoldand slide it into placeover the studs, makingsure it seats against the gasket. Install bolts and nuts and tighten as described under heading lntake/Fxhaust Mar=ifond.

’,..LC4

860017 Eng,ne/eng

3-11

12. Adjust valve lash as outlined under heading Valve Lash Adjustment. JnstaJl rocker arm cover and gasket. Tighten screws to 65 in. Ibs. (7,3 N.m)= 13. Connectthrottle linkage and adjust. 14. Connectfuel line and overflow hose to carburetor and install fuel line support clamps(two). Clean and install flame arrestor. Z~ 15. Start engine and check for fuel, coolant, and exhaust leaks.

Timing Gear Cover Removal 1. Drain coolant from block and exhaust manifold. Z~ 2. Securely support engine and removefront engine mount. 3. Removealternator and power steering beJts. Next remove harmonic balancer and pulley assembly from pulley hub. [~ 4. Install puller tool J-6978-Eto pulley hub with three 3/8-24 x 2 in. bolts and removehub. Removepuller tool. 5. Removecirculating

860019

pumppuIRey.

6. Removecrankcase oil drain tube cap and withdraw oil with a suction pump. Disconnect oi~ drain tube and removeoil pan. 7. Removetiming gear cover attaching screws. Removecover and gasket. OiR Seal Replacement 1. After removingtiming gear cover, pry oil seal out of cover from front with a large screwdriver. E~2. Install newlip seal with tip (open side of seal) facing inside of cover, and drive or press seal into place with tool J-23042. 860O2O

Oil Nozzle Repmacement E~] Removeold nozzne with pliers. Drive new nozzle in place using a suitable 6ight plastic or rubber hammer.

SafetyReJated

3-12

Englne/eng

TimingGear Coverinstallation 1. Clean gasket surface on block and cover. 2. Install centering tool J-23042over end of crankshaft. 3. Coat both sides of a newgasket with a light grease, and stick gasket in position on block. [~4~ 4, Place cover over centering tool and install cover screws. Tighten screws to 80 in. Ibs. (9 N.m) and removecentering tool. 868022

5. Install oil pan using newgaskets. Tighten 1/4-20 inch screwsto 80 in. Ibs. (9 N.m). Tighten s/i6-18 inch screwsto 165 in Ibs. (18,6 N,m). 6. Connectoil drain tube to oil pan. HarmonicBalancer instagation ~ [~ I. Coat oil seal contact area on harmonic balancer with engine oil. Position hub over crankshaft and key, and start hub into position with a mallet. Using tool J-5590, drive hub onto crankshaft until it bottomsagainst crankshaft gear.

fi

[~.ot----~ Crankshaftextendsslightly through hub and a hollow tool is necessary to driw~ hub completely into bottomedposition. FN°t~ 2. There are two 3/8 in. holes and one %6in. hole that must be matchedon hub in order to properly position timing mark. 3, Install circulating pumppulley. 4. install alternator’ specifications.

and power steering belts and adjust to

5.. Install front enginemount.

860023

6, Fill engine crankcasewith proper amountof oil. 7rr Lakeor tank test unit and checkfor leaks°

860024

Engme/eng

3-13

Camshaft MeasuringCamshaftLift Removeboth connectors from ignition

coin.

If improper valve operation is indicated, measurethe lift push rod in consecutive order and record the readings.

of each

1. Removevalve cover and rocker arms. [~ 2. Position indicator with bali socket adapter (Tool J-8520) push rod. 3. Rotate crankshaft slowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position. 4. Set dial indicator on zero. Rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the pushrod is in the fully raised position. 5. Comparethe total lift recorded from the dial indicator with specifications. Thecorrect nift is 0.253 inch - 0.005 inch (6,426 0,127 ram). 6. Continueto rotate the crankshaft until the indicator reads zero. This "will be a check on the accuracy of the original indicator reading.

860028

7. If camshaft readings for all lobes are within specifications, removedial indicator assembJy.Install and adjust valve mechanism. Removal 1. Withdraw oil from crankcase. Drain coolant from block and exhaust manifoBd. 2. Removevalve cover and gasket. Loosenvalve rocker arm nuts and pivot rocker arms clear of push rods. 3. After noting position of rotor, removedistributor. 4. Removecoil, valvelifters.

side cover, and gasket. Removepush rods and

5. Removecrankshaft pulley and hub. Disconnect oil drain tube. Removeoil pan and timing gear cover. [~J 6. Removetwo camshaft thrust through holes in camshaft gear.

plate screws by working

3-14

860027

~Q,o~en~

7. Removethe camshaft and gear assembly by pulling through the front of the block. Support shaft carefully damagecamshaft bearings.

it

out

when removing so as not to

inspection The camshaft has three bearings, all with the same journal diameter of 1.8692 in. to 1.8682 in. (4,7478 to 4,7452 cm). These dimensions should be checked with a micrometer for an out-ofround condition. If the journals exceed 0.001 in. (0,025 mm) out-of-round, the camshaft should be replaced. The camshaft should also be checked for alignment. The best methodis by use of "V" blocks and a dial indicator. The dial indicator will indicate the exact amountthat the camshaftis out of true. If it is out morethan 0.002 in. (0,051 ram) dial indicator reading, the camshaft shound be replaced. Whenchecking, the h:gh reading of the dial indicator indicates the high point of the shaft. Examinethe camshaft bearings and if any bearing needs replacement, repnaceaIB bearings. Gear and Thrust Plate r~]~] If the inspection indicated that the camshaft,gear and thrust plate were in good condition, the camshaft end play should be checked.This clearanceshould be 0.001 in. to 0.005 in. (0,025 to 0,127 ram). Disassembly E4~if the inspectiotn indicated that the shaft, gear or plate should be replaced, the gear must be removedfrom the shaft. Support the camshaft gear and press shaft out of gear. [~ot~ Thrust plate must be positioned so that woodruff key in shaft doesnot damageit whenshaft is pressed out of gear. Also, support the hub of the gear orthe gear will be seriously damaged. Assembly T(:~ assemblecamshaftgear, thrust plate and gear spacer ring to camshaft, proceed as follows: 1. Firmly support shaft at back of front journal in an arbor press. Place gear spacer ring and thrust plate over end of shaft, and install woodruff key in shaft keyway. 2. Install camshaftgear and press it onto the shaft until it bottoms against the gear spacer ring. Theend clearanceof the thrust plate should be 0.001-0.005 in. (0,025-0,127 mm)

Engrt3e/eng

3-15

860028

CamshaftBearings RemovaJ Camshaftbearings can be replaced while the engine is disassembled for overhaul, or without compUetedisassembly of the engine after camshaft and flywheel have been removed. Operation is easier if crankshaft is also removed. See Crankshaft in this section. 1. With camshaft and flywheel removed,drive out expansion plug for rear cambearing by driving from inside.

860030

2. Position bearing pilot in inner bearing, install nut on puler screw far enoughso puller screw can be threaded into pilot while nut extends out front of block. 3. Install removersection onto puller screw, and then install screw through cambore and thread it into pilot. [~ 4. Using two wrenches, hold screw shaft and turn puller nut to removebearing. r"-R~ 5. Removepilot from shaft and install on drive handle with shoulder to handle. Drive out front and rear bearings from outside to inside of block.

v

|nstalation Inner bearing should be installed first bearing with screw shaft.

860031

to prevent damagingend

Bearing O.D.’s for number one and number two are 1.999-2.001 in. (5,077-5,083 cm) and numberthree is 2.009-2.011 in. (5,103-5,108cm). 1. Remove handle from pilot, install inner bearing on pilot. 2. Position inner bearing and pilot to rear of inner bearing bore= Install screw shaft (with removeradapter on it) through the block from front of engine into pilot. 3. Align oil hole on bearing with ol hole from oii gallery. Snug puller nut against adapter.

C.E ¯
IL.

.

//

!

’~

[~ 4. Using two wrenches, hold screw shaft and turn puller nut to pull bearing into place. Oil hole is on top side of bearing and cannot be seen during instalation. First align bearing oil hole with oil hole in bore, and mark opposite side of bearing and block at bore to easily index oil hole during installation.

3-16

860032

Engme/eng

5. Attach drive handle to pilot, beating on pilot.

then place new number one

[~ 6. Align oil hoh~on bearing with oil hole from oil gallery and drive bearing in from front of engine. I-~Z] ~ The front bearing must be driven approximately 1/8 in. behindfront of cylinder block to uncoveroil hole to timing gear oil nozzle. 7. Repeatstep (5) and (6) aboveto drive rear bearing into position from rear of block.

860033

I~_°t~i Rearbearing installed position is flush with inner edgeof rear cambearing bore. 8. Install a newexpansionplug at rear beating. CamshaftInstallation 1. if crankshaft has been removed,instaU it at this time. Follow procedures under the title Crankshaft in this section. If a new camshaft is to be installed, coat cam lobes with G.M. Super Engine OilSupplement(G.M. P/N 1051858) and add rest of can to crankcaseoil.

880034

2. install the camshaftassemblyin the engine block, being careful not to damagebearings or cam. [~] 3. Turn crankshaft and camshaft so that the valve timing marks on the gear teeth will line up, then push camshaft into position. Install camshaftthrust plate to block screwsand tighten themto 72-90 in. Ibs. {8-10 N.m). E~-] 4. Check camshaft and crankshaft gear runout with a dial indicator. The camshaft gear runout should not exceed 0.004 in. (0,102 mm)and the, crankshaft gear runout should not exceecl 0.003 in. (0,076 mm).

880035

5.. If gear runout is excessive, the gear will haveto be removed, and any burrs cleaned from the shaft or the gear replaced. [~] 6. Check the backlash betweenthe timing gear teeth with a narrow feeler gaugeor dial indicator. The backlash should not be less than 0.004 in. (0,102 mm)nor morethan 0.006 in. (0,152 ram). 7. hstall timing gear cover with newgaskets. Install newgaskets and sealer. Connectoil drain tube.

oil pan with 860036

8. Install harmonicbalanceras describedundertitle TimingGear Coverin this section.

Engtr~e/er~g

3-17

9. Install valve lifters and pushrods. Install side cover with a new gasket and sealer. Attach coil and wires. Install distributor, positioning rotor to reference mark. 10. Pivot rocker arms over push rods. Adjust valve lash as outlined under heading Valve Lash Adjustment. 11. Add oil to engine, install the alternator and power steering belts, then adjust tension. Checkand adjust timing.

Crankshaft Removaland Unstallation 1. Removemain bearing caps and connecting rod caps and lift crankshaft out of cylinder block. Pushpistons to top of bores. 2. Inspect the crankshaft: Main bearing journals are ground to 2.2983-2.2993 in. (5,83775,8402 cm). Crankpin journals are ground to 2.099-2.100 in. (5,331-5,334 cm). These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in. (0,025 mm)out-of-round or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings. The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the front center and rear center journals using a dial indicator. The runout limit of eachof thesejournals is 0.002in. (0,051 ram). If the runout exceeds 0.002 in. (0,051 mm), the crankshaft must repaired or replaced. 3. Removerear main bearing oil seal. 4. Removeold bearings from cylinder block and caps. hstall new bearings in the cylinder block and caps. [~ Main bearings with oil holes are the upper halves of the bearings and are inserted between the crankshaft and cylinder block. 5. Oil crankshaft journals and carefully place the crankshaft in the bearings.

3-18

Engme/eng

& InstaIB all bearing caps and bolts. Tighten all mainbearing cap bolts, except the rear mainbearing, to 60-70ft. Ibs. (81-95 N.m). Whentightening rear main bearing cap, tighten botts to 10-12 ft. Ibs. (14-18 N.m)first, then tap end of crankshaft rearward with lead hammer(this will locate bearing cap and bearing). Thenta0 crankshaft forward (this will line up both upper and lower crankshaft bearing thrust surfaces). Proceedwith final tightening of rear main bearing cap bolts to 60-70 ft. Ibs. (81-95 N.m). 7. Checkmain bearing clearance and crankshaft end play. Install newrear bearing oil seal. Unstall connecting rod bearings and caps.

Connecting Rod Bearings Connecting rod bearings are available in standard sizes and undersizesof 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (0,025, 0,,051, 0,254, 0,508 mm). These bearings are not shimmedand when clearances becomeexcessive the next undersize bearing should be used. ~ Do not file

rod or rod caps.

Removaland Inspection 1. Withdrawoil, disconnect oil drain tube and removeoil pan. 2. Removethe connecting rod bearing cap. Wipe bearing and crankpin clean of oil. 860037

D=] 3. Place a piece of Plastigage gaugingplastic the full width of the bearing on crankp[n (parallel to the crankshaft). 4. Reinstall the bearing cap and evenly tighten the retaining nuts to 35 ft. Ibs. (47 N.rn). ~ot-~ Do not turn crankshaft with the gauging plastic installed. E~ 5. Remove the bearing cap and, without removing the gauging plastic, check its width at the widest point with the PI astigagescale. ~=ot~ If the crankpin is out-of-round be sure to fit the bearing to the maximum diameter of the crankpin. If the flattened plastic is not uniform from end to end in its width, the crankpin or bearing is tapered, has a low spot or someother irregularity. Checkthe crankpin with a micrometer for taper if the flattened gauging plastic indicates morethan 0.001 in. (0,025 ram) difference.

860038

Engme/eng

3-1g

6. If the readingis not over 0.0009in. (0,0229ram) or not less than 0.0014 in. (0,0356 ram) the fit is satisfactory, tf however, the clearances are not within these limits, replace the bearing with the proper undersize bearing. The bearings are not adjustable and no attempt should be madeto adjust by filing or shimmingthe bearing caps. Installation Newbearing clearance should be 0.00085-0.00135 in. (0,021590,03429 ram). 1. Rotate the crankshaft after bearing adjustment to be sure the bearings are not too tight. EEl 2. Check connecting rod end clearance between connecting rod cap and side of crankpin. See Engine Specifications for clearance. 3. Install oil pan with newgaskets and seals. Connectoil drain tube. Refill with engineoil. Crankshaft

Bearings

The main bearings are of the precision insert type and do not utilize shims for adjustment, ff the clearances are found to be excessive, a new standard or oversize bearing, both upper and lower halves, wiJl be required. [~ if, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirements will be determined by bearing clearance. The clearance may be checked by using Piastigage gauging plastic. Whenone bearing is being checked, all the other main bearing caps must be in place and tightened to specifications. The main bearings used as service replacement are of high qua(ity with close tolerances of fit and will not require line reaming on installations. The close dimensional tolerances ensure an equalized bearing surface at all points on the crankshaft whenreplaced in sets. Main bearings may be replaced without crankshaft.

removing the

1. Withdraw oil from crankcase. Disconnect oil drain tube. Removethe oil pan.

3-20

Engme/eng

2. Removethe spark plugs. 3o Removecap on main bearing requiring replacement and remove bearing from cap. Install a main bearing removing and installing tool in the oil hole in the crankshaft. ~ot~ Usetool J-6098-01. ff such a tool is not available, a cotter pin maybe bent as required to do the job. 4. Rotate the crankshaft clockwise as viewedfrom the front of the engine. This will roll upper bearing out of engine. 5. Oil newupper bearing and insert plain (unnotched) end of the bearing betweencrankshaft and indented or notched side. Rotate the bearing into place. 6. Install new bearing in bearing cap. The rear main bearing journal has no oil hole drilling. To removethe upper bearing half proceed as follows after cap is removed: a. Use a small drift punch and hammerto start the bearing rotating out of block. E~ b. Usea pair of pliers to hold the bearing thrust surface to the oil slinger, and rotate the crankshaft to pull bearing out. C,

d®

To install, start the bearing (side not notched) into notchedside of block by hand, then use pliers as before to turn bearing half into place. Thelast 1/4 in. movement maybe done by holding just the slinger with pliers (taped jaws) or tap in place with a drift punch.

7. Check bearing clearance per paragraph below. Main Bearing Clearance Plastigage gaugingplastic is a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface. To obtain the most accurate results with gauging plastic, certain precautions should be ob-. served, ff the engine is upside down, the crankshaft will rest on the upper bearings and it can be assumedthat the total clearance can be measuredbetween the cap bearing and journal. ~__°t-"~l To ensure the proper seating of the crankshaft, the rear main bearing oil seal should be removedand all bearing cap bolts, should be at their specified torque, in addition, preparatory to checkingfit of bearings, the surface of the crankshaft journal and bearing should be wiped clean of oil. 1. Starting with the rear main bearing, removebearing cap. [~ Wipe oil from journal gauging plastic.

E..i,~/~.~

and bearing cap before applying

3-21

860040

2. Place a piece of gauging plastic the full bearing (parallel to the crankshaft) on the journal.

width of the

Do not rotate the crankshaft while the gauging plastic is between the bearing and journal.

\

3. Install the bearing cap and evenly tighten the retaining bolts to 60-70ft. Ibs. (81-95 N.m). 4. Removebearing cap. The flattened gauging plastic will be found adhering to either the bearing or journal. Onthe edge of gauging plastic packing envelope there is a graduated scale measuring in thousandths of an inch.

860041

[~ 5. Without removing the gauging plastic, check its compressed width (at the widest point) with the graduations on the gauging plastic envelope. [~ Normally, main bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround journaB be sure to fit to the maximumdiameter of the journal. If the bearing is fitted to the minimumdiameter of the journal, and the journal is out-of-round 0.001 in. (0,025 mm) more, interference betweenthe bearing and journal will result in rapid bearing failure. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating a taper, low spot, or other irregularity of the bearingor iournal. Be sure to check the journal with a micrometer if the flattened gauging plastic indicates more than 0.001 in. (0,025 ram) difference. 6. If the bearing clearance is not over 0.0035 in. (0,0889 ram} (worn) or 0.003 in. (0,076 ram) (new), or less than 0.001 in. mm),the bearing is satisfactory, ff the clearance is not within these limits replace the bearing. [~ If a new bearing cap is being installed and clearance is less than 0.001 in. (0,025 mm),check for burrs or nicks; if none are found then install shims as required. 7. A 0.002 in. (0,051 ram) undersize bearing mayproduce the proper clearance, if not, it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. Bearings are available in standard sizes and various undersizes. See your parts catalog. 8. Oil newbearings with engine oil prior to installing end caps. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to see that there is no excessive drag.

3-22

Eng,ne/eng

L~3---~ 9. Checkthe end play by forcing the crankshaftto its extreme front position. Checkat the front side of the rear main bearing with a feeler gauge.. This clearanceshould be from 0.002-0.006in. (0,051-0,152 mm).

t ,o"

’10. Installa newrear mainbearing oil seal in the cylinder block and main bearing oil cap as described below.

Rear Main Bearing Oil Seal Replacement ~o-’~ Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft seaning surface. [-4--1 1.Insert a screwdriver into the notchesprovided in the seal retainer and pry the seal out. Take care not to damagethe crankshaft seaning surface.

860043

2. Inspect chamferon crankshaft for grit, nooserust, and burrs. Clean seal running surface on the crankshaft with a non-abrasive cleaner. [~5~ 3. Lubricate the inner and outer diameter of newseal with engine oil. Install the seal on J-35621. Position J-35621against the crankshaft. Threadthe attaching screws into the tapped holes i~b the crankshaft. 4. Tighten screws securely. This will ensure the seal is installed squarely over the crankshaft. Turn handle until it bottoms then remove J-35621.

OiR Seal Retainer Replacement 1. RemoveFlywheel and oil pan. Removescrews, nuts and seal retainer. Remove gasket. 2. Remove rear crankcase oil seal as previously stated and clean gasket surfaces on block and seal retainer. Wheneverseal retainer is removed,a new retainer gasket and rear crankshaft oil seal mustbe installed.

DR1878

/,wl iii

1// [ ! "\ i!

31. Attach gasket to block. No sealer is required. Install seal retainer, screwsand nuts. Tighten to 135 in. Ibs. (15,3 N.m). 4. Install oil pan. Install rear crankshaft oil seal as outlined previously. Install flywheel.

Piston and ConnectingRod P~ston and Rod Removal 1. Withdrawcrankcaseoil. Disconnect oil drain tube. Remove oil pan. 2. Drain coolant from block and exhaust manifold, then remow; cylinder head. E,g,,~’~,9

3-23

DR1879

3. Remove anyridge and/ordepositsfromthe upperendof the cylinder boreswith a ridge reamer. ~Movepiston to the bottomof its travel and place a cloth on top of pistonto collect the cuttings. After ridge and/ordepositsare removed, turn crankshaftuntil pistonis at the top of its strokeandcarefully remove cloth with the cuttings. 4. Checkconnectingrods andpistonsfor cylinder number identification and if necessary,markthem. 5. Remove connectingrod cap nuts andcaps. Pushthe rods awayfrom the crankshaftandinstall capsandnuts looselyto their respectiverods. 6. Pushpiston androd assembliesawayfrom crankshaftandout of the cylinders. Note1It will be necessary to turn the crankshaftslightly to disconnect some of the rods andpushthemout of the cylinder. Piston and RodDisassembly 1. Install pilot of pistonpin removing andinstalling tool J-24086 onpiston pin. 2. Install piston andconnectingrod assemblyon supportandplace assembly in an arbor press. Presspin out of connectingrod. 3. Remove assemblyfrom press. Remove piston pin from support and remove tool frompiston androd. 4. Pistonpins are a matched fit to the pistonandnot availableseparately. Piston pins will not become looseenough to causea knockor tappinguntil after prolongeduse. In suchcasesa newpiston and pin assemblyshouldbe installed. Pistonpins shouldbe capableof supportingtheir ownweightin either pin bosswhencoatedwith light engineoil at 60° R Higheror lower temperatures will causefalse indications. Pistonsandpins are servicedas assemblies. Checkfit of usedpiston pins. Usea dial boregaugeor telescopingsnap gaugefor the bore,anda micrometer for the pin. Wearlimit on piston pin is productionclearanceplus 0.001in. (0,025mm).Replacepiston andpin assemblyif wearis excessive.

GR970257

Cleaning and |nspection Cleanvarnish frompiston skirts andpins with a cleaningsolvent. DONOT WIREBRUSH, ORSAND BLASTTHEPISTONSKIRT. Particles of the wire brushor sandwill become embedded in the surface of the piston and cause severecylinder wear.Cleanthe ring grooveswith a groovecleaner,and makesureoil ring holesandslots are clean.

3-24

Engine/eng

Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts, or eroded areas at top of the piston. Replace pistons that are damagedor otherwise showsigns of excessive wear. Piston and Rod Assembly 1. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin. 2. Position connectingrod in its respective piston so that flange or heavy side of rod at the bearing end will be towards front of piston (cast depressionin top of piston head). ~D 3. Install piston pin @on installer pilot @in support(E~.

® and pilot spring © and

4. Install piston and rod on support, indexing pinot through piston and rod.

®®

5. Place support on arbor press, start pin into piston and press on installer until pin pilot bottoms. 6. Removeinstaller and support assembly from piston and connecting rod assembly. Checkpiston pin for freedom of movement in piston bore.

PistonRings Piston rings are furnished in standard sizes as well as several oversizes. See your parts catalog. Oil control rings used on all engines consist of two segments (rails) and a spacer. Compressionrings in all engines are the deep section twist type, 0.0775-0.0780in. (1,969-1,981 ram) wide. This type compressionring takes its name, twist type, from its installed position which is cocked or twisted. It assumesand maintains this position for life becausethe upper edge of its diameter is chamfered, making the ring unbalanced in cross section. EN=°=~All compression rings are marked with the letter "GM" cast in the upper side of the ring. Wheninstalling compression rings, makesure the side marked"GM" is toward the top of the piston. Removal 1. Removepiston rings by expanding them and sliding them off the ends of the piston. Tool No. J-8037 is available for this purpose.

Eng’,ne/eng

3-25

860047

2. Checkpiston ring groovesby carefully removingall particles of carbon. Also check for burrs or nicks that might cause rings to hang up. Installation 1. Select rings comparablein size to the piston being used. It is important that each ring be fitted to its individuaR cytinder for proper gap spacing and to its individual piston and groove for proper clearance. 2. Slip the ring in the cylinder bore; then, using the head of a piston, press the ring down into the cylinder bore about two inches. Using a piston in this way will place the ring square with the cylinder walls. [~ 3. Checkthe space or gap betweenthe ends of the ring with a feeler gauge. 4. If the gap betweenthe endsof the ring is belowspecifications, removethe ring and try another for fit.

p

,

1-3

860048

5. Fit eachring separatelyto the cyninder in whichit is going to be used. 6. New pistons, rings and cylinder bores wear considerably during seating and gaps widen quickly; however, engine operation wil~ not becomeseriousRyaffected if ring gapsdo not become greater that %2in. I~ 7. Slip the outer surface of the compression ring into the piston ring groove. Roll the ring entirely around the groove to makesure that the ring is free and does not bind in the groove at any point. If binding occurs, the cause should be determined and removedby carefully dressing with a fine cut file. However,if the binding is causedby a distorted ring, install a newring.

860049

I

8. Install the oil ring spacerin the oil ring grooveand position gap in line with piston hole. Hold spacer endsbutted and install steel rail on top side of spacer. Position gap at least oneinch to left of spacer gap, then install second rail on lower side of spacer. Position gap at least one inch to right of spacer gap. g. Flex the oil ring assemblyin its grooveto makesure ring is free and doesnot bind in the grooveat any point. If binding occurs, the cause should be determined and removedby carefully dressing with a fine cut file. However, if the binding is caused by a distorted ring, install a newring.

3-26

860050

Englne/eng

E~3--7 10. Proper clearance of the piston ring in its piston ring groove is very important in maintaining engine performanceand in preventing excessive oil consumption. Therefore, whenfitting new rings, the clearances betweenthe top and bottom surfaces of the ring grooves should be inspected. E~ 11. The compression rings should be fitted cbearanceis 0.0020.-0.0035in. (0,051-0,089 ram).

so that the

12. Assemblethe rhlgs to the pistons as they are fitted and makea final test of the ring fit in the groovesby repeating the fitting procedure given above. Expanderends must not align with the ring gap. Piston and Rodinstallation t r Lightly coat pistons, rings and cylinder walls with light engine oil. E4~] 2. With bearing caps removed, install bearing cap bolts.

tool J-6305-01 on

E4~] ~ 3. Install each piston in its respective bore, using tool J-.8037 on each assembly. The side of the piston with the cast depressionin the headshould be to the front of the cylinder block and the oil hole on connecting rod toward the camshaft side of the engine. Guide the connecting rod bearing into place on the crankshaft journals with the long detail of tool J-6305-01. Use J-8037 to compresspiston rings. 4. Oil bearings and install bearing caps. Install cap retaining screws and nuts. Tighten nuts to 35 ft. Ibs. (47 N.m). Checkthe bearing clearance as described previously. 5. Install oil pan gaskets, seals and oil pan. SeeOiB Pan. Connect oil drain tube. 6. Install cylinder Installation.

860051

V

head gasket and head. See Cylinder Head

7. Refill crankcaseand checkfor leaks. Lakeor tank test unit and checkfor coolant leaks.

Cylinder Block I,nspection 1, Checkthe cylinder block for cracks in the cylinder walls, water jacket and main bearing webs.

860052

Enq,ne/eng

3-27

[~ 2. Checkthe cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator (use "Fool J-8087). Set the gaugeso that the thrust pin must be forced in about 1/4 in. to enter gauge in cylinder bore. Center gauge in cylinder and turn dial to "O". Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine the out-ofround condition. Bf cylinders were found to have morethan 0.002 in. (0,051 mm)out-of-round, boring will be necessary. Repair The performanceof the following operations is contingent upon engine condition at time of repair. If the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders, they can be conditioned by honing, or boring and honing. 860053

If the cylinders were found to haveless than 0.005 in. (0,127 mm) taper or wear, they can be conditioned with a honeand fitted with 0.001 in. (0,025 ram) oversize pistons. A cylinder bore of less than 0.005 in. (0,127 mm)wear or taper maynot entirely clean up when fitted to a 0.001 in. (0,025 mm)oversize piston. If it is desired entirely clean up the bore in these cases, it will be necessaryto rebore for an oversize piston, ff morethan 0=005in. taper or wear exists, they should be bored and honed to the smallest oversize that will permit completeresurfacing of all cyJinders. Piston Selection Replacementpistons are available in two sizes, see the appropriate parts catalog for part numbers.The size identification of the piston is markedin ink on the piston top. To determine the correct size of piston needed, measure the cylinder bore with a telescope gauge and micrometer, and subtract the base cylinder bore diameter, 4.000 in. (10,160 cm) from the measureddiameter. Next locate this dimension on the Piston Selection Chart. The numbershownon the chart in the box above the dimension is the marking on the piston which should be used.

3-28

Enome/eng

Cylinder Bore Measurement Base Cylinder Bore Diameter

4.002 in. (10,165 cm) (WornBore)

Difference

0.002 in. (0,051 mm)

4.000 in. (10,160 cm)

The numberin the box above 0.002 (0,051 mm)in is $7. There-. fore, in this case a 0.001 in. (0,025 mm)oversize piston marked would be used. Example"’B": CyMinder Bore Measurement Base Cylinder Bore Diameter

4.032 in. (10,241 cm) (Bored Out Bore)

Difference

0.032 in. (0,813 mm)

4=000in. (10,180 cm)

The numberin the box above 0.032 in. (0,813 mm)is 4. In this example, a 0.030 in. (0,762 mm)oversize piston marked4 would be used.

SERVICE PISTON MARKING

¯ £)

o

o

o

o

o

o

o

o

o

o

DR4649

Boring 1’,. Before using any type boring bar, the top of the cylinder block should be dressed to remove any dirt or burrs. This is very important. Otherwise, the boring bar maybe tilted which would result in the reboredcylinder wall not being at right angles to the crankshaft. 2. The piston to be fitted should be checkedwith a micrometer-, measuringjust below the lower ring groove and at right angles to the piston pin= The cylinder should be bored to the samediameter as the piston and honedto give a clearance of 0.0025-0.0035in. (0,064-0,089 mm). 3, The instructions furnished by the manufacturer of the equipment being used should be carefully followed. E~,~,oe/eoQ

3-29

Honingand Piston Fit 1. Whenthe cylinders are to be honedonly for use of a standard piston or for final finishing after they havebeenreboredto within 0.002 in. (0,053 mm)of the desired size, they should be finished with a hone. Roughstones maybe used at first and fine stones for the final operation. 2. Place the hone into a cylinder bore and expandthe stones until the honecan just be turned by hand. Connecta 1/2 in. (0,217 ram) electric drill to the hone and drive hone at drill speed while moving hone up and down entire length of cylinder until hone begins to run free. During this operation a liberal amountof keroseneshould be used as a cutting fluid to keep the stones of the hone clean. Move hone snowly up and down with rough stones, but movehone up and downrapidly enoughwith the fine stones to producea final bore finish of very fine surface scratches in a cross-hatch pattern of approximately 45° to 60°. The marks should be clean but not sharp, and free from embedded particles or torn or folded metal. 3. Expandthe stones against the cylinder bore and repeat the honing operation until the desired bore diameter is obtained. 4. Occasionaimyduring the honing operation, the cylinder bore should be thoroughly cleaned and the piston selected for the individual cylinder checkedfor correct fit. 5. Checkfit

of the aluminumpistons in the following manner:

Thoroughly clean cylinder bores with soap and hot water to removeanl grit particles. Measure the cylinder bore diameter with a telescope gauge and micrometer 21/2 inches (6,35 cm) from top cylinder bore at gO° from crankshaft axis. b,

Next measurethe diameter of the piston skirt just betow the lower ring groove and at right angles to the piston pin. if the difference is greater than the maximum allowable (see Boring, step 2), try another piston or lightly honethe cylinder bore to obtain the proper fit.

d,

Should the difference be less than the minimumallowable (see Boring, step 2), try another piston. If proper fit cannot be obtained, it will be necessary to rebore the cylinder to the next oversize piston.

e. Mark each piston after fitting to correspond with the cylinder to which it has been fitted. Proceed to hone cylinders and fit the remaining pistons.

3-30

Engme/eng

~Jot’~ Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been bored to correct size. This type piston can be distorted through careless handling. 6. Thoroughly clean the cylinder bores with hot water and soap. Scrubwell with a stiff bristle brush and rinse thoroughly with hot water. It is extremely essential that a goodcleaning operation be performed°if any of the abrasive material is allowed to remain in the cylinder bores, it will rapidly wearthe newrings and cylinder bores. In addition, the bearing will be lubricated by the contamiinated oil The bores should be swabbedseveral times with light engine oil and a clean cloth and then wipedwith a clean dry cloth. Cylinder should not be cleaned with kerosene or gasoline. Clean the remainderof the cylinder block to removethe excess material spread during the honing operation.

Distributor LowerBearing \-

The distributor lower bearing is a bronze bushing pressed into the lower side of the engineblock. Its upperinside diameterpilots the distributor shaft, and the outside diameter extending below the block pilots the oil pump. Someengines have a thrust washer at the upper end of the bushing bore. The thrust washer, whereused, maybe replaced a~t the sametime the bushing is replaced. Thelower bushing will ordinarily require only a clearance or wear check during engine overhaul. Whendistributor shaft-to-bushing clearance exceeds 0.0035 in. (0,0889 mm)the bushing shoukt replaced as follows with oil pumpand distributor removed:

860655

E1-’] 1. Install tool J-9534-01 into bushing and using a slide hammer, remove the bushing. Protect your eyes from fragrnents. Wearsafety glasses whe=~ striking these tools, handles, drivers, etc. Tool end may mush,room after being repeatedly struck. Alwaysgrind off any rolled

edges before using tool. possible.

Use soft face hammerswhenever

r~&=-1

L_"£J 2. Using a drift upthroughbushing bore, drive thrust washer (if installed) out of bore and removefrom block. 3. Clean bushing bore in block and check for burrs or damage. [~3~ 4. If thrust washer was removed, start new washer in position in bore and drive into place using toot J-9534-01. 5. Usingtool J-9535with driver-bolt in driver handle, install driver into new bushing from large inside diameter.

E,,~,~,~ Z~ Safety Related

860056

3-31

E~] 6. Place bushingand driver on block and drive the bushingin position. Depthis determinedby tool bottomingagainst the block. 7. Remove tool from bushing. It is possible that the bushingwith minimum I.D. will collapseenough,duringinstallation, to slightly seizethe installer arbor. If this happens,removeinstaller tool using slide hammer in driver bolt hole of driver handle. [--~-~ This will not damage the bushingand the tool is designedfor this purpose,shouldit occur.

Circulating Pump Removal 1. Openpetcocks on port side and drain coolant from block and exhaust manifold. Disconnectwater hose from circulating pump. 2. Loosenfour screwsholding circulating pumppulley to circulating pump. 3. Loosenalternator bracket bolts and removealternator belt. Remove circulating pumppulley and bolts. Unscrewbolts and removethe circulating pumpfrom the engine. ~Pull the pumpstraight out of the block first, impeller.

860057

to avoid damageto

Inspection If the seal is leaking replacethe pump.If the bearingis roughor allows excessivesidewaysmovement of the shaft, replace the pump.If the impeller has excessive erosion replace the pump. Installation ~This pumphas a special shaft and bearing assembly and a special seal assemblyintendedfor marineservice. Donot substitute with an " automotive pump. 1. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to a new pumpto block gasket. Install pumpassemblyon cylinder block and tighten bolts securely. 2. Install circulating pump pulley. Attachalternator belt andadjust. Referto GeneralInformationsection for specifications. 3. Connectcoolant hosesto circulating pump.Lakeor tank test unit and checkfor leaks.

Oil Pan Replacernent Removal 1. Remove oil using a suction pump.

3-32

Eo.~ ne/eng

2. Removeoil gasket.

witlhdrawal

tube. Removescrews, oil

pan and

kestaHation I. Thoroughlyclean all gasket sealing surfaces. Apply RTVsealer to the front and rear of the block. 2. Install gasket on the block, install oil pan. Tighten1/4x20screws to 80 in. Ibs. (g N.m)and5/16x18screwsto 165in. Ibs. (18,6 N.m). Install oil drain tube and fill crankcasewith engineoil.

Oil Pump EEl The oil pumpconsists of two gears (~ and a pressure relief valve ® enclosed in a two-piece housing @. The pumpis driven from the distributor driveshaft which in turn is driven by a helix gear on the camshaft. The oil pumpis flange mountedto the cylinder block with two bolts, and piloted on the outside of the lower distributor bronze bearing. Oil pressure passes through an opening in the mounting flange to the cylinder block, then into the full flow oil filter. The pumpcover is equipped with the pressure regulator valve that regulates oil pressure at approximately 40-60 PSI (135,1-202,6 kPa) at 2000 RPM.The pumpintake is of the fixed screen type. meshscreen @filters out smalKparticles of dirt and sludge which maybe present. [~o-~ A baffle incorporated on the intake screen has been designed to eliminate pressure loss due to suddensurging stops, turns, and acceleration. In the event that a screen becomesplugged a steel grommet opens and bypasses oil to the pump. Removanand Disassembly 1. Withdrawoil. Disconnect oil withdrawal tube. Removescrews, oil pan and gasket.Removeoil withdrawal tube fitting from oil pan° 2. Removeoil pickup tube clamp bolt. Removetwo flange mounting bolts. Removepump and screen as an assembly. 3. Remove four cover attaching screws, cover, gasket, idler gear, and drive gear and shaft. 4 Remove pressure regulator valve and valve parts. If necessary, removeoil pumpsuction pipe and screen by pulling from pump housing.

Engme/eng

3-33

860058

[~ Do not disturb oin pickup pipe on screen. This pipe is located at assembly. 5. Washall parts in cleaning solvent and dry using compressed air. Inspection Should any of the following conditions be found during inspection operations, the defective parts should be replaced. 1. Inspect pumpbody for cracks and excessive wear. Inspect oil pumpgears for excessive wear or damage. 2. Checkshaft for Boosenessin the housing. Checkinside of cover for wearthat would permit oil to leak past the endsof gears. 3. Checkthe oil pick-up screen for damageto screen or relief grommet. 4. Checkpressure regulator valve plunger for fit

in cover.

Assemblyand Installation 1. Place drive gear and shaft in pumpbody. Install idler gear so that smoothside of gear will be toward the cover. 2. Unstall a new pumpto cover gasket to ensure correct end clearance of the gears. 3. Install suction pipe and screen assembly to pumpbody and instaBI cover and attaching screws. Tighten screwsto 65-75in. Rbs. (7-8 N.m) and check to see that shaft turns freely. 4. Install regulator valve plunger, spring, retainer and pin. 5. Align oil pumpdriveshaft slot to matchwith distributor tang. Install oil pumpto block, positioning flange over distributor lower bushing. Use no gasket. Oil pumpshould slide easily into place. If not, removeand reJocate slot or determine other problem. 6. Attach and tighten oil pickup tube clamp. 7. Install oil pan using newgaskets and seals. E~ 8. Install withdrawal tube fitting to pan; leave screw boose. Orient fitting and attach withdrawal tube. Then tighten both fitting screwandflare nut to 15-18ft. Ibs. (20-24 N.m).

31576

9. Fill crankcasewith oil.

3-34

Engme/eng

Oil Filter BypassValve inspection Removethe oil filter and check the spring and fiber valve for operation. Checkfor a cracked or broken valve. Replacement If repHacement is necessary: 1. Remove the valve by prying it out with a screwdriver.

2888

2. Install a newvalve and seat it by tapping into place using a g/t6 ir~. thin wall deep socket and hammer. 3. Install oil filter

accordingto manufacturer’sinstructions.

Front Engine Mount Removal E2~1. Removetwo lag screws and washers from mounts.

34732

~ 2, Lift enginewith hoist capableof lifting at aeast 1000 lb. (454 kg} minimum capacity hoist to allow removalof front mou~,t and bracket. E,~ 3. Removefour mount screws and lock washers. Remove front engine mount and spacer (port side) from engine. Disassembly r~ 4--’-1 ~ Prior to disassembly of front mount assembly, measure distance betwe, en large washer on bracket and small washer on lower mount and record for reference during reassembly. ES~ ~-] 1. Put w,rench on flat of trim adjustment shaft and socket on top nut, and removeengine bracket and spacer.

22687

16383

16351

22656

22654

[~ 2. Removetwo bolts from engine bracket and remove rubber mount assembly. /

3. Removelower nut and washer on shaft and removeshaft from lower mount. 4. Upon complete disassembly, check pieces and replace where necessary.

ReassembUy z~ 1. Place one nut and washer on trim shaft, then set trim adjustment shaft in lower mount, install remaining washer, and screwon lower nut. Makesure at Ueastthree shaft threadsextend through nut. Tighten nuts finger tight, do not tighten at this time.

16383

E~ 2. Place engine bracket spacer on shaft. [~ 3. Attach rubber mount to engine bracket with two bolts and tighten to 30-35ft. Ibs. (41-47 N-m). 4. Place engine bracket assembly on shaft with large and small washerand tighten nut to 50-60 ft. Ibs. (68-81 N.m).

22653

Installation 1. Attach engine bracket and port side spacer to the engine with two long bobts and lock washers (port side) and two short bolts and lock washers(starboard side). Tighten long port side bolts to 48-56ft. Ibs, (65-76 N.m)and starboard bolts to 32-40 ft. Ibs. (43-54 N.m). [~ ~ 2. To reset engine height to original position, refer to measurementpoints and dimension recorded in Step 4 of RemovaL Loosen nuts to adjust shaft and mount position to desired height° Hold one nut and tighten the other to 115-140 ft. Ibs. (156-190 N.m).

3-36

16382

34731 Eng,ne/eng

[~ L~ 3. Install lag screwsand tighten securely.

Front MountHeight Adjustment [_1~ 1. Supportengine with a hoist capableof lifting (454 kg).

at least 1000lb.

[2~] [~ L~ 2. Removeboth lag screws from lower front mount. :3. Loosennuts securing lower mountto trim shaft. Reposition lower mount to desiredposition, then retighten lower mountnuts to 115-140ft. Ibs. (156-190 N m). [~ L~ 4. Install

16367

two lag screws in Jower mount and tighten securely.

High-Rise Exhaust Elbow Replacement Removal 1. Loosenall four hose clamps. Lubricate exhaustpipe with a soapywater solution, and slide hose downoff exhaustelbow. 2’.. Loosenhose clampand disconnectcooling hose from inside of exhaust elbow. Thenremovehosefitting.

2972

[~ 3. Remove the two screws - and swing anchor bracket out of the way. Thenremovethe two nuts and lock washers(id. 1~14. Loosenthe elbowwith a soft hammer, then lift Remove and discard the elbow gasket.

it off the manifold.

Installation 1. Thoroughlyclean the manifold and elbowgasket surfaces. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a new gasket, and place it on the manifold.

2888

34729

Eng[ne/eng

3=37

22649

[~ 2. Mount the elbow on the manifond. {nstall the throttle anchor bracket, and secure with the two screws Q and the two nuts and lock washers®.Tighten all four to t2-14 ft. Ibs. (16-19 N.m). Slide the exhaust hose all the way onto the elbow. 3. Install hose fitting hose.

on the inside of elbowand connect cooling

4. Position the upper clamps in the top two channels and tighten them securely. Position the two lower clamps in the channels and tighten them securely. Z~ 5. Reconnectthrottle cable to carburetor and throttle plate. Securewith cotter pin.

Dinkage

34728

Exhaust Hose Replacement Removal 1. Removehigh rise exhaust elbow following High-Rise Exhaust EabowReplacement.

procedure in

[~ 2. Removeclamps and slide hose off exhaust pipe.

34727

Installation E~ ~ One end of exhaust hose has two ribs @ around the circumference. Position this end up when installing hose to ensure secure attachment. 1. Place two No. 64 hose clamps over exhaust pipe if they were removed. E~ 2. For ease of installation lubricate inside diameter of hose with a soapy water solution, and slide hose all the way onto exhaust pipe. Place two No. 64 clamps around top section of hose.

22647

3. Complete hose and high-rise elbow installation following procedure in High=Rise Exhaust Elbow Replacement

16350

Exhaust (Flapper)Valve Replacement Removal 1. Theexhaustvalve is at the upper end of the exhaustpipe. Remove exhaust elbow and exhaust hose. E~ 2. Using a small drift of the exhaustpipe.

or punch@,push the exhaust valve pin (~ out

E~ [~ 3. Removepin and valve. Push out two rubber bushings. 6373

installation ES~1. Apply 3Ms Scotch Grip RubberAdhesive 1300 to two new rubber bushingsand push into exhaust pipe. ~_~3~J ~ 2. Lightly lubricate exhaustvaive pin with oil. Position valve in exhaustpipe with Pongside of valve down. Pushpin through bushingand exhaustvalve until flush with both sides of pipe. Checkexhaustvalve for freedom of movement. E~If the valve is ,lot positioned properly (long lip down),it will restrict exhaustflow and fail to prevent water from backingup into exhaustsystem. Boat performancecould be adversely affected, and major powerhead damagecould occur.

6375A

3. Install exhausthose and elbow.

6376

6377

6378 En’.},ne/eng

3-39

6675

Engine Coupler Replacement Removal 1. Removeengine from boat following instructions in Engine Removal and installation section. If coupler is being replaced due to coupler failure (rubber hub of sp~ined hubl, check engine alignment after installing new coupler. See Engine AJignment in EngineRemovaland installation section. 2. Cut tie strap holding flywheeJ housing drain hose to starter motor. [~ [~ 3. Take out screws holding flywheel housing cover (~), then slide out cover. [~ 4. Removenut, lock washer, and ground leads from ground stud. Removeinner nut, lock washer and washer. Removesimilar ground stud hardware on opposite side of block, 5. Removescrews and washers holding 10 pin connector and relay, and movebracket aside.

6712

6. Unscrewremaining flywheel housing bolts, lock washers and washers. Note position of clamps so they can be installed in original position. [~ 7. Lift flywheel housing off engine block and set aside. [~ 8. Unscrewsix Iocknuts, then pull coupler off flywheel.

3-40

Eng,ne/eng

~nstallation [6-] 1. Slide coupEeronto crankshaftstuds. Install Iocknuts. Usea crowfoot wrenchand tighten nuts to 50-55ft. lb. (54-61N*m)applied in a "star" sequence. Repeat torque procedure once more. ET~2. Install flywheeL housing.Placeclampsin their original positions, and attach 10 pin connectorand relay bracket. Tightenscrewsto 28-36ft. Ibs. (38-49 N-m). ~3. Place washer, lock washerand nut on ground stud. Tighten inner nut to 35-40ft. Ibs. (47-54N®m). Attachelectrical leadsto groundstud. Install lock washerand tighten outer nut securely. Install groundstud hardwareon oppositeside of block.

6711A

EB~]4. Slide flywheel cover up into place. Install screwsand tighten themto 60-84in. Ibs. (7-9 N-m). ~9~] 5. Attach flywheel housingdrain hose® to starter motor with tie strap. 6. Install enginein boatfollowinginstructionsin EngineRemoval and Installation section. 20034

14704

Eo,~,r,o/on~ Z~ Safety Related

3-41

EngineSpecifications 1. GeneralSpecifications Type - No. of Cylinder ..................... Bore and Stroke .......................... Piston Displacement ....................... Cylinder No. (front to rear) .................. Firing Order ............................. Compression Ratio ........................ Thermostat Opens at ...................... Full Throttle Operating Range ...............

4 - In-line 4.000in. x 3.60 in. 181Cu. In. (3.0 Litre) 1- 2- 3- 4 1 - 3 - 4- 2 9.3 to 1 160° F 4200-4600 RPM

2. EngineDimensions,Fits and Adjustments Pistons: Type ................................ Clearance Limit at Top Land .............. Clearance Limit at Skirt .................. Compression Ring Groove Depth .......... Oil Ring Groove Depth .................. Piston Rings: Compression Ring Material ......................... Type ............................ Coating - Upper Ring ............... Coating - Lower Ring ............... Width ........................... Gap ............................ Oil ring Material ......................... Type ............................ Coating (rail) ..................... Width (Piston Groove) .............. Gap (Ring) ....................... Width (Ring) ...................... Expanders ....................... Piston Pins: Length .............................. Diameter ............................. Clearance in Piston (new) ................ Wear Limit in Piston .................... Clearance in Rod .......................

Flat Hea::l 0.0255 - 0.0345 in. 0.0025 - 0.0035 in. 0.209 - 0.211 in. 0.190 - 0.199 in.

Cast Iron Radius Face (Upper) Tape Face (Lower) Molybdenum Wear Resistant 0.0775 - 0.0780 in. 0.010 - 0.020 in, (Upper) 0.013 - 0.025 in. (Lower) Flat Spring Steel Multi-piece Rail Expanderand Spacer Chrome 0.188 - 0.189 in. 0.015 - 0.055 in. 0,154 - 0.160 in. One-Piece Expander-Spacer

2.990 - 3.010 in. 0.9270- 0.9273in. 0.0003- 0.0004in. 0.001in, 0.0008- 0.0021in.

3-42

Engme/eng

EngineSpecifications Connecting Rods: Material ............................. Length CL to CL ....................... Connecting Rod Bearing Material ......................... Effectiw ~. Length ................... Clearance ........................ End Play ......................... Crankshaft: Material .............................. End Play .............................. End Thrust Taken By .................... Crankpin Journaa Diameter ............... Main Bearing Type ............................ Journal Diameter .................. Length .......................... Clearance ........................

Drop Forged Steel 5.700in. M400 0.792 - 0.822 in. 0.00085- 0.00135in. 0.008 - 0.015 in.

Nodular Cast Iron 0.002 - 0.006 in. Rear Main Bearing 2.099- 2.11)0in. Precision Removable 2.2983- 2.2993in. 0.822in. (rear} 0.830 in. (others} 0.0003- 0.{)029 in.

Camshaft: Camshaft Bearing Material ......................... Steel BackedBabbitt Journal Diameter x Bearing Length .... 1.8692in. x .860 in. Bearing Outer Diameter- Nos. 1 and 2 . 1.999 - 2.001 in. Bearing Outer Diameter - No. 3 ....... 2.009- 2.011in. Type of Drive ......................... Gear Crankshaft Gear Material ................ Helical Cut Nodular Cast Iron Helical Cut Bakelite and Fabric Composition Camshaft Gear Material ................. Lobe Lift ............................. 0.253 in. +- 0.005 in. Valve Systems: Lifter Type ........................... Rocker Arm Ratio ...................... Valve Lash Adjustment mntake and Exhaust (hot) ............ Valve Face Angle ...................... Valve Seat Angle ....................... Stemto Guide Clearance Intake Valve ...................... Stemto Guide Clearance Exhaust Valve .................... RecommendedValve Seat Width Intake ........................... Exhaust .........................

Hydraulic 1.75 to 1 3/4 to 1 Turn DownFrom "Zero Lash" Point °45 °46 0.0010- 0.0027in. 0.0010- 0.0027in. 1/3~in. to 1/~ in. 1/~6in. to 3/3~_ in.

EngineSpecifications Valve Systems(cont.): Outer Valve Spring Free Length ................................ Outer Valve Spring Pressure Lb. @In ......................................... EngineLubrication: Type Oil Pump............................................... Normal Oil Pressure ........................... Crankcase Capacity ....................... Oil Grade Recommended: Service SG-IVleeting GMSpec 6094 32° F. and Above ........................................... 0° R to 32° F .......................................... Below 0° F ...............................................

2.08 in. 78-86 @1.66 in.

Gear 40-60 PSI @2000 RPM 31/2qts. (4 qts. with newfilter) SAE 30 SAE 20W-20 SAE 10W

Werecommend DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil which is specially formulated for heavy duty marine TM use. DuraPlus SAE30 HeavyDuty Synthetic Motor Oil provides superior anti-wear qualities, especially important during prolongedhigh speedoperation. It also neutralizes acids created in all internal combustionengines.This motoroil is formulatedto offer superior protection against corrosion and to resist oxidation and high temperaturesludge formation. [~ The use of multi-viscosity oils is not recommended. Disregard any reference to multi-viscosity oil printed on engine. Suchreference is intended for automotiveuse only, not marineuse. Fuel Grade Recommendation............

3-44

See General Information section

Eng,ne/eng

TorqueSpecifications Usea reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. Thesespecifications are for clean threads only. Dirty threads produce friction which prevents accurate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

Adaptor -Oil Pressure Sender Alternator- Bracket to Engine Camshaft Thrust Plate Circulating Pump Crankshaft Oil Seal Retainer Distributor Clamp Exhaust Elbow Flywheel Bei[housing Flywheel Cover Front Mount - Port Front Mount - Starboard Oil Pan(1/4 x 20) Oil Pan(5/16 x 18) Oil PumpCover Oil Withdrawal TubeFitting Power Steering PumpBracket Starter Motor Starter Motor Bracket Supply PumpBracket Thermostat Housing Timing Chain Cover Valve Cover

10-14 26-30 72-90 13-17 135 20 12-14 28-36 60-84 48-56 32-40 15-18 26-30 30-38 16-19 13-17 12-16 -

80 165 65-75

80 65

14-19 35-41 8-10 18-23 15,3 27 16-19 38-49 7-g 65-76 43-54 9 18,6 7-8 20-24 35-41 41-49 22-26 18-23 16-22 9 7,3

TorqueSpecifications= (Cont.)

. LFT. LBS.I

Connecting Rod Cap Crankshaft Oil Seal Retainer FlameArrestor Cover Flare - Oil WithdrawalTube Flywheel and Coupler Flywheel Belihousing Intake/Exhaust Manifold

I IN. LBS.]

35 135 30-40 15-18 50-55 35-40 20-25

Cylinder Head Step 1 Step 2 Step 3 Intake/Exhaust Manifold Main Bearing Cap(exe. rear) Main Bearing Cap, Rear Step 1 Step 2 Oil Pump

35 65 95 20-25 60-70

88 129 27-34 81-95

110-120 65-80 10-15 13-15

Oil Filter Retainer - Oil PanDrain Sender, OiE Pressure Sender, Water Temperature Spark Plugs

15-18 10-14 18-22 2O

47 15,3 3,4-4,5 20-24 54-61 47-54 27-34

47

10-12 60-70

FlameArrestor to Carburetor Flywheel and Coupler Power Steering PumpBracket

_

14-16 81-95 12-14 7-9 14-20 18-20

Oneturn after contact

3-46

20-24 14-19 24-30 27

Engine/eng

NOTES

3-47

NOTES

3-48

Section 4 4.3 GL, GS and Gi Engine

Table of Contents Accessories ......................... Balance Shaft ...................... Balancer, Crankshaft ................. Camshaft .......................... Cleaning ........................... Circulating Pump.................... Crankshaft and Bearings .............. Cylinder BBock ...................... CyUinder Head ...................... Engine Coupler Replacement ............... Draining .......................... Front Cover ....................... Front Mount ...................... Lubrication ........................ Exhaust (Flapper) Valve Replacement ......... Manifold .......................... High-Rise Elbow Replacement ........ Hose Replacement .................

4-4 4-23 4-15 4-22 4-4 4-34 4-30 4-31 4-12 440 4°4 4-20 4-35 4=5 4-39 4-6 4-37 4-38

Generan Description ................... intake Mar|ifold ...................... intermediate Pipe Replacement ......... Oil Pan ............................ Oil Pump .......................... Pistons and Connecting Rods .......... Rear OiJ Seal, Crankshaft .............. Rear Oin Seal Housing ................ Rocker Arm Cover .................... Rocker Arm Stud Replacement ......... Special Tools - GM................... Specifications Engine .......................... Torque .......................... Timing Chain and Sprockets ........... Tools and Shop Equipment ............. Valve Train .........................

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual Alwaysuse the correct fastener in the proper location. Whenyou replace a fastener, use ONLYthe exact part number for that application. The text will call out those fasteners that require replacementafter removal. The text will also |:all out the fasteners that require thread lockers or thread seahmt. UNLESSOTHERWISE SPECiFiED, do not use supplement coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joiint clampingforce, and may damagethe fastener. Whenyou install fasteners, use the correct tightening sequence and tightening specifications. Following these instructions can help you avoid damageto parts and systems=

Eng,ne/eng

4-

4=2 4-7 4-38 4-16 4-17 4=25~ 4=29~ 4-29~ 4-9 4-13 4-47 4-44 4-42 4-21 4-3 4-10

General Description Engine Construction The 4.3L engine is a biquid-cooled 90 degree V6 type with overheadvalves, a balance shaft, and cast-iron block and cylinder heads. Cylinder Block The cylinder block has 6 cylinders arranged in a "V" shapewith 3 cylinders in each bank. Starting at the front of the engine, cylinders in the right bank are numbered1-3-5 and cylinders in the left bank are numbered2-4-6 (when viewed from the front). Thefiring order of the cylinders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets. Cylinder Heads The cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is located betweenthe valves in the side of the cylinder head. The valve guides are integral and the valve rocker arms are retained on individual threaded studs. Crankshaft The crankshaft is supported by four crankshaft bearings. The numberfour bearing at the rear of the engine is the end thrust bearing. The bearings are retained by bearing caps that are machinedwith the block for proper alignment and clearances. Camshaft The camshaft is supported by four full round, sleeve-type bearings. A sprocket on the crankshaft drives a camshaft timing chain which in turn drives the camshaft through a sprocket. Pistons and ConnectingRods The pistons are madeof cast-aluminum alloy using two compression rings and one oil control ring assembly.Piston pins are offset 0.0354 in. (0,9 ram) toward the major thrust side (right side) reduce piston slap as the connecting rod travels from one side of the piston to the other side after a stroke. Thepins are a press fit in the connectingrod and a floating fit in the piston. Balance Shaft The cast-iron balance shaft is mountedin the crankcase above and inline with the camshaft. A camshaft gear drives the gear attached to the balanceshaft. Thefront end of the balance shaft is supported by a ball-type bearing. The rear end of the balance shaft uses a sleeve-type bearing.

4-2

Engm~eng

Valve Train Thevalve train is a ball-pivot type. Motion is transmitted from the camshaftthrough the valve lifter and valve push rod to the valve rocker arm. Thevalve rocker arm pivots on its ball and transmits the camshaft motion to the valve. The valve lifters with roller followers keepall parts of the valve train in constant contact. Each lifter acts as an automaticadjuster and maintains zero lash in the valve train. This eliminates the need for periodic valve adjustment. intake Manifold The intake manifold assembly is a two-piece design. The upper portion is madefrom a composite material and lower portion is cast-aluminum. The throttle body attaches to the upper manifold.

Tools and Shop Equipment A clean, well-lit, work area should be available° Other necessary equipment includes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and an adequateset of hand tools. An approvedengine repair stand will help aid with the work and help prevent personal injury or component damage. Special tools are listed and illustrated throughout this section with a completelisting at the end of the section. Thesetools (or their equivalents) are specially designed to quickly and safely accomplishthe operations for which they are intended. The use of these special tools will also minimize possible damageto engine components. Someprecision measuring tools are required for in,;pection of certain critical components.Torque wrenchesare necessaryfor the correct assemblyof various parts.

Eng,ne/eng

4-3

Accessories The various procedures in this manual assumethat the engine accessories have been removed.These accessories include all of the following: ¯ ¯ ¯ ¯ ® ¯

Power Steering Pump A~ternator Distributor Water Supply Pump Accessory Brackets and Electrical Starter Motor

Wiring

Cleaning Removethe engine accessories before cleaning to provide better access to the engine’s exterior surfaces. After removing the distributor, accessorybrackets, etc., cover the openingswith tape to prevent the entry of contaminants. Methods used to clean the engine will depend on the means which are available. Steamcleaning, pressure washing, or solvent cleaning are some of the acceptable methods. Allow the engine to dry thoroughly before beginning any work. It is important that the engine be as clean as possible to prevent dirt, water, or any other contaminantsfrom entering critical areas during disassembBy.

Draining The Engine Follow the procedures in Section 1, General Information of this manua~to drain crankcase engine oil and the cooling system.

4-4

Ei~gme;eng

r

==

-.%=

|

m

DRC6583

Engine Lubrication Full pressurelubrication, through a full-flow oil filter is suppliedby a gear-typeoil pump.Oil is drawn up through the oil pump screen and passesthrough the pumpto the oil filter. Theoil filter is a full-flow paper element unit with an anti-drain backvalve. An oil filter bypassvalve is used to ensure adequateoil supply, in the event the filter becomesplugged or develops excessive pressure drop.

Engme/eng

Filtered oil flows into the main ganlery and then to the camshaft, balance shaft, rear bearing, and crankshaft bearings. The valve lifter oil gallery supplies oit to the valve lifters. Oil flows from the valve lifter.,; through the hollow valve pushrods to the valve rocker arms. Oil drains back to the crankcasethrough oil drain holes in the cylinder head. The camshaft timing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash.

4-5

ExhaustManifold Removal 1. Drain waterfromexhaustmanifolds. 2, Disconnectwaterhosefrommanifold. 3. Loosenupperexhausthoseclamps,then removehigh rise elbow. 4. Remove manifoldattaching nuts and washers.Discardnuts. Inspection 1. Inspectfor cracks. 07 2. Topressurecheckmanifold, fabricate a plate suchas pictured (~) anda newelbowgasket(~) to seal waterpassage in manifold. Besure applyseater to gasket.Install rubberdrain capsto manifoldandsecurewith clamps. Attach a GearcasePressureTester © (such as StevensCompany S-34)to the waterinlet hose. A bushingcanbe madeto securepressure tester to hose.With the pressuretester attachedto the manifold,submerge manifoldin water. Pressurizethe manifoldto 10-15PSI(22-25kPa) and checkfor leaks. Manifoldshouldnot leak aroundclampsandplate. If so, retighten clampsor reseal plate. Nodropin pressureshouldbe realized.

dr2642

installation [~] 1 Cleanmatingsurfaces on manifold andhead. Install newexhaust gasket,then install manifoldandsecurewith bolts. Tightenbolts @to 20-26 ft. Ibs. (27-35N.m). 2. Install a newgasketandhighrise elbowto manifold.Tightenbolts to 12-18ft. Ibs. (16-24Nm). 3. Install exhausthoseandsecurewith clamps.

28287

4. Connect waterhose.Install andtighten drain petcocks. /~5. Start engineandcheckfor fueB leaks.

4-6

Engine/eng

intake Manifold Removal [==3~~ 1. Draincoolantfrommanifolds andbothsidesof block. ;.L Disconnect: a.

Batterycablesfrombattery.

b. Coolanthosesat thermostathousing. C.

Throttle cablefromcarburetorandanchorblock.

d. Crankcase ventilation hosefromrocker armcovers(both sides). e.

f.

Wireat temperaturegaugesenderunit andenginewiring harnessfromalternator. Distributorhightensionandignition primaryleadsfromcoil.

3. Remove: a. Distributor capand markthe position of the rotor on the housing. Scribe a line on distributor housingandintake manifotd for reassemblyin the sameposition. Remove the distributor. b. Alternator andalternator mounting bracketfromengine. fuel line fromcarburetorandfuel pump or fuel c. Carburetor lines fromthrottle bodyandfuel pump/vapor separator. d. Oil pressuresendingunit. e. Manifoldattachingbolts andsolenoidbracket.Lift manifold fromengine.Discardfront andrear sealsandgaskets. If manifold is to bereplaced,transfer: carburetor or throttle bodyand ECMbracket, thermostatand housing(use new gasket),throttle cableanchorblockassembly, distributor clampandtemperature sendingunit. Transferadditional hardware as required.

Eng[ne/eng

4-7

¯ Old pieces of gasket or RTVfrom the gasket surfaces. e Excessive carbon build-up in the intake passagesof the intake manifold. o Scale and deposits from the coolant passages of the intake manifold. installation [~ important:

Do NOTreuse intake manifold gaskets. DRC8590

E~] Install

or Connect:

12.7 mm (0.499 IN.)

o

~

1. Sealant to the intake manifold gasket, cylinder head side. [~ Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly. 2. Gaskets onto the cylinder head.

-,

%

a. Use gasket Iocator pins to properly seat gasket on cyninder head. ~ b. Apply a 0.499 in. (13 mm)bead of GMSealant, P/N 12346141,or equivalent to the front and rear block sealant areas. c. Extend the sealer bead 0.157 in. (4 ram) onto each gasket. 3. GMThreadlocking Sealant, P/N 12345382,or equivagent to the threads of the eight lower intake mounting bolts. 4. Lower intake manifold onto engine block. DRC6592

5. Lowerintake manifold bolts. [~

8

Tighten:

4~

I~ Bolts in three steps, using the following sequence: a. Snugall bolts to 27 in. lb. (3 N-rn) to minimizeshifting intake. b. Bolts to 106 in. lb. (12 N-m). 6

c. Bolts to 11 ft. Ibo (15 N.m).

DRC6593

4-8

Engme./eng

d. Distributor with rotor andaligned exactly as markedduring removal. ~NO-O-~ If enginewascrankedwhile distributor wasout, completeignition timing proceduremust be followed. Seethe appropriate Ignition Circuit in Electricallfgnition SystemsService Manual. e. Alternator with mountingbracket. f.

g.

Distributor cap and high tension leads. Seethe General Informationsection in Electrical/Ignition ServiceManua~ for correct firing order and sparkplug wire routing. Oil pressuresendingunit.

3. Connect:

a. All

electrical connections. Apply Black NeopreneDip, on all exposedconnections.

b. Fuel lines to carburetor and fuel pumpor throttle bodyand fuel pump/vaporseparator. c. Throttle cable. d. All water hoses, and close all drain petcocks. e. Both crankcaseventilation hoses. f. Battery cables. g. Start engine.Checkignition timing, carburetor idle speed and mixture. Checkfor leaks.

Rocker ArmCover Removal ~5=~ Remove or Disconnect: 1. Valverocker armcover botts. 2. ’Valve rocker armcover. 3. ,Gasket.

Eqgme/eng

4-9

DRC6584

Clean: o Parts in solvent. Remove all sludge and varnish. e Old gaskets from the gasket surfaces. inspect: ® Gasket flanges for bending or damage. ® Rubber grommetsand parts for deterioration. Rnstallation DRC6584

i~ Install

or Connect:

J

1. Newgasket. 2. Valve rocker arm cover. 3. Valve rocker arm cover bolts. Tighten: Valve rocker armcover bolts to 106 in. lb. (12 N.m).

DRC6585

ValveTrain Removal ~] Important: Store all reusable components in an exact order, so they can be reassembled in the samewear pattern location from which they were removed.Mark the front end of the retainer. E~ Remove or Disconnect: I~ 1. Valve rocker arm nuts, bails, and vaJve rocker arms.

DRC6588

[~ 2. Valve push rods. [~ 3. Bolts and valve lifter

retainer.

[~ 4. Valve lifters. Removethe lifters one at a time using J 9290-01/J 3049 or equivalent and place them in an organizer rack. EEl Urnportant: Store all reusabae components in an exact order, so they may be reassembled in the same wear pattern location from ,which they were removed.

4-10

DRC6586

Erlgine/eng

¯ AIB parts in clean solvent and dry them with compressed air. ¯ Makesure oil passagesin valve push rods are clear. [~ Inspect: e Valve rocker arms and baBIs at their mating surfaces. These surfaces should be free from wear or any damage. 0

Valve rocker arm areas that contact the valve stems and the socket areas that contact the ends of the valve push rods. These areas should be free of damageor wear.

¯ Valve rocker arm nuts. e Valve push rod ends for scoring, roughness, or bends. [~et-~ Roll the valve push rod on a flat surface to determine its straightness. If the rod is bent, the rod will not roll freely. Replace if necessary. Vamve Lifters This engineuses hydraulic valve lifters. Valve lifters are serviced only as an assembly. No internal parts are available. Service is limited to a disassemblyand cleaning. Discard valve lifters that are excessively worn or damaged. E~ important: Whenever the camshaft needs to be re= placed, a newset of valve lifters mustalso be installed. Instagation [~ important: Replace all valve roller lifters, change the engine oil and filter, and add GMEngine Oil Supplement,P/N 1052367,

or equrivalent

to

the

engine

oil

whenever

a new

camshaftis installed. Lubricate the valve lifter bodies and roller Engine Oil Supplement,P/N 1052367, or equivalent. E3 Instal|

with GM

or Co,,nect:

~ 1. Valve lifters

to the block=

~ 2. Valve lifter

guide.

¯ Note previously mademark on valve lifter guide. Reference mark should be pointing toward front of engine.

Eo~ ......g

4-11

Tighten: Bolts to 12 ft. lb. (16 N-m). [~ 3. Valve push rods. a. Seat the valve pushrods into the socket of the valve Uifters. b. Coat the mating surfaces of the valve rocker arms and balls with GMEngine Oil Supplement, P/N 1052365, or equivalent. J~ 4. Valve rocker arms with balls on to the proper stud.

DRC6588

J~ 5. Valve rocker arm nuts onto the studs. o Align the vaPvepush rod into the valve rocker arm while tightening valve rocker arm nut. [~ Important: No Bash adjustment is needed. These models use screw-in rocker arm studs with positive stop shoulders. J~ Tighten: Valve rocker arm nuts to 20 ft. lb. (27 N.m).

DRC658g

Cylinder Head Cylinder Head Removal Removeor Disconnect: 1. Spark pnugs. 2. Cyninder head bolts. 3. Cylinder heads. 4. Headgaskets. Cylinder HeadDisassembmy Tool Required: J 8062 Valve Spring Compressor [~]

~3

[~ ~ Remove or Disconnect:

1. Compressthe springs with J 8062. 2. Keys Q. 3. Tool J 8062. 4. Valve spring cap (~.

DRC6595

5. Spring (~. 6. Seal ~). 7. Valves ~ and (~. Place the valves in an organizer rack so they can be replaced in their original position at reassembly.

4= 1 2

Engme/eng

Cmeaning, inspection,

and Measurement

Refer to General Engine MechanicaUsection in this manual.

Rocker Arm Stud Replacement Removeor Disconnect: Valve rocker arm stud by unscrewing. Install

or Connect:

Screwvalve rocker arm stud into cylinder head. Tighten: Valve rocker armstud to 35 ft. lb. (47 N.m). CyJinder Head Assembly Tools Required: J 8062 Valve Spring Compressor Install

or Connect:

E~E] 1. Valves ~ and ~. a. Lubricate the valve stemswith clean engine oil. b. Insert the valves into the proper valve guides until the face of the valve contacts the valve seat.

2.Seal ®. a= Install the seal over the valve stem. b. Hold the valve against the valve seat. c. Push the seal down the valve stem until against the head[.

it bottoms out

[~4~ 3. Springs (~. [~ 4. Valve spring cap (~. a. Compressthe valve spring using J 8062, enoughso the lower valve stern groove can be seen clearly. b. Apply a small amountof grease to the area of the upper valve stem groove. [~ c. Assemble the two valve keys O into the upper groove using the grease, to hold them in place.

En!~,ne/eng

4-13

[~ d. Release the compressor tool J 8062, making sure the valve keys O stay in place. e. Repeat the preceding steps on the remaining valves. r~ Measure: Refer to General Engine Mechanicalsection in this manualfor valve spring installed height. Clean: Gasketsurfaces on the block and cyninder head.

DRC6595

Cylinder Headinstallation Tool Required: J 36660 Torque/Angle Meter 3 install

or Connect:

1. Headgasket. ¯ Do not use sealer on head gaskets. ¯ Place the gasket over the block dowel pins with the head up.

DRC6587

2. Cylinder head. Carefully guide the cylinder headinto place over the dowel pins and gasket. 3. Cylinder head bolts. Coat threads of the cylinder head bolts with GMSeating Compound,P/N 12346004, or equivalent and install fi[~r-tig ht. [~

~ Tighten: a. Bolts in sequenceto 22 ft. lb. (30 N-m). b. Bolts in sequenceusing J 36660to: ¯ Short length bolt (11, 7, 3, 2, 6, 10) 55 degrees. e Mediumlength bolt (12, 13) 65 degrees. ¯ Long length bolt (1, 4, 8, 5,9) 75 degrees.

4. ~k plugs. Tighten: a. Spark plug into newcylinder headto 22 ft. lb. (30 N.m). b. All other subsequentinstallations to 15 ft. lb. (20 N.m).

4-14

Engine/eng

Crankshaft Balancer Removal -tool Required: J 39046 Crankshaft Balancer Remover The inert[at weight section of the crankshaft balancer is assembledto the hub with a rubber sleeve. The removal procedures must be followed (with the proper tools) or movement the inertial weight section of the hub will destroy the tuning of the crankshaft balancer and the engine timing reference.

.emo.., o,Di,co°.ect: t Crankshaft balancer bolt and washer. 2. Crankshaft balancer using J 39046.

J 3g046

3. Crankshaftkey, (if necessary). ~--~ Inspect: Crankshaft balancer weight for signs of shifting on the hub. Replace as needed. The area of the crankshaft hub shaft that contacts the front crankshaft seal for roughnessor nicks. Replace the balancer if this condition exists. If balancer is replaced, new balance weights of the samesize must be installed on the new balancer in the samelocation as the old balancer.

DRC6641

Installation J 39046

-[i~ol Ree~uired: J 39046CrankshaftBalancerInstaller

1. Apply GMRTVSea~ant, P/N 12345739,or equivalent to crankshaft keyway. 2. Crankshaft key (if removed). [~o~ The inertial weight section of the crankshaft balancer is assembled to the hub with rubber type material. The correct installation procedures(with the proper tool) must be followed movementof the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 3. Stud (part of J 39046)to the crankshaft. Threadstud fully into the tapped hole in Lhe crankshaft. 4. Crankshaft balancer over the end of the stud. Align the keyway in the crankshaft balancer shaft with the crankshaft key.

Englne/eng

4-15

\ DRC6~4

5. Bearing, washer, and nut. a. Turn the nut to pull the crankshaft baRancerinto place. b. Removethe tool. 6. Crankshaft balancer boRt and washer. [~ Tighten: Bolt to 74 ft. lb. (100 N.m).

Removal [~ B Remove or Disconnect:

% , 1. Oil pan nuts. 2. Oil panbolts. 3. Oil pan.

DRC6642

4. Gasket. [~

Clean: ® Parts in solvent. Removeall sludge and varnish. ® Old gaskets and RTVsealant from the gasket surfaces.

®

Inspect: ¯ Gasket flanges for bending or damage. ¯ Oil pan for damageor cracks. ¯ Oil pandeflector for lack of fit. ® Drain plug threads for stripping.

Installation Tool Required: J 34673 Straight Edgeor Equivalent E~ Important: The alignment between the rear of the oil pan and rear of the block flange is critical. The two surfaces must be flush to provide a rigid engine-to-transom bracket alignment.

4-16

DRC6539 Englne/eng

~ Install

or Connect:

~.~ [] Apply GMRTVSealant, P/N 12346141, or equivalent to the engine front cover to block joint and to the rear crankshaPt housing to block joint. Apply the sealant about 1.00 in. (25,4 mm) in both directions from each of the four corners. 1. Oil pan gasket onto pan. E4-’] 2. Oil pan against cylinder block.

25.4 turn (1,00IN.)

[~5~ 3. Slide oil pan back against straight edge using J 34673or equivalent.

DRC6640

4. O~anbolts and nuts but do not tighten. N~3~N Measure: [~ Use a feeler gauge to check the clearance between the three oil pan-to-transmission bell housing contact points as shown,if clearanceexceeds0.010 in. (0,254 mm)at any of th, three points repeat steps 2 and 3 until the clearance is within specification. [~ If the clearance is more than 0.010 in. powertrain durability maybe affected. [~

DRC6642

(0,254 mm),

~ Tighten: e Bolts to 18 ft. lb. (25 N.m) in the sequenceshown. ¯ Nuts to 17 ft. lb. (23 N.m). Measure: ¯ Clearance betweenthe three oil pan-to-transom bracket contact points to verify proper alignment.

5. Lubricate newoil filter

DRC6648

®

seal with cneanengineoil.

6. Newoil filter.

®

® ®

Oil Pump Removal

®

[7~ [~ Remove or Disconnect:

®

@ DRC6645

1. Bolt from oil pumpto crankshaft bearing cap. 2. Oil pump assembly. 3. Driveshaft and retainer

Engnne/eng

4-17

DRC6643

FT]

~ Disassemble:

1. Driveshaft ~ and retainer (~. [~ Do not remove the oil pump screen unless replacement is required. The oil pumpscreen has a press fit in to the pump cover. Do not remove the screen from the pipe (~. The oil pumpscreen is serviced as a complete assembly only. 2. Oil pumpscreen pickup ~. 3. Bolts (~. 4. Pumpcover (~. Mark where the idler gear and drive gear and shaft (~ meshtogether, so they can be reinstalled with the samegear teeth indexed. 5. Idler gear and drive gear and shaft O. 6. Retaining pin Q. 7. Pressure regulator spring (~. DRC6624

8. Pressureregulator valve (~). r~

Clean: All_~rts in clean solvent and dry them with compressedair.

[~][I~[~L~.j inspect: ~-~ important: The pump gears, cover, and body are not serviced separately. If any of the parts are damaged or worn, the entire oil pumpassembly must be replaced. ¯ Pumpbody ~ for cracks, wear, or other damage. ¯ Inside of the cover (~) for cracks and wear that would permit oil to leak past the endsof the gears. ¯ nd[er and drive gear (~ for wear. ¯ Drive gear and shaft for lack of fit

in the pumpbody.

¯ Oil pumpscreen for damageto the screen or loose fit the pipe.

of

¯ Pressure regulator valve (~) for fit. The regulator valve should slide freely in its bore without sticking or binding.

4-18

Engme/eng

Assemble J 21882

[~ ~ instalm

or Connect:

1, Pressure regulator valve ® into the pumpcover Q. [~ important: Replace the pressure relief when reusing the oil pumpassembly,

valve spring ~

2, Pressureregulator spring (~) into the pumpcover (~). 3, Retaining pin O into the pumpcover Q.

DRC6625

4. Drive gear and shaft O into the pumpbody ~. 5, Idler gear Q into the pumpbody [~. [~ Match together the index marks on the two gears made during disassembly. 6, Pumpcover (~. 7, Bolts (~). Tighten: Bolts (~)to 106 in. lb. (12 N.m). With the driveshaft (~) installed on the pump,turn the driveshaft by hand to check for smooth operation. ~o-~ Be careful of twisting, shearing, or collapsing the pipe wheninstalling it to the pump.A damaged pipe can cause lack of lubrication and engine failure. Oil Pu~.~ScreenInstallation E2~ ~ install

or Connect:

1, Oil pumpscreen pickup (~). a. The oil pumpscreen assembly @should be replaced with a newpart. Lossof press fit condition could result in an air leak and loss of oil pressure. b. Mount the oil pumpin a soft jawed vise. c. Apply sealer to the end of the pipe. d. Tapthe pickup screen and pipe into place, using J 21882and a hammer. e. The oil pumpscreen must be parallel with the bottom of the oil pan wheninstalled. E1=-] 2. Oil pumpdriveshaft (~)and retainer

Engme/eng

4-19

~

P~ Instal|ation Install or Connect:

1. Oil pumpto the engine. a. Align the slot in the oil pumpshaft with the tang on the distributor shaft. b. Theoil pumpshould slide easily into pnace. c. No gasket is used.

DRC6643

2. ~umpand bolt onto crankshaft bearing cap. I,~)!

Tighten: Bolt to 66 ft. lb. (90 N.m)=

Engine Front Cover Removal [~ important: Once the composite engine front cover is removedDONOTreinstall it. Alwaysinstall a newengine front cover. [~ Remove or Disconnect: 1. Enginefront cover bomts. 2. Enginefront cover. Installation E~ Important: Once the composite engine front cover is removedDONOTreinstall it. Alwaysinstall a newengine front cover°

Do not reuse the original O-ring seal wheninstalling onto crankshaft sensor body. Lubricate new O-ring seal with engine oil. Wheninstalling crankshaft position sensor be sure the sensor is fully seated and held stationary in the engine front cover bore. Torquehold downbolt to the specification shownbelow. A sensor that is not seated will cock in the engine front cover bore and may result in erratic engine operation.

4-20

Eng,ne/eng

E~’~ Install

or Connect:

1. Enginefront cover to engine. 2. E~nefront cover bolts. B~)U Tighten:

b’

Bolts to 106 in. ab. (12 N.m).

Timing Chain and Sprockets DRC6633

Tool Required: J 5825-A Crankshaft Sprocket Puller Measure:

J 5825-A

Checkcamshaft timing chain free pnay. If the camshaft timing clhain can be movedback and forth in excessof 0°625in. (16 ram), makea note that tile camshaft timing chain should be replaced during assembly. Removal E2~ E~ Remove or Disconnect:

DRC6615

1, Camshaftsprocket bolts Q. 2. Camshaftsprocket (~ and camshaft timing chain (~ together. The sprocket has a light interference fit on the carnshaft. Tapthe sprocket on its lower edge to loosen it. 3. Balanceshaft drive gear. E2-~ [~ 4. Crankshaft sprocket (~ using J 5825-A. 5, Key ~ (if

Englne/eng

damaged).

4-21

inspect: 1. Sprockets for chipped teeth and wear. Excessively worn sprockets will

rapidly

wear a new

chain. 2. Camshafttiming chain for damage. An excessively worn chain will rapidly wear a new set of sprockets. DRC6694

installation Tool Required: J 5590 Crankshaft Sprocket Installer [~ Instag or Connect: 1. Crankshaft key (if removed). [~ 2. Crankshaft sprocket using J 5590. 3. Balanceshaft drive gear,

View A DRC6634

4. Camshaftsprocket and camshaft timing chain. [~ E~ important: Line up the sprocket alignment marks ® on the camshaft sprocket and crankshaft sprocket. [~ The number 4 cylinder is at top dead center of the compression stroke with the timing marksin this position. 5. Camshaftsprocket bolts (~). [’~

4

Tighten: Bolts 21 ft. lb. (28 N.m).

DRC6633

Camshaft Removal E~ Remove or Disconnect: 1. Camshaftretainer bolts and camshaft retainer, 2. Camshaft. DRC6635

[~ a. Install three 5/16 - 18 (4.0 in.) long into the camshafts threaded holes. Use these bolts to handle the camshaft. [~ b. PulD the camshaft out from the block being careful to prevent damageto the camshaft bearings.

4-22

Enome/eng

E~ Measure: CamshaftJournals.. Refer to General Engine Mechanical section in this manual. Bearings Refer to General Engine Mechanical section in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly. Instagation E3 install

or Connect:

Coat the camshaft lobes and journals with a high quality GMEngine Oil Supplement, P/N 1052367, or equivalent. Apply GMEngine Oil Supplement, P/N 1052367, or equivalent to all the teeth on the distributor drive gear. ~,4~] 1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft threaded holes. Use these bolts to handle the camshaft. E4~ 2. Camshaftinto the engine. Handle the camshaft carefully to prevent damageto the camshaft bearings. 4

3. Camshaftretainer and retainer bolts. ¯ Coat camshaft retainer plate with GMEngine Oil Supplement, P/N 1052367,or equivalent. [~ Tighten: Bolts to 124 in. lb. (14 N.m).

Balance Shaft

0RC6631

Removal Tools Required: J 38834 Balance Shaft Bearing Service Kit J 26941 Rear Balance Shaft Bearing Remover p...=,.~ ES~ ~ Remove or Disconnect: 1. Bolt Q. 2. Drivengear (~). DRC6617

3. Retainer bolts ®. J

4. Retainer (~. EsZ] ~ 5. Balance shaft (~ using a soft faced hammer. E~ 6. Balance shaft rear bearing using J 38834 and J 26941.

388~

°~

. DRC6618

En(jine/eng

4-23

[~ inspect: Balanceshaft front roller bearing and rear sleeve bearing for damageor excessive wear. The bearings are serviced as an assembly.Use the proper tools for properly servicing the bearings. e Balanceshaft drive and driven gears for nicks or burrs. Replace gears that are damaged. Front and rear bearing journal diameters. Replace the balance shaft if the diameter exceedsthe specifications. Refer to Specifications in this section.

DRC6629

’~J

Rear sleeve bearing journal clearance. Replace the balance shaft if the clearance exceeds the specification. Refer to Specifications in this section.

J 38

36996

/

installation Tools Required" J 38834 Balance Shaft Bearing Service Kit J 36996 BalanceShaft Installer J 8092 Driver Handle J 36660 Torque/Angle Meter E~ Install

DRC6618

or Connect:

1. Dip bearing in clean engineoil before installation. EEl [~ 2. Balance shaft rear bearing using J 38834. EEl 3. Balance shaft into block using J 36996 and J 8092. J 8092 J 6996

a. Dip the front balance shaft bearing into clean engine oil before assembly. b. Retaining ring on balance shaft front bearing must be seated

DRC6630

on case.

4

[~ 4. Install balance shaft bearing retainer (~) and bolts (~).

2

Tighten: [~E] Balanceshaft retainer bolts (~) to 124 in. lb. (14 N.m). [~ 5. Balance shaft driven gear (~ and bolt Q.

’I

[~ Tighten: DRC6631

EEl Balanceshaft driven gear bolt Q to 15 ft. lb. (20 N.m) plus an additional turn of 35 degreesusing J 36660. i~ i~ Rotate balance shaft (~) by hand to make sure there is clearance betweenthe balance shaft and retainer. If balance shaft does not rotate freely, check to be sure retaining ring on front bearing is seated in case.

4-24

Engme/eng

e Turn the camshaft with the balance shaft drive gear temporarily installed. The timing mark on the drive gear must be straight up. o With the balance shaft drive gear removed, turn the balance shaft so the timing mark on the driven ge~ir points straight down. 6. Balanceshaft drive gear onto camshaft. E~ important: Make sure the timing marks on the balance shaft drive gear and driven gear aine up.

Pistons and ConnectingRods Removal Tool Required" J 5239 Guide Set B Remove or Disconnect: Before attempting to remove piston, refer to General Engine Mechanicalsection in this manualfor cylinder bore ridge reamer procedures. 1. Mark the cylinder numberson the tops of each piston. Mark them from the front to the rear, with the engine in an upright position and viewed from the front. e The right bank is numbered1=3-5 e The left bank is numbered2-4-6 2. Checkthe connecting rod and cap for identification marks. If reusing the connecting rods, mark the parts in the sameway as istons.

~

important: Store the connecting rod and cap together as mating parts, so they may be reassembled in the same wear pattern and balance in which they were removed. 3.. Connectingrod nuts, cap and bearings. important: If reusing bearings, keep bearings with their original connecting rod and cap.

E.,~i.~le.g

4-25

DRC6632

4. Connecting rod and piston. a. Attach J 5239 to the connecting rod bolts. [~ b. Use the long guide rod J 5239 to push the connecting rod and piston out of the bore. Disassembly Refer to General Engine Mechanical section in this manual for piston and connecting rod disassembly. Assembly Refer to GeneramEngine Mechanical section in this manual for piston and connecting rod assembly. Bearing Selection [~ important: Connecting rod bearings are of the precision insert type and do not use shims for adjustment. DONOTFiLE RODSOR ROD CAPS. If clearances are excessive, install a newbearing. Service bearings are available in standardsize 0o001in. (0,0254 ram) and 0.002 in. (0,0508 ram) undersize for use with new and used standard size crankshafts. For reconditioned crankshafts 0.010 in. (0,254 ram) and 0.020 in. (0,508 mm)undersize bearings are available.

DRC6619

Piston Selection Measuringthe Piston Checkthe used piston to cylinder bore clearance, as follows: 1. Cylinder bore diameter. Use a telescoping bore gauge, located 2.5 in. (65 ram) below the top of the cylinder bore.

DRC8507

[~] 2. Piston diameter. Measurethe skirt at a right angle to the piston pin hole, 1.0 in. (25 ram) belowthe oil ring groove.

DRC6514

4-26

Engme/eng

ENe-~ Measurepiston diameter at 70 degrees F (20 degrees C). 3. Subtract the piston diameter from the cylinder bore diameter 1:o determine piston to bore clearance. 4, Locate the piston-to-bore c;earance, refer to EngineSpecifications. Determine if the piston-to-bore clearance is within the acceptable range. Piston Ring End Gapand Fit Refer to General Engine Mechanical section in this manual. [~ Important: The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cyainder bore. If a connecting rod is ever transposedfrom one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be renumbered to correspond with the new cylinder number.

Tools Required: J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Torque/Angle Meter E3 Install

or Connect:

1. Lubricate the cylinder walls lightly with engineoil. 2. Makesure the piston is installed in the matchingcylinder. 3. Connecting rod bearings. a. Makesure the crankshaft bearings are the proper size. b. Install the crankshaft bearings in the connecting rod and connecting rod cap. c. Lubricate the bearings with engine oil.

4. Piston and connecting rod into the proper bore. a. With the connecting rod cap removed, install onto the connecting rod bolts.

J 5239

[~] b. Locate the piston ring end gaps. Lubricate the piston and rings with engine oil. [~ c. Without disturbing the ring end gap location, install 8037 over the piston and compression rings.

J 5239

J

d. The piston must be installed so that the notch in the piston faces the front of the engine. [~ e. PEacethe piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft. Using light blows with a hammerhandle, tap the piston downinto its bore. At the sametime, from beneath the engine, guide the connecting rod on to the crankpin with J 5239. Hold the ring compressoragainst the block until all rings have entered the cylinder bore. [~ f. RemoveJ 5239 from the connecting rod bolts° [~ important: Each connecting rod and bearing cap should be marked,beginningat the front of the engine. Cylinders 1, 3, and 5 are the right bank and 2, 4, and 6 are the left bank (whenviewed from the front). The numberson the connecting rod and bearing cap must be on the sameside wheninstaIRed in the cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod shouUdbe numberedto correspond with the new cylinder number.

DRC6619 ENG}NELEFT

i

’~

ENGINE FRONT ENGINE RIGHT

-=--- A, D

A OIL RING SPACERGAP (TANGIN HOLEOR SLOTWITHINARC) 8 OIL RiNGRAILGAPS C 2NO COMPRESSION RING GAP RING CAP 0 TOP COMPRESSION

5. Connecting rod cap with crankshaft bearing. 6. Connecting rod bolt nuts. [~

DRC6627

Tighten: o Connectingrod bolt nuts to 20 ft. lb. (27 N-m). e Connecting rod bolt nuts an additional 70 degrees using J 36660.

[~

J 8037

Measure:

Refer to General Engine Mechanical section in this manual for connecting rod side clearance procedure.

4=28

DRC6628

Eng,neleng

CrankshaftRear Oil Seal P, emoval Take care whenremovingthe rear crankshaft oil seal so as not to damagethe crankshaft sealing surface. F=...I [+=~J Removeor Disconnect: E4:~] hsert a screwdriver into the notches provided in the seal retainer and pry the seal out. DRC6858

Installation "[bol Required: J 35621Crankshaft Rear Oil Seal Instatler

I-H-I

F_=~LL.LJ Install

or Connect:

1. Lubricate the inner and outer diameter of the oil seaBwith clean engine oil. 2. Install the oil seal on J 35621. 3. Position J 35621 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.

J 35621 DRC6626

4. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft, 5. Turn the handle until it bottoms. 6. RemoveJ 35621.

C oankshaftReanrOil Seal Housing DRC6657

Remevan E~] ~ Remove or Disconnect: 1. Bolts and nuts. 2. Oil seal housing. 3. Gasket=

Gasketsurfaces on the block and seal retainer.

Eo~ ........ g

4-29

installation ~ Install

or Connect:

1. Newgasket to the block. It is not necessary to use sealant to hold the gasket in place. 2. Oil seal retainer. 3. Screws and nuts.

DRC6657

[~ Tighten: Screwsand nuts to 11 ft. lb. (15 N.m).

Crankshaft And Bearings Removal The crankshaft need not be removedfor replacement of the rear oil seal or crankshaft bearings. Those proceduresare covered in oth~=~arts of this section. ITI i=.t--! Irnportant: Checkthe crankshaft bearing caps for location markings. Mark the caps if necessary. The caps must be returned to their original locations during assembly. Removeor Disconnect: 1. Crankshaft bearing cap bolts. 2. Crankshaft bearing caps and lower crankshaft bearings. 3. Crankshaft from the cylinder block with extreme care, taking care to avoid damageto crankshaft journals and thrust flange surfaces. 4. Uppercrankshaft bearings. Refer to General Engine Mechanical section in this manual for cleaning, inspection, and measurements. InstaUation [~ Install

or Connect:

1. ~,~er crankshaft bearing to the block. Urnportant: if any undersized bearings are used, they mustbe fitted to the proper journals. 2. Crankshaft. 3. Lower crankshaft bearings to the crankshaft bearing caps.

4-30

Engme/eng

Measure: Refer to General Engine Mechanical section in this manual for crankshaft bearing clearance procedures. 4, Apply engine oil to the crankshaft bearings, Instalt crankshaft be~ caps (except rear cap) and bolts to the block. Tighten: Crankshaftbearing cap bolts to 77 ft. lb. (105 N.m}. 5, Rear crankshaft bearing cap. Apply engine oil to the crankshaft bearings° 6, Rear crankshaft bearing cap bolts. Tighten: Rear crankshaft bearing cap bolts to 124 in. lb. (14 N.m). Measure: Refer to General Engine Mechanical section in this manual for crankshaft end play procedure. [~ Tighten: Finally tighten rear crankshaftbearingcap bolts to 77 fto lb. (105 N.m)

Cylinder Block Disassembly F--=I DRC6623

E’~=..J Remove or Disconnect: 1, Coolantdrain fittings. 2.. Camshaftand balance shaft cup plugs. ~_~3. Front oil gallery cup plugs. ~ 4. Port side oil galaery plugs. ~ 5= Rear oil

ganlery plugs.

~=~ Clean:

DRC6621

1. Sealing material from mating surfaces. 2r. Boil cylinder bnockin caustic solution. o Flush with clean water or steam.

DRC6622 Engme/eng

4-31

3. Cylinder bores. 4. Threaded holes¯ 5. Oil galleries and passages. 6. Scale deposits from coolant passages. 7. Spray or wipe cylinder neoil.

~

bores and machined surfaces with

Inspect:

1. All block core plugs for lack of fit or leakage. 2. Camshaftlifter

bores for deep scratches and deposits¯

3. Cracksin the block ¯ Cylinder walls. ¯ Water jackets. ¯ Engine mount bosses. ¯ Crankshaft bearing webs. ¯ Crankshaft bearing bores and caps. ¯ All crankshaft bearing bores should be rounded and uniform in inside diameter (I.D.} at all of the bearing supports. e The area where the crankshaft bearings contact the crankshaft bearing bore should be smooth. ¯ If a crankshaft bearing cap is found to be damaged, replace the cap and line bore the block. [~ 4. Cylinder block head mountingsurface for flatness, using a precision straight edge and feeler gauge. a. Set the straight edgeon the sealing surface to be inspected. b. Takethe feeler gaugeand at various locations, checkthe gap betweenthe straight edge and the sealing surface. c. If the gap is found to be greater than 0.004 in. (0,1016 mm) within 5.984 in. (152 ram) at any sealing location, the block must be replaced.

4-32

DRC6620

Engme/eng

d. If the gap is found to be less than 0.004 in. (0,1016 mm) within 5.984 in. (152 mm)at any seabing location and a cause for leakage is suspected, then the minor irregularities maybe carefully machinedfrom the block. ¯ Oil pan and intake manifold mountingsurfaces for nicks. Minor irregularities maybe cleaned up with a flat file.

~

nder Bore Inspect:

Cylinder boresfor scoringor other damage.Refer to Generz~! EngineMechanicalsection in this manual. Measure: Cylinder bore taper and out-of-round. Refer to General Engine Mechanicalsection in this manual.

~

nder Bore Reconditioning Measure:

Refer to General Engine Mechanical section in this manual.

~

nder Block Assembly Install or Connect:

1. Front oil gallery plugs. Coat pnug outside diameter with GM Sealant, P/N 12346004,or equivalent. ~-] [~ ~ 2. Rear oil

gallery

plugs.

Tighten: DRC6623

¯ Left rear plug to 15 ft. lb. (20 N.m). ¯ Right rear plug to 18 ft. lb. (25 N.m). ¯ Left side plug to 15 ft. lb. (20 N.m). 3. :Camshaft and balance shaft cup plugs to proper depth. Coat bo~re inside diameter with GMSealant, P/N 12346004,or equivalent. [=~] important:

Do not allow residue on camshaft bear-

ing or seizure mayresult.

DRC6621

DRC6622 Engine/eng

4-33

Circulating PumpDescription TheVoLvoPentacirculating pumpis manufacturedspecially for marineuse. It is serviced only as an assembly.Donot replace with an automotive circulating pump. Inspection 1. Remove alternator and powersteering belts. 2. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag. 3. Look for water leaking from indicator hole beneathpumpshaft behind pulley. Replacepumpif play, drag, or leakageare evident. Removaland Installation 1. Drain water from block and disconnectwater hose from circulating pump. 2. Remove pulley. Remove circulating pumpbolts, pumpand gaskets. 3. Usenewpumpto block gaskets and sealer. Install on cyFinderblock and tighten bolts as specified.

newpumpassembly

4. Install pulley. Install alternator andpowersteering be~ts, then adjust tension. 5. Install hoseto circulating pump. 6. Lakeor tank test unit and checkfor leaks.

4-34

Engme/eng

Front Engine Mounts Removal LTJ 1. Removetwo lag screws (~ and washers from mounts. 2. Lift engine with a hoist capableof lifting at least 1500lb. (680 kg) to allow removalof front mount and bracket. ~=~ 3. Removethree mount screws and lock washers ®. Note sc.rew lengths and location. 25929

I~ Prior to disassembly of front mount assembly, measure distance and record measurement between large washer and flat on upper mount bracket. Disassembly ~ 1. Removethree nuts © and engine mount bracket @ from mount bolt while holding bolt secure with socket (~. ~] 2. Removetwo fiat washers, one large ® and one smaller @. Removelock washer ®, and engine mount bolt (D from mount.

25917

11980

11979

’®’® 11978

Reassembly ~]] 1. Place small washer(~) on mountbolt and insert bolt up through mount.Install large washerand securewith nut (~). Tightento 60-75ft. Ibs. (81-102Nora). 2. Install upper inner nut and place engine mountbracket on engine mountbolt. ~ Measure distance between large washer and flat bracket. Adjust distance to recorded measurement.

on upper mount 11983

3. Install lock washerand top nut.Tightennut to 100-120ft. Ibs. (138-163 N®m). Instalmation [~ 1. Spray the engine mountscrew threads with Loctite ~ Primer N and allow to air dry. Apply Volvo Penta TreadSealing AgentP/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screws and washers(~). Tighten to 32-40ft. Ibs. (43-54N [~ 2. Install washersand lag screws(~) and tighten securely. 11979

Height Adjustment [~ 1. To changeengine height, tighten or loosen nuts (~) and ~) required. Z~2. Lift enginewith a hoist capableof lifting at least 1500lb. (68(} kg). Position engineat desired height. 3. After setting mountposition, turn nut (~) up against undersideof engine bracketand hold nut with a wrench.Tighten nut (~ to 100-120ft. Ibs. (136-163 N°m). ~Any large adjustments to engine height should be followed by a checkof enginealignment. Failure to checkalignmentcould result in rapid enginecoupler failure. SeeDrive Removaland Installation section of the Sterndrivefrransom Bracket Service Manualfor alignment procedures.

25917

21929

4-36

2953 Eng=ne/eng

High-Rise Exhaust Elbow RepJacernent RemovaJ E~ 1. Loosentwo dampssecuring upper hose to elbow, lubricate inside of hose with a soapywater solution= E~2oStarboard Elbow: Removecircuit breaker bracket 3 and set aside. Remove four screws, flat washers, and lock washersmountinghigh-rise elbow. E~ [~ 3. Use a soft hammerto free elbow from manifold. Usea twisting motion to pull elbow from hose, Remove and discard the elbow gasket.

34719

Installation 1. Thoroughlyclean manifold gasket surface. Apply Volvo PentaGasket Sealing Compound P/N 1161231-4to both sides of a newmanifold gasket and place it on the exhaustmanifold. EgZ] ~ 2. Lubricate the inside of the exhaust hose with a soapy water solution. Insert the high-rise elbowinto the hosewith a twisting motion,and pushit into hoseas far as it will go. 3472q

34718

34718

Eng,ne/eng

4-37

34717

[~ 3. Position elbow on manifold. Secure eUbowsand brackets with four screws, flat washers, and lock washers. Tighten screws to 12-18 ft. Ibs. (16-24 N.m). Starboard Elbow: Install circuit breaker bracket @. Z~ 4. Slide caamps®up onto hose and position them in the two surface channels. Tighten clamps securemy.

Exhaust Hose and intermediate Pipe Replacement 34720

Removaa [~ 1. Loosen eight clamps that secure the upper @and lower @ exhaust hoses. [~ 2. Lubricate inside of lower hose with a soapy water solution, and slide lower hose downonto exhaust Y-pipe. 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose if necessary to ease removal. 4. Slide upper hose off high-rise elbow. Slide lower hose off exhaust Y-pipe.

32371

32374

\

32375

Z~ Safety Related

4-38

32363 Engine/~;ng

Installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower hose with a soapy water solution. Slide it aJl the way onto the exhaust Y-pipe. I~] ~ The inside diameter of both the upper and lower hoses has a step (~ 1=5 in. (3,81 cm) from one end. The stepped end of the hose must face the intermediate pipe wheninstalled. 2. Slide hoseonto high-rise elbowuntil it seats. If hoseis not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment.

32370

~=j EEl/~ 3. Place four No. 68 clamps on upper hose. With a twisting motion, insert intermediate pipe all the way into the upper hose. Place four No. 64 clampson lower hose. Align lower’ end of pipe with exhaustY-pipe, then slide lower hoseup until it’s; halfway onto the intermediate pipe. Position dampsin channels, and tighter= clampssecurely.

Exhaust (Flapper) Valve Replacement

32366

Removal 1. Remove the intermediate exhaust pipe following the procedure under Exhaust Hoseand Intermediate Pipe Replacement. ~’~ 2. Smidethe lower hose downfar enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the. vaJve. EEl 3. Inspect the two rubber bushings inside the pipe. Replace: them as necessary.

32367

32368

Engme/eng

~ Safety Related

4-39

Installation ® ScotchGrip Rubber 1= If installing newrubberbushings,apply3M Adhesive 1300to outsideof tips, andinsert into insideof exhaust pipe. ~2. Positionvalvewith longestlip pointingdown,andinsert into pipe. Pushpivot pin throughbushings andvalveuntil pin endis flush with outside of pipe. Checkexhaustvalvefor freedomof movement. [~lf valveis not positionedproperly(long lip down),it will restrict exhaust flow andfail to preventwaterbackingup into engine.Boatperformance wouldbe adverselyaffected, andenginemaysuffer water damage.

32368

3. Install intermediatepipe following procedure underExhaustHoseand Pipe Replacement.

EngineCoupler Replacement Removel

1. Remove enginefrom boat. If coupleris beingreplaceddueto couplerfailure (rubberhubof splined hub), checkenginealignmentafter installing newcoupler.SeeDrive Removal andInstallation section of the Sterndrive/Transom Bracket ServiceManual.

32369

2. Disconnect all wires, lines andconnectors frombellhousing. [~ ~] 3. Remove screwssecuring belihousing cover, and slide cover out.

20034

~9085

4-40

Engine/eng

ES~4. Pull drain hoseout of bellhousing. E~ 5. Unscrewbolts and nuts retaining beflhousing. Disconnect ground wires. Remove powersteering cooler bracket. 6 Remove belihousing from engine bfock. LT~’-j 7. Unscrewsix nuts securing coupler and removecoupler from studs. 8. Remove old gasketfrombellhousingcover. Cleangasketsurfacethoroughly. 19842

Instalmatiort ES~1. Install couplerand secure’with six Iocknuts. Usea suitable adaptor andtighten to 40-45ft, Ibs. (54-61N=m). E’~2. Install belihousing and attach powersteering cooler. Tighten nuts and bolts to 32-40ft. Ibs. (43-54 N,m). Attach groundwires and tighten nuts to 15-20ft. Ibs, (20-27Nom). 3. Pushdrain hoseinto belihousing. 4. Apply Vo0voPenta Gasket Sealing Compound P/N 116t 231-4 to both sides of a newbelihousinggasket and position it on cover.

6710

~.~ 5. Cleansevenself-tapping screwswith a wire brush, install bellhousing cover and screws.Tighten to 60-84in. Ibs. (7-9 N.m). 6. Connectall wires, Einesand connectorsto bellhousing. 7. Install enginein boat.

6712

8714

4-41

18996

TorqueSpecifications Balance Shaft Driven Gear Bolt .........................

15 ft. Ibs. (20 N.m)(Plus 35 degrees) 124 in. Ibs. (14 N.m}

Balance Shaft Retainer Bolts ........................................ Bell Housing Cover Screws .......................................

60-84 in. Ibs. (7-g N-m)

Bell Housing Nuts and Borers .....................................

32-40 ft. Ibs. 43-54 N-m)

Block Drain Plug ..................................................

15 ft. lbs. (20 N-m)

Block Oil Gallery Plug, Left Rear ......................................

15 ft. Ibs. (20 N.m)

Block Oil Gallery Pmug, Right Rear .....................................

18 ft. Ibs. (25 N.m)

Bkock OiR Gallery Plug, Left Side Rear ..................................

15 ft. Ibs. (20 N.m)

Camshaft Retainer

Bolt

Camshaft Sprocket Bolts

............................................

124 in. Ibs. {14 N.m}

............................................

Connecting Rod Nut .................................. Crankshaft

Balancer Bolt

Crankshaft

Bearing Cap Bolt

21 ft. Ibs. (28 N.m) 20 ft. Ubs. (27 N.m)(Plus 70 degrees)

........................................... ........................................

Crankshaft Rear Oin Seal Housing Nut and Bolt ...........................

74 ft. Ibs. (100 N.m) 77 ft. Ibs. (105 N.rn) 11 ft. Ibs. (15 N.m)

Cylinder HeadBolt First

Pass ......................................................

22 ft. Ubs. (30 N.m)

SecondPass Torque Angle all Bolts in Sequence: Short Length Bolt ................................................... Medium Length Bolt ................................................. Long Length Bolt ...................................................

55 degrees 65 degrees 75 degrees

Engine Coupler Nuts ..........................................

40-45 ft. Ibs. (54-61 N.m)

Engine Mount Screws .........................................

32-40 ft. lbs. (43-54 N.m)

Exhaust Manifold

20-26 ft. Ibs. (27-35 N-m)

Front

Nuts .........................................

Cover BoUt .................................................

106 in. Ibs. (12 N.m)

Front Mount Nut Lower ................................................... Upper ................................................

60-75 ft. Ibs. (81-102N.m) 100-120ft. Ibs. (136-163N.m)

4-42

Engme/eng

"[brqueSpecifications High Rise Elbow Nuts ..........................................

12-18 ft. Ibs. (16-24 N.m}

intake Manifold Boats First Pass ...................................................... Second Pass .................................................. Final Pass .....................................................

27 in. Ibs. (3 N.m) 106 in. Ibs. (12 N.m) 11 ft. Ibs. (15 N=m)

Oil Pan Nuts ......................................................... Bolts ......................................................... Studs in Engine Block ............................................. Oil

Pump Bolt

.....................................................

Oil

Pump Cover Bolt

..............................................

17 ft. Ibs. (23 N.m) 18 ft. Ibs, (25 N.m) 18 ft. Ibs, (25 N.m) 66 ft. Ibs. (90 N.m) 106 in. nbs. (12 N.m}

Spark Plugs Cylinder Head (New) .............................................. Cylinder Head (All Subsequent Installation} ............................ Valve Lifter

Guide Retainer Bolt .......................................

Valve Rocker Arm Cover Bolts

.......................................

22 ft. Ibs. (30 N.m} 15 ft. Ibs. (20 N.m} 12 ft. Ibs. (16 N.m) 106 in. Ibs. (12 N.m}

Valve Rocker Arm Nut ..............................................

20 ft. Rbs. (27 N.m}

W~lve Rocker Arm Stud .............................................

35 ft. nbs. (47 N.m}

E,~,,,,e;oog

4-43

EngineSpecifications Type ............................................................. Dispbacement ...................................................... Bore ......................................................... Stroke ....................................................... Compression Ratio ......................................................... Firing Order ..........................................................

OUCapacity Without Filter Change ............................................ With Filter Change Add ........................................

4 Qts=(3,75 Litres) 0.42 Qts. (0,398 Litres) 6.0 PSm(41,4 kPa) at 1,000 engine RPM 18.0 PSi (24,1 kPa) at 2,000 engine RPM 24.0 PSI (165,5 kPa) at 4,000 engine RPM

OiJ Pressure (Minimum Hot) ..........................

Oil Fi|ter

90 Degree V6 4.3L (262 CID} 4.00 in. (101,6 ram} 3.480 in. (88,39 ram} 9.2:1 1-6-5-4-3-2

System ..........................................................

OH Pump Type .........................................................

Diameter .................................... Out-of-Round ........................................... Taper ..................................................

Full Flow Gear Driven

4.0007 -4.0017 in. (101,618 - 101,643 mm) 0.002 in. (0,0508 ram) MAX. 0.001 in. (0,0254 ram) MAX.

Piston Bore Clearance ...................................

0.0024 in. (0,06096 ram} MAX.

Piston CompressionRing Groove Clearance ........................................... Gap ...................................................

0.0042 in= (0,10668 ram) 0.035 in. (0,889 ram) MAX.

Piston Oil Ring Groove Clearance ........................................ Gap ........................................................

0.008 in. (0,2032 ram) MAX. 0.065 in. (1,651 ram)

4-44

Eng,ne/eng

EngineSpecifications Engine Block Clearance Tolerance

...............................................

0.010 in. (0,254 ram) MAX.

Diameter ....................................... 0.927 - 0.926 in. (23,545 - 23,548 ram) Clearance in Piston ....................................... 0.001 in. (0,0254 ram) MAX. Fit In Connecting Rod ................ 0.0008 - 0.0016 in. (0,02032 - 0,04064ram) Interference

Surface Flatness

..........................................

0.010 in. (0,254 ram) MAX.

Surface Flatness

.........................................

0.004 in. (0,1016 ram) MAX.

Crankshaft Journal Diameter #1 ................................... Diameter #2, #3 ............................... Diameter #4 ................................... Taper .................................................. Out-of-Round .......................................... Crankshaft Bearing Clearance Bearing #1 .................................... Bearings #2, #3 ................................ Bearing #4 .................................... Crankshaft End Play .................................

2.4488 - 2.4495 in. (62,199 - 62,217 mm) 2.4485 - 2.4494 in. (62,192 - 62,215 ram) 2.4480 - 2.4489 in. (62,180 - 62,202 ram) 0.001 in. (0,0254 ram) MAX. 0.0010 in. (0,0254 ram) MAX.

0.0010 - 0.0015 in. (0,0254 o 0,0381 ram) 0.0010 - 0.0025 in. (0,0254 - 0,0635 ram) 0.0025 - 0.0035 in. (0,0635 - 0,0889 ram) 0.002 - 0.008 in. (0,0508 - 0,2032 ram)

Connecting Rod Journal Diameter ..................................... Taper .................................................. Out-of-Round ........................................... Rod Bearing Clearance ........................... Rod Side Clearance ...............................

2.2487- 2.2497in. (57,11-7 - 57,142 ram) 0.001 in. (0,0254 ram) MAX. 0.001 in. (0,0254 ram) MAX. 0.0010 - 0.0030 in. (0,0254 - 0,0762 ram) 0.006 - 0.017 in. (0,1524 - 0,4318 ram)

EngineSpecifications Journal Diaraeter

.................................

1.8677 - 1.8697 in. (47,440 - 47,490 mra)

End Pnay .......................................... Lobe Lift

0.001 - 0.009 in. (0,0254 - 0,2286 mra) - 0.002 in. (--- 0,051 ram)

...................................................

intake ..................................................... Exhaust ....................................................

0.2763 in. (0,7180 mm) 0.2855 in. (0,7252 mm)

Front Bearing Journal Diameter .................... Rear Bearing Journal Diameter ..................... Rear Bearing Journal Clearance ....................

Valve Valve Valve Face Seat Seat

2.1648 - 2.1654 in. (55,985 - 55,001 mm) 1.4994 - 1.500 in. (38,084 - 38,100 mm) 0.001 - 0.0036 in. (0,0254 - 0,09144mra)

Lifter ...................................................... Rocker Arm Ratio ..................................................... Lash Net Lash ................................................ Angle ........................................................... Angle ........................................................... Runout ............................................

Seat Width Intake ............................................ Exhaust ..........................................

Hydraulic Roller 1.50:1 No Adjustment 45 degree 46 degree 0.002 in. (0,0508 mm)MAX.

0.040 - 0.065 in. (1,016 - 1,651 mm) 0.065 - 0.098 in. (1,651 - 2,489 ram)

Stem Clearance High Limit Production + 0.001 in. (0,0257 mra) High Limit Production + 0.002 in. (0,0508 rata)

intake ................................... Exhaust ................................. Valve Spring Free Length ...................................................... Installed Height ....................................

2.03 in. (52 tara) 1.690 - 1.710 in. (42,92 -43,43 rata)

Spring Pressure Closed .................................... Open ...................................

76 - 84 lb. at 1.70 in. (338 - 374N at 43 tara) 832 - 187 - 203 lb. at 1.27 in. (903 N at 32 mm)

ValveLift intake ....................................................... Exhaust .....................................................

0.414 in. (10,51 ram) 0.428 in. (10,87 ram)

4-46

Engme/eng

GM

Special

Tools

J 5590

J 5239

J 3049

DRC6597

DRC6596

J 5825-A

-5-7

DRC6598

J 8037

j 8001

DRC6599

E~

~_~~

DRC6600

DRC6601

Pliers, Valve Lifter Remover

E2~ ConnectingRod Bolt Guide Set E3~ CrankshaftSprocketinstaller ~

Crankshaft Sprocket Remover

~

Dial indicator Set

[~

Piston Ring Compressor

J 8062 DRC6602

Valve Spring Compressor [8~ Driver Handle

J 8092 DRC6603

E rlgme/eng

4-47

Girl Special Tools

J 9290-1

J 21882 DRC6604

J 35621

J 36996

5~ J 36660 DRC6608

DRC6607

Hydraulic Valve Lifter

DRC6606

DRC6605

DRC6609

Remover

Oil Suction Pipe Installer Straight Edge

J 38834

Rear Main Seal Installer Torque/Angle Meter BalanceShaft installer

DRC6610

Balance Shaft Bearing Service Kit Harmonic Balancer Remover/Instaler

8-7 J 39046

4-48

DRC6611

Engme/eno

Section 5 5.0GL and Gi 5.7GS and GSi Table of Contents Accessories ............................... Crankshaft And Bearings .......................... Balancer .............................. Rear Oim Seal ........................... Rear Oil Seal Housing ................... Camshaft ................................ Circulating Pump.......................... Cleaning .................................. Cylinder Block ............................ Cylinder Head ............................ Engine Coupler Replacement.................... Draining ................................ Lubrication ............................. Exhaust High-Rise Elbow Replacement............ Hose Replacement ...................... (Flapper) Valve Replacement.............. Manifold ................................ Front Cover ..............................

5=6 5-31 5-17 5-30 5-31 5-25 5-38 5-4 5-35 5-14 5-43 5-6 5-4 5-40 5-41 5-42 5-7 5-23

Safety

Front Mounts ............................. GeneramDescription ........................ Special Tools ............................. intake Manitold ............................. intermediate Pipe Replacement.............. Oil Filter ................................. Oil Pan .................................. Oil Pump................................. Oil Seal, Rear, Crankshaft ................... Oil Seal Housing, Rear, Crankshaft ........... PCV System .............................. Pistons and Connecting Rods ............... Rocker Arm Cover ......................... Rocker Arm Stud Replacement.............. Specifications Engine ................................ Torque ................................ Timing Chaiin and Sprockets ................ Tools and Shop Equipment .................. Valve Train ...............................

Warnings

Before workingon any part of the engine, read the section called Safety at the endof this manual. Alwaysuse the correct fastener in the proper location. Whenyou replace a fastener, use ONLY the exact part numberfor that application. Thetext will call out those fasteners that requre replacementafter removal.The text will also cal~ out the fastenersthat require thread rockersor thread sealant. UNLESSOTHERWISE SPECiFiED, do not use supplement coatings (paint, grease,or other corrosion inhibitors) on threadedfasteners fastener joint interfaces. Generally, suchcoatings adverselyaffect the fastener torque and the joint clampingforce, and maydamage the fastener. Whenyou install fasteners, use the correct tighter~ing sequenceand tightening specifications. Followingthese instructions will help youavoid damageto parts and systems.

Engine/eng

5-1

5-39 5-2 5-54 5=6 5=41 5-20 5-18 5-2(} 5-3G 5-31 5-45 5-27 5-10 5-15 5=48 5=48 5-24 5=6 5-11

General Description Cylinder Block The engine bnock is madeof cast iron and has eight cylinders arranged in a "V" shape with four cyUinders in each bank. Wsa one piece casting with the cylinders encircled by coolant jackets. Cyainder Head The cylinder heads are cast iron and have powderedmetal valve guides and valve seats pressed into the intake and exhaust ports. The spark plugs are located between the intake and exhaust ports. Camshaft A steel camshaft is supported by five bearings pressed into the engine block. The camshaft sprocket, mountedto the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain. Motion from the camshaft is transmitted to the valves by hydraulic roiaer vamvelifters, vamvepush rods, and ball-pivot type rocker arms. Crankshaft Thecrankshaft is madeof cast nodular iron. It is supportedby five crankshaft bearings that are retained by crankshaft bearing caps which are machined with the bJock for proper aJignment and clearances. Light duty 5.7L engines have two bolts per cap. Heavy duty 5.7L engines have four bolts per cap on caps two, three, and four. Thenumberfive crankshaft bearing at the rear of the engine is the end thrust bearing. Four connecting rod journals (two rods per journal) are spaced90 degrees apart.

5=2

Engine/eng

Pistons and ConnectingRods The pistons are cast aluminumthat 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 chromiumsteel. They have a floating fit in the piston and are retained by a press fit in the connecting rod assembly. The connecting rods are madeout of either forged powderedmetal or forged steel. They are machinedwith the rod cap installed for proper clearances and alignment. Lubrication The gear-type oil pumpis driven through an extension driveshaft. The extension driveshaft is driven by the distributor which is gear driven by the camshaft. The oil is drawnfrom the oil pan through a pickup screen and tube. Pressurized oil is delivered through internal passagesto lubricate camshaft and crankshaft bearings and to provide valve lash control in the hydraulic valve lifters. Oil is metered from the valve lifters through the valve push rods to lubricate the valve rocker armsand ball pivots. Oil returning to the oil pan from the cylinder heads and the front camshaft bearing, Lubricates the camshaft timing chain and crankshaft and camshaft sprockets. V~alveTrain TIhe valve train is a ball pivot type. Motionis transmitted from the camshaftthrough hydraulic roller valve lifter,,; and tubular valve push rods to the valve rocker arms. The valw; rocker arm pivots on a ball to openthe valve. Thehydraulic roller valve lifters keep all parts of the valve train in constant contact. The valve rocker armball is retained on the valve rocker arm stud with a locking nut. Thevalve rocker armstuds are pressedinto the cylinder head. intake Manifold The intake manifold is a single piece design. It supports either a thrott!e bodyor multiple iniectors to meter and distribute fuel to each engine cylinder.

Engtne/eng

5-3

Cleaning Before cleaning the engine, remove the engine accessories to provide better access to the engine’s exterior surfaces. After removingthe throttle body, distributor, etc., cover the openings with tape to prevent the entry of cooaant, solvent, or dirt. Methodsused to cnean the engine will dependon what equipment is available. Steamcleaning, pressure washing, or solvent cleaning are someacceptable methods. ARIowthe engine to dry before beginning the work. It is important that the engine be as clean as possible to prevent dirt from entering critical areas during disassembly.

EngineLubrication "~ Full pressure lubrication, through a full-flow oil filter is supplied by a gear-type oil pump. Oil is drawn up through the oi~ pumpscreen and passesthrough the pumpto the oil fieter. The oil filter is a ruin-flow paper elementunit with an anti-drain back valve. An oil filter bypass vaUveis used to ensure adequateoil supply, in the event the filter becomesplugged or develops excessive pressure drop. Filtered oil flows into the maingallery and then to the camshaft, rear bearing, and crankshaft bearings. Thevalve ~ifter oil gallery supplies oil to the valve lifters. Oil flows from the valve lifters through the hollow valve push rods to the valve rocker arms. Oil drains back to the crankcase through oil drain holes in the cylinder head. The camshaft timing chain is drip fed from the front camshaftbearing. The pistons and piston pins are lubricated by oil spmash.

5-4

Engine/eng

o@

; s,-cT,oN c-c I

Front View

Rear View

I __ "---’--

Side View Engmne/eng

5-5

i

Tools and Shop Equipment A clean, well lit work area should be available. Other necessary equipment includes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and an adequateset of hand tools. An approvedengine repair stand will help prevent personal injury or damageto engine components. Special tools are illustrated throughout this section and listed at its end. Thesetools (or their equivalents) are specially designed quickly and safely accomplish the operations for which they are intended. The use of these tools will also minimize possible damageto engine components. Someprecision measuring tools are required for inspection of certain critical components.Torquewrencheswill be necessaryto correctly tighten various fasteners. Thosefasteners will be called out within this section.

Accessories This manuaRassumes that the engine accessories have been removed. These accessories may include one or more of the following: o o e o o o

Power Steering Pump Alternator Distributor Water Supply Pump Accessory Brackets and Electrical Starter Motor

Wiring

It is beyondthe scopeof this section to detail the manydifferent accessory installations. Refer to the proper Service Manualfor this information. Diagrams of vacuumhose routing, wiring harness routing, accessory drive belt layout, etc., should be made before removing these components.

Draining The Engine Follow the procedures in Section 1, General information of this manualto drain crankcase engine oil and the cooling system.

ExhaustManifold Removal 1. Drain waterfrom exhaustmanifolds. 2. DisconnectwaterhosefrommanifoSd. 3. Loosenupperexhausthoseclamps,then removehigh rise elbow. 4. Remove manifoldattaching nuts and washers.Discardnuts. inspection 1. Inspectfor cracks. E~2. To pressurecheckmanifold, fabricate a plate (~) as shown,and newelbowgasket(~) to seal waterpassage in manifold.Be sure to apply sealerto gasket.Install rubberdrain capsto manifoldandsecurewith clamps. Attach a GearcasePressureTester © (such as StevensCompany S-34)to the waterinlet hose.A bushingcanbe madeto securepressure tester to hose.Withthe pressuretester attachedto the manifold,submerge manifoldin water. Pressurizethe manifoldto 10-15PSI(22-25kPa) and checkfor leaks. Manifoldshouldnot leak aroundclampsandplate. If so, retightenclampsor resealplate. Nodropin pressureshouldbe realized. Installation r~ 1. Cleanmatingsurfaces on manifold and head. Install newexhaust gasket, then install manifoldandsecurewith newIocknutsandwashers. Tightennuts @to 20-26ft. Ibs. (27-35N,m). 2. Install a newgasketandhighrise elbowto manifold.Tightenbolts to 12-18ft. Ibs. (16-24N,m). 3. Install exhausthoseandsecurewith clamps. 4. Connect waterhose.Install andtighten drain petcocks. L~ 5. Start engineandcheckfor fuel leaks.

Englne/eng

5-7

intakeIVlanifoid Removal ~ 1. Drain coolant from manifoldsand both sides of block. 2. Disconnect: a. Battery cables from battery. b. Coolanthosesat thermostathousing. c. Throttle cable fromcarburetorandanchorblock. d. Crankcase ventilation hosefrom rocker armcovers(both sides). e. Wire at temperaturegaugesenderunit andenginewiring harnessfromalternator. f. Distributor hightensionandignition primaryleadsfromcoil. 3. Remove: a. Distributor cap andmarkthe position of the rotor on the housing. Scribe a line on distributor housingand intake manifold for reassemblyin the sameposition. Remove the distributor. b. Alternator andalternator mountingbracketfromengine. or fuel c. Carburetorfuel line fromcarburetorandfuel pump lines fromthrottle bodyandfuel pump/vapor separator. d. Oil pressuresendingunit. e. Manifoldattachingbolts andsolenoidbracket.Lift manifold fromengine.Discardfront andrear seals andgaskets. If manifoldis to be replaced,transfer: carburetoror throttle body and ECMbracket, thermostat and housing (use new gasket),throttle cableanchorblockassembly, distributor clampandtemperaturesendingunit. Transferadditional hardwareas required.

5-8

Engme/eng

® Old pieces of gasket or RTVfrom the gasket surfaces. ¯ Excessive carbon build-up in the intake passagesof the intake manifold. o Scale and deposits from the coolant passages of the intake manifold. Instaffation [~] Important: Do NOTreuse intake manifold gaskets. DRC6591

E3 nnstall

or Connect:

1. Sealant to the intake manifold gasket, cylinder head side. Care must be used to apply the correct amountof sealanl; onto the gasket. Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly. 2. Gasketsonto the cylinder head. a. Use gasket Iocator pins to properly seat gasket on the cylinder head.

DRC6592

[~] ~ b. Apply a 0.499 in. (13 ram) bead of GMSealant,P/N 12346141,or equivalent to the front and rear block sealant areas. c. Extend the sealer bead 0.157 in. (4 ram) onto each gasket.

4 0 rnrn 0.157IN }

3. GMThreadLocking Sealant, P/N 12345382,or equivalent to the threads of the eight Jower intake mounting bolts. 4. Lower intake manifold onto engine block.

DRCb"59g

5. Lowerintake manifold bolts.

8 4

7 ’1

Tighten: [=6~ Bolts in three steps, using the following sequence. a. The first pass to 27 in. lb. (3 N.m). Snugall bolts minimize shifting of the intake. b. Thesecondpass to 106 in. Kb. (12 N.m). DRC6593

c. Final passto 11 ft. Ib. (15 Nora).

EngIne/eng

5-9

d. Distributor with rotor and aligned exactly as markedduring removal. ~lf engine was cranked while distributor was out, complete ignition timing proceduremustbe followed. Seethe appropriate Ignition Circuit in Electrical/Ignition SystemsService Manual. e. Alternator with mounti ng bracket. Distributor cap and high tension leads. Seethe General Informationsection in Electrical/Ignition Service Manualfor correct firing order and spark plug wire routing. g. Oil pressuresendingunit. 6. Connect: a. AHelectrical connections. Apply Black NeopreneDip, on all exposedconnections. b. Fuel lines to throttle body and fuel pump/vapor separator. c. Throttle cable. d. All water hoses, and ciose all drain petcocks. e. Both crankcaseventilation hoses. f. Battery cables. 9. Start engine. Checkignition timing. Checkfor leaks.

Rocker Arm Cover Removal [~ Remove or Disconnect: 1. Valverocker armcover bolts. 2. Valverocker armcover. 3. Gasket.

5-10

DRC6647 Engme/eng

Cnean: ¯ Parts in solvent. Remove all snudgeand varnish. ¯ Old gaskets from the gasket surfaces. [~ inspect: ¯ Gasket flanges for bending or damage. ¯ Rubber grommetsand parts for deterioration. installation E~ 53 Install.or

Connect:

1. Newgasket= 2. Valve rocker arm cover. 3 Valve rocker arm cover bolts. [~ Tighten:

bolts to:

106 in= Lb. (12 N-m)

ValveTrain Removal important: Store all reusable componentsin an exact order, so they can be reassembnedin the samewear pattern location from which they were removed.Mark the front end c:f the retainer. E3 Remove or Disconnect: Tools Required:J 3049-AValve Lifter Removal(Plier Type) J 9290-01 Valve Lifter Removal (Slide Hammer Type)

/

Every effort should be madeto ensure that the mating parts are installed in their original nocations during assembly. A simple valve train componentorganizer rack can be madefrom a piece of wood. [=~ 1. Valve rocker arm nuts, balls, and valve rocker arms. E’~ 2. Valve push rods. DRCG648

DRC6850

[~] 3. Valve lifter

guide retainer and bolts.

E~] 4. Valve lifter

guides.

5. Valvelifters. Removethe valve lifters one at a time using a magnet.Place the valve lifters in the organizer rack, or tag themin a way to ensure they can be returned to the valve lifter bore from which they were removed. [~] ~ Somevalve lifters may be stuck in their bores due to gum or varnish deposits. These valve lifters can be removed using either J 3049-Aor J 9290-01. [~

DRC~49

Clean: ¯ Parts in solvent. Blow dry with compressedair. o Makesure the oil passagesin the valve push rods are clear.

[~ |nspect: o Valve rocker arms and balls at their mating surfaces. These surfaces should be smooth and free from scoring or other damage. ¯ Valve rocker arm areas that contact the valve stems and the sockets that contact the valve pushrods. Theseareas should be smooth and free of damageand wear. ¯ Valve rocker arm nuts or bolts. ["~

DRC6651

~

J9290-1

/

Important:

All enginesuse prevaiUingtorque nuts. At least 55 in. lb. (6,2 N.m) of torque should be required to thread the nuts onto the valve rocker armstuds, if not, it is possible that the nut(s) could backoff during engine operation causing a loss of lash and create valve train noise.

5-12

DRC6586

Engine/er~g

Installation important: Replace all valve roller lifters, changethe engine oil and filter, and add GMEngine Oil Supplement,P/N 1052367, or equivalent to the engine oil whenever a new camshaftis installed. Lubricate the valve lifter bodies and roller Engine Oil Supplement, P/N 1052387, or equivalent. 3 Install

with GM

or Connect:

I~ Valve lifters

in samelocation from which they were removed.

EI~ 2. Valve lifter guides, valve lifter lifter guideretainer bolts.

guide retainer and valve

Vamvelifter guide retainer must contact a01 valve lifter guides. If valve lifter guide retainer is bent it mustbe replaced. Tighten: bolts to 18 ft. lb. (25 N.m). 3. Coat valve rocker armand rocker arm ball bearing surfaces with prelube, GMEngine Oil Supplement,P/N 1052367,or equivalent:, when installing. Keep these componentsand valve push rods in samesequenceto ensure their return to the originaB position from which they were removed. = E~ 4. Valve push rods. Makesure valve push rods seat in valw, lifter sockets. ~ 5. Valve rocker arms, balls,

and nuts.

Valve Adjustment DRC6650

~] Adjust: Valve rocker arm nuts until all lash is eliminated. 1. Turn crankshaft until cast arrow on crankshaft balancer hub i,¢ in 12 o’clock position and number1 cylinder is in firing position (top dead center). ¯ Watchnumber1 cylinder valves as crankshaft balance~" = hub arrow approaches 12 o’clock position, if a valw, movesas arrow movesto position, engine assemblyis in number6 cylinder firing position. Crankshaft must then be turned one more time to reach number 1 cylindefr firing position.

Eng,ne/eng

5-13

0RC6648

2. With engine assembly in number1 cylinder firing following valves can be adjusted:

position,

¯ Exhaust1, 3, 4, 8 ¯ intake 1, 2, 5, 7 3. E}ackoff valve rocker armnut until lash is felt in valve push rod. Thentighten valve rocker armnut until all lash is removed. Zero lash can be felt by moving valve push rod up and down between thumb and forefinger until there is no more movement. 4. Whenall free play has been removed,tighten valve rocker arm nut one additional turn (360 degrees).

DRC6673

5. Turn crankshaft one revolution until hub arrow is again at 12 o’cnock position. This is number6 cylinder firing position. Following valves can now be adjusted" o Exhaust2, 5, 6, 7 ¯ intake 3, 4, 6, 8

Cylinder Head

~

nder Head Removal Removeor Disconnect:

1. Spark plugs, 2. Cylinder head bolts. 3. Cylinder heads. 4. Headgaskets. i~ Important: Use care when handling the cylinder prevent damageto the gasket sealing surfaces.

~

heads, to

nder Head Disassembly

DRC6595

J 8062

Removeor Disconnect:

Tool Required: J 8062 Valve Spring Compressor ~ 1. Valve keys. Compressthe valve springs with J 8082. Removethe valve keys and tool J 8062.

5-14

Engine/eng

~ 2. Caps and springs. 3. Valve stem oil seals, valves, and components.Place them in a rack so they can be returned to their original position at assembly. Cleaning, Inspection, and Measurement Refer to GeneralEngineMechanicalsection in this manual. Rocker Arm Stud Replacement Tools Required: J 5802-01 Valve Rocker Arm Stud Removal J 5715 Reamer0.003 in. (0,0762 mm)oversize) J 6036 Reamer0.013 in. (0,3302 mm)oversize) J 6880 Valve Rocker Arm Stud Installation

DRC6664

Valve rocker arm studs that have damagedthreads or are loose in cylinder heads should be replaced. Newstuds are available in 0°003 in. (0,0762 mm)and 0.013 in. (0,3302 mm)oversize. r47 1. Place J 5802..01 over the stud to be removed.Install a nut and flat washer. Removethe stud by turning the nut. ~] 2. Reamthe hole to the proper size for the replacement oversize stud. UseJ 5715for 0.003 in. (0,0762 mm)oversize studs, J 6036 for 0.013 in. I0,3302 mm)oversize studs.

DRC6665

3. Coat lower end (press-fit area} of stud with hypoid axle lubricant. Drive the stud into place with a hammerand J 6880. Stud is installed to proper depth whenthe tool bottoms on the cyllinder head. Cylinder Head Assembly Tools Required" J 8062 Valve Spring Compressor E~ Instag

J 6880

or Connect:

1. Valves. ¯ Lubricate the valve stems with clean engine oil. ¯ insert the valves into their proper location. 2. Oil seals. Install the oil seals over the valve stemsand seat them against the cylinder head. 3. Valve springs. DRC6666

Eng,ne/eng

5-15

4. Caps. J 8062

a. Compressthe vane spring, using J 8062. Compressthe spring enoughso the Uowervalve stem grooves can be clearly seen.

b. Apply a smaln amountof grease to the area of the upper vane stem groove. Assemble the two valve keys using the grease to hold the keys in place. Makesure the keys seat properly in the valve stem grooves. c. Release the compressortool. Makesure the valve keys stay in place.

DRC6663

d. Repeat the preceding steps on the remaining valves. [~ [~] Measure: Valve spring installed valve spring as follows"

height of each

1. Use a narrow, thin scale. A cut awayscale @maybe helpful. 2. Measurefrom the cylinder head spring seat to the top of the cap. DRC6667

Cy0inderHeadinstallation Tool Required: J 36660 Torque/Angle Meter 1~ C|ean: ® Gasket surfaces on block and cylinder head. Bnstall or Connect: 1. Headgasket onto engine block. 2. PLacethe gasket in position over the cylinder head dowel pins aligning the gasket locating mark facing up.

DRC6668

3. Cylinder headonto bBock. Carefully guide the cylinder headinto place over the dowel pins and head gasket.

5= ~ 6

Engme/eng

4. Coat threads of cylinder head bolts with GMSealing Compound, P/N 12346004,or equivalent. 5. ~der head boJts. 133)| L~J Tighten: [~ 1. in sequencefirst

pass to 22 ft. lb. (30 N-m).

E~] 2. in sequencefinal pass using J 36660 to" Short bolts -{3,4,7,8,11,12,15,16) 55 degrees. Mediumbolts - (14,17) 65 degrees. Longbolts - (1,2,5,6,9,10,13) 75 degrees.

Crankshaft Balancer RemovaJ

16

12

8 4 3 7 11

15

ToolRequired: J 39.046 Crankshaft Balancer Remover The inertial weight section of the crankshaft balancer is assembledto the hub with a rubber sleeve. The removal procedures must be followed (with the proper tools) or movement the inertial weight section of the hub witi destroy the tuning of the crankshaft balancer and the engine timing reference.

DRC6672

[~ Remove or Disconnect: J 35’(}46

1. Crankshaft balancer bolt and washer.

\

D~ 2. Crankshaft balancer using J 39046. 3. Crankshaftkey, (if necessary). DRC6671

~==’~ Inspect: Crankshaft balancer weight for signs of shifting on the hub. Replace as needed.. The area of the crankshaft hub shaft that contacts the front crankshaft seal for roughnessor nicks. Repnace the balancer if this condition exists. If balancer is replaced, new balance weights of the samesize must be installed on the new balancer in the samelocation as the old baaancer.

|nstallatien Tool Required: J 39046 Crankshaft Balancer Installer E~ install

or Connect: J 39046

The inertial weight section of the crankshaft batancer is assembledto the hub with a rubber type material. The correct installation procedures(with the proper tool) mustbe followed movementof the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

\\ DRC$671

1. Use a small amountof RTVsealant to seal the ba[ancer keyway to crankshaftjoint. [~ 2. Crankshaft balancer hub, until completeKy seated against the crankshaft position sensor reluctor ring using J 39046. 3= Removetool J 39046. 4. Bolt and washerinto front of crankshaft. Tighten: bolt to specifications: 74 ft. lb. (100 N-m).

Oil Pan

=f

Removal E~ Remove or Disconnect:

1. Oil pan bolts, nuts, and studs. DRC6637

2. Oil pan reinforcements. 3. Oil pan. 4. Oil pan gasket. Clean: o Parts in solvent. Removeall sludge and varnish. ¯ Old gaskets and RTVsealant from the gasket surfaces.

5-1

8

Engme/eng

inspect: ® Gasket flanges for bending or damage. ¯ Oil pan for damageor cracks. ¯ Drain plug threads for stripping. Installation E~ Install

or Connect:

E3-] I~ 1. Apply a small amount of GMSealer, P/N 12346141, or equivalent, to engine front cover and engine block junction, and to crankshaft rear oil seal housing and engine block junction. Apply sealer 1.0 in. (25 mm)in either direction of radius cavity junctions.

DRC6639

%

2. Oil pan gasket, oil pan and reinforcements. 3. Oil pan nuts, bolts and studs. ~ Tighten: Cornerbolts or stud, and nuts to 15 ft. lb. (20 N.m). Remainderof bolts and studs to 106 in. lb. (12 N.m). 4. Organ drain plug and gasket. Tighten: Oil pan drain plug to 18 ft. lb. (25 N.m).

Engme/eng

5-1 9

25.4 mm (1,OOIN.} DRC6640

OUFilter Removal [~ ~[~ Remove or Disconnect: 1. Oil filter, 2. Oil filter

adapter bolts and washers.

3. Oil filter

adapterand oil filter

adaptergasket.

[~ |nspect: ® Oil filter adapter bypassvalve and spring for operation. ¯ For cracked or broken bypass valve. installation Oil filter

adapter and bypassvalve must be replaced as a

unit. [~ ~] Install

or Connect:

1. Oil filter

adapterandoit filter

2. Oil filter

adapter bolts and washers.

DRC6638

adaptergasket.

Tighten: Oil filter

adapterbolts to 20 ft° lb. (26 N.m).

3. Oil filter. Tighten: Oil filter to 12 ft. lb. (16 N.m).

Oil Pump Removal []

B Remove or Disconnect:

1. Crankshaftoil deflector nuts. 2. Crankshaftoil deflector.

DRC6654

5-20

Engme/eng

3. Bolt attaching oil pumpto rear crankshaft bearing cap. 4. Oil pump,retainer, and driveshaft from rear crankshaft bearing Disassemble:

1. Driveshaft ~ and retainer (~). Do not removethe oil pumpscreen unless replacement is required. Theoil pumpscreen has a press fit in to the pump cover. Do not removethe screen from the pipe (~). The oil pumpscreen is serviced as a complete assembly only.

3

j~7

,tl

2. Oil pumpscreen pickup (~). 3, Borers (~ and pumpcover (~. Mark where the idler gear and drive gear and shaft C) meshtogether, so they can be reinstalled with the samegear teeth indexed. DRC6624

4. Idler gear and drive gear and shaft O. 5. Retaining pin 0. 6. Pressureregulator spring (&) and valve (~). [~

Clean: AIl~,,~rts in clean solvent and dry them with compressedair.

~3~II~m~ inspect: E~ important: The pump gears, cover, and body are not serviced separately. Thepressurerelief valve spring is the only serviceable component. If any of the parts are damagedor worn, the entire oil pumpassembly must be replaced. ¯ Pumpbody ~ for cracks, wear, or other damage. ¯ Inside of the cover (~) for cracks and wear that would permit oil to leak past the endsof the gears. e idler and drive gear Q for wear. ® Drive gear and shaft for lack of fit

in the pumpbody.

e Oil pumpscreen for damageto the screen or loose fit the pipe.

of

¯ Pressure regulator valve ® for fit. The regulator valve shouldslide freely in its bore without sticking or binding.

E,~,n~/ong

5-21

Assemble: r~ ~ Install

or Connect:

1. Pressure regulator valve (~ into the pumpcover (~. important: Replace the pressure relief when reusing the oil pumpassembBy.

valve spring (~

2. Pressure regulator spring (~ into the pumpcover (~. 3. Retaining pin (~ into the pumpcover (~). 4. Drive gear and shaft O into the pumpbody ~. 5. Idler

gear O into the pumpbody ~.

Match together the index marks on the two gears made during disassembly. 6. Pumpcover (~. 7. Bolts (~. [~ Tighten: to 106 in. lb. {12 N-m). With the ddveshaft ~) instalned on the pump, turn the ddveshaft by hand to check for smoothoperation.

J 21882

Be careful of twisting, shearing, or collapsing the pipe wheninstalling it to the pump.A damaged pipe can cause lack of lubrication and enginefailure. Oi| PumpScreeninstallation [~ Install

or Connect: DRC6525

1. Oil pumpscreen pickup. a. The oil pumpscreen assembly shoutd be replaced with a newpart. Loss of press fit condition could result in an air leak and loss of oil pressure. b. Mount the oil pumpin a soft jawed vise. c. Apply sealer to the end of the pipe. d. Tap the pickup screen and pipe into place, using J 21882and a hammer. e. The oil pumpscreen must be parallel with the bottom of the oil pan wheninstalled.

5-22

Engme/eng

Oil Pump installation ~ install or Connect: [~1~] 1. Oil pump driveshaft ® andretainer ®. E3~2. Oil pumpto engine. a. Align the slot in the oil pump shaftwith the tangonthe distributorshaft. b. Theoil pump shouldslide easily into place. c. Nogasketor sealeris used. E~3. Oil pumpand bolt onto crankshaftbearingcap.

~ Tighten: Boltto 66ft. lb. (£0N-m).

Engine Front Cover ~ Removeor Disconnect: ~Ot~Thecompositetiming chain cover and comeswith an integrated gasket and is NOTREUSABLE! Oncethe cover is remove,a newcover mustbe installed. E~1. Enginefront cover bolts. 2. Enginefront cover.

~ install or Connect: [NOt~A newcompositeenginefront cover mustbe usedon all "BY" model 5~0and5.7 engines.Donot reusethe composite enginefront cover , Lubricate thesealing surface of thecranksha/t frontoil sealwithcleanengine oil. L=4J1. Enginefront cover. 2. Enginefront coverbolts.

To108in. lb. (12N®m).

Eng~ne/e.g

5-23

Timing Chain and Sprockets ToolRequired" J 5825-A Crankshaft Sprocket Puller Removal [~ To prevent damageto pistons or valves, do not turn the crankshaft after the camshaft timing chain has been removed. p=.....~

~ Remove or Disconnect:

D~C6656

1. Camshaftsprocket bolts. ~

J 5825-A

2. Camshaftsprocket and camshaft timing chain together. The sprocket has a light interference fit on the cam= shaft. Tapthe sprocket on its lower edgeto loosen it. ~-~ 3. Crankshaft sprocket using J 5825-A. 4. Key (if damaged). DRC6615

inspect: 1. Sprockets for chipped teeth and wear. Excessively worn sprockets will

rapidly

wear a new

chain. 2. Camshafttiming chain for damage. [~ An excessively worn chain will of sprockets.

rapidly

wear a new set

3. Crankshaft sprocket for wear in the keywayarea. 4. Crankshaft sprocket key for wear.

5-24

Engme/eng

Installation Tool Required: J 5590 Crankshaft Sprocket Installer 53 Install

or Connect:

1. Crankshaft key (if removed). ~__4~2. Crankshaft sprocket using J 5590. [~ Bmportant: Make sure the sprocket alignment mark faces away from the engine block. Make sure the sprocket is fully seated against the crank shoumder. ES~] 3. Camshaftth~ing chain to the camshaft sprocket. 4, Camshaftsprocket and camshaft timing chain to the front of camshaft. important: E~ ¯ Makesure’that align.

camshaft and crankshaft timing marks (~)

DRC6633

The number6 cylinder is at top dead center of the compression stroke with the timing marksin this position. e Makesure the camshaft dowenpin and camshaft sprocket hole are properly aligned ¯ Gears and chain mesh. 5. Camshaftsprocket bolts. Use the bolts to draw the camshaft sprocket onto the camshaft. DONOTATTEMPT TO HAMMER THE:. CAMSHAFTSPROCKETONTOTHE CAMSHAFT. TO DO SO MAY DqSLODGETHE REAR CAMSHAFTPLUG AND/OR DAMAGETHE:. CAMSHAFT. Tighten: bolts to 21 ft. lb. (28 N.m).

Camshaft Re.oval R,====I

EJRemove Disconnect: ~=ot~] All camshaft journals are the samediameter so care must be used in removing the camshaft to avoid damage to the bearings.

En~=ne/eng

5-~5

DRC6670

1. Camshaftretainer bolts and camshaft retainer. 2. Camshaft. EEl a. Install three 5/16 - 18 (4.0 in=) long into the camshafts threaded holes. Use these bolts to handle the camshaft. t~ b. Pull the camshaft out from the bmockbeing careful to revent damageto the camshaft bearings.

[~

Measure:

CamshaftJournals. Refer to General Engine Mechanical section in this manual.Do not attempt to repair the camshaft. Replacethe camshaft if damaged. Whenever the camshaft needs to be replaced, a newset of valve lifters must also be installed.

DRC6636

Bearings Refer to General EngineMechanicalsection in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly. Installation install or Connect: Coat the camshaft lobes and journals with a high quality GMEngine Oil Supplement, P/N 1052367, or equivalent. Apply GMEngine Oil Supplement, P/N 1052367, or equivalent to all the teeth on the distributor drive gear. 1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft threaded holes. Use these bolts to handle the camshaft. [~ 2. Camshaft into the engine. Handle the camshaft carefully to prevent damageto the camshaft bearings. 3. Camshaftretainer and retainer bolts. ¯ Coat camshaft retainer plate with GMEngine Oil Supplement,P/N 1052367, or equivalent. Tighten: 106 ft. lb. (12 N.m).

5-26

Eng,ne/eng

Pistons and Connecting Rods Removal "Fool Required" J 5239 Guide Set F.==t [~.J Removeor Disconnect: 11. Before attempting to removepiston, remove cylinder bore ridge as necessary. ~ Refer to General Engine Mechanical section in this manual for cylinder bore ridge reamerprocedures. 2. Mark the cylinder numberson the tops of each piston. Mark them from the front to the rear, with the engine in an upright position and viewed from the front. ¯ The right bank is numbered1-3=5-7 ® The left bank is numbered2-4-6-8 3. Checkthe connecting rod and cap for identification marks. If none, place match marks or numbers on connecting rods and caps. Markthe parts from the front to the rear, with the engine in an upright position and viewed from the front. Connecting rod s must be assembledto their original connecting rods.

~

Important: Store the connecting rod and cap together as mating parts, so they may be reassembled in the same wear pattern and balance in which they were removed. 4. Connecting rod nuts, cap and bearings. |mportant: if reusing bearings, keep bearings with their original connecting rod and cap. ¯ Wipeoil from bearings and crank pins. 5. Connecting rods and pistons. a. Attach J 5239 to the connecting rod bolts. b. Use the long guide rod J 5239 to push the connecting rods and pistons out of the top of the engine block. Disassembly R~;fer to General Engine Mechanical section in this manualfor pi.ston and connecting rod disassembly. Assembly Refer to General Engine Mechanical section in this manual for pi~ton and connecting rod assembly.

Piston Selection Measuringthe Piston Checkthe used piston to cylinder bore clearance, as follows: [~ 1. Cylinder bore diameter. Use a tenescoping bore gauge, located 2.5 in. (65 ram) belowthe top of the cylinder bore. I~] 2. Piston diameter. Measurethe skirt at a right angle to the piston pin hole, 1.0 in. (25 ram) belowthe o[I ring groove. [~ Measure piston diameter at 70 degrees F (20 degrees C).

DRC6507

3. Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance. 4. Locate the piston-to-bore clearance, refer to Engine Specifications. Determine if the piston-to-bore clearance is within the acceptable range. Piston Ring EndGapand Fit Refer to General EngineMechanicalsection in this manual. DRC6514

[~ Important: The numberson the connecting rod and bearing cap must be on the sameside wheninstamnedin the cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be renumbered to correspond with the new cylinder number. Installation Tools Required: J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Torque/Angle Meter !~ |nstall

or Connect:

1. Lubricate the cyninder walls lightny with engineoil. 2. Makesure the piston is installed in the matchingcylinder. 3. Connecting rod bearings. a. Makesure the crankshaft bearings are the proper size. b. Install cap.

the crankshaft bearings in the connecting rod and

c. Lubricate the bearings with engine oil.

5-28

Eng,ne/eng

4. Piston and connecting rod into the proper bore. a. With the connecting rod cap removed, install onto the connecting rod bolts.

}

J 5239

b. Locate the piston ring end gaps. Lubricate the piston and rings with engine oil. [~ c. Without disturbing the ring end gap location, install ,J 8037 over the piston and compressthe rings. d. Place the piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft. Using light blows with a hammerhandle, tap the piston down into its bore. At the sametime, from beneaththe engine, guide the connecting rod onto the crankpin with J 5239. Hold the ring compressoragainst the block until all rings have entered the cylinder bore. e. RemoveJ 5239 from the connecting rod bolts. E~ important: Each connecting rod and bearing cap should be rnarked, beginningat the front of the engine. Cylinders 1, 3, and 5 are the right bank and 2, 4, and 6 are the left bank (whenviewed from the front). The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore. if a connecting rod is ever transposedfrom one block or cylinder to another, newconnecting rod bearings should be fitted and the connecting rod should be numberedto correspond with the new cylinder number.

D1~(~10

ENGINELEFT

ENGINEFRONT

ENGINERIGHT

..~-- A, D

A OIL RINGSPACER GAP (TANGrN HOLEORSLOTWITHINARC) B OIL RINGR/UL GAPS RING GAP C 2NOCOMPRESSION RINGGAP 0 TOPCOMPRESSION

DRC6627

J 8037

5. Connecting rod cap with crankshaft bearing. 6o Connectingrod bolt nuts. [~ Tighten: DRC6628

20 ft. lb. (27 N.mj plus an additional 55 degreesusing J 36660. L=~"3 Measure: Refer to General Engine Mechanical section in this manual for connecting rod side cUearanceprocedure.

Engme/eng

5=29

CrankshaftRear Oil Seal Removal [~ Take care whenremoving the rear crankshaft oil as not to damagethe crankshaft sealing surface=

seal so

E~ Remove or Disconnect: [~ Insert a screwdriver into the notches provided in the oin seal housing and removethe oil seal. DRC6658

Installation TooJRe~_~uired: J 35621CrankshaftRearOia Seal Installer [~i’~’~L=LJ |nstail

or Connect:

1. Lubricate the inner and outer diameterof the oil seal with clean engineoil. 2. InstalB the oil seal on J 35621. 3. Position J 35621against the crankshaft. Threadthe attaching screws into the tapped holes in the crankshaft.

J 35621

4. Tighten the screws secureny with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft. 5. Turn the handle until it bottoms. 6. RemoveJ 35621.

5-30

Englne/er~g

Crankshaft Rear Oil Seal Housing Removal E3~ B Remove or Disconnect: 1. Bolts and nuts. 2. Oil seal housing. 3. Gasket. DRC6657

Clean: Gasketsurfaces on the block and seal retainer. Instai|ation [3~ ~ Install

or Connect:

® Always use new crankshaft rear oil seal and newhousing gasket during installation of rear oil seal housing. 1, Newgasket to the block. It is not necessary to use sealant to hold the gasket in place. 2. Oil sear retainer. 3 Screws and nuts. [~ Tighten: to 11 ft.

lb. (15 N.m).

Crankshaft And Bearings Removal The crankshaft need not be removedfor replacement of the rear oil seal or crankshaft bearings. Thoseproceduresare covered in othr~arts of this section. !¥1 LtJ Important: Check the crankshaft bearing caps for aocation markings, Mark the caps if necessary, The caps must be returned to their original locations during assembly,

Engme/eng

5-31

B Remove or Disconnect: [~ 1. Crankshaft bearing cap bolts and studs. 2. Crankshaft bearing caps and lower crankshaft bearings. 3. Crankshaft from the cylinder block with extreme care, taking care to avoid damageto crankshaft journals and thrust flange surfaces. 4. Upper crankshaft bearings. Cleaning, inspection, and Repair Refer to GeneralEngineMechanicalsection in this manual for cleaning, inspection, and measurements. The following is the recommended gasket cleaning procedure for General Motors engine components: Carefully removeaH gasket material from the part using a plastic or woodscraper. Use Loctite brand "Chisel Gasket Remover"(P/N 4MA)or equivalent. Do not use any other methodor technique to removegasket material from a part. Do not use abrasive pads, sand paper or power tools to ctean gasket surfaces. These methods of cleaning can damagethe part. Abrasive pads also producea fine grit that the oil filter cannot removefrom the oil. This grit is abrasive and has been knownto cause internal engine damage.

DRC6659

mf the engine is damaged internally and needsto be rebuilt, make sure all foreign material is completely flushed out of the cooling and lubrication systems. Failure to rid the oil or cooaing systems of debris can result in damageto the rebuilt engine. Measure: Crankshaft bearing vertical inside diameter (ID). Use an inside micrometer. This dimension should be the same as the other crankshaft bearing bore vertical diameters. [~

Clean:

[~ Use care not to scratch crankshaft journams. ¯ Crankshaft with solvent. ¯ Blow all debris from the oil passageswith compressed air. ¯ Crankshaftbearings. Wipefree of oil with a soft cloth. ¯ Oil seal surfaces with a non-abrasive cleaner.

5-32

Engme/eng

hstallation [~ important: Crankshaft bearings are the precision insert type and do not use shims for adjustment. If clearances are excessive, a newbearing will be required. Service bearings are available in standard size and 0.001 in. (0,0254 mm},0.002 in. (0,0508 mm),0.010 in. (0,2540 ram), and 0.020 in. (0,5080 mm)undersize. Also a 0.009 in. (0,2286 ram) is avaiJable for 5.7L enginesonly. Selective fitting of both connectingrod and crankshaft bearings is necessary to obtain close tolerances. For this reason you may use, for example, one half of a 0.001 in. (0,0254 mm}undersize bearing which will decreasethe clearance 0.0005 in. (0,0127 mm) from using a full standard bearing. Undersize Crankshaft Journals Whena production crankshaft cannot be precision fit by the methoddescribed previousUy, it is then ground 0.009 in. (0,2286 ram) undersize. GRIND ONLY THOSECRANKSHAFT JOURNALS THAT CANNOTBE PROPERLYFITTED. ALL JOURNALSWILL NOT NECESSARILYBE GROUND. A 0.009 in. (0,2286 ram} undersizebearing or 0.010 in. (0,254 ram) undersize bearing will then be used for precision fitting in the samemanner as previously described. Oversize Rear Crankshaft Bearing Thrust Faces Someproduction engines mayhave rear crankshaft bearings that are 0.008 in. (0,2032 ram) wider than standard across the thrust faces. Thecrankshaft on these enginescan be identified by "’.008’" stampedon the rear counterweight. If the rear crankshaft bearings are replaced, they must have the proper distance between thrust faces to obtain correct crankshaft end play. ~2=~ ~3 install

or Connect:

er crankshaft bearing to the block.

=

~]

important: if any undersized bearings are used, they mustbe fitted to the proper journals.

2. Crankshaft. 3. Lowercrankshaft bearings to the crankshaft bearing caps. Measure:, Refer to GeneraUEngine Mechanical section in this manu~al for crankshaft bearing clearance procedures.

E~,oe’~..

5-33

4. Apply engine oil to the crankshaft bearings. Install crankshaft bearing caps and bolts to the baock. DONOTinstall the rear crankshaft bearing cap at this time. [~E] In order to prevent the possibitity of cylinder block and/or crankshaft bearing cap damage,the crankshaft bearing caps are to be lightly tapped into their cylinder block cavity using a brass or leather mallet before attaching bolts are installed. DONOT USE ATTACHINGBOLTSTO PULL CAPS INTO THEIR SEAT. IT]

Important:

The arrows on the crankshaft

bearing caps

mustbe facing the front of the engine. [~ Tighten: Crankshaft main bearing cap bolts to specifications. All inboardbolts 74 ft. lb. (100 N.m). Outboardbolts (four bolt caps} 67 ft. lb. (90 N.m). 5. Rearcrankshaft bearing cap and bolts to the baock. [~ Tighten: bolts temporarily to 35 in. lb. (4 N.m). I~

Measure: Crankshaft end play, as follows:

EEl 1. Firmly thrust the crankshaft first rearward then forward. This will line up the rear crankshaft bearing and crankshaft thrust surfaces. [~

Tighten:

Rear crankshaft bearing cap bolts to specifications" 74 ft. lb. (100 N.m}.

DRC$530

5-34

Engineieng

2. With the crankshaft wedgedforward, measureat the front end of the rear crankshaft bearing with a feeler gauge. The proper c’iearance is 0.002 - 0.006 in. (0,0508 - 0,1524ram). 3. If correct end play cannot be obtained, makesure the correct size rear crankshaft bearing has been installed. Production engines mayhaverear crankshaft bearings that are 0.008 in. (0,2032 ram) wider across the thrust faces than standard, as expnained iousJy.

~

|nspect:

Crankshaft for binding° Try turning the crankshaft to check for binding. If the crankshaft doesnot turn freely, loosen the crankshaft bearing cap bolts on one cap at a time until the tight bearing is located. Burrs on the bearing cap, foreign matter betweenthe bearing and the block or the bearing cap, or a faulty bearing could cause a lack of clearance at the bearing. ¯ A bent crankshaft could cause binding. Makesure the steps outlined in GeneramEngine Mechanical section have been performed when checking for a bent crank= shaft. DRC6661

Cylinder Block Disassembly ~] Remove or Disconnect: 1. Coolantdrain fittings, 2. CooUingjacket plugs. DRC6662

Obtain a suitable self-threading screw. Drill a hole into the pSug and install the self-threading screw. Remove jacket plugs. 3. Oil gallery plugs. [~

Clean:

1. Sealing material from mating surfaces. 2. Boil cylinder block in caustic solution. o Flush with clean water or steam. 3. CyUinderbores. 4° Threadedholes.

Englne/eng

5-35

5. OHgalleries and passages. 6. Scale deposits from coolant passages. 7. Spray or wipe cylinder neoil.

~

bores and machined surfaces with

|nspect:

1. All block core plugs for lack of fit or leakage. 2. Camshaftlifter

bores for deep scratches and deposits.

3. Cracksin the b~ock a. Cylinder walls. b. Waterjackets. c. Engine mount bosses. d. Crankshaft bearing webs. e. Crankshaft bearing bores and caps. ¯ All crankshaft bearing bores should be rounded and uniform in inside diameter (i.D.) at all of the bearing supports. ¯ The area where the crankshaft bearings contact the crankshaft bearing bore should be smooth. ® If a crankshaft bearing cap is found to be damaged, repRacethe cap and line bore the block. [~ 4. Cylinder block head mounting surface for flatness, using a precision straight edge and feeler gauge. a. Set the straight edgeon the sealing surface to be inspected.

DRC6521

b. Takethe feeler gaugeand at various locations, checkthe gap betweenthe straight edge and the sealing surface. c. If the gap is found to be greater than 0.004 in. (0,1016 ram) within 5.984 in. (152 ram) at any sealing location, the block must be replaced. d. if the gap is found to be less than 0.004 in. (0,1016 mm) within 5.984 in. (152 mm}at any sealing location and a cause for leakage is suspected, then the minor irregularities maybe carefully machinedfrom the block. ¯ Oil pan and intake manifold mountingsurfaces for nicks. Minor irregularities maybe cleaned up with a fiat file.

5-36

Englne/eng

Cylinder Bore [~ inspect: Cylinder bores for scoring or other damage.Refer to General Engine MechanicaUsection in this manual. ~]

Measure: Cylinder bore taper and out-of-round. Refer to General Engine Mechanicansection in this manual. DRC6660

C~nder Bore Reconditioning Measure: Refer to General Engine Mechanical section in this manual, Cylinder Block Assembly Instal| or Connect: 1. Oil gallery plugs. Coat plug outside diameter with GM Sealant, P/N 12346004,or equivalent. DRC6661

2, Camshaftcup plugs to proper depth. Coat bore inside diameter with GMSealant, P/N 12346004,or equivalent. important: Do not allow residue on camshaft bearing or seizure mayresuJt. 3, Coolantdrain fittings. DRC6662

En;ime/eng

5-37

Circulating Pump Description The Volvo Pentacirculating pumpis manufactured specially for marine use. It is serviced only as an assembly.Donot replace with an automotive circulating pump. inspection 1. Remove alternator and powersteering belts. 2. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag. 3. Look for water leaking from indicator hole beneathpumpshaft behind pulley. Replacepump if play, drag, or leakageare evident. Removaland installation 1. Drain water from block and disconnectwater hose from circulating pump. 2. Remove pulley. Remove circulating pumpbolts, pumpand gaskets. 3. Usenewpumpto block gaskets and sealer. Install on cylinder block and tighten bolts as specified.

newpumpassembly

4. Install pulley. Install alternator andpowersteering belts, then adjust tension. 5. Install hoseto circulating pump. 6. Lakeor tank test unit and checkfor leaks.

5=38

Engme/eng

25829

11980

25917

Front Engine Mounts Removal E1-=] 1. Removetwo lag screws ~) and washers from mounts. ,~’~ 2. Lift enginewith a hoist capableof lifting at least 1500lb. (880 kg) to aJlow removalof front mountand bracket. [=2--] 3. Removethree mount screws and lock washers ®. Note screwlengths and IIocation. [~ Prior to disassembly of front mount assembly, me~,sure distance and record measurement between large washer and flat on upper mount bracket.

11979

O

Disassembly [:’~ 1. Removethree nuts © and engine mount bracket @from mountbolt while h onding bolt secure with socket ~. ~-~ 2. Removetwo flat washers, one large O and one smaller @. Removelock washer ®, and engine mount bolt (~ from mount.

"®’@ 11978

Reassembly ~B--’] 1. Place small washer@on mountbolt and insert bolt Ul;) through mount, install large washer and secure with nut ©. Tighten to 60-75ft. Ibs. (81-102 N.m). E4~2. Install upper inner nut and place engine mount bracket ~ on engine mount bolt. Measuredistance between large washer and fiat on upper mount bracket. Adjust distance to recorded measurement. 3. Install lock washerand top nut. Tighten nut to 100-120ft. Ibs. (136-163 N-m).

E.,~,.~/~.~ Z~ Safety Related

5-39

11983

25817

25929

2953

installation ~1 Spray the engine mountscrew threads with Loctite ~ Primer N and allow to air dry. Apply Volvo PentaTreadSealing Agent P/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screwsand washers.Tighten to 32-40ft. Ibs. (43-54N,m). [~ 2. Install washersand lag screwsand tighten securely. Height Adjustment E~ 1 To changeengine height, tighten or loosen nuts (~ and @required. ~2. Lift engine with s hoist capable of lifting kg). Position engineat desired height.

34719

at least 1500lb. (680

E~ 3. After setting mountposition, turn nut @up against undersideof enginebracket and hold nut with a wrench.Tightennut (~ to 100-120ft. Ibs. (136-163 Nom). ~Any large adjustments to engine height should be followed by a checkof enginealignment.Failure to checkalignmentcould result in rapid engine coupler failure. SeeDrive Removaland Instamlation section of the SterndrivefrransomBracket Service Manualfor alignment procedures.

34720

High-Rise ExhaustElbowReplacement Removal ~1. Loosentwo clamps securing upper hose to elbow. Lubricate inside of hosewith a soapywater solution. E~ 2~ Starboard Elbow: Remove circuit breaker bracket (E) and set aside. Remove four screws, flat washers,and lock washersmountinghigh-rise elbow.

34718

[~ E~ 3. Usea soft hammerto free elbow from manifold. Use a twisting motion to pull elbow from hose. Remove and discard the elbow gasket.

5-40

34716 Engme/eng

1. Thoroughlyclean manifold gasket surface. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a new manifold gasket and place it on the exhaustmanifold. E~ [~ 2. Lubricate the inside of the exhaust hose with a soapy water solution. Insert the high-rise elbowinto the hosewith a twisting motion,and pushit into hoseas far as it will go. E~ 3. Position elbow on manifold. Secureelbowsand brackets with four screws,flat washers,and lock washers.Tighten screwsto 12-18ft. Ibs. (16-24 N®m}.StarboardElbow:Install circuit breakerbracket (~. Eg--] ~ 4. Slide clamps (~ up onto hose and position them in the two surface channels. Tighten clamps securemy.

Exhaust Hose and intermediate Pipe Replacement Removal [~r~ 1. Looseneight clamps that secure the upper © and lower exhaust

hoses®. 32371

[] 2. Lubricate inside of lower hose with a soapywater solution, and slide lower hose downonto exhaust Y-pipe. [~"~ 3. Twist intermediatepipe out of upper hose. Lubricate inside of upper hose if necessaryto ease removal. 4. Slide upperhoseoff high-rise elbow.Slide lower hoseoff exhaustY-pipe.

32374

32375

32363 Eng,ne/eng

5-41

32370

32366

32363

anstaIiation ~] 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.Do lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe. [~ ~ The inside diameter of both the upper and lower hoses has a step (~ 1.5 in. (3,81 cm) from one end. The stepped end of the hose must face the intermediate pipe wheninstalled. 2. Slide hoseonto high-rise elbowuntil it seats.

32374

ff hose is not properly positioned, it will not completely engagethe high-rise elbow or allovv secure attachment. [~ [~ L~ 3. Place four No. 68 clamps on upper hose. With a twisting motion, insert intermediate pipe all the way into the vpper hose. Place four No. (]4 clampson lower hose. Align lower end of pipe with exhaustY-pipe, then slide lower hoseup until it’s hatfway onto the intermediate pipe. Position clampsin channels and tighten cOamps secureOy.

Exhaust {Flapper) Valve Replacement

32367

Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hose and Intermediate Pipe Repmacement. 2. Slide the lower hose downfar enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the valve. [~ 3. Inspect the two rubber bushings inside the pipe. Replace them as necessary.

Z~ Safety Related

5-42

32368

Engme/eng

Installation E6=71. If installing newrubber bushings, apply 3M® ScotchGrip Rubber Adhesive1300to outside of tips, and insert into inside of exhaustpipe. [~7~2. Position valve with longestlip pointing down,andinsert into pipe. Pushpivot pin throughbushingsandvalve until pin endis flush with outside of pipe. Checkexhaust valve for freedomof movement. [~ If valve is not positioned properly (long lip down),it will restrict exhaustflow and fail to preventwater backingup into engine. Boat performancewould be adversely affected, and engine maysuffer water damage.

32369

3. Install intermediate pipe following procedureunder ExhaustHoseand Pipe Replacement.

Engine Coupler Replacement Removal 1. Remove engine from boat. ENO-~if coupler is being replaced due to coupler failure (rubber hub of splined hub), checkengine alignmentafter installing newcoupler. SeeDrive Removaland installation section of the Sterndrive/TransomBracket Service Manual.

20034

2. Disconnectall wires, lines and connectorsfrom bellhousing. [] ~ 3. Removescrews securing bellhousing cover, and slide cover out.

19085

Er,.£,ne/eng

5-43

[~ 4. Pull drain hose out of bellhousing. [~] 5, Unscrewbolts and nuts retaining bellhousing. Disconnectground wires. Remove powersteering cooler bracket. 6. Remove bellhousing from engine block. [~7. Unscrewsix nuts securing coupler and removecoupter from studs, 8. Remove old gasket from bellhousing cover. Clean gasket surface thoroughly. 1%842

installation E~I. Install coupler and secure with six Iocknuts. Usea suitable adaptor andtighten to 40-45ft. Ibs. (54-61N®m). [~ 2. mnstall bellhousing and attach powersteering cooler. Tighten nuts and bolts to 32-40ft. Ibs. (43-54 N.m). Attach groundwires and tighten nuts to 15-20ft. ~bs. (20-27N,m). 3. Pushdrain hoseinto bellhousing. 4. Apply Volvo Penta Gasket Seating Compound P/N 1161231-4to both sides of a newbellhousing gasketand position it on cover.

6710

[~] 5. Cleansevenself-tapping screwswith a wire brush. Install beflhousingcover and screws.Tightento 60-84in. robs. (7-9 N,m). 6. Connectall wires, lines and connectorsto bellhousing. 7. Install enginein boat.

6712

6714

5-44

19996 Engme/eng

Positive Closed-TypeVentilation System A malfunctioning closed crankcase ventilation system may be indicated by loping or rough engine idle. Do not attempt to compensatefor this idle condition by disconnecting the crankc, ase ventilation systemand makingcarburetor adjustments. The removal of the crankcaseventilation systemfromthe enginewilll adverseUyaffect fuel economy and engineventilation with resul’rant shortening of engine life. To determine whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the following tests.

1. RemovePCVvalve from its mounting, but leave vacuuminlet side connectedto hose. If the valve is functioning properly and not plugged, a hissing noise will be heard as air passesthrough valve. A strong vacuumwill be felt whena finger is placed over valve inlet. Check for vacuumleaks in hose line and at all connections. 2. Reinstall PCVvalve, then removecrankcase air inlet hose at flame arrestor connection. Loosely hold a small piece of stiff p~lper (such as a 3 x 5 memo card or parts tag card) over opening at end of inlet hose. After a minute or so, (to allow crankcase pressure to lower) the piece of paper should be sucked against hose opening with a noticeable force.

-__ o,-,= RemovePCVvalve from its mounting and shake it. A metallic clicking noise should be heard, indicating that valve parts are free, andnot sticking. if ventilation systempassesthese two tests, it can be considered functionally OK,andno further service is required. If it fails either test, replace PCVvalve and repeat Engine idling Test. If ..system still doesnot pass test, clean ventilation systemhoses ar, d all passagesto induction systemin accordancewith estab-. lished procedures. Servicing PCVValve Donot attempt to c~eancrankcaseventilation regulator valve, it should be replaced. Clean crankcase ventilation system connection(s) on intake manifold by probingwith a flexible wire or bottle. brush. Clean hoses, tubes and associated hardware with a Ioww31atility, petroleum-basesolvent and dry ,with compressedair.

E rl(ll ne/eng

5-45

TorqueSpecifications Metric

English

12N,m

106in Ib

25 N,m 25 N,m

18ft Ib 18ft Ib

27 Nora

20ft Ib

Camshaft CamshaftRetainer Bolt ...................................... CamshaftSprocketBolt ...................................... Valve Lifter GuideRetainer Bolt ................................

Crankshaft Connecting Rod Nut ......................................... First Pass ................................................. Second Pass .............................................. Crankshaft Balancer Bolt ..................................... CrankshaftBearingCapBolt and Stud First Pass (Two Bolt Bearing Cap) .............................. SecondPass (Two Bolt Bearing Cap) ........................... First Pass (Four Bolt Bearing Cap) ............................. Final PassOutboardBolt (Four Bolt Bearing Cap) ................. Final PassInboard Bolt and Stud (Four Bolt BearingCap)........... Crankshaft Pulley Bolt ....................................... Crankshaft RearOil Seal HousingNut and Bolt .................... Crankshaft Rear Oil Seal HousingRetainer Stud .................. Engine Coupler Nuts (SX/DP-S) ............................... Engine Flywheel Bolt (DP-D/DP-E)............................. Windage Tray Nut ..........................................

55 Degrees 95 N-m

70ft lb.

20 N,m

15ft Ib 73 Degrees

20 N,m

15ft Ib 43 Degrees 73 Degrees

58 Nora 12 N,m

43ft Ib 106in Ib

6 N,m 56 N,m 100 N®m 40 N,m

53in Ib 43ft Ib

30 N,m

22ft Ib

74ft Ib 29ft Ib

Cylinder Head Cylinder HeadBolt All Bolts First Pass( In Sequence).............................. Long Bolt Final Pass (In Sequence)............................ MediumBolt Final Pass (In Sequence).......................... Short Bolt Final Pass (In Sequence)............................ Cylinder HeadCore Hole Plug ................................. Distributor CapBoEt ......................................... Distrubutor ClampHold DownBolt ..............................

75 Degrees 65 Degrees 55 Degrees 20 N,m 2.4 Nora 25 N,m

15ft Ib 21in Ib 18ft Ib

15 N°m

11ftlb 22ft Ib 106in lb

ExhaustManifoldBolts First Pass ................................................. Final Pass ................................................ Rocker Arm Cover Bolt .......................................

30 N,m 12 N,m

5-46

EngineJeng

TorqueSpecifications Metric

English

Engine Block Circulating Water PumpBolt .................................. Engine Block Coolant Drain Plug ............................... Engine Block Oil Galley Plug .................................. Engine Coolant Temperature(ECT) GaugeSensor................. Engine Front Cover Bolt ...................................... Engine Oil Pressure GaugeSensor .............................

45 N.m 20 N®m 20 N,m 20 N°m 12 Nom 15 N,m

33ft Ib 15ft Ib 15ft Ib 15ft Ib 106in Ib 11ft Ib

81-102 N®m

60-75ft Ib 100=120 ft Ib 15ft Ib 15ft Ib

Front Mount Lower Nut ................................................. Upper Nut ................................................. KnockSensor(fuel injected models) ............................ SquareSocket Plug (Engine Block Oil Galley) ....................

136-163 N®m 20 N,m 20 N,m

Oil Pan Oil Pan Drain Plug ..........................................

25 N,m

Oil Pan Stud (Fronl) ......................................... Oil Pan Stud Nut ............................................ Oil Pan Bolt or Stud Bolt .....................................

6 N,m 25 N,m 12 N.m

Oiil Filter .......................................... Oil Filter BypassValve Bolt ...................................

18ft Ib 53in Ib 18ft Ib 106in Ib

16 N-m

t2 ft Ib

26 N,m

20ft Ib

90 N,m 12 N,m

66ft Ib 106in Ib

30 N-m 15 Nom

22ft Ib 11ft lb

3 N,m 12 N,m 15 N,m

27in Ib 106in Ib 11ftlb 11ftlb

Oil Pump Oil PumpBolt to RearCrankshaft Bearing Cap.................... Oil PumpCover Bolt ......................................... Spark Plug ................................................ Initial Installation (NewCylinder Head).......................... All Subsequentinstallations ...................................

#1take Manifold First Pass (in sequence) ..................................... SecondPass (in sequence) ................................... Final Pass (in sequence)..................................... Final Pass (in sequence).....................................

Engfne/eng

5-47

15 N,m

5.0GLand Gi EngineSpecifications Metric

English

Engine Engine Type .......................................... Displacement .........................................

V8 5.0 L 94.89mm

Bore ................................................ Stroke ............................................... CompressionRatio ..................................... Firing Order ..........................................

88.39mm 9.4:1 1-8-4-3-6-5-7-2 1.52mm

Spark Plug Gap ....................................... Oil Pressure(min. hot) .................................. Oil Pressure (rain, hot) .................................. Oil Pressure (rain. hot) ..................................

41.4 kPa@1000 r/m 124 kPa @2,000 r/m 165 kPa@4,000r/m

305 CID 3.736in 3.480in

0.060in 6.0 psig @1,000 r/m 18.0 psig @2,000 r/m 24.0 psig @4,000 r/m

Camshaft End Play ............................................. Journal Diameter ...................................... Lobe Lift (Exhaust) ..................................... Lobe Lift (intake) ...................................... ConnectingRod Bearing Clearence(Production) ........................... Bearing Clearence (Service) ............................. Connecting RodJournal Diameter ......................... ConnectingRodJournal Taper (Production) ................. ConnectingRodJournal Taper (Service) .................... ConnectingRodJournal Out-of-Round(Production) ........... ConnectingRodJournal Out-of=Round(Service) .............. Connecting rod Side Clearence ...........................

0.11 - 0.30mm 47.440 - 47.490 mm 7.20 - 7.30 mm 6.97 - 7.07 mm

0.004- 0.012in 1.8677- 1.8697in 0.283- 0.287in 0.274- 0.278in

0.033 - 0.078 mm 0.025 - 0.063 mm 53.304 - 53.334 mm 0.007 mmMax. 0.025 mmMax. 0.007 mmMax. 0.025 mmMax. 0.15 - 0.68 mm

0.0013- 0.0031in 0.0010- 0.0025in 2.0986- 2.0998in 0.0003in Max. 0.0010in Max. 0.0003in Max. 0.0010in Max. 0.006- 0.027in

0.018- 0.053 mm 0.030 - 0.068 mm

0.00070.00120.00080.00100.0010-

Crankshaft CrankshaftBearing Clearence#1 (Production) ............... CrankshaftBearingClearence#2,#3, and #4 (Production) ...... CrankshaftBearing Clearence#5 (Production) ............... CrankshaftBearing Clearence#1 (Service) .................. CrankshaftBearingClearence#2,#3, and #4 (Service) ......... CrankshaftBearing Clearence#5 (Service) .................. CrankshaftEnd Play ................................... CrankshaftJournal Diameter #1 and #5 ..................... CrankshaftJournal Diameter#2, #3 and #4 .................. CrankshaftJournal Taper(Production) ...................... CrankshaftJournal Out-of-Round(Priduction) ................ CrankshaftRunout at Rear Flange .........................

5"48

0.020 0.025 0.025 0.038 -

0.060 mm 0.051 mm 0.064 mm 0.063mm

0.05 - 0.20 mm 62.189 - 62.212 mm 62.181 - 62.207 mm 0.005 mmMax. 0.005 mmMax. 0.038 mm

0.0021in 0.0027tn 0.0024in 0.0020 m 0.0025in

0.0015- 0.0025=n 0.002- 0.008in 2.4484- 2.4493in 2.4481- 2.4491in 0.002 in Max. 0.002in Max. 0~0015 in

Eng~ne/eng

.......

..............

5.0GL and Gi EngineSpecifications Metric

English

94.876 - 94.929 mm 0.025 mm 0.05 mm 0.025 mm 0.012 mm 0.025 mm

3.7353- 3.734in 0.001in

0.10 mm 0.05 mm 0.10 mm

0.004in 0.002in 0.004in

0.018 - 0.053 mm

0.0007- 0.002in 0.0007- 0.0026in

Cylinder Bore Diameter ............................................. Out-of-Round (Production) ............................... Out-of-Round (Service) ................................. Taper (Production - Relief Side) ........................... Taper(Production .1 Thrust Side) ........................... Service Limit ........................................... Cylinder Head Surface Flatness (Engine Block Deck) ...................... Surface Flatness (Exhaust Manifold Deck) .................. Surface Flatness (intake Manifold Deck).................... Pi,~ton Piston Bore Cleare~qce(Production) ........................

0.002in 0.0010in 0.0005in 0.0010in

Piston Bore Clearence(Service) .......................... Piston Pin

0.018- 0,068

Clearencein Piston (Production) .......................... Clearencein Pistor, (Service) ............................. Diameter ............................................. Interfearence Fit in ConnectingRod........................ Piston Rings (End GapsMeasuredin Cylinder Bore)

0.010 - 0.020 mm 0.013- 0.025 mm 23,545 - 23.548 mm 0.021 - 0.040 mm

0.0004- 0.0008in 0.0005- 0.0010in 0.9270- 0.9271in

0.030 - 0.070 mm

0.0012- 0.0027in

0.040 - 0.080 mm

0.0015- 0.003in

0.030 - 0.090 mm

0.0012- 0.0035in

0.040 -0.100 mm 0.25 - 0,51 mm 0.46 = 0.66 mm 0.25 - 0.65 mm 0.46- 0.90 mm 0.051 - 0.17 mm 0.051 - 0.22 mm

0.0015- 0.0040in 0.010- 0.020in 0.018- 0.026in 0.010- 0.025in 0.18- 0.035in 0,002- 0.006in 0.002- 0.009in

0.25 - 0.76 mm 0.25- 0.89 mm

0.010- 0.30in 0.010- 0.35in

Piston Compression Ring GrooveClearence (Production - Top Groove) ............................... Piston Compression Ring GrooveClearence (Production - 2rid Groove)............................... Piston Compression Ring GrooveClearence (Service - Top Groove) .................................. Piston Compression Ring GrooveClearence (Service ° 2nd Groove) .................................. Piston Compression Ring Gap(Production - TopGroove)....... Ring Gap(Production - 2nd Groove)...... Piston Compression Piston Compression Ring Gap(Service - Top Groove)......... Piston CompressionRing Gap(Service- 2nd Groove)......... Piston Oil Ring GrooveClearence(Production) ............... Piston Oil Ring GrooveClearence(Service) ................. Piston Oil Ring Gap(Production) .......................... PistonOil Ring Gap(Service) ............................

Engirm/eng

5-49

0.0008- 0.0016in

5,0GL and Gi Engine Specifications Metric

English

Valve System HydrauticRoller

Valve Lifter ........................................... Valve Roker Arm Ratio .................................. Valve Lash ........................................... degrees(1 Turn) fromzero lash Valve Face Angne...................................... Valve Seat Angle ......................................

1.5"1 Rotate Valve RockerArmNut Clockwise360

Valve Seat Runout ..................................... Valve Seat Width (Exhaust) .............................. Valve Seat Width (Exhaust - HeavyDuty) ................... Valve Seat Width (intake) ................................ Valve Spring Free Length ................................ Valve Spring Installed Height (Exhaust) ..................... Valve Spring installed Height (Intake) ...................... Valve Spring Pressure (Closed) ........................... Valve Spring Pressure (Open) ............................ Valve StemClearenceExhaust(Production) ................. Valve Stern Clearenceintake (Production) .................. Valve StemC~earneceExhaust(Service) ................... Valve StemCJearenceIntake (Service) .....................

5-50

45 Degrees 46 Degrees 0.05 mmMax. 1.65 - 2.49 mm

0.002 in Max. 0.065- 0.098in

1.14 - 1.78 mm 51.3 mm 42.92 - 43.43 mm 42.92 - 43.43 mm

0.045- 0.070in 2.02in 1.67- 1.70in 1.67- 1,70in 338 - 374 N @43.2 mm76 - 84 Ib @1.70 in 832 - 903 N @32.2 mm187 - 203 Ib @1.27 in 0.025 - 0.069 mm 0 0010- 0.0027in 0,025 - 0.069 mm 0 0010- 0.0027in 0.025 - 0.094 mm 0.0010- 0.0037in 0.025 - 0.094 mm 0.0010- 0.0037in

Engineteng

5.7GS and GSi Engine Specifications Metric

English

Engine Engine Type .......................................... Displacement ......................................... Bore ................................................ Stroke ............................................... CompressionRatio ..................................... Firing Order .......................................... Spark Plug Gap.......................................

V8 5.7 L 101.63 mm 88.39 mm 9.4:1 1-8-4-3-6=5-7-2 t .52mm 41.4 kPa@1000 dm 124 kPa @2,000 r/m

350 CID 4.0012in 3.480in

165 kPa@4,000r/m

0.060in 6.0 psig @1,000 r/m 18.0 psig @2,000 r/m 24.0 psig @4,000 dm

0.11 - 0.30ram 47.440 - 47.490 mm

0.004- 0.012in 1.8677o 1.8697in

Lobe Lift (Exhaust) ..................................... Lobe Lift (intake) ...................................... Connecting Rod

7.20 - 7.30 mm 6.97- 7.07 mm

0~283- 0.287in 0.274- 0.278in

Bearing Clearence (Production) ........................... Bearing Clearence (Service) ............................. Connecting Rod Journal Diameter ......................... ConnectingRodJournal Taper(Production) ................. ConnectingRodJournal Taper (Service) .................... ,ConnectingRodJournal Out-of-Round(Production) ........... ,ConnectingRodJournal Out-of-Round(Service) .............. Connecting rod Side Clearence ........................... Crankshaft

0.033 - 0.078 mm 0.025 - 0.063 mm

0.0013- 0.0031in 0.0010- 0.0025in

53304 - 53.334 mm 0.007 mmMax. 0.025 mmMax. 0.007 mmMax.

2.0986- 2.0998in 0.0003in Max. 0.0010in Max. 0.0003in Max. 0.0010in Max. 0.006= 0.027in

Oil Pressure(min. hot) .................................. Oil Pressure(min. hot) .................................. Oil Pressure(min. hot) .................................. Camshaft End Play ............................................. Journal Diameter ......................................

,CrankshaftBearing Clearence#1 (Production) ............... CrankshaftBearingClearence#2,#3, and #4 (Production) ...... CrankshaftBearing Clearence#5 (Production) ............... CrankshaftBearing Clearence#1 (Service) .................. CrankshaftBearingClearence#2,#3, and #4 (Service) ......... CrankshaftBearing Clearence#5 (Service) .................. CrankshaftEnd Play ................................... CrankshaftJournal Oiameter #1 and #5 ..................... Crankshaft Journal Diameter#2, #3 and #4 .................. Crankshaft Journal Taper(Production) ...................... CrankshaftJournal Out-of-Round(Priduction) ................ Crankshaft Runout at Rear Flange .........................

0.025 mmMax. 0.15- 0.68turn 0.018 - 0.053 mm 0.030 - 0.068 mm 0.020 - 0.060 mm 0.025- 0.051 mm 0.025 - 0.064 mm 0.038 - 0.063mm 0.05 - 0.20 mm 62.t89 - 62.212 mm 62.181 - 62°207mm

0.0007- 0.0021m 0.0012- 0.0027in

0.0015- 0.0025in 0.002- 0.008in 2.4484- 2.4493in 2.4481- 2.4491in

0.005turn Max. 0.005 mmMax. 0.038 mm

0.002 in Max. 0.002 in Max. 0.0015in

0.0008- 0.0024=n 0.0010- 0.0020in 0.0010- 0.0025In

5.7GS and GSi Engine Specifications_ Metric

English

Cylinder Bore Diameter ............................................. Out-of-Round (Production) ............................... Out-of-Round (Service) ................................. Taper(Production - Relief Side) ........................... Taper (Production - Thrust Side) ..........................

101.618- 101.643mm 4.0007- 4.0017in 0.025 mm 0.001in 0.002in 0.05 mm 0.0010in 0.025 mm 0.012 mm 0.025 mm

0.0005in 0.0010in

Surface Flatness (Engine Block Deck) ......................

0.10 mm

Surface Flatness (Exhaust Manifold Deck) .................. Surface Flatness (Intake Manifold Deck).................... Piston

0.05 mm 0.10 mm

0.004in 0.002in

Piston Bore Clearence(Production) ........................ Piston Bore Clearence (Service) .......................... Piston Pin

0.018 - 0.053 mm 0.018 -0.068

0.0007- 0.002in 0,0007- 0.0026in

Clearencein Piston (Production) .......................... Clearencein Piston (Service) ............................. Diameter ............................................. Interfearence Fit in ConnectingRod........................ Piston Rings (End GapsMeasured in Cylinder Bore)

0.013 - 0.023mm 0.013 - 0.025 mm 23.545 - 23.548 mm 0.021 - 0.040 mm

0.00050.00050.92700.0008-

0.030 - 0.070 mm

0.0012- 0.0027in

(Production - 2nd Groove) ............................... Piston CompressionRing GrooveClearence (Service - Top Groove) .................................. Piston Compression Ring GrooveClearence

0.040 - 0.080 mm

0.0015- 0.003in

0.030 - 0.090 mm

0.0012- 0.0035in

(Service - 2nd Groove) .................................. Piston Compression Ring Gap(Production - Top Groove)....... Piston Compression Ring Gap(Production - 2nd Groove)...... Piston Compression Ring Gap(Service - Top Groove)......... Piston CompressionRing Gap(Service- 2nd Groove).........

0.040- 0.100 mm

0.0015- 0.0040in

0.25 0.46 0.250.46 -

0.098- 0.015in 0.018- 0.025in

Piston Oil Piston Oil Piston Oil Piston Oil

0.046 - 0.096 mm 0,046 - 0.100 mm 0.25 - 0.76 mm 0.25 - 0.90 mm

Service Limit .......................................... Cylinder Head

Piston Compression Ring GrooveClearence (Production - Top Groove) ............................... Piston CompressionRing GrooveClearence

Ring GrooveClearence(Production) ............... Ring GrooveClearence(Service) ................. Ring Gap(Production) .......................... Ring Gap(Service) ............................

5-52

0.40 mm 0.66 mm 0.50 mm 0.80 mm

0.004in

0.0009in 0.0010in 0.9271in 0.0016in

0.009- 0.019in 0.018- 0.031in 0.0018- 0.0037in 0,0018- 0.0039in 0.010- 0.30in 0.010- 0.35in

Engineleng

5.7GSandGSi EngineSpecifications Metric

English

valve System HydraulicRoller

Valve Lifter ........................................... Valve Roker Arm Ratio .................................. ’valve Lash ........................................... 360degrees(1 Turn) from zero lash Valve Face Angle ...................................... Valve Seat Angle ...................................... Valve Seat Runout ..................................... Valve Seat Width (Exhaust) ..............................

4!5 Degrees 46 Degrees 0.05 mmMax. 1.65 - 2.49 mm

0.002in Max. 0.065- 0~098in

Valve Seat Width (Exhaust - HeavyDuty) ................... Valve Seat Width (I, ntake) ................................ Valve Spring Free Length ................................ Valve Spring Installed Height (Exhaust) ..................... ValveSpring Installed Height (Intake) ......................

1.50 ° 2.56 mm 1.02 - 1.65 mm 51.3 mm 42.92 - 43.43 mm 42.92 - 43.43 mm

0.059- 0.101in 0.040- 0.065in 2.02in 1.67- 1.70in 1.67- 1.70in

ValveSpring Pressure (Closed) ........................... ValveSpring Pressure (Open) ............................. ValveStemClearenceExhaust (Production) .................

338 - 374 N @43.2 mm76 - 84 Ib @1.70in 832 - 903 N @32.2 mm187- 203Ib @1.27 in 0.025 - 0.069 mm 0 0010- 0.0027in 0.025 - 0.069 mm 0 0010- 0.0027in 0.025 - 0.094 mm 0.0010- 0.0037in 0.025 - 0.094 mm 0.0010- 0.0037in

1.5:1 Rotate Valve RockerArmNut Clockwise

ValveStemClearenceIntake (Production) .................. ValveStemClearnece Exhaust (Service) ................... ValveStemClearenceIntake (Service) .....................

Eng~ne/eng

5-53

GIVI SpecialTools

J 5715

2~

DRC6675

DRC6674

4-~

J 6880

J 5802-01

J 6036

"~

5~ J 24086-C DRC66"/7

DRC6676

J 24270

DRC657S

DRC6582

® J 35468

DRC6~07

DRC6678

[~ [~ [~ [~ I~ [~ [~

J 36660

J 35621

RockerArmStud Bore Reamer0.003 in. (0,0762 ram) O.S. RockerArmStud Bore Reamer0.013 in. (0,3302 ram) O.S. Rocker Arm Stud Remover RockerArmStudInstaller) Piston Pin Remover / Instanler Cylinder Bore Ridge Reamer Front CoverAligner / Oil Sealinstaller CrankshaftRearOil Seal installer Torque Angle Meter CrankshaftBalancer Remover/ Installer

3

Engine;eng

5-54

DRC6608

J 39046 DRC6611

GMSpecial Tools

J 3049

J 5239 DRC6596

_-~

J 5590 Df~6597

J 8037

J 5825-A DRC$Sg9

DRC6598

3 8062 DRCSS01

DRC6802

J 38834

DRC6680

E~

VaJve Lifter

J 21882

J 9290-01

J 8358

Remover (plier

D~C6610

DRC6605

type)

E~] Connecting Rod Guide Tool Crankshaft Sprocket Unstaller ~D Crankshaft Sprocket Remover ~D Piston Ring Compressor ~ ~-~ Valve Spring Compressor

J 23738-A

E/~ Carbon Removal Brush Valve Lifter Remover(slide hammertype) ~

DRC6681

Oil PumpScreen installer ~

Vacuum Pump

5-55

Engme/eng

NOTES

5-56

Section 6 7A Gi Engines Table of Contents Camshaft installation ................................................. 6-24 Removal ..................................................... 6-10 Circulating Pump ............................................ 6-31 Crankshaft Balancer Installat:ion ................................. 6-30 Balancer Removal ....................................... 6-7 BearingCapandBearingRemoval ......... 6=12 8earing installation ................................... 6.21 Rear Oil SealInstallation.......................... 6=23 Cylinder Block Assembly ................................................... 6-14 Clean andinspect ..................................... 6-13 Disassembly ............................................... 6.12 Cylinder Head installation .................................................. 6.27 Removan ........................................................ 6-9 Service ....................................................... 6.20 Engine Coupler Replacement ........................ 6-35 Engine Front Cover Clean andinspect ..................................... 6.15 |nstaliation ................................................. 6.26 Removal ....................................................... 6-9 Engine Specifications ..................................... 6.37 Exhaust (Flapper)VaJve Replacement .................. 6-34 Hose Replacement ................................... 6.34 Manifo|d Replacement ................................ 6.6 Front EngineMountReplacement ................ 6-31 General Description .......................................... 5=2

General MotorsSpeciaR Tools........................ 6-42 High-RiseExhaustElbowReplacement ....... 632 intake Manifold Installation ................................................. 6-29 Removal ....................................................... 6=7 Service ....................................................... 6.16 intermediate PipeReplacement ................... 6.34 Lubrication System ......................................... 6=18 Oil Pan installation ................................................. 6-26 Removal ....................................................... 6.9 Oil Pump Instalhition ................................................. 6=26~ Removal ....................................................... 6=91~ Service ....................................................... 6.18 Piston, ConnectingRod, and Bearing installation ................................................. 6-23 Removal ..................................................... 6.11 Piston Selection .............................................. 6-14 Timing Chain and Sprockets InstaUlation ................................................. 6-25 Removal ..................................................... 6.10 Torque Specifications ..................................... 6=40 Valve Rocker Arm Cover installation ................................................. 6-29 Removal ....................................................... 6.7 Valve Rocker Arm and Push Rod Installation.................................................

6-28

Removal ..................................................... 6-10 ValveTrainComponents ................................ 6-19

Safety Warnings Before workingon any part of the engine, read the section calRed Safety at the end of this manual. Alwaysuse the correct fastener in the proper location. Whenyou replace a fastener, use ONLYthe exact part numberfor that application. The text wUl call out those fasteners that require replacement8fter removal. The text will also call out the fasteners that require thread lockers or thread sealant. UNLESSOTHERWISE SPECIFIED, do not use supplement coatings (paints, greases, or other corrosioninhibitorsl on threaded fasteners or fastener joint interfaces. Generally, suchcoatings adverselyaffect the fastener torque and the joint clampingforce, and may damagethe fastener. Whenyou install fasteners, use the correct tightening sequence and tightening specifications. Following these instructions can help you avoid damageto parts and systems.

General Description Cylinder Block The engine block is madeof cast iron and has eight cylinders arranged in a "V" shape with four cylinders in each bank. it is a one piece casting with the cylinders encircled by coolant jackets. Cylinder Head The cylinder heads are cast iron and have parent metal inlet valve guides and inlet valve seats. Cast iron exhaust valve guides and powered metal valve seats are pressed into the exhaust ports. Camshaft A steel camshaft is supported by five bearings pressed into the engine block. The camshaft sprocket, mountedto the front of the camshaft, is driven by the crankshaft sprocket through a camshaft timing chain. Motion from the camshaft is transmitted to the valves by hydraulic roller valve lifters, valve push rods, and ball-pivot type rocker arms.

6-2

Engme/eng

Crankshaft ]’he crankshaft is madeof cast nodular iron. The crankshaft is supported by five crankshaft bearings. The crankshaft bearings are retained by the crankshaft bearing caps which are machined with the block for proper alignment and clearances. The engine crankshaft bearing caps are retained by four boEts each. The numberfive crankshaft bearing at the rear of the engine is the end thrust bearing. Four connecting rod journals (two rods per journa0 are spaced 90 degrees apart. Pistons and Connecting Reds ]’he pistons are cast aluminum that use two compression rings and one oil control ring assembly.The piston pins are a floating fit i,n the pistons and are retained by a press fit i~n the connectingrod assembly. Connecting rods are forged steel, with precision type insert crankpin bearings. Lubrication The gear-type oil pumpis driven through an extension driveshaft. The extension ddveshaft 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. Pressurized oiR is delivered through internal passages to gubricate camshaft and crankshaft bearings and to provide valve lash control in the hydraulic valve lifters. Oil is metered from the valve lifters through the valve push rods to lubricate the valve rocker armsand ball pivots. Oil returning to the oil pan from the cylinder heads and the front camshaft bearing, lubricates the camshaft timing chain and c;rankshaft and cams haft sprockets. Valve Train "[’he valve train is a ball pivot type. Motionis transmitted from the camshaft through hydraulic roller valve lifters and tubular valve push rods to the valve rocker arms. The valve rocker arm pivots on a ball to openthe valve. Thehydraulic roller valve lifters keep all parts of the valve train in constant contact. The valve rocker arm and balls are retained by bolts.

Englne/eng

6-3

DRC6932

EngineLubrication

Cleaning

EEl Full pressure lubrication, through a full-flow oil filter is suppliedby a gear-typeoil pump.OiEis drawn up through the oil pump screen and passesthrough the pumpto the oil filter. The oil filter is a full-flow paper e~ementunit with an anti-drain back valve. An oil filter bypassvalve is used to ensure adequateoil supply, in the event the filter becomesplugged or develops excessive pressure drop.

Before cleaning the engine, remove the engine accessories to provide better access to the engine’s exterior surfaces. After removing the throttle body, distributor, etc., cover the openings with tape to prevent the entry of coolant, solvent, or dirt. Methods used to clean the engine wial dependon what equipment is available. Steam cleaning, pressure washing, or solvent cleaning are some acceptable methods. Allow the engine to dry before beginning the work.

Filtered oil flows into the main gallery and then to the camshaft, rear bearing, and crankshaft bearings. The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the valve lifters through the hollow valve push rods to the valve rocker arms. Oil drains back to the crankcase through oil drain holes in the cyUinder head. The camshaft timing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oit splash.

It is important that the engine be as clean as possible to prevent dirt from entering critican areas during disassembly.

-4

Eng[neleng

Too|s and Shop Equipment A clean, wenl lit work area should be available. Other necessary equipment incaudes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and an adequate set of hand tools. An approvedengine repair stand will help prevent personal injury or damageto engine components. Special tools are illustrated throughout this section and listed at its end. Thesetools (or their equivalents) are specially designed quickly and safely accomplish the operations for which they are intended. The use of these tools will also minimize possible damage to engine components. Someprecision measuring toons are required for inspection of c, ertain critical components.Torquewrencheswill be necessaryto correctly tighten various fasteners. Thosefasteners will be called out within this section. Accessories ]’his manual assumes that the engine accessories have been removed. These accessories may include one or more of the following: ¯ ¯ e ¯ e e

Power Steering Pump Alternator Distributor Water Supply Pump Accessory Brackets and Electrical Starter Motor

Wiring

It is beyondthe scopeof this section to detail the manydifferent accessory instaltations. Refer to the proper Service Manual for this information. Diagrams of vacuumhose routing, wiring harness routing, accessory drive belt layout, etc., should be made before removing these components. Draining The Engine Follow the procedures in Section 1, GeneraRinformation of this manual to drain crankcase engine oil and the cooling system.

Errglne/eng

6-5

Exhaust Manifold Replacement Removal ~ Drain water from respective exhaust manifold before beginning procedure. 1. Remove high-rise exhaustelbowfollowing procedureunderHigh-Rise ExhaustElbow Replacement. 2. Carefullypull wiresoff sparkplugs. 3. Loosenhoseclampat front of manifold,andpull off waterhose. 4. Remove manifoldattaching screws,nuts andwashers.Discardnuts. Remove manifold and discard manifold gasket. Cleaning Cleanmatingsurfaceson manifold andcylinder head.Cleanthe threadson the exhaustmanifoldbolts. Inspection Inspectfor cracks.Topressurecheckmanifold,fabricate a plate (~) shownand a newelbowgasket ® to seal water passagein manifold. Be sure to applyseafer to gasket.Install rubberdrain capsto the manifoldand securewith clamps.Attach a gearcasepressuretester (such as Stevens Company S-34) to the plate. An adaptorbushingcan be usedto secure pressuretester to the plate. Withthe pressuretester attachedto the manifold, submerge manifoldin water. Pressurizethe manifoldto 10-15PSi (22-25kPa) andcheckfor leaks. Installation 1. Install a newexhaustmanifoldgasket.

B[]E~2. Install

manifold and securewith bolts, washersand new Iocknuts.Tightennutsto 20-26ft. Ibs. (27-35N,m).Tightenbolts to 24=28 ft. Ibs. (33-38N,m). 3. Attachwaterhoseto nipple at front of manifoldandtighten clamp 4. Attachsparkplug wiresto plugs. Makesurefiring orderis correct. 5. Install high-rise exhaustelbowfollowing procedureunderHigh-Rise Exhaust Elbow Replacement ~6. Start engine and checkfor water and exhaustleaks,

6-6

Engtne/ertg

Crankshaft Baiancer Removal Tools Required: J 23523-F Crankshaft Balancer Remover/hstaller

\

\

Removeor Disconnect: J 23523 -

1. Crankshaft balancer retaining bolt and washer. ~4~ 2= Crankshaft balancer using Special Tool P/N J 23523-F Crankshaft BaJancer Remover/InstaLler. DRC6913

Intake Manifold Removal Removeor Disconnect: 5~ 1. Upper intake manifold bolts. 2. Upper intake manifold and gaskets. Discard the gaskets. 3, Lower intake manifold bolts. Do not attempt to loosen the manifoJd by prying under the gasket surface with any tool. The lower intake manifold gaskets are reusabRe,

DRC6891

4. Lower intake manifold by pulling up on the manifold. 5. Lower intake manifold gaskets and seals,

Valve Rocker Arm Cover Removal Removeor Disconnect: 1. Valve rocker arm cover bolts.

DRC6893

2. Valve rocker arm cover and gasket. Discard the gasket.

DRC6895

Engme/eng

6=7

Valve Rocker Arm and Push Rod Removal Tools Requited: J 3049-A Valve Lifter Removal(Plier Type) J 9290-01 Valve Lifter Removal (Slide Hammer Type) {]~~~ Every effort should be made to ensure that the mating parts are installed in their original locations during assembly. Removeor Disconnect: I~ 1. Valve rocker arm bolts, guides.

balls,

rocker arms and push rod

DRC6898

I~ 2. Valve push rods. Note: The exhaust valve push rods are longer than the intake valve push rods. EE] 3. Splash shield. EE] 4. valve lifter

guide retainer bolts and retainer.

EEl 5. Lifter guides. DRC6897

6. Valvelifters a. Usea magnetin order to removethe valve lifters time.

one at a

b.Tag the valve lifters in a way to ensure they can be returned to the valve lifter bore from which they were removed. c. Somevalve lifters maybe stuck in their bore due to gum or varnish deposits. These valve lifters can be removed by using either J 3049-A Valve Lifter Removal (Plier Type), or J 9290-01 Valve Lifter Removal(Slide Hammer Type).

DRC5914

DRC6915

6-8

DRC6916 EnglneJeng

Cylinder Head Removal Removeor Disconnect: 1, Cylinder headbolts. 2, Cylinder Head. Note: Handle the cylinder heads carefully prevent damageto the gasket sealing surfaces.

to

3. Cylinder head gasket. Discard the gasket. DRC6907

C)il Pan Removal Removeor Disconnect: ET~1. Oil pan bolts, 2. Oil pan. 3. Oil pan gasket. Discard the gasket.

Oil PumpRemoval

DRC6909

Removeor Disconnect: 1. Bolts that attach the oil pumpto the rear crankshaft bearing cap. o 2. Oi~ pump, the retainer, crankshaft bearing cap.

and the driveshaft

from the rear

Engine Front Cover Removal DRC6910

Removeor Disconnect: EEl 1. Engine front cover bolts.

¢

2. Engine front cover and gasket. Note: The engine front cover gasket is reusable.

b= I

~C6901

E,~g,ne/eng

6-g

riming Chain and Sprockets Removal Tools Required: J 28509-A Crankshaft Sprocket Remover Measure:Thecamshafttiming chain free play, if the chain can be movedback and forth in excessof 0.825 in. (16 ram), makea note that the camshaft timing chain and sprockets must be repJaced during assembly. Removeor Disconnect: FT] 1. Camshaft sprocket bolts.

DRC6903

2. Camshaft sprocket and camshaft timing chain. 3. Crankshaft sprocket using J 28509-A Crankshaft Sprocket Remover. 4, Crankshaft key, if necessary.

Camshaft Removal [~ Removeor Disconnect: 1. Camshaftretainer bolts and camshaft retainer. 2. Install three 5/1e - 18 x 4 in. bolts in the camshaftfront bolt holes. 3. Carefully rotate and pull the camshaft out of the engine block.

DRC6906

6-10

Englne/eng

Piston, Connecting Rod, and Bearing RemovaJ Tools Required: J 24270 Ridge Reamer J 5239 Connecting Rod Guide Tool ~D,o not remove excessive material from the cylinder bore. Excessive removal of material mayrequire cylinder boring to the next oversize. Removeor Disconnect: ~_~ 1. Cylinder bore ridge as necessary.

/

a. Rotate the crankshaft until the piston is at BDC= b. Place a cloth on top of the piston. c. Perform the cutting operation using J 24270 Ridge Reamer.Refer to the manufacturer’s instructions before using the tool. d. Removethe special tool e. Rotate the piston to TDC and remove the cloth cuttings

and

f. Repeatthe; procedure for the remaining pistons.

DRC6510

~Place the match marks or numbers on the connecting rods and the connecting rod caps. The rod caps must be assembledto their original connecting rods. 2. Connecting rod nuts. ~lf reusing keep the bearings with their orighlal connecting rods and rod caps. Wipe the oil from the bearings and crank pins. 3, Connecting rod caps and bearings.

DRC6619

E-~ 4. Connecting rod and piston out of the top of the engine biock using J 5239 Connecting Rod Guide Tool, 5. Remaining piston and connecting rod assemblies from the engine block.

Engme/eng

6-11

Crankshaft Bearing Cap and Bearing Removal ~ Check the crankshaft bearing caps for location markings. Mark the caps if necessary. The caps must be returned to the original nocations with the arrow pointing forward during assembly. Removeor Disconnect: E~ 1. Crankshaft bearing cap bolts. 2. Crankshaft bearing caps.

DRC6917

3. Crankshaft. 4. Crankshaft upper bearings from the engine block. 5. Crankshaft lower bearings from the crankshaft bearing caps. 6= Rear crankshaft oil seal from the crankshaft. Discard the seal.

Cylinder Block Disassembly Removeor Disconnect: [~ 1. Cooling jacket plugs by using the following

procedure:

a. Obtain a suitable self-threading screw. b. Drill a hole into the pJug. c. Install the serf-threading screw. d. Removethe jacket plug 2. Oil gallery plugs. DRC6918

3. Oil pumpswitch. 4. Knock Sensor. 5. Oil bypass valves. Discard the valves.

6-12

Englne/eng

Cylinder Block Clean and inspect Clean: 1, Sealing material from the mating surfaces, 2. Boil the cylinder" block in a caustic solution. 3. Flush the cylinder block with clean water or steam. 4. Cylinder bores. 5. Oil galleries and the passages. 6. Scale deposits from the cooling system passages, 7. After cleaning the engine block, spray or wipe the cylinder bores and machinedsurfaces with clean engine oil. |nspect: t. VaNenifter

bores for deep scratches and varnish deposits.

2. Checkthe bores, for cracks. 3. Cylinder walls for scoring. 4. Cooling jackets. 5. Crankshaft bearing webs. 6. Engine mounting bosses. 7. Crankshaft bearing bores and the crankshaft bearing caps for the following: 8. All crankshaft bearing bores must be round and uniform in inside diameter (ID) at all the bearing supports. a. The area where the crankshaft bearings contact the crankshaft bearing bore must be smooth. b. Note if a crankshaft bearing cap is damagedand requires replacement. Refer to Crankshaft and Bearings Ch,~an and inspect

b ..

E.3_~__9. Checkcylinder head gasket surfaces for flatness using a straight edge and a feeler gauge. The surface must be flat within 0,004 in. (0,10 mm). DRC6620

E’~glne/eng

{3-13

Cylinder Block Assembly Tools Required: J 35748 Fuel Pump/Oil Pressure Switch Installation Socket install or Connect: 1. Newoil bypass valves. 2. Knock Sensor into cylinder block after applying a water base caulk to the sensor threads. Tighten: KnockSensorto 14 ft.

Ibs. (19 N.m).

3. Oil pressure switch using J 35748 Fuel Pump/Oil Pressure Switch Installation Socket. [~ 4. Oil gallery plugs. Tighten: Oil gallery plugs to 15 ft. Ibs. (20 N.m). 5. Cooling jacket plugs. 6. Cylinder block cooling drain plugs. Tig hten: Cylinder block drain plugs to 15 ft. Ibs. (20 N.m).

Piston Selection DRC6918

Measure: Checkthe used piston-to cylinder bore clearance in the following manner: [~ 1. Using a telescoping bore gauge located 2.5 in. (65 ram) below the top of the cylinder bore, measure the cylinder bore diameter. [~ 2. Piston diameter at 70° F (20° C)0 3. Skirt at a right angle to the piston pin hole, 1 in. (25 mm)below the oil ring groove.

6-14

DRC6507

~---~

DRC6514 Engme/eng

4. Subtract the piston diameter from the cylinder bore diameter in order to determine the piston-to-bore clearance. 5. Determineif the piston-to-bore clearance is within the acceptable range. Refer to Specifications found elsewherein this section. 6. if the used piston is not acceptable, determine if a newpiston will fit the cylinder bore. 7. If the newpiston will not bring the clearance within tolerances, the cylinder must be reconditioned. Refer to Cylinder Boring and Honing found in tile General Engine Mechanical section in this manual 8. Markthe piston to identify the cylinder for which it was fitted.

EngineFront Cover - Clean and Inspect Disassemble: E4-=~Remove the crankshaft front oil seal. Drive the seal out with multiple hits on the inside of the seal from the inside of the cover. Caean: Sealer from the front cover and engine case. Inspect: 1. Timing tab marker. 2. Front cover. Assembly: DRC6921

Tools Required: J 22102 Crankshaft Seal Installer 5~ 1. Coat the seal lips with grease.

J 22162

:2. Place the open end of the seal toward the inside of the front cover. Use J 22102Crankshaft Seal Installer to install the seal.

DRC6900

Englne/eng

6-15

intake Manifold Service Upper intake Manifold Disassembly Removeor Disconnect: [~ 1. Throttle

body nuts.

E~ 2. Throttle

body.

E~ 3. Throttle

body gasket and studs. DRC6922

Lower intake Manifold Disassembly

%

Removeor Disconnect: 1. MAPSensor nut, retainer

and the MAPSensor.

2. Fuel rail bolts and stud. E~ 3. Fuel rail. 4. Coolant housing bolts, coolant housing, and thermostat from lower intake manifold.

DRC6923

5. CoomantTemperature Sensor from the lower intake manifold. Cmeanand inspect: 1. Gasketsurfaces. 2. Intake passagesof the intake manifold. 3. Coolant passagesof the intake manifold. Lower intake Manifold Assembly []~~~ Do not install the thermostat without the rubber O-ring seal. Omitting the rubber O-ring seal may result in poor engine warm-up. Install or Connect: 1. Thermostat, coolant housing and bolts to lower intake manifold. Tighten: DRC6925

Bolts to 30 ft. Ibs. (40 N-m).

N i ..........

6-16

DRC6926 Engine/eng

2. Coolant Temperaturesensor to Rowerintake manifold. Tighten: Sensorto 15 ft. Ibs. (20 N.m). ~ L.ubricate the injector O-ring seals with dean engine oil and instaUl on the spray tip end of each injector. L-~ 3. Fuel rail assembly in the intake manifoJd. Tilt assemblyto install the injectors.

the rail

E4~4. FueJ rail attaching bolts and stud. Tighten: Bolts to 89 in. Ibs. (10 N.m) Stud to 18 ft. Ibs. (25 N.m). 5, MAPSensor, retainer,

and nut to the lower intake manifold.

Tighten: Nut to 18 ft. Ibso (25 N.m). Upper intake Manifold Assembly Install or Connect: E3-=] 1. Throttle bodystuds. Tighten: Studs to 106 in. tbs. (12 N-m). 2. ThrottJe body gasket. ~2:~ 3. Thrott}e body. EI:~] 4. Throttle body nuts. Tighten: Nuts to 89 in. Jbs. (10 N.m).

Eng,ne/eng

6-17

Oil PumpService Disassembly Removeor Disconnect: ~J~~ Do not

remove

the

pick

up screen

and pipe.

They are only serviced as part of the oil pump. [~ 1. Oil pumpshaft and retainer. 2. Oil pumpbody screws.

DRC6927

3. OiL pumpbody cover. ~Mark the gear teeth so the pump can stalled with the samegear teeth indexed.

be in-

4. Drive gear and shaft. 5. Idler gear. 6. Pressure relief valve spring retaining pin. 7. Pressurerelief

valve spring.

8. Pressurerelief valve. Clean and Inspect: ~The oiD pump is serviced as an assembly. Do not attempt to service the individual components. The pressure relief valve spring is the only serviceable component.Replacethe pumpif any wear to the pumpgears or housing exists. 1. Oil pump housing and cover for cracks, imperfections and damagedthreads.

scoring,

casting

2. Drive gear shaft, ff the shaft is loose in the pumphousing, replace the oil pump. 3. Pressure relief valve for scoring and sticking removedwith a fine stone.

Burrs may be

4. Oil pumpscreen for broken wire meshor looseness. 5. Gears for chipping, galling and wear.

6- "1 8

Engme/eng

Assembly Instal| or Connect: 1~ Pressurerelief valve. 2, Pressurerelief valve spring. 3. Pressurerelief valve spring retaining pin. 4. Drive gear and shaft. 5. idler gear. & Oil pump body cover= 7. Oil pumpbody screws. Tig hten: Oil pumpbody screws to 106 in. Ibs. (12 N.m). 8. Oil pumpdriveshaft and retainer. to check for smooth operation.

Turn the driveshaft by hand

Valve Train Components C~ean: 1, All parts in solvent. 2. Blow dry the parts with compressedair. Inspect: 1. Valve rocker arms and balls at the mating surfaces. Theseparts should be smooth and free from scoring or other damage. 2. Valve rocker arm areas that contact the valve stems and the sockets that contact the push rods. These areas should be smooth and free of damage,and wear. 3. Valve rocker are bolts for signs of cracking at the bolt shoulder. Replace as necessary. 4. Valve push rods for bending. Roll the push rod on a flat surface in order to determine if it is bent. Replaceas necessary. 5. Ends of the valve push rods for scoring or roughness. 6. Valve push rod oil passagefor restrictions.

Ertglne/eng

6-19

Cylinder HeadService J 8062

Disassembly [~ [-~

Removeor Disconnect:

Tool Required: J 8062 Valve Spring Compressor 1, Spark plugs. 2. Valve keys 0 as follows: DRC6863

a. Compressthe valve springs using J 8062 Valve Spring Compressor b. Removethe valve keys. c. Removethe valve spring compressor. E~] 3. caps (~, springs (~) and rotators. 4. Valve stem oil seals @. 5. Valves ~. Place valves in a rack to ensure that they ’will returned to their original locations at assembly.

be DRC6595

6. Remaining valves and components. Cleaning, Inspection, and Measurement Refer to General Engine Mechanical section in this manual. Assembay Tool Required: J 8062 Valve Spring Compressor [~ Install

or Connect:

1. Lubricate the valve stem with clean engine oil. 2. Valves(~)(~) into their proper location. 3. Oil seals (~) over the valve stems. 4. Rotators. 5. Valve springs (~).

6-20

Eng,ne/eng

6. Valve keys as follows: a,

b,

Compress the valve spring using J 8062 Valve Spring Compressor. Compressthe spring enough to clearly see the valve stem groove. Apply a small amountof grease to the valve keys to hold them in ph]ce. Makesure the keys are properly seated in the valve stem grooves.

c. Removethe compressor tool. stay in place.

Make sure the valve keys

d. Repeat the procedure on the remaining valves. ~ 7. Measure the installed the following procedure: a. Use a narrow, thin helpful.

height of each valve spring using

scale.

A cut away scale may be

b. Measurefrom the cylinder head spring seat to the top of the cap. If this measurementexceeds the amount giw~n under Specifications found in this manual, install the valve spring shims of sufficient thickness between the rotator and the cylinder headin order to give the desired measurement. ~ Never shim the spring so as to give installed height under the specified amount~

DRC6668

an

CrankshaftBearing installation ~J~~ If undersized bearings are used, bearings are fitted to the proper journals.

ensure that

the DRC6667

install or Connect: ~5,-] 1. Uppercrankshaft bearingsto the block. 2 Lower crankshaft bearings to the crankshaft bearing caps. 3 Lubricate the crankshaft bearings with clean engine oil. 4 Crankshaft. r~t~ In order to prevent the possibility of cylinder block or crankshaft bearing cap damage,the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Donot use the attaching boffs to pull the crankshaft bearing caps into the seats. Failure to observe this information maydamagea cylinder block or a bearing cap.

Engl ~e/eng

6-21

DRC6917

[~ 5. Crankshaft bearing caps and the boKts. Ensure that the arrows on the crankshaft bearing caps are facing the front of the engine. Donot install the rear crankshaft bearing cap at this time. ~ Tighten the inside bearing the outside bearing cap bolts last.

cap bolts

first

and

Tighten: Crankshaft bearing cap bolts to 100 ft. Ibs. (135 N-m). DE] 6. Apply anaerobic sealing compoundto the rear bearing cap sealing face or to the rear bearing cap channel of the engine block, from the corner of the rear thrust bearing pocket to the edge of the channel.

DRC6917

7. Rear crankshaft bearing cap and bolts to the rear of the engine block. Temporarily tighten the bolts to 35 in. Ibs. 94 N.m). [~ 8. Measure the crankshaft end play as follows: a. Firmly thrust the crankshaft first rearward then forward. This will line up the rear crankshaft thrust surfaces. ~ Tighten the inside bearing the outside bearing cap bo~ts last.

cap bolts

first

and

DRC6929

Tighten: Rear crankshaft bearing cap bolts to 100 ft. Ibs. (135 N.m). b.With the crankshaft wedged forward, measure at the front end to the rear crankshaft bearing with a feeler gauge, the proper clearance is 0.002-0.010 in. (0,05080,2540 mm). DRC6530

9. Inspect the crankshaft for binding as follows: a. Try turning the crankshaft to check for binding. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on one cap at a time until the tight bearing is located. c.A bent crankshaft or a lack of bearing clearance could cause binding. 10. A lack of bearing clearance maybe caused by the following conditions: ® Burrs on the bearing cap. ¯ Foreign matter between the bearing and the block. o Foreign matter between the bearing and the bearing cap.

6-22

Engme/eng

CrankshaftRear Oil Seal Installation Tool Required" J 38841 Crankshaft Rear Oil Seal Installer 1. Makesure the crankshaft rear chamferis free of grit, loose rust, and burrs. Correct as needed. 2. Lubricate the inner and outer diameter of the seal with engine oil. [~ 3. Install Installer.

the seal on J 38841 Crankshaft Rear Oil Seal

4. Position J 38841Crankshaft Rear Oil Seal Installer against the crankshaft.Thread the attaching screws into the tapped ho~es in the crankshaft. 5. Tighten the screws securely with a screwdriver in order to ensure that the seal is installed squarely over the crankshaft. 6. Turn the handle until it bottoms. 7. RemoveJ 38841 Crankshaft Rear Oil Seal Installer. DRC6939

Piston, ConnectingRod, and Bearing installation J~239

Tools Required: J 5239 Connecting Rod Guide Tool J 8037 Piston Ring Compressor In order to determine the correct replacement bearing size, the bearing clearance must be measuredaccurately. Either the micrometer or plastic gauge method may be used, however the micrometer methodgives more reliable results and is preferred. Refer to Crankshaft and ConnectingRod Bearings, Cleaning and inspection found in this manualfor either procedure. 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.

DRC661g

ENG,NE LEFT ENGINE FRONT ENGiN.~E RIGHT

hstall or Connect: 1. Connecting rod bearings to the connecting rods and connecti~g rod caps.

A OiL RING SPACERGAP ,[TANGIN HOLEOR SLOT WITHINARC) O,L RING RNL GAPS C 2ND COMPRESSION RING C, AP D TOp COMPRESSION RINGGAP

2. Lubricate the cylinder walls lightly with engine oil. D~ 3. J 5239 Connecting Rod Guide Tool onto the connecting rod bolts. ~ 4. Align the piston ring end gaps.

En,q....... g

6-23

DRC6627

5. Lubricate the piston and the rings with engine oil. FT] 6. J 8037 Piston Ring Compressorover the piston and rings assembly without disturbing the eng gap locations° J 8037

7. Compressthe piston rings.

\

EEl 8. Ensurethat the dimple faces the front of the block. U~]~I~ Each connecting rod and bearing cap should be markedfor proper location and orientation. Cylinder 1,3, 5, and 7 are the right bankand 2, 4, 6, and 8 are the left bank(whenviewed from the front of the engine). The numberson the connecting rod and bearing cap must be on the sameside when installed in the cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be numberedto correspond with the new cylinder number.

DRC6628

EEl 9. Piston and connecting rod into proper cylinder bore. 10. Use a hammerto lightly bore.

tap the piston downinto the cylinder

11. Guide the connecting rod into position on the crankpin, while tapping the piston into the bore.

<;= DRC6919

12. Coat the connecting rod bearings with clean engine oil. 13. Coat the crankpin with clean engine oil. 14. Connecting rod cap with the bearing and connecting rod nuts. Tighten: Connectingrod nuts to 45 ft. Ibs. (61 N.m). DRC6906

CamshaftInstallation install or Connect 1. Camshaftas follows: a. Install three 5/18 - 19 X 4 in. bolts into the camshaftfront bolt holes in order to handle the camshaft. b. Use care to avoid damagingthe camshaft bearings. c. Remove the three bolts after the camshaft is installed.

6-24

Engme/eng

2. Camshaftretainer and bolts. Tighten: Camshaftretainer bolts to 10 ft. Ibs. (14 N.m).

TimingChainandSprocketsinstallation Tools Required: J 22102 Crankshaft Sprocket Installer install or Connect 1. Crankshaft key, as necessary. ~ Ensure that the sprocket alignment mark faces away from the engine block. Ensure that the sprocket is fully seated against the crank shoulder. ~-] 2. Crankshaft sprocket using J 22102 Crankshaft Sprocket Installer. ~ Ensure

the

following

conditions

exist:

a. The camshaft and crankshaft timing marks are aligned. b. The camshaft dowel pin and camshaft sprocket hole are properly aligned. .Z_

c, The gears and timing chain mesh. 3. Camshaft timing chain to the camshaft sprocket.

~~J

22102

7

[~5~ 4. Camshaft sprocket and the camshaft timing chain to the front of the camshaft. IN’°t~ Do not hammerthe camshaft sprocket onto the camshaft. To do so may dislodge the rear camshaft plug and damagethe camshaft.

DRC6905

5, Camshaft sprocket bolts. Use the bolts to draw the camshaft sprocket onto the camshaft. Tighten: Camshaftsprocket bolts to 25 ft. lbs. (34 N.m). DRC6902

EngineFront Coverinstallation Install or Connect: [~ 1. Lubricate the sealing surface of the crankcasefront oil seal with clean engine oil. 2. Apply GMR-I’V Sealer, P/N 12345739,or the equivalent in two places where the front cover meetsthe oia pan rail. 3. Engine front cover. DRC6921

4= Engine front cover screws. Tighten: Engine front cover screws to 106 in. Ibs. (12 N.m).

Oil PumpInstallation Instal| or Connect: [~ 1. Oil pumpdriveshaft

and retainer.

2. Oil pump. 3. Oil pumpbolt. Tig hten: Oil pumpbout to 65 ft. Ibs. (90 N.m}.

Oil PanInstallation DRC6910

Install

the oil pan within 10 minutes of the RTV

application, install or Connect: 1. Appny GMRTV Sealer, P/N 12345739, or the equivalent in four pBaceswherethe front and rear crankshaft bearing caps meet the engine block. 2. Oil pan gasket to the engine block. DRC6909

6-26

EngineJeng

3, Oil pan. Ensurethat the oil pan gasket stays in place. 4. Oil pan bonts. Tighten: Oil pan bolts to 18 ft. Ibs. (25 N.m). 5. Oil pan drain plug. Tighten: Oil pan drain plug to 20 ft. Ibs. (28 N-m}.

Cylinder HeadInstallation install or Connect

/

1. Cylinder head gasket onto the engine block. ~Do not use sealer composition gasket.

on any

engines

that

use

a ¯ ¯

2. Align the gasket locating mark to face up. 3. Cylinder head onto the block. Guide the cylinder head carefulily into place over the dowel pins and head gasket. 4. Coat the threads of the cylinder head boffs with GMSealing Compound,P/N 12346004, or equivalent. 5. Cylinder head bolts and tighten in the following three sequential steps: Tighten: DRC6908

a. First pass to 30 ft. Ibs. (40 N.m). b. Secondpass to 60 ft. Ibs. (80 N.m). c. Third pass to 85 ft. Ibs. (115 N-m). 6 Spark plugs. Tighten: ¯ Newcylinder headsto 22 ft. Ibs. (30 N.m). ¯ Subsequentinstallations

Eng,~e/eng

to 15 ft. Ibs. (20 N.m).

6-27

Valve RockerArmandPushRodinstallation ,~J~~ If a new camshaft valvelifters.

is installed,

repJace all

the

install or Connect: 1. Coatthe valve lifter rollers andinside of the valve lifter with GMPrelube, P/N 1052367, or equivaHent. EEl 2. valve lifters removed. 3. Valve lifter

guides

in the samelocation from which they were DRC6916

guides.

I~~1=~1~ The vaDve lifter guide retainer must contact all of the valve lifter guides=If the valve lifter guide retainer is bent, the valve lifter guide must be replaced. EEl 4. valve lifter 5. Valve lifter

guide retainer.

guide retainer bolts.

Tighten:

DRC6915

Bolts to 20 ft. Ibs. (26 N.m). The 7.4 L engine uses different length intake and exhaust valve push rods.The exhaust valve push rods are longer than the intake valve push rods. EEl 6. Valve push rods. Be sure that the valve push rods seat in the valve lifter sockets. 7. Valve rocker arms, balls and the bouts. DRC8897

Tighten: Bolts to 45 ft. Ibs. (61 N.m). I~ 8. Splash shield.

DRC6914

6-28

Engme/eng

Valve RockerArmCoverInstallation Install or Connect: D~ 1. Valve rocker arm cover and gasket. 2. Valve rocker arm cover bolts. Tighten: Valve rocker arm cover bolts to 72 in. Ibs. (8 N.m). DRC689

intake Manifoldinstallation install or Connect ~=~ 1. Seals on the cylinder block. 2. Gasket onto the cylinder head. 3. Lower intake manifold onto the engine block. 4. Coat the lower intake manifold bolts with GMThread Locking Sealant, P/N 12345382,or equivalent.

DRC6893 1

12 8

3

5

9

~/~ 5. Lower intake manifold bolts. Tighten: Bolts in sequenceto 30 ft. Ibs. (40 N.m). E~=~6. upper intake manifold gaskets.

7

7. Upper intake manifold.

7--77

8. Cover a minimumof eight threads of the upper intake manifond bolts with GMThread Locking Sealant, P/N 12345493, or equivalent.

4

2

6 10

<~ DRC6694

DRC689I

Engme/eng

6-29

E~] 9. Upper intake manifold bolts and tighten in the following two sequential steps: Tighten: a. First passto 72 in. Ibs. (8 N-m). b. Secondpass to 10 ft. Ibs. (14 N.m)o

CrankshaftBalancerinstallation DRC6892

Tools Required: J 23523-F Crankshaft Balancer Installer Inspect:

J 23523 - F

1.Crankshaft balancer weight for signs of shifting on the hub. Replace the crankshaft balancer if the weight has shifted. 2. Crankshaft balancer hub sealing surfaces for grooves, nicks, or damage. Replace the crankshaft balancer if any of the above conditions exist. ~The inertial weight section of the balancer is assembled to the hub with a rubber must follow the installation procedurescarefully, er tool, or movement of the inertial weight section destroy the tuning of the crankshaft balancer.

crankshaft material. You using the propof the hub will

DRC6982

|nstall or Connect: 3. Use a smanl amountof RTVsealant to seal the balancer key to the crankshaft ke/way groove. 4. Key into the crankshaft keyway, if the key has been removed. 5. Crankshaft balancer hub, until the hub is completely seated against the crankshaft ridge using J 23523-F Crankshaft BalancerInstaller. & Removethe J 23523-F Crankshaft Balancer Installer. 7. Bolt and washerinto the front of the crankshaft. Tighten: Bolt to 110 ft. Ibs. (149 N.m).

6-30

Englne/eng

Circulating Pump E~O=-~ TheVolvoPentacirculating pumpis manufactured specially for marineuse. It is servicedonly as an assembly. Donot replacewith an aL~tomotive circulating pump. In,spection Remove alternator and powersteering belts. Graspcirculating pumppu;ley andcheckendandside play. Turnpulley to checkfor drag. Lookfor water leaking from indicator hole beneathpump shaft behindpulley. Replace pump if play, drag, or leakageare evident.

11982

Removal and installation 1. Drain waterfrom block anddisconnectwaterhosefromcirculating pump. Remove pulley. Remove circulating pumpbolts, pumpandgaskets. 2. Usenewpumpto block gasketsand sealer. Install newpumpassembly on cylinderblockandtightenbolts as specified.Install pulley. Install alternator andpowersteering belts, then adjust tension. Connect hoseto circulating pump.Lakeor tank test unit andcheckfor leaks.

Front Engine MountReplacement

11981

RemovaJ ~-~ 1. Remove two lag screws(~) and washersfrom mounts. ~’~/~ 2. Lift engine with 1500 lb. (680 kg) minimumcapacity hoist to allow removam of front mountandbracket. Remove three mount screws and lock washers®. E,~ ~ Prior to disassembly of front mount assembly, measure distance betweenlarge washerand flat on uppermountbracket. 11989

Disassembly !. Remove three nuts ©, one Iockwasher,and engine mountbracket @from mountbolt @while holding bolt securewith socket.

11979

Engine/eng

6-31

E!] 2. Remove one large washer® one small washer @and engine mountbolt (~ from mount. Reassembly E~1. Place small washer@on mountbolt and insert bolt up through mount.Install large washer® and securewith nut @.Tightento 60-75ft. Ibs. (81-102N-m). E~2. Install upperinner nut and place enginemountbracket on engine mountbolt. 11978

3. Install lock washerandlowernut. Tightennut to 50-70ft. Ibs, (68-95 N,m). Instalmation 1. Spraythe enginemountscrewsthreadswith Loctite~ Primer N andallow to air dry. ApplyVolvo PentaTreadSealingAgentP/N1161053-6 to the screws. Attach enginemountassemblyto enginewith three screwsand washers.Tightento 32-40ft. Ibs. (43-54N,m). 2. Install lag screwsandtighten securely. 11983

Height Adjustment E~] 1 To changeengineheight, tighten or loosen nuts (~) and(~ required. ~2. Lift enginewith 1500 Ib.(680 kg) minimum capacity hoist. Positionenginest desiredheight. [~] 3. After setting mountposition, turn nut (i) up againstunderside enginebracket and hold nut with a wrench.Tightenuppernut ® to 100-120ft. Ibs. (136-163N.m).

High-Rise Exhaust EBbowReplacement

2953

Removal [~ Drain water from respective exhaustmanifold. 1. Loosentwo clampssecuring upperhoseto elbow.

8- 3 2

Engine/eng

2. Port Elbow- Remove four thru-bolts, lock washers,and washers.Move remote oil filter aside.

/

E4~3. StarboardElbow-Remove two thru-bolts (~), lock washers,and washersattaching circuit breakerbracket. Set bracketassembly aside. [~ 4. Lubricate inside of exhausthosewith a soapywatersolution, then remove remainingelbowbolt. Tapelbowwith a soft hammer to free it, then twist it out of the hose.Remove anddiscard the manifoldgasket. Ir=stailation EsZ] 1. Apply Volvo PentaGasketSeating Compound P/N 1161231-4to both sides of a newgasket@~andplace it on the manifold. Lubricate inside of exhausthosewith a soapywatersolution to easeelbowinstallation. 2. Twist elbowinto hoseandpositionit on the gasket.Install the outer rear thru-bolt, washer,andlock washer,andturn it in finger tight. 3. Port Elbow- Positionremoteoil filter at front of elbow. 4. Install four thru-bolts, washers, andlock washers finger tight. E4--’~ 5. StarboardElbow-Position circuit breakerassembly at front of elbowInstall twothru-.bolts (~, washers,andlock washers finger tight. 6~ Tightenall elbowthru-boltsto 12-18ft. Ibs. (16-24N.m). ~7. Properly position the two exhaust hoseclampsand tighten them securely.

DR6451

Exhaust Hose and intermediate Pipe Replacement Removal 1. Loosen eight cJampsthat attach the upper and lower exhaust hoses, and slide clamps down onto exhaust Y-pipe. tion,

2. Lubricate inside of lower hose with a soapy water soluand push lower hose down onto exhaust Y-pipe.

3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose with a soapy water solution for ease of removal 4. Slide upper hose off high-rise exhaust Y-pipe.

elbow. Slide lower hose off

installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe. 28264

2. Onthe inside ofthe 4 in. (10,16 cm) I.D. upper hose, there is e circular rib 1.5 in. (3,81 cm) from one end. Theribbed end the hose must face the intermediate pipe (rearward) when it’s installed. Slide hose onto high-rise elbow until it seats. NOTE:If hose is not properly positioned, it will not completely engagethe high-rise elbow or anlow secure attachment. [~ 3. With a twisting motion, insert intermediate pipe all the way into the upper hose. Slide the lower hose up until it’s halfway onto the intermediate pipe. Z~ 4. Sfidefour No. 88clamps up onto the upper hose. Slide four No. 64 clamps up onto lower hose. Position champs in their proper channels and tighten them securely.

16041

Exhaust (Flapper) Valve Replacement Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hose and Intermediate Pipe Replacement. [~ 2. Slide the lower hose down far enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the valve. [~ 3. Inspect the two rubber bushings inside replace them as necessary.

Z~ Safety ReBated

the pipe, and

6-34

19444 Engme/eng

Installation e ScotchGrip Rrubber I. If installing newrubberbushings,apply 3M Adhesive 1300to outsideof tips, andinsert into inside of exhaustpipe. E6~2. Positionvalvewith longestlip pointing downandinsert into pipe. Pushpivot pin throughbushingsandvalveuntil pin endis flush with outsideof pipe. ~No--~If valveis not positionedproperly(long lip down),it will restrict exhaustflow andfail to preventwaterbackingup into engine.Valvemu,,~t also movefreely and not bind. Boat performance wouldbe adversely affected, and enginemaysuffer water damage.

19443

3. Install intermediatepipe following procedureunderExhaustHoseand intermediate Pipe Replacement.

Engine Coupler Replacement Removal 1. Remove engine from boat. 2. Disconnectall wires, lines andconnectors frombellhousing.

20034

E~3. Remove sevenscrewssecuring bellhousing cover and slide coveroff.

19996

~,~i,e/e,g

6-35

[~ 4. Pull drain hoseout of bellhousingif equipped, 5. Remove bolts andnuts retaining bellhousing. Disconnectgroundwires andoil coolerbracket.Noteoil coolerorientation. 6. Remove bellhousing. E~7. use an offset box end wrenchto removethe six nuts securing the coupler,andslide coupleroff studs. 8. Remove old gasketfrom bellhousingcover. Cleangasketsurface thoroughly. Instamlation 1. Install couplerandattach six Iocknuts,Usea suitable adaptorand tighten nutsto 40-45ft. Ibs. (54-81N.m). 2. Install bell housing.Attachoil coolerwith sameorientationas notedin a previousstep. Tightennutsandbolts to 32-40ft. Ibs. (43-54N.m).Attach groundwires andtighten nuts to 15-20ft. Ibs. (20-27N,m). 3. Pushdrain hoseinto bellhousing,if equipped. 4. Apply Volvo PentaGasketSealing Compound P/N 1161231-4to both sidesof a newbellhousinggasketandposition it on cover.

6712

~] 5. Cleansevenself-tapping screwswith a wire brush. Install belthousing coverandscrewsandtighten to 60-84in. Ibs. (7-9 N-m). 6. Connect all wires, lines andconnectors to bellhousing.Install enginein boat.

8714

19083

- 3 ~

Engine/eng

7.4Gi EngineSpecifications Metric Engine Type ..................................... Displacement .................................... Bore ........................................... Stroke .......................................... CompressionRatio ............................... Firing Order ..................................... Spark Plug Gap ..................................

V-8 7.4L 107.95 mm 101.6 mm 9.0:1 1-8-4-3-6-5-7-2 0.8890 mm

English 454 CID 4.25 in 4.00in

0.060in

Cylinder Head Surface Flatness ................................. Maximum Cylinder head block deck resurfacing ........

0.0762 mm 0.3048 mm

0.003in 0.012in

Exhaust Manifold .................................

0.251 mm

0.010in

5.7liters 68.65 kPa @600 r/m 10 psi @600 r/m Full Flow GearDriven

6.0 quarts

107.950- 107.968mm 0.0254 mm(maximum) 0.051 mm(maximum) 0.0127 mm(maximum) 0.0254 mm(maximum)

4.2500- 4.2507in 0.001 in (maximum) 0.002 in (maximum) Cylin0.0005 in (maximum)Cylin0.001 in (maximum) Cylin-

0,0254 mm(maximum)

0.001 in (maximum)

1.07891- 1.07904 mm 0.0457 = 0.0762 mm 0,0457 - 0.219 mm

4.2477- 4.2482in 0.0018- 0.0030in 0.0018- 0.0048in

0.031 0.031 = 0.305 0.254 0.254 0.408 0.406 -

0.0012- 0.0029in 0.0012- 0.0029in 0.0012- 0.0039in 0.010- 0.018in 0.010- 0.028in 0.016- 0.024in 0.016- 0.034in

Lubrication System Oil Capacitywithout filter Oil pressure (hot oil)

...........................

Oil Filter System.................................. Oil PumpType ...................................

172.37 kPa@2,000 r/m 25 psi @2,000 r/m

Cylinder Bore Diameter ....................................... Out-of-Round (Production) ......................... Out-of=Round(Service) ............................ der Taper- Thrust side (Production) .................. der Taper- Relief side (Production) ................... der Tapoer (Service) ..............................

Piston Piston Diameter .................................. Clearence (Production) ............................ Clearence (Service Limit) .......................... Piston Ring - Compression......................... Top GroovePriduction Ciearence .................... SecondGroove Production Clearence ................ Service Limit GrooveClearence ..................... Top Ring Gap(Production) ......................... Top Ring Gap(Service) ............................ SecondRing Gap(Porduction) ...................... SecondRing Gap(Service) .........................

0.074 mm 0.074 mm 0.0991 mm 0.457 mm 0.711 mm 0.609 mm 0.863 mm

7.4Gi EngineSpecifications Metric

English

Oil Ring Production GrooveClearence .......................

0.127 - 0.165 mm

0.0050- 0.0065in

Service Limit GrooveClearence ..................... Production Gap.................................. Serivece Limit Gap................................

0.127 - 0.191 mm 0.254 - 0.762 mm 0.254 - 1.016 mm

0.0050- 0.0075in 0.010- 0.030in 0.010- 0.040in

Diameter .......................................

25.132 - 25.137 mm

0.98945- 0.98965in

Clearencein Piston Production ...................... Clearencein Piston Service limit ..................... Fit in Connecting Rod .............................

0.005 - 0.017 mm 0.005 - 0.025 mm 0.078 - 0.053 mm

0.0002- 0.0007in 0.0002- 0.0010in 0.0021- 0.0031in

0.051 mm(maximum) 69.804 - 69.822 mm

0.002 in (maximum) 2.7482- 2.7489in

0.010 mm(maximum) 0.025 mm(maximum) 0.010 mm(maximum)

0.0004 in (maximum) 0.0010 in (maximum) 0.0004 in (maximum)

PistonPin

Crankshaft Crankshaft Run Out ............................... CrankshaftJournal Diameter#1, #2, #3, #4, #5 ......... Crankshaft Journal Taper (Production) ................ Crankshaft Journal Taper (Service) ................... CrankshaftJournal Out-of-Round(production) .......... CrankshaftJournal Out-of-Round(service) ............. CrankshaftBearing Clearence#1 (production) ..........

0.025 mm(maximum) 0.043 - 0.076 mm CrankshaftBearingClearence#2, #3, #4 (production) .... 0.028 - 0.061 mm CrankshaftBearing Clearence#5 (production) .......... 0.063 - 0.096 mm CrankshaftBearingClearence#2, #3, #4 (service limit) ... 0.025 - 0.076 CrankshaftBearing Clearence#5 (production) .......... 0.063 - 0.101 mm Crankshaft End Play .............................. 0.127- 0.279 mm 46.1391 - 46.2153mm Crankshaft Thrust Wall Width ........................ Crankshaft Thrust Walt Maximum Run Out ............. 0.025 mm Crankpin Diameter ................................ 55.854 - 55-896 mm Crankpin Taper (production) ........................ 0.0127turn 0.025 mm Crankpin Taper(service limit) .......................

0.0010 in (maximum) 0.0017- 0.0030in 0.0011- 0.0024in

Crankpin Out-of-Round(production) ..................

0.0005in 0.0010in 0.0011- 0.0029in 0.0011- 0.0039in 0.0013- 0.0230in

CrankpinOut-of-Round(service limit) ................. RodBearing Clearence (production) .................. RodBearingCiearence(service limit) ................. Connecting Rod Side Clearence .....................

0.013 mm 0.025 mm 0.028 - 0.074 mm 0.028 - 0.099 mm 0.033 -.0584 mm

6-3 8

0.0025- 0.0038in 0.0010- 0.0030in 0.0025- 0.0040in 0.005- 0.011in 1.8165- 1.8195 in 0.001in 2.1990- 2.1996in 0.0005in 0.0010in

Engine/en

7.4Gi EngineSpecifications Metric

English

Camshaft Camshaft Run out ................................ Lobe Lift (Intake) ................................. Lobe Lift (Exhaust) ................................ Journal Diameter .................................

0.051 rnm (maximum) 7.115 - 7.216 mm 7.170 - 7.272 mm 49.471 - 49.522 mm

0.002 in (maximum) 0.2801- 0.2841in 0.2823- 0.2863in 1.9477- 19497in

Valve System Lifter

...........................................

Rocker Arm Ratio ................................. Valve Lash Intake ................................. Valve Lash Exhaust ............................... Face Angle (Intake & Exhaust) ...................... Seat Angle (Intake & Exhaust) ....................... Seat Runout (intake & Exhaust) ..................... Seat Width (Intake.) ............................... Seat Width (Exhaust) .............................. StemClearenceIntake (production) .................. StemClearenceExhaust (production) ................. StemClearenceIntake (service limit) ................. StemClearenceExhaust(service limit) ................ Varve Sping Pressure Closed ....................... Vafve Spring Pressure Open........................ in ............................................. 1,838 - 1.869 in .................................. Maximum Valve Spring installed Height Shim........... Maximum Valve Spring Tension Shim ................. Maximum CombinedValve Spring Installed Height and Valve TensionShim..............

HydraulicRoller Followers 1.70:1 Net Lash Net Lash 45 Degrees 46 degrees 0.051 mm(maximum) 0.762 - 1.524 mm 1.524 - 2.413 mm 0.025 - 0.0737 mm

0.002 in (maximum) 0.030- 0.060in 0.060- 0.095in 0.0010- 0.0029in

0.030 - 0.079 mm 0.025 - 0.094 mm 0.030 - 0.124 mm

0.0012- 0.0031in 0.0010- 0.0037in 0.0012- 0.0049in

316 - 3!51 N @46.685mm71 - 79 Ib @1.838 in 1059 - 1165 N @34.213 mm238 - 262 Ib @1.347 Valve Spring Installed Height 46.685 - 47.479 mm 0.726 mm 0.726 rnm

0.030in 0.030in

1.542 rnm

0.060in

Oil Recommendation 32° F (0° C) and above ................................. 0° F (-17° C) to 32° F (0° C) .............................. 0(; F (-17 ° C) and below .................................

S AE30 SAE 20W-20 SAE 10W

TM Synthetic MotorOil, whichis specially formulatedfor heavyduty marine Werecommend Volvo PentaDuraPlus

use, andideal for VolvoPentaEngines.It providesbetter anti-wearqualities, especiallyduring long high speed operation,tn addition, it neutralizesacidscommon to all internal combustion engines,offers superiorcorrosion protection, andis lormulatedto offer better resistanceto oxidationandhigh temperature sludgeformation. Fuel Recommendation..................................

See General|nforrnation Section

7.4Gi TorqueSpecifications Metric

English

12 N.m 30 N,m 25 N,m

106in Ib 22ft Ib 18ft Ib

64 N°m 149 Nom 138 N.m 56 N°m

47ft Ib 1lOft lb. 102ft Ib 43ft Ib

88 N,m 40 N,m

65ft Ib 29ft lb

Camshaft CamshaftRetainer Bolt ...................................... CamshaftSprocket BoJt ...................................... Valve Lifter Guide Retainer Bolt ................................

Crankshaft Connecting Rod Nut First Pass ................................................. Crankshaft Balancer Bolt ..................................... Crankshaft Bearing Cap Bolt and Stud .......................... Engine Coupler Nuts (SX/DP-S) ............................... Engine Flywheel Bolt (DP-D/DP-E/DPX) ......................... WindageTray Nut ...........................................

Cylinder Head Cylinder HeadBolt All Bolts First Pass ( In Sequence)............................. SecondPass (In Sequence) .................................. Final Pass Long Bolt (In Sequence)............................ Finar Pass Short Bolt (In Sequence)............................ Distributor Cap Bolt ......................................... Rocker Arm Cover Bolt ...................................... Rocker Arm Bolt ............................................

50 Nora

2.4 N.m 12 N.m 54 N°m

37ft Ib 60 Degrees 90 Degrees 30 Degrees 21 in lb 106in Ib 40ft Ib

Engine Block Circulating Water PumpBolt .................................. Circulating Water PumpPulley Bolt ............................. Engine Block Coolant Drain Plug ............................... Engine Block Oil Galley Front Plug ............................. Engine Block Oil Galley Left Side Plug .......................... Engine Block Qil Galley Rear Plug ............................. Engine Block Oil Galley Top Plug ............................... Engine Coolant Temperature(ECT) GaugeSensor ................ Engine Front Cover Bolt ...................................... Engine Oil Pressure GaugeSensor ............................. Flywheel Housing Bolt ....................................... PowerSteering PumpBracket .................................

40 25 20 20 20 20

N,m N-m N.m N-m N-m N-m

20 20 10 15 40 38

N,m N.m N,m N-m N.m N°m

30ft 18ft 15ft 15ft 15ft 15ft 15ft

Ib Ib Ib Ib Ib Ib Ib

15ft Ib 89in Ib 11ft Ib 30ft Ib 31ft Ib

ExhaustManifold Bolts 15 N,m

First Pass ................................................. Final Pass ................................................ High Rise Elbow ............................................

30 N,m 20 N,m

11ft Ib 22ft Ib 14ft Ib

Front Mount Lower Nut .................................................

81-102 N-m 136-163 N.m

Upper Nut ................................................. 8- 40

60-75ft {b 100-120 ft Ib

Engme/eng

Im

7.4Gi TorqueSpecifications Metric

English

25 N.m 6 N,m 25 N.m 12 N®m

18ft Ib

90 N.m 12 N,m

66ft Ib 106in Ib

30 N°m 15 N,m

22ft Ib 11ft fb

33 N°m 3.4 N,m 25 N-m 40 Nora

24ft Ib 30in Ib 18ft Ib 30ft Ib

25 40 10 12

18ft Ib 30ft Ib 89 in Ib 106in Ib

Oil Pan Oil Pan Drain Plug .......................................... Oil Oil Oil Oil Oil Oil

Pan Stud (Front) ......................................... Pan Stud Nut ........................................... Pan Bolt or Stud Boat ..................................... Pump................................................. PumpBolt to Rear Crankshaft Bearing Cap................... PumpCover BoLt .........................................

53in Ib 18ft Ib 108in Ib

Spark Plug Initial Installation (NewCylinder Head).......................... All SubsequentInstallations ................................... Intake Manifold Distrubutor ClampHold DownBolt ............................. Flame Arrestor ............................................. Fuel Rail .................................................. Lower Intake Manifold ....................................... Map Sensor Nut ............................................ Thermostat Housing ........................................ Throttle Body Nut ........................................... Throttle Body Stud .......................................... UpperIntake ManifoldBolt (in sequence) First Pass .................................................

8 N,m 18 N.m

Final Pass ................................................

Engineleng

N°m N°m N°m N°m

6-41

71 in Ib 13ft Ib

GMSpecial Tools

J 3049

J 5239 DRC6596

DRC6597

J 8062

8-~

DRC6680

DRC6604

DRC6582

DRC6938

J 24270

DRC6936

~L] Valve Lifter

J 9290-1

J 8358 DRC6602

DRC6601

Remover(Plier Type)

Connecting Rod Guide Tool Piston Ring Compressor ~=] Valve Spring Compressors DE] Carbon Remover Brush ’valve Lifter Remover(Slide HammerType) [~

Crankshaft Oil Seal and Sprocket Installer

[~

Cylinder Ridge Remover

[~

Crankshaft Sprocket Remover

~]

Crankshaft Rear Main Seal installer

DRC6939

6-42

Eng,rJe/eng

Section 7 7.4GSi and 8.2GSi Table of Contents Camshaft ........................................................... Camshaft LobeLift, Measuring ...................... Circulating Pump ............................................. ConnectingRodBearing Replacement ......... Crankshaft ......................................................... Cylinder Bnock .................................................. Cylinder Head ..................................................... EngineCoupler Replacement ......................... Engine Specifications ...................................... Exhaust Hose Replacement ........................... Exhaust ManifoldReplacement ........................ Exhaust(Flapper) ValveReplacement .......... Front EngineMountReplacement ................. High-RiseExhaustElbowReplacement ........

7-15 7-19 7-24 7-21 7-20 7-23 7-9 7-28 7-30 7-27 7-5 7-27 7-24 7-25

intake Manifold ................................................... 7-3 Intermediate PipeReplacement .................... 7-27 Lubrication System .......................................... 7-15 OilPan ...............................................................7-17 OilPump ........................................................... 7-17 Oil Seal Replacement,RearMainBearing .... 7-19 Piston,RingandConnecting Rod.................. 7-22 Remote Engine Oil Filter ................................. 7-16 7-2 Sealants,Lubricants,andAdhesives .............. Special Tools ...................................................... 7-2 TimingChain,Cover,andSeal....................... 7=12 Torque Specifications ...................................... 7=34 Valve Lifter,Hydraulic ....................................... 7-5 ValveSpringandSealRepair........................... 7-8

Safety Warnings Beforeworkingonanypart of the engine,readthe sectioncalledSafetyat the end of this manual.

Unlessinstructedotherwise,alwaysdisconnect the batterycablesfromthe battery beforeworking on electrical system to preventpossiblesparksor arcingin the enginecompartment. Beforestarting engineafter repairor maintenance procedures, alwaysmake sure engine compartment is free of fuel vapors to preventpossiblefire andexplosion. When workingonan enginethat is runningor beingcranked,useextreme careto avoidgettinghands, fingersor clothingcaught in thealternator,power steering pump, raw-water pump andcirculatingpump belts, pulleysandothermoving parts.

Engine/eng

7-1

General Motors Tools item

Part Number

Air Line Adaptor ........................................... Crakshaft Seal/Sprocket mnstaller .............................. Crakshaft Sprocket Puller ..................................... Dial Indicator Set ............................................ Hydraulic Lifter Remover.................................. Hydraulic Lifter Remover................................... Main Bearing Replacer ....................................... Ring Compressor ........................................... Seal Installer .............................................. Seal Installer .............................................. Stud Protector .............................................. Valve Spring Compressor ................................... Torsional DamperPuller ................................... Valve Spring Compressor .....................................

J-23590 J-22102 J-1819 J-8520 J-9290-01 J-3049-A J-8080 J-8037 J-35468 J-38841 J-5239 J-5892-C J-23523-E J-8062

Order D}rectly from: Kent-MooreTool Division 28835 Mound Road Warren, M148092800-345-2233 Price and ordering information are available from Kent-Moore Tool Division.

Varsoi or Equivilent CleaningSolvent Molykote Lubricant Volvo Penta Gasket Sealing CompoundP/N 1161231-4 e No. 2 Permatex GMSuperEngine Oil Supplement GMSilicone RubbverSealer, P/N 1052366 Plastigage TM(Green) DuraPlusT# SAE30 HeavyDuty Synthetic Motor Oil Black NeopreneDip For additional service information not coveredin this manual,obtain the appropriate Chevrolet EngineService Manualfrom: HelmInc. P.O.Box 07130 Detroit, M148207

7-2

Engine/eng

intake Manifol,d Removam SeeOn-Board Servicesection of GMEFI DiagnosticsManualfor removalof components from intake manifold. E~ ~ Disconnectbattery cablesat battery, and drain coolant from both sidesof blockandmanifolds. 2. Remove alternator. If electrical leadsare not disconnected, tie alternator to oil hosesto prevenlalternator weightdamaging leads.

19846

3. Remove thermostathousing. 4. Remove mainelectrical harnessfrom clampson port side of manifoldand at front of manifold.Disconnect other wire connections as necessary. E~5.Remove distributor cap andmarkthe position of the rotor on the housing.Scribea line onthe distributor housingandintake manifoldfor reassembly in the sameposition. Remove the distributor. 6. Unscrew attaching bolts andremoveintake manifold. ENO---~If necessaryto pry manifoldawayfromcylinder heads,do not damage gasket sealing surfaces. 7. Remove anddiscard intake manifoldgasketsandseals. CReaning FIemove all gasketmaterialandclean the sealingsurfacesof the manifold, block and thermostathousing. Remove excessivecarbondeposits from exhaustpassages,scale anddepositsfrom cooling passages.Cleanthe manifoldin a suitablesolventanddry it with compressed air. inspection Inspectthe manifoldfor cracks, damaged gasketsurfaces, or other defects tt~at wouldmake it unfit for further service.Replace all studsthat are stripped or otherwisedamaged. Remove all filings andforeignmatterthat mayhaveenteredthe manifoldas a result of repairs.

Engine/eng

7- 3

25140e

Installation 1. Install newmanifold seals on block, and newgasketson cyPinderheads. Useonly side gaskets having metal inserts covering the center exhaust passage.Usesealer at water passagesand whereseals butt to gaskets. ~2. Install intake manifold. Tighten bolts in the sequenceshown.See TorqueSpecifications at end of section for torque figure. ~ Check torque of the intake manifold screws annually. The center screws can becomeloose under normal usage. 3. Install distributor with rotor and align exactly as markedduring removal. Install clampand tighten screwto 25 ft. Ibs. (34 N-m). ~N---ot-~ If enginewascrankedwhile distributor wasout, completeignition timing proceduremust be followed. 4. Install distributor capandhigh tensionleads. 5. Place main wire harnessunder clampson port side of manifold and at front of manifold. Makeother wire connectionsas necessary. 6. Attach throttle cabFeto carburetor and anchorblock.

DR6351

7. Connectpurple/whitestripe wire to chokehousing.Attach fuel line to carburetor. ~8. Apply Volvo Penta Gasket Sealing CompoundP/N 1161231-4 to both sides of a newthermostat housinggasket and place it on manifold. Placelifting eye on long bolt, then instam8and tighten both bolts to 12-16 ft. Ibs. (16=22N*m). 9, Install alternator and properly tension belt. Tighten mountingscrews securely. 10. Install flamearrestor andtighten nut to 25-35ft. Ibs. (2,8-4,0 Nom). Install flamearrestor coverand tighten nut 30-35ft. Ibs. (3,4-4,0 N°m). //~11. Attach battery cables at battery. Start engineandcheckfor fuel and water leaks.

7-4

Engme/eng

ExhaustManifold Replacement Removal [~ Drain water from respective exhaust manifold before beginning procedure. 1. Remove high-rise exhaust eBbowfollowing procedureunder High-Rise Exhaust Elbow Replacement. 2. Carefully pull wires off sparkplugs. 3. Loosenhoseclampat front of manifold, and pult off water hose. 4. Remove manifold altaching screws, nuts and washers.Discard nuts. Remove manifold and discard manifold gasket. Cleaning Ctean mating surfaces on manifold and cylinder head. Clean the threads on the exhaustmanifoldbolts. inspection E~ Inspect for cracks. To pressurecheckmanifold, fabricate a plate (~) shownand a newelbow gasket (~) to seal water passagein manifold. sure to apply sealer to gasket. Install rubberdrain cap to manifoldand secure with clamp. Attach a gearcasepressure tester © (such as Stevens Company S-34) to the water inlet hose. A bushing can be madeto secure pressuretester to hose. With the pressuretester attachedto the manifold, submergemanifold in water. Pressurize the manifold to 10-15 PSI (22-25 kPa) and checkfor leaks.

DR2875

Bnstallation 1. Install a newexhaustmanifoldgasket. E3-’=l [] 2. Install manifold and secure with screws, washersand new Iocknuts. Tighten nuts to 20-26 ft. Ibs. (27-35 N®m).Tightenscrewsto 24°28 ft. Ibs. (33-38N®m). 3. Attach water hoseto nipple at front of manifoldand tighten clamp 4~ Attach spark plug wires to plugs. Makesure firing order is correct. 5. Install h{gh-rise exhaustelbowfollowing procedureunder High-Rise Exhaust Elbow Replacement ,~/.~ 6. Start engine and check for water andexhaustleaks.

E ng,ne/eng

7-5

18944

Hydraulic Valve Ufter CheckingHydraulic Valve Lifter When checkinghydraulic valve lifters, remember that grit, sludge, varnish, or other foreign matterwill seriously affect their operation.If anyforeign substanceis foundin the lifters or enginewhereit maybe circulated by the lubrication system, a thoroughcleaning job must be doneto avoid a repetition of lifter trouble. To help preventlifter trouble, the engineoil and oil filter mustbe changed as recommended in Generalinformationsection. The engine oil must be heavy-dutytype (for Service SG)and must also conformto General Motors Specification 6094Mto avoid detrimental formation of sludge and varnish. WerecommendDuraPluszi SAE30 Heavy Duty Synthetic Motor Oil. The boat ownershould be specifically advised of these requirementswhenthe unit is delivered. Faulty valve lifter operationusually appearsunderone of the following conditions: 1. Rapping Noise Only WhenEngine is Started: Whenthe engine is stopped, any lifter on a camshaftlobe is under pressure of the valve spring; therefore, leak downor escapeof oil from the lower chambercan occur. Whenthe engine is started, a few secondsmaybe requiredto fill the lifter, particularly in colderweather.If noiseoccursonly occasionally, it maybe considerednormal, requiring no correction. If noise occursfrequently, however,checkfor either oil too heavyfor prevailing temperatures,or excessivevarnish in lifters. 2. Intermittent RappingNoise: An intermittent rapping noise that appearsand disappearsevery few secondindicates leakageat checkball seat due to foreign particles, varnish, or defective surfaceof checkball or seat. Replacelifters as necessary. 3. Noise at Idle and LowSpeed: If one or morevalve lifters are noisy at idle speedand up to approximately 1200RPM,but quiet at high speeds,it indicates excessiveleak downrate or fautty checkball seat or plunger. Withengineidling, lifters with excessive leak downrate maybe spotted by pressing downon each rocker arm above the pushrod with equal pressure. Reconditionor replacenoisy lifters.

7-6

Engmeleng

4, GenerallyNoisyat: All Speeds: Check for low or highoil level in crankcase. Highoil levels will causeoil foaming fromthe crankshaft andwill force air bubbles into the lifters. Lowoil levels allow pump to pump air at highspeed.Withengineidling, strike each rocker armabovethe pushrod severalsharpblowswith a mallet; if noise disappears,it indicates that foreign materialwaskeepingcheckball from seating. Stopengineandplacelifters oncamshaft basecircle. If there is lash clearance in anyvalvelinkage,it indicatesa stucklifter plunger,worn lifter roller, or worncamshaft lobe. 5. LoudNoiseat Norrr|a| OperatingTemperature Only:

11508

If a lifter develops a loudnoisewhenthe engineis at normaloperating temperature,but is quiet whenengineis belownormaltemperature,it indicatesan excessivelyfast leak downrate of scoredlifter plunger.Reconditionor replacelifter. Removam 1. Withair hoseandcloths, cleandirt fromcylinder headsandadjacent partsto avoidgettingdirt into engine.It is extremely importantthat nodirt getsinto the valvelifters. 11509

2. Remove intake manifold, Remove exhaustmanifolds. 3. Remove rocker armcovers.Donot pry. If coversstick userubbermallet andstrike coverendto jar loose. Loosen rocker armnutsandpivot the rockerarmfree of the pushrods.

J 3049 A

EI~ [~ 4. Remove pushrods. Remove the hydraulic lifter guides and lifters that requireserviceoneat a timeandplacethemin an organizerrack. Thelifters mustbe installed in the sameborefromwhichthey wereremoved. E~[~ A stuck hydraulic lifter can be removed using Tool J-3049-A(plier type) orToolJ-9290-01(slide hammer type).

D 31350

5. If less thana complete set of lifters is beingremoved, immediately is assemble oneor twofor presence of dirt or varnish.If lifters containdirt or varnish,it is advisableto remove all lifters for replacement. Otherwise, it will besatisfactoryto serviceonly thoselifters that are not operatingproperly. ’E~ 6. Examine the camroller (4) of the lifter. If this surfaceis excessively worn,galled or otherwisedamaged, discardthe lifter assembly. In this case, also examinethe matingcamshaftlobe for excessivewearor damage. UnstaHation [.~O--0~Beforeinstalling anynewlifters, coatthe bottomof the lifter with Molykote or its equivalent.

//3

T~5-

Engineteng

7-7

1. Install valve Fifters in cyRinderblock. If any newlifters or a new camshaft has been installed, an additive containing EPlubricant such as G.M. Engine Oil Supplement must be added to the crankcaseoil for break-in. 2. Install pushrods onto lifters.

Install intake manifold.

3. Pivot rocker armsin place and install rocker armbolts. Tighten bolts to 40 ft. abs. (54 N.m). 4. Install rocker arm covers, using G.M. Sealer No. 1052289,and tighten nuts to 115 in. Ibs. (13 N-m). 5. Install exhaustmanifold. Start engine and checkfor oil leaks at rocker arm covers.

Valve Spring and Sear Repair RernovaJ r~l.

Remove rocker

arm cover.

2. Remove spark plug, rocker arm, and push rod on the cylinder(s) to be serviced. [~ 3. Install Air Line Adapter tool J-23590to spark plug port and apply compressedair to hold the valves in place. [~ 4. Using tool J-5892-C, compress the valve spring and removethe valve locks. Release and removetool. Removevaave cap and shield, and valve spring and damper. 5. Remove the valve stem oil seal. installation DR3796

1. Install seal over valve stem and seat against head. J 5892-C .... ~

2. Set the valve spring and damper,valve shield and valve cap in place. Compress the spring with tool J-5892-Cand install oil seal in the lower groove of the stem, makingsure the seal is flat and not twisted. NOTE: A light coat of oil on the seal will help prevent twisting. 3. ~nstal} the valve locks and re~easethe compressortool making sure the locks seat properly in the upper groove of the vanvestem. NOTE:Grease may be used to hold the locks in place while releasing the compressortool

~.

\y

/ DR3794

4. Install spark plug and torque to 20 ft. lb. (27 N.m). 5. Install rocker armcover. Tightennuts to 115 in. Ibs. (13,0 N.m).

7-8

Engine/eng

Cylinder Head Removal 1, Drain water from block and exhaust manifolds. Removeintake and exhaust manifolds. 2. Removevalve covers and spark plugs. = 3. Loosenrocker arm bolts and turn rocker arms aside. Remow, pushrods. If lifters are to be serviced, removethemat this poinl. Otherwise protect the lifters and the camshaft from the entrance of dirt by covering the area with clean cloths. 4. Removecylinder head bolts, cylinder heads and gasket. Place cylinder heads on bench, supporting them at each end on blocks of wood to prevent damageto gasket faces of heads. Disassembly 1. Remove rocker arm bolts, ball seats and rocker arms. 2. Using tool J-8062, compressthe valve springs and remove the valve keys. Releasethe compressortool, and removerotators, springs and spring dampers,then removeoil seals. 3. Removevalve from bottom of cylinder heads and place them and their respective valve springs in a rack in their proper sequenceso they can be assembledin their original positions. CHeaningand inspection Refer to General Engine Mechanical section in this manual for cylinder head cleaning and inspection. Repair 1. ValveSeats: Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the power and performancebuilt into it. Another important factor is the cooling of the valve heads. Good contact betweeneachvalve and its seat in the head is imperative to ensure that the heat in the valve head will be properly carried away.

Eng,ne/eng

7-9

DR3125

Several different types of equipmentare available for reseating valve seats; the recommendationsof the manufacturer of the equipment being used should be carefully followed to attain proper results. Regardless of what type of equipment is used, however, it is essential that valve guides be free from carbon or dirt to ensure proper centering of pilot in the guide. a. lnstall expanding pilot in the valve guide bore and expandpilot by tightening nut on top of pilot. b.

Place roughing stone or forming stone over pilot and just clean up the valve seat. Usea 46° stone for both the inlet and exhaust valve seats. Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smoothfinish.

d,

Narrowdownthe valve seats to the proper width for the intake and exhaust. SeeSpecifications at the end of this section.

°This operation is done by grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding piJot and clean cylinder head carefully to remove all chips and grindings from above operations. E~] ~ Valve seats should be concentric to within 0.002 in. total indicator reading. 2. Valves: Valves that are pitted can be refaced to the proper angle, ensuring correct relation between the head and stem on a valve refacing machine. Valve stems ,which showexcessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be groundon part or aH of the valve head due to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this knife edge. If the edgeof the valve headis less than ½2in. thick after grinding, replace the valve.

7-10

10425

1

Engme/eng

a°

If necessary, dress the vaUverefacing machinegrinding °wheelto makesure it is smoothand true. Set chuckat 45 mark for grinding valves.

b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheenby movingthe lever to the left. d=

Turn the feed screw until the valve head just contacts wheel. Movevalve back and forth across the wheel and regulate the feed screw to provide light valve contact. Continue grinding until the valve face is true and smooth ¯all aroundvalve. If this makesthe valve thin, the valw, must be replaced as the valve will overheat and burn.

f. Removevalve from chuck and place stem in "V" block. Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem. NOTE:Onnythe extreme end of the valve stem is hardenedto resist wear. Do not grind end of stem excessively. g°After cleaning vaave face and cylinder head valve seat of grinding partic6es, makepencil marksabout 1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve.

@@

Remove valve and checkface carefully. If all pencil marks have not been removedat the point of contact with the valve seat, it will be necessary to repeat the refacing operation and against recheck for proper seating. i. Grind and check remaining valves in the samemanner. Assembly ~’et-~ Whenreplacing valve springs, refer to the latest part,,; catalog for ordering information. ~] Starting with number 1 cylinder, place the valves in the designated ports and assembleall but the seal and locks. Then, using tool J-5892-C,compressthe spring (~) and install the seal and locks ©. Seethat the seal is flat and not twisted in the valve stem groove, and that the locks seat properly in the valve stem groove. DR3795

~ Place valve spring in position with the closed coil end toward the cylinder head. Installation 1. Wipeoff engineblock gasket surface and be certain no foreign material hasfallen into the cylinder bores,bolt holes, or the valve lifter area.It is goodpractice to clean out bolt holes with an air hose. ~This engine has special marine head gaskets. Do not substitute automotive head gaskets. 2. Install newheadgasketon cylinder block. Dowelsin the block will hold the gasket in position. Alwayshandlegasketscarefully to avoid kinking or damage to the surface treatment of the gaskets. DONOTuse any type of sealing material on headgaskets. Thegaskets are coatedwith a special lacquer to provide a goodseal, once the parts have warmedup. 3. Carefully set in place on the engineblock dowelpins. 4. Clean and lubricate the headbolts with VolvoPentaGasketSealing Compound P/N 1161231-4.Install bolts. 5. Tighten the headbolts with a torque wrench,in three progressive steps, following the sequenceshown. Step1 - 35 ft. Ibs. (47 N®m) Step2 - 65 ft. Ibs. (88 N®m)

®

Step3 - 85 ft. Ibs. (115Nom) ~ Damage to the cylinder block threads can result if bolts are not lubricated with VoRvoPenta Gasket Sealing Compound P/N 1161231-4 prior to installation or if the bolts are tightenedexcessively.Usean accurate torque wrenchwheninstalling headbolts and do not overtighten. Uneven tightening of the cylinder headbolts candistort the cylinder bores, causing compressionloss and excessive oil consumption.

®

®

@

DR2905

Timing Chain, Cover and Seal Harmonic Balancer Removam 1. Remove alternator and powersteering belts, and crankshaft pulley. \

[~ 2. Attach tool J-23523-Eto baEancer,and turn puller screw to remove balancer from crankshaft. DR3573

Oil Seal Replacement ~-~ Cover need not be removedto replace the craknkshaft seal. 1. Pry oil seal out of front of coverusinga large screwdriver.

7-12

Eng,ne/eng

L_,LJ 2. Coat seal lips with engine oil. Install newseal with lip toward inside of cover. Use too} J-35468 to drive seal into position.

11

Timing Chain Covet" Removal 1. RemovecircuBating pumppulley, aUternator brace, and power steering pump. 2. Drain cooling system and remove hose at circulating pump. Disconnect temperature sender wire, then remove circulating pumpand discard gaskets.

787

3. Remove oil pan. See Oil Pan in this section. 4, Removethe front cover-to-block front cover and gasket.

attaching screws. Remove

Timing Chain and Sprocket Replacement ~ 1. Crank engine until "0’" marks on camshaft and crankshaft sprocketsare in alignment,in this position, engineis timed to firE: No. 6 cylinder. DR3579

2. Removecamshaft sprocket bolts. Removesprocket and timing chain together. Sprocketis a slight press-fit for approximately1/i~ inch. If sprocket does not comeoff easily, a light blow with a plastic-faced hammeron the lower edge of the camshaft sprocket should dislodge it. 3. If crank sprocket requires replacement,use a two or three jaw puller such as J-1619 that pilots on end of crankshaft to pull off sprocket. E~ 4. Install crank sprocket using tool J=22102to drive it into place over keyway.

DR3574

[~ 5. Install timing chain on camshaft sprocket. Hold the sprocket vertical with the chain hanging below. Align the camand crank sprocket timing marks, and attach the chain to the crank sprocket.

DR3577

/// ~ //’x-’~,¢"

/’ ,

DR3571

6. Align dowelin camshaftwith dowelhole in sprocket and install sprocket on camshaft. De not hammersprocket onto camshaft. This may loosen rear camshaft welsh plug. 7. Drawsprocket onto camshaft using the mounting bolts. Lubricate the timing chain with engine oil. TimingChain CoverInstallation 1. Clean gasket surface on block and crankcasefront cover. 2. Install section.

new oil pan gasket and oil pan. See Oil Pan in this

3. Coat the gasket with sealer and place in position on cover. Apply a 1/8 inch bead of GMSilicone RubberSealer, P/N 1052366 (or equivalent), to the joint formed at the oil pan and cylinder block. 4. Position crankcase front cover over crankshaft. Press cover downward against oil pan until cover is aligned and installed over dowel pins on block. 5. Install the front cover-to-block attaching screws. 6. Tighten front cover to block bolts. See TorqueSpecifications at the end of this section for the torque figure. Harmonic Balancer lnstaBatien 1. Coat machinedouter surface of balancer hub with engine oil. Align keywayand start balancer onto crankshaft. [~ 2. Using appropriate end of tool J-23523-E threaded into crankshaft, or a large washerand a 7/16-20 x 4 in. bolt and nut threaded into center hole in crankshaft, tighten nut to seat harmonic balancer on crankshaft.

DR3576

[~E} 3. Removeinstalling tooi. Install crankshaft puiley and tighten screws securely. Thread 7/16-20 x 2 in. bolt and thick washer into crankshaft and tighten. See Torque Specifications at the end of this section for the torque figure. 4. Install circulating pumpand pulley, and tighten screws securely. Attach water hose to pump= 5. Install alternator and power steering pumpbrackets. Install alternator and powersteering belts and adjust tension to specifications.

7-14

24965

Eng,ne/eng

Camshaft Removal [::3~ 1. Remove distributor (~. Remove intake manifold and circulating pump. 2. Removerocker arm covers, loosen rocker arms, then remove pushrods and valve lifters. 3. Removecrankshaft pulley, harmonic balancer, timing chain cover, timing chain, and camshaft sprocket.

28257

E4--’~ 4. Install two or three 5/16-18x 4 in. bolts in camshaftsprocket bolt holes and carefully pull out camshaft. Use care not to damagecamshaft bearings. Measure: Camshaft Journals. Refer to General Engine Mechanical section in this manual.Do not attempt to repair the camshaft. Replacethe c~]mshaft if damaged. Whenever the camshaft needs to be replaced, a newset: of valve lifters mustalso be installed. Bearings Refer to General Engine Mechanical section in this manual for camshaft bearing disassembly, cleaning, inspection, and assem,b!y. Installation 1. Lubricate camshaftjournals with engine oil. ~ot~ Whenevera new camshaft is installed, lubricate the camshaft lobes with Molykote or its equivalent. Also add one can cf G.M. Engine Oil Supplementto crankcase oil. 2. Install three 5/lS-18 x 4 in. bolts in camshaftbolt holes, install camshaft, being careful not to damagebearings. 3. Install camsprocket (making sure timing marksface outward),, timing chain, and timing chain cover. 4. Install harmonicbalancer andcrankshaft pulley. Install circulating pumpand connect coolant hose. 5. Install valve lifters, push rods, rocker arms, and intake manifold. Install rocker armcovers. 6. Install distributor andset initial timing.

DR3790

Lubrication System Description and Operation The oil pumpconsists of two gears and a pressure relief valve enclosed in a two-piece housing, and is driven by the distributor driveshaft which in turn is driven by a helix gear on the camshaft. The pumpis flange mountedto the cylinder block with two bolts. The pumpcover is equipped with a pressure regulator valve that regulates oil pressure at approximately 40-60 PSnat 2000 RPM. Thepumpintake is of the fixed screen type. A meshscreen filters out small particles of dirt and sludge which maybe present. A baffle incorporated in the intake screen has been designed to eliminate pressure toss due to suddensurging stops. In the event that a screen becomesplugged, a steel grommetopens and bypasses oil to the pump. Oil passes through an opening in the mountingflange to the cylinder block, then into an oil filter adapter. The mainoil galleries run the full Dengthof the crankcaseand cut into the valve lifter guide holes to supplyoil at full pressureto the lifters. The rocker arms and valves are lubricated by an oi0 channel in each pushrod. Excessoi6 drains off and returns to the oil pan through passagesin the cylinder head and block. Connecting passagesdrilled in the crankcase permit delivery of oil at full pressure to all crankshaft and camshaft bearings, distributor drive gear, and shaft, and the timing chain. Holes drilled in the crankshaft carry oil from the crankshaft bearings to the connecting rod bearings. Pistons and cylinder walls are lubricated by oil forced through a small notch in the bearing parting surface on the connecting rod, ,which registers with the hole in the crankpin once every revolution. Piston pins are lubricated by splash.

28256

RemoteEngineOil Filter tIT [~ A full flow oil filter ~ is mountedto a bracket attached to the port exhaust elbow. Twohoses connect it to an oil cooler and an engine block adaptor ®. [~ [~ Oil exits the block through the rear opening © of the adaptor, andtravels througha hoseto the rear oil cooler fitting. It leaves the front cooler fitting, and travels through a hose that connectsto the filter bracket inner (starboard) opening@. Return oil leavesthe filter bracket at the outer (port) opening(~), travels through a hose and re-enters the engine at the forward opening (~) of the adaptor.

19~6A

If hosesare improperly attached at adaptor or filter bracket, oil flow will be reversed. Oil pressure wilt drop and engine damagemay result.

7-16

Engme/eng

[~ Normally, all engine oil passes from the bJock through an OEMfilter adapter @. If the remote oil filter or lines become restricted, a spring loaded bypass vaBve ® opens in the adaptor and circuJates oil back into the block.

©

E’3~ Inspect bypass valve spring and valve disc ® for proper operation or damage.If repmacementof bypass valve is necessary, removebolts and adaptor. Clean valve chamberin block and replace adaptor.

DR2906

Removal 1. Removetiming chain cover. See Timing Chain, Cover and Seal in this section. 2. Removeoil dipstick and withdraw oil using a suction pump. 3. Removeoil dipstick tube. Removescrews, oil pan and gasket. 4. Remove oil dipstick tube fitting

from oil pan. DR3788

installation 1. Thoroughlyclean all gasket sealing surfaces. ~-] 2. Apply RTVsealer to the front and rear corners of the block. 3. Attach gasketto block. Install rear portion of oil panseal in groove in rear main bearing cap. ~ 4. Install front portion of oil pan seal by pressing the corner,,; im.o sealer applied to block. 5. install oil pan and tighten screws. SeeTorqueSpecifications al: the end of this section for the torque figure.

31576

[~ 6. Install dipstick tube fitting to pan; leave screw loose.. Orient fitting and attach dipstick tube. Thentighten fitting screw and flare nut. SeeTorqueSpecifications at the endof this sectiorT: for the torque figure. 7. Fill crankcasewith specified engine oil. See CrankcaseOil in the General information Section.

Oiil Pump

DR3580

Removal and Disassembly 1. Removeoil pan. [~] 2. Removepumpto rear main bearing cap bolt, and remove pump,extension shaft, and collar. NOTE:Baffle nuts have to be loosened.

Englrle/eng

7-17

3. Disconnect pump shaft from extension. Removefour cover attaching screws, cover, gasket, idler gear and drive gear, and shaft. 4. Removepressure reguKator valve and valve parts° 5. If the pickup screen or pipe needreplacing, replace the entire pump and pickup screen assembly. 6. Washall parts in cleaning solvent and dry using compressed air. inspection Should any of the following conditions be found during inspection operations, the pumpand pickup screen assembly should be replaced. 1. Inspect pumpbody for cracks or excessive wear. Inspect oil pumpgears for excessive wear or damage. 2. Checkshaft for looseness in the housing. Checkinside of cover for wearthat would permit oil to leak past the endsof gears. 3. Check the oil pickup screen for damageto screen or reBief grommet.Checkfor oil in the air chamber. 4. Checkpressure regulator valve plunger for fit

in cover.

Assemblyand installation 1. Place drive gear and shaft in pumpbody. Install idler gear so that smoothside of gear will be toward the cover. 2. Install a new pumpto cover gasket to ensure correct end clearance of the gears. 3. install cover and attaching screws. Tighten screwsto 80 in. Ibs. (9 N.m), and check to see that shaft turns freely. 4. Install regulator valve plunger, spring, retainer, and pin. 5. Assemble collar end of extension shaft assembly over pump driveshaft, aligning tang of extension shaft with slot in end of pumpdriveshaft. 6. Assemblepumpand extension shaft to rear main bearing cap, aligning slot on top end of extension shaft with drive tang on lower end of distributor shaft. NOTE:Oil pumpshould slide easily into place. If not, remove and relocate slot or locate other problem. Install mounting screws and tighten. See Torque Specifications at the end of this section for the torque figure. 7. Tightenbaffle nuts. 8. Install oil pan using newgasket. Connectoil drain tube.

7-18

Englne/eng

MeasuringCamshaftLobeLift E~ 1. Removerocker arm covers. Loosen rocker arms and pivot awayfrom push rods. Position indicator with ball socket adapter (]bol J-8520) on push rod. Makesure push rod is in the lifter socket. 2. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position. 3. Set dial indicator on zero, then rotate the crankshaft stowly, or attach an auxiliary starter switch and "bump" the engine over, until the pushrod is fully raised position.

DR3791

Wheneverthe engine is cranked: Removegray and black connectors from ignition preventaccidental starting ef engine.

coil

to

4. Comparethe total lift recorded from the dial indicator with specifications. If camshaftreadingsfor all lobes are ,within specifications, removedial indicator assembly. DR5555

5. Install

valve mechanismas outlined. Install

rocker arm covers.

Rear Main Bearing Oil Seal Replacement

Pry out rear crankcase oil seal. NOTE:Care should be taken when removing the rear crankcase oil seal so as not to nick tl~e crankcase seal surface. Cleaning and Inspection Clean sealing surface on crankshaft with a non-abrasive cleaner. Inspect chamfer on crankshaft for grit, loose rust, and burrs. Correct as necessary. Rnstaliation 1. Lubricate the inner and outer diameter of the seal with engine oil D~ 2. Position the seal onto tool J-38841(~ so seal lip will face the block. ~ 3. Position tool J-38843 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft and tighten securely. This will ensure that the seal ® is installed squarely over the crankshaft. Turn the handle until it bottomsthen removethe tool.

Eog,o~;~.g ~ Safety Related

7-19

Crankshaft Description Main bearings are of the precision insert type and do not utilize shims for adjustment. If clearances are found to be excessive, a new bearing, both upper and lower halves, will be required. Bearings are available in standard size and 0.001 in. (0,0254 ram), 0.002 in. (0,0508 mm), 0.010 in. (0,245 ram) and 0.020 in. (0,508 mm)undersize. Selective fitting of both rod and main bearing inserts is necessary in production in order to obtain close tolerances. For this reason you mayfind one-haft of a standard insert with one-half of a 0.001 in. (0,0254 mm)undersize insert which ,will decrease the clearance 0.0005 in. (0,0127 mm)from using a full standard bearing. Whena production crankshaft cannot be precision fitted by this method,it is then ground 0.009 in. (0,2286 mm)undersize on only those main journals that cannot be properly fitted. All journals will not necessarily be ground undersize. A 0.009 in. (0,2286 ram) undersize bearing and 0.010 in. (0,245 ram) undersize bearing maybe used for precision fitting in the samemanneras previously described. if, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirement will be determined by bearing clearance. Cleaning, Inspection and Repair [~ Refer to General Engine Mechanical section in this manual for cUeaning, inspection, and measurements. in general, (except No. 1 bearing) the lower half of the bearing showsa greater wear and the most distress from fatigue, ff upon inspection the lower half is suitable for use, it can be assumed that the upper half is also satisfactory. If the lower half shows evidence of wear or damage,both upper and lower halves should be replaced. Never replace one half without replacing the other half. These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in. (0,0254 mm)out-of-round, or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings. The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the rear intermediate and front intermediate journals, using a dial indicator. The runout limit of each of these journals is 0.002 in. (0,0508 ram). if the runout exceeds 0.002 in. (0,0508 ram), crankshaft must be repaired or replaced.

7-20

Engme/eng

Main Bearing Replacement [~ 1. Install a main bearing removing and installing tool 3-8080 ~) in oiE hole in crankshaft journal. NOTE:If such a tool is not available, a cotter pin maybe bent as required to do the job. 2. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper bearing out of block. 3. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of brock. Rotate the bearing into place, and removetool from oiE hole in crankshaft journal. 4. Oil new Jower bearing and install in bearing cap. Install main bearing cap with arrows pointing toward front of engine. Torque main bearing cap bolts to specifications. Measure: Refer to General Engine Mechanicansection in this manual for crankshaft bearing clearance procedures.

Connecting Rod Bearing Replacement Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. DO NOTFILE RODSOR ROD CAPS,If clearances are found to be excessive a newbearing will be required. Bearings are available in standard size and 0.001 in. undersize for use with standard size crankshafts. 1, With o[I pan and oil pumpremoved, removethe connecting rod cap and bearing. 2. Wipethe bearings and crankpin clean of oil. Inspect the bearing for evidence of wear or damage. 3. Measurethe crankpin for out-of-round or taper with a micrometer. ff not within specifications, replace or recondition the crankshaft. If within specifications and a newbearing is to be installed, measure the maximumdiameter of the crankpin to determine new bearing size required. 4. If within specifications, measurenew or used bearing clearances with Plastigage or its equivalent. [~ If a bearing is being fitted to an out-of-round crankpin, be sure to fit to the maximum diameter of the crankpin. If the bearing is fitted to the minimumdiameter and the crankpin is out-ofround 0.001 in., interference between the bearing and crankpin will result in rapid bearing failure. a. Place a piece of gauging plastic the full width of ttne crankpin parallel to the crankshaft. (Note: Surfaces must be free from oil.)

Englne/eng

7-21

DR2£1

b. Install

the bearing in the connecting rod and cap.

c. Install the bearing cap and evenly tighten nuts to specifications. [~ Do not turn the crankshaft insta||ed.

with the gauging plastic

d. Removethe bearing cap and using the scale on the gauging plastic envelope, measurethe gauging plastic width at the widest point. 5. If the clearanceexceedsspecifications select a new, correct size bearing and remeasure the clearance. 6. Coat the bearing surface with oil, install the rod cap and tighten nuts to specifications. 7. Whenall connecting rod bearings have been installed tap each rod lightly (parallel to the crankpin) to makesure they have clearance. [~ 8. Measureall connecting rod side clearances (see Specifications at end of this section), betweenconnecting rod caps. 47427

Piston, Ring and Connecting Rod Piston and Rod Removal 1. Removeoil pan, oil pump, and cylinder head. Turn crankshaft until piston is at bottomof stroke. Place a cloth on top of piston to collect cuttings. 2. Before attempting to remove piston, ridge as necessary.

remove cylinder

bore DR3792

Refer to GeneralEngineMechanicalsection in this manual for cylinder bore ridge reamer procedures. 3. Inspect connecting rods and connecting rod caps for cylinder identification. If necessarymark them. DE] 4. Removeconnecting rod cap and install tool J-5239 on studs. Push connecting rod and piston assembly out of top of cylinder block. [~ It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder. Disassembly Refer to General Engine Mechanicalsection in this manual for piston and connecting rod disassembly.

7-22

Engine/eng

Assembly Referto GeneralEngineMechanical section in this manualfor piston and connectingrod assembly. PistonandRodUnstallation 1. Lightlycoatpistons,rings andcylinderwarlswith light engineoil. 2. Withbearingcapsremoved, install tool J-5239on bearingcapbolts. [~o-0-t-~ Checkposition of ring endgaps.Theymustbe alignedwith each ().’.her as describedpreviously.SeeGeneralEngineMechanical. 3 Install eachpiston in its respectivebore, usingtool J-5239on each assembly. For valveclearance,the teardropin the piston facesup andthe oil holeon the connecting rod shouldbe to the centerof the cylinderbtock. Guidethe connectingrod into placeon the crankshaftjournals with the long detail of tool J-5239. E3~]4. Usetool J=8037to compress the piston rings. 5. Install bearingcapsandcheckthe bearingclearance.Referto General EngineMechanical section in this manualfor connectingrod side clearance procedure.

Cylinder Block C~,linderBore [~ Inspect:

J 8037~

Cylinderboresfor scoringor other damage. Referto GeneralEngineMechanicalsectionin this manual.

\

[~_~ Measure: Cylinderbore taper andout-of-round.Referto GeneralEngineMechanical sectionin this manual. C, ylinder BoreReconditioning [~ Measure: Referto GeneralEngineMechanical section in this manual. Piston Selection 1. CheckUSED piston to cylinder bore clearanceas follows: a. MeasL,re the "CylinderBoreDiameter"with a telescope gauge21/2in. (64 mm)fromtop of cylinderbore. b. Mesure the "PistonDiameter"(at skirt acrosscenterlineof pistonpin). c. Subtractpiston diameterfrm cylinder borediameterto determine"Piston to CylinderCtearence.." d. Calculatepiston diameterfrom cylinder clearenceand determine if pistonto cylinderwall clearence is within servicelimits. 2. If usedpiston is not acceptable,checkif a newpiston maybe usedto fit cyinderborewithin servicelimits.

Engine/eng

7-23

5159

3. If cylinder boremustbe reconditioned,measure newpiston diameter (acrosscenterlineof piston pin), thenhonecylinderboreto correct clearancePreferablerange).Markthe piston to identify the cylinderfor whichit wasfitted. Handlethe pistons with care, anddo not attemptto force themthroughthe cylinderuntil the cylinder hasbeenboredto correct size as this typepiston canbe distorted throughcarelesshandling.

Circulating Pump ~TheVolvo Penta circulating pumpis manufacturedspecially for marineuse. It is servicedonly as an assembly.Donot replacewith an automotivecirculating pump. inspection Remove alternator andpowersteering belts. Graspcirculating pumppulley andcheckendandside play. Turnpulley to checkfor drag. Lookfor water leaking from indicator hole beneathpumpshaft behindpulley. Replace pump if play, drag, or leakageare evident. Removal and Installation 1. Drain waterfrom block anddisconnectwaterhosefrom circulating pump. Remove pulley. Remove circulating pumpbolts, pumpand gaskets. 2. Usenewpumpto block gasketsand sealer, install newpumpassembly oncylinderblockandtightenbolts as specified.Install pulley. Install alternator andpowersteering belts, then adjust tension. Connecthoseto circulating pump.Lakeor tank test unit andcheckfor leaks.

Front Engine MountReplacement Removal E~ 1. Removetwo lag screws @and washersfrom mounts. Z~ 2. Lift engine with 1500lb. (680 kg) minimum capacityhoist to allow removalof front mountand bracket. Remove three mount screwsand lock washers(E).

11982

11981

7-24

Engineleng

E3~~ Prior to disassembly of front mount assembly, measure d,stance betweenlarge washerandflat on uppermountbracket. Disassembly [~] t. Remove three nuts ©; one Iockwasher,and engine mountbracket @from mountbolt ~:) while holding bolt securewith socket. L-~ 2. Remove one large washer ®, one small washer @and engine mountbolt (~) from mount.

\ 11980

Reassembly 1. Pfacesmall washer@on mountbolt andinsert bolt up through mount.Install large washer® andsecurewith nut @.Tightento 80-75ft. Ibs. (81-102N.m). E~2. Install upperinner nut and place enginemountbracket @on enginemountbolt. E~ Measuredistance betweenlarge washer and flat on upper mount bracket. Distancemustbe the sameas that prior to disassembly.

11879

3. Install lock washer andlowernut. Tightennut to 50-70ft. Ibs. (68-95 N,m). installation 1. Spraythe enginemountscrewsthreadswith Loctite~ PrimerN and allow to air dry. ApplyVolvoPentaTreadSealingAgentP/N1161053-6 to the screws. Attach enginemountassemblyto enginewith three screwsand washers.Tightento 32-40ft. Ibs. (43=54N-m). 2. Install lag screwsandtighten securely.

m 11978

Height Adjustment ~T~1. To changeengineheight, tighten or loosen nuts (~ andC) required. L~2 Lift enginewith 1500 ib.1680 kg) minimum capacity hoist. Positionengineat desiredheight. [~7~3. After setting mountposition, turn nut C) up against undersideof enginebracket andhold nut with a wrench.Tightenuppernut ® to 100120ft. tbs. (138-163N-m).

11983

High-Rise ExhaustElbowReplacernent Removal I~O-~ Drain water from respective exhaustmanifold. 1, Loosentwo clampssecuring upperhoseto elbow.

2953 Engine/eng

7-25

Ei=] 2. Port Elbow- Remove four thru-bolts and lock wahsers@. Move the remotefilter aside 3. StarboardElbow- Remove four thru-bolts lock washers,and washersattaching high rise elbowandcircuit breakerbracket ®. Set bracket assemblyaside. [~ 4. Lubricate inside of exhausthosewith a soapywatersolution, then removeremainingelbowbolts. Tapelbowwith a soft hammer to free it, then twist it out of the hose.Remove anddiscardthe manifoldgasket. 28~67

Installation 1. Apply VolvoPentaGasketSealing Compound P/N 1161231-4to both sides of a newgasket©, andplace it on the manifold. Lubricate inside of exhausthosewith a soapywatersolution to easeelbowinstallation. 3. Twist elbowinto hoseandposition it on the gasket.Install the outerrear thru-bolt, washer,andlock washer, andturn it in finger tight. [~ 4. Port Elbow- Positionremoteoil filter at front of elbowandalign the ECM/throttlelinkagebracketwith the bolt holesof the high rise elbow. Install four thru-bolts, washers, andlock washers finger tight.

CAUTION Do not

damageor bind throttle

37349

linkage during reassembly.

E~5. StarboardElbow- Position circuit breakerassemblyat front of elbowInstall twothru-bolts (~, washers,andlock washers finger tight. 6.Tightenall erbowthru-bolts to 12-18ft. Ibs. (16-24N.m). /t~7. Properly position the two exhausthoseclampsand tighten them secureJy. 28265

28266

7- 2 6

Engine/eng

Exhaust Hoseand intermediate Pipe RepUacement

1. Loosen eight dampsthat attach the upper and lower exhaust hoses, and slide cramps down onto exhaust Y-pipe= [~6---’] 2. Lubricate inside of lower hosewith a soapywater solution, and push lower hose down onto exhaust Y-pipe0 ETml 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose with a soapy water solution for ease of removal.

19377A

4. SJide upper hose off high-rise elbow. Slide lower hose off exhaust Y=pipe. Installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapywater solution. Slide it all the wayonto the exhaust Y=pipe. 28264

ES-=-I 2. Onthe inside of the 4 in. (10,16 cm)i.D. upperhose, there is a circular rib 1.5 in. (3,81 cm) from one end. Theribbed end the hose must face the intermediate pipe (rearward) whenit’s installed. Slide hoseonto high-rise elbowuntil it seats. NOTE:If hoseis not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment. EThEl3. With a twisting motion, insert intermediate pipe aln the wayinto the upper hose. Slide the lower hoseup until it’s halfway onto the intermediate pipe. L~ 4. Slide four No. 68 clampsup onto the upper hose. Slide four No. 64 clamps up onto lower hose. Position clamps in theiir proper channels and tighten them securely.

Exhaust {Flapper) Valve Replacement

1. Removethe intermediate exhaust pipe following the procedure under E×haust Hose and intermediate Pipe Replacement. Eg~2. Slide the Rowerhose downfar enoughto expose the valve pivot pin= Hold the valve while pulling out the pin, then lift out the valve. EIO~] 3. Inspect the two rubber bushings inside the pipe, and replace them as necessary.

I g445

installation 1. If installing newrubberbushings,apply3/t,P ScotchGripRrubberAdhesive 1300to outsideof tips, andinsert into inside of exhaustpipe. [~ 2. Positionvalvewith longestlip pointing downandinsert into pipe. Pushpivot pin throughbushings andvalveuntil pin endis flush with outside of pipe. If valveis not positioned properly(longlip down),it will restrict exhaustflow andfail to preventwaterbackingup into engine.Valvemust also movefreely andnot bind. Boatperformance wouFd be adverselyaffected, and enginemaysuffer water damage.

19443

3. Install intermediatepipe following procedureunderExhaustHoseand intermediatePipe Replacement.

Engine Coupler Replacement Removal 1. Remove enginefrom boat. 2. Disconnect all wires, lines andconnectors frombellhousing.

20834

E~] [~] 3. Remove sevenscrewssecuring bellhousing cover and slide coveroff.

7- 2 8

Engine/eng

E4~]4. Pull drain hoseout of bellhousingif equipped. 5. Remove bolts andnuts retaining belthousing.Disconnectgroundwires and oil coolerbracket.Noteoil coolerorientation. 6. Remove bell housing. LT~7. usean offset boxendwrenchto removethe six nuts securingthe coupler,andslide coupleroff studs. 8 Remove old gasketfrombellhousingcover. Cleangasketsurfacethor-. oughly.

19842

Installation [:6-~ 1. install couplerandattachsix Iocknuts.Usea suitable adaptorand tightennutsto 40-45ft. nbs.(54-61N,m). 2 Install bell housing.Attachoil coolerwith same orientationas notedin a previousstep. Tightennutsandbolts to 32-40ft. Ibs. (43-54N-m).Attach groundwiresandtighten nutsto 15-20ft. Ibs. (20-27N,m). 3 Pushdrain hoseint,o bellhousingif equipped. 4. Apply Volvo PentaGasketSealing Compound P/N 1161231-4to both sidesof a newbellhousinggasketandposition it on cover. ET~5. Cleansevenself-tappingscrewswith a wire brush. Install bellhousing coverandscrewsandtighten to 60-84in. lbs. (7-9 N,m). 6 Connect all wires, lines andconnectors to bellhousing.Install enginein boat.

Er~gme;eng

7-29

6712

7.4 and 8.2GSi EngineSpecifications Type - No. of Cylinder .................................. Valve Arrangement .............................. Bore and Stroke: 7.4 models ................. 8.2 models .................

90° - V-8 OverheadValves

4.250 x 4.000 in. (107,95 x 101,6 ram) 4.468 x 4.000 in. (113,48 x 101,6 ram)

Piston Displacement 7.4 models ......................... 8.2 models .........................

454 Cubic Inches (7.4 Liters) 502 Cubic Inches (8.2 Liters)

Cylinder Numbers- Front to Rear Starboard ............................................. Port .................................................. Firing Order .................................... Compression Ratio 7.4 GSi ................................................. 8.2 GSi ................................................. Water Temperature Control ........................... Thermostat Opens @ .............................. Fu|! Throttle Operating Range 7.4 GSi ...................................... 8.2 GSi ......................................

2-4-6-8 1-3-5-7 1-8-4-3-6°5-7-2 8.6:1 8.8:1 Thermostat 160°F(71 °C) 4800 - 5200 RPM 4400 - 4800 RPM

Pistons: Production Clearance 7.4 Models ................. 0.003 - 0.004 in. (0,0762 - 0,1016 ram) 8.2 Models ................. 0.004 - 0.005 in. (0,1016 - 0,1270 ram) Service Limit .............................. 0.005 in. (0,127 ram) Piston Rings: Top GrooveClearance..... 0.0012 - 0.0029 in. (0,0304 - 0,0736 ram) SecondGrooveClearance . .0.0012 - 0.0029 in. (0,0304 - 0,0736 ram) Third Ring Groove Clearance .0.005-0.0065in.(0,127-0,1651 ram) Service Limit ........................... +0.001 in. (+0,0254 ram) Top Ring Gap ................. 0.010 - 0.018 in. (0,254 = 0,457 mm) Second Ring Gap ............. 0.016 - 0.024 in. (0,406 - 0,609 ram) Third Ring Gap ............... 0.010 - 0.030 in. (0,254 = 0,762 ram) +0.010 in. (0,254 mm) Service Limit .............................

7-30

Engine/eng

7.4 and 8.2GSi Engine Specifications = Piston Pins: Diameter ................. 0.9895 - 0.9897 in. Clearance Production ............... 0.0002 -0.0007 in. Service Limit .............................. RodFit, interferencefit ..... 0.0031 - 0.0021 in.

(2,5133 - 2,5138 mm) (0,0050 - 0,0177 mm) 0.001 in (0,0254 mm) (0,0787 - 0,0533 mm)

Connecting Rod: Bearing Clearance, New...0.0011 - 0.0029 in. (0.0279 - 0.07366 mm) Bearing Clearance, Service Limit ............ 0.003 in. (0,0762 ram) Side Clearance............ 0.0013 - 0.023 in. (0,0330 - 0,5842 ram) Crankshaft: Thrust ......................

0.006 - 0.010 in.( 0,1524 - 0,254 mm)

Main Journal O No.l, 2, 3, 4, 5 ......... 2.7482 - 2.7489 in. (89.8042 - 69.8220 mm) Taper Production .......................... 0.0002 in. (0.0051 ram) Max Service Limit ......................... 0.001 in. (0.0254 mm)Max Out-of-round Production .......................... 0.0002 in (o.0051 mm)Max Service Limit .......................... 0.001 in (0.0254 ram) Max Main Bearing Clearance, Production No.l, 2, 3, 4 .............. 0.0017 - 0.0030 in. (0,0432 - 0,0762 mm) No. 5 .................... 0.0025 - 0.0040 in. (0,0635- 0,0965 mm) Main Bearing Clearance, Service Limit No. 1, 2, 3, 4 ............. 0.0010 - 0.0030 in. (0,0254 - 0,0762 ram) No. 5 .................... 0.0025 - 0=0040in. (0,0635 - 0,1016 mm) Crankpin Diameter 7.4 GSi .................. 2.199 - 2.1996 in. (55,854 -55,8698 mm) 8.2 GSi .................................... 2.20 in. (55.88 mm) Taper and Out-of-Round, New.............. 0.0005 in. (0,0127 mm) Taper and Out-of-Round, Service Limit ....... 0.001 in. (0,0254 mm) Camshaft: CamshaftBearing Journal E~ .. 1.9497 - 1.9477 in. (49,5224 - 49,4716 mm) Lift, Intake ................ 0.284 + 0.002 in. (7.2136 + 0,0508 mm) Lift, Exhaust............... 0.284 + 0.002 in. (7.2136 + 0,0508 mm)

Engine/eng

7- 31

7.4 and8.2GSiEngineSpecifications Valve Systems: Lifter

Type ......................................

Hydraulic Roller

Rocker Arm Ratio 7.4, 8.2GSi .............................................. 1.7:1 Valve Adjustment ............................ zero lash + one turn °45 Valve Angle .............................................. °46 Seat Angle ............................................... Valve Seat Run-out ............... +0.002 in (0.0508 mm)Maximum Valve Stem Clearance Intake, New.............. 0.0010 - 0.0027 in. (0.0254 - 0,0270 mm) Exhaust, New............. 0.0012 - 0.0029 in. (0,0304 - 0,0736 ram) Intake, Service Limit ...................... +0.001in. (0,0254 ram) Exhaust, Service Limit .................... +0.002 in. (0,0508 mm) Valve Seat Width, Intake ....... 1/32 to 1/16 in. (0,794 to 1,587 mm) Valve Seat Width, Exhaust ...... 1/16 to 3/32 in. (1,587 to 2,381 mm) Valve Spring Length ......................... 2.15 in. (54,41 mm) Valve Spring Installed Height, Installed ...... 1 51/64 in. (45,641 mm) Valve Spring Pressure Ibso @in. (kg @mm)[email protected] in. (33,[email protected]) Ibs. @in. (kg @mm)compressed.......... [email protected].([email protected]) Installed Height ............................ + 1/32 in. (0,794 mm) Valve Spring Fit In Damper....... 0.042 - 0.094 in. (1,06 - 2,38 ram) Engine Lubrication: Type Oil Pump............................................. Gear 10 psi (70,3 kPa) @500 RPM Normal Oil Pressure, WarmEngine ..... 40-60 psi (281-422kPa) @2000 RPM Crankcase Capacity 8 qts (7,57 liters); 9 qts (8,51liters) w/filter Oil Grade Recommended 32° F (0 ° C) and above .................................. 0° F (-17 ° C) to 32~’ F (0 ° C) ........................ 0° F (-17 ° C) and below ...............................

SAE 30 SAE 20W-20 SAE 10W

TMSynthetic MotorOil. which is specially Werecommend Volvo PentaDuraPlus formulatedfor heavyduty marineuse, andideal for VolvoPentaEngines.It providesbetter anti-wearqualities, especially during long high speedoperation.In addition, it neutralizes acids common to all internal combustion engines,offers superiorcorrosionprotection,andis formulated to offer better resistanceto oxidation andhigh temperaturesludgeformation. Fuel Recommendation............

See General Information Section

7- 3 2

EngineJeng

NOTES

7-33

TorqueSpecifications Usea reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. Thesespecifications are for clean threads only. Dirty threads produce friction which prevents accurate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

Camshaft Sprocket Circulating Pump Distributor Clamp Dipstick -[ijbe Fitting Flywheel BeHhousing Flywheel Cover Front Mount Bracket to Block Oil Filter BypassValve Oil Pan to Block Oil Pan to Front Cover Oil PumpCover Power Steering PumpBracket Rocker Arm Cover Starter Motor Thermostat Housing Timing Chain Cover

2O 3O 25 15-18 32-40 60-84 32-40 20 160 70 80 28-30 60-90 30-38 12-16 96

7-34

27 40 34 20-24 43-54 7-9 43-54 27 18,1 7,9 9 35-41 7-10 41-49 16-22 10,8

Engme/eng

lbrque Specifications(cont.)

m

Er, gme/eng

Connecting Rod Cap Exhaust Manifold Flame Arrestor Flame Arrestor Cover (GL Models) Flare-Dipstick Tube Flywheel Bellhousing Flywheel and Coupler Front Mount (lower) Front Mount (upper) Power Steering PumpBracket

48 20-26 25-35 30-35 15-18 32-40 40-45 50-70 100-120 13-15

65 27-35 2,8-4,0 3,4-4,0 20-24 43-54 54-61 68-95 136-163 18-20

Cylinder Head Step I Step 2 Step 3 Exhaust Manifold Front Mount Harmonic Balancer High-Rise Elbow Intake Manifold Main Bearing Cap (All) Oil Pump RemoteOil Filter Adaptor (to block) Rocker Arm Sensor and Cover

35 65 85 24-28 65-75 85 12-18 30 100 65 20-25 40

48-60

47 88 115 33-38 81-102 115 16-24 40 135 90 27-34 54 5-7

Flywheel and Coupler

10-15

-

14-20

Oil Filter Spark Plugs

22

7-35

one turn after contact 30

NOTES

7-36

Eng,neieng

Section 8 Steering System Table of Contents Mechanical (Non-power) Steering System ................................ Cable installation ........................ Cable Removal .......................... Lubrication ............................. Sealants, Lubricants and Adhesives ........ Steering Tube Replacement................ Trim Tab Adjustment .................... Power Steering System ...................... Belt Adjustment ........................ Cable Installation ....................... Cable Installation Problems .............. CheckingFluid Level ..................... Cylinder Installation ..................... Cylinder Removal........................ Cylinder Servicing ...................... Description ............................. Diagnosis Chart .........................

8=2 8=2 8-2 8=3 8-1 8-3 8=15 8-4 8-10 843 8-20 8=9 8-12 8-11 842 8-4 8=16

PowerSteering System(cont.) Extemai Leakage ....................... Feedback To Helm ...................... Hoses ................................ Hydraulic Fluid .......................... Lubrication ............................ Pumpi=~staHation ........................ PumpLeakage ......................... PumpOperation ......................... PumpPressure Test ..................... PumpRemoval ........................... Purging Air FromSteering System.......... Sealants, Lubricants, and Adhesives........ Special Tools ............................ Specifications - Torque .................. Steering Without PowerAssist ............. SystemDiagnosis ....................... SystemOperation ........................

Special Tools Required:

Materials Required:

CrowfootWrench(steering cable anchornut) P/N 9995443-08.2 GLPumpPulley Remover P/N 9995444-8 8.2 GLPumpPulley installer P/N 3854367-4 Volvo PentaHydraulic Cylinder Rod H older

Volvo PentaGrease VolvoPentapowertrim/tilt & steeringfluid or GMPowerSteering Fluid Dexron,or DexronII

Ax Safety

Warnings

Beforeworkingon anypart of the engine,read1hesection called Safetyat the endof this manual. Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfrom the battery beforeworkingon electrical systemto preventpossible sparksor arcing in the enginecompartment. Beforestarting engineafter repair or maintenance procedures,always makesure enginecompartment is free of fuel vaporsto prevent possiblefire andexplosion. When workingon an enginethat is runningor beingcranked,use extreme care to avoidgetting hands,fingers or clothing caughtin the alternator, powersteering pump,supplypump,andcirculating pump belts, pulleys andother movingparts.

Engine/eng

8 =1

8-18 8-21 8-14 8=9 8-14 8=8 8=19 8-5 8=19 8=8 8-9 8-1 8=1 8=21 8-7 8=14 8-8

® 18638

CO2740

Mechanical(Non-power)Steering System Description The mechanicalsteering system consists of a helm assembly(~, the steering cable (~), and attaching hardware© that connectthe steering systemto the inner transombracket and steering arm. Steering Cable Removal The steering cable is serviced as an assembly.

6825

[~ I’~ 1 To removethe steering cable, removethe cotter pin (~) and steering arm pin ~) securing the cable ram to the steering arm(E). Remove both steering arm bushings@. 2. Turnthe helmto the port full lock position. 3. Loosenthe cabie anchor nut ®, and removethe cable. SteeringCable Installation ~ Steering tube position in the anchor block is preset at the factory for proper centering of the steering system.Donot loosen the jam nut or changethe position of the steering tube.

31837

EEl//~1. Turn the steering wheelto fully extend the steering cable ram to its maximum extension. Lubricate the full ~engthof the steering cable ram with Volvo Penta GreaseP/N 828250-1o 2. Install the steering cable ramthroughthe steering tube. 3. Whileholding the steering cable in the steering tube, thread the steering cable anchornut onto the steering tube until the steering cable anchornut bottomson the end of the steering tube.

2921

//~ 4. Attach a crowfoot wrench~) at a 90° angle to the torque wrench.Tightenthe steering cable anchornut to 120 in. Ibs. (14 N,m).

18653

8-2

Eng,ne;eng

E2-7 E~5. Insert bushings@into steering arm. Install the steering arm pin (~) throughthe top hole in the steering armand throughthe hole of the steering cable ram. L~ ~ 6. Install the: cotter pin @through the steering arm pin and secureby spreadingthe ends of the cotter pin. L~7. Turn the steering wheelto fully extendand retract the steering cable ram @.The steering arm should movefrom stop to stop as the steering rammovesfrom fully retracted to fully extended.Steering armmustnot contact inside of transomcutout in either direction. Checkfor equal clearance of steering arm. Centerthe steering wheeland checkcentering of steering arm. Readjust as necessary.

3253

Steering SystemLubrication [~] Z~ Lubricate the steering ram with Volvo Penta Grease P/N 828250-1every 50 hoursor 60 days, whichever comesfirst. E~ Due to local conditions, it maybe necessary to lubricate your steering ramat morefrequent intervals.

Steering Tube Replacement DR172

1. Loosenthe jam nut and screwthe steering tube out of the anchorblock. Remove the jam nut from the steering tube. E9--’1 2. Screwthe jamnut (~ alJ the wayonto a newsteering tube.

®

E~9~3. Measure3¼in, (8,26 cm) @in from the end of the steering tube. Cleanthe following 11Ain. (3,18 cm) of thread (~ with Loctite~ PrimerN and allow to air dry. Apply Volvo PentaTreadSealing AgentP/N 1181053-6to the 1¼in. (3,18 cm) thread area (~). ~4. Screwthe anchor block onto the steering tube until the block is 35/32in. (8,02 cm) (~ "romthe end. This dimensionpositions the steering tube for accurate centering of the steering system,

DR1727

5, Screwthe jamnut up against the anchorblock and tighten to 35-40ft. Ibs. (47-54 N=m).Donot disturb the anchorblock position while tightening the nut. B~ ~ ~ 6. If the anchor block was removedfrom the transom plate, apply a small mountof VolvoPenta GreaseP/N 828250-1to both bushings. Install the block with the original screw&Tightenbothto 40-45ft. Ibs. (54-61 N~m). Secure screws with two cotter pins. [~ Filling the bushing pockets with grease can cause the screws to hydraulically lock and break the transomplate whentightened.

Englne/eng

8-3

8012

8011

® © -®

DR2959

Power Steering System Description

¯ The oil cooler © is a heat exchangerthat uses engine cooling water to keep the hydraulic fluid cool.

]’he power steering system consists of a mechanical cable from the helm to the inner transom plate, an engine mounted pump, and a power cylinder to movethe vertical drive steering arm.

¯ A high pressure hydraulic hose (~) carries fluid from the pump to the control valve, and low pressure hoses ~ and ® carry the fluid from the valve to the o[I cooler, and back to the reservoir.

hydraulic pump ~) is mounted on the [~The front of the engine and is belt driven by the

e The steering cable casing @attaches to the steering cylinder valve.

crankshaft pulley. The reservoir fill dipstick attached.

cap has a

¯ The cable ram passes thru the valve and attaches to the cnevis ®. ]’he drive steering arm is also attached to the clevis.

® Thecontrol valve and cylinder ® is a single unit mountedto the inner transom bracket.

8-4

CobrEng/eng

®

® P-@

DR3067

DR3008

PumpOperation E2~ During normal operation, fluid is drawn into dual pump intake ports @from the reservoir CK~.Thereservoir is supplied by a low pressure return line (~) from the powersteering oil cooler. The pumpoutput is thru ports ~). The vanes (~ are held ou:t against the pumpbore by pressure behind the vanes. The pum13 has sufficient output @to allow quick boat maneuverseven ~t engine idle RPM.The pumpoutput at high RPMis limited to about 2.3 gallons per minute by a flow restriction orifice ®. The pumpoutput pressure is determinedby the resistance to flow of the system. Whenno steering changes are being made, the pressure will be about 50-100 PSI. Whenthere is steering input, the pressure will be higher and will dependon the steering forces required due to the boat attitude, drive trim position, throttle position and quickness of the maneuver. ~3~] The pump is protected from very high pressures by a pressure relief valve @that is located in the pumpbody. If the steering load becomesextremely high, the relief valve will open and limit the output pressure ® to about 1,000-1,100 PSI. ~ot-~ Internal damageto the pumpwill occur if the system is operated at relief valve pressure for more than a few seconds. E~ The pumphas a metric output fitting. metric fitting.

Use only a hose with a

2635

Eng,ne/eng

8-5

STARBOARD

PORT

®

STARBOARD

PORT

-® ’S DR3508

SystemOperation

DR3506

Steering To Port - Steering WheelTurning To Left

No Steering input - Steering WheelNot Turning

~-~ Whenthe helm is turned to port (either turning boat to left or straightening from a right turn) the steering armis pulled to starboard. The steering cable casing pushes the valve spool (~ tO port. Fluid from the pumpenters the valve at ©, is routed to the rod-end outlet (~, and to the low volume side end of the cylinder ®. The pump pressure movesthe piston and steering arm to starboard. Fluid in the high volume side of the cylinder @is forced out thru the valve from @to return port ® and back to the reservoir. As long as the helmis turning to port this motion continues, swinging the outdrive to port.

~-~ Whenthere is no steering input from the helm, the spring @in the control valve keeps the spool ® centered. Fluid from the pumpenters the control valve thru the pressure port ©, flows past both cylinder ports @and (~) with titt{e restriction, then thru the return port ~ and back to the reservoir. There is a small equal force at both ends @ and ® of the cylinder and the cylinder does not move. With no steering input, the outdrive is held in one position and the boat movesin a constant turn or in a straight line.

Whenthe helm input stops (steering wheel not turning}, the steering cable stops pulling the steering arm to starboard, and the steering casing stops pushing the valve spool to port. When the spring @moves the valve spool to a "centered" position, hydraulic fluid is again routed past both cylinder outlets. The steering cylinder has an equal force at both ends and stops moving. The steering system is then back to the No Steering input condition described previously=

8-6

Englne/eng

STARBOARD

PORT

STARBOARD

PORT

1

DR3509

Steering To Starboard - Steering Wheem TurningTo Right

DR3507

Steering Without PowerAssist

D-’] Whenthe helm is turned to starboard (either turning boat to right or straightening from a left turn), the steering arm is pushed to port. The steering cable casing puJls the valve spooJ ® to starboard. Fluid from the pumpenters the valve at © and is routed to the piston-end outlet @and to the high volume side of the cylinder @. The pump pressure moves the piston and steering arm to port. Fluid at the low volume side of the cylinder ®is forced out and thru the valve from to return port (~) and backto the reservoir. long as the helm is turning to starboard this motion continues, swinging the outdrive to starboard. Whenthe helm input stops (steering wheel not turning), the steering cable stops pushing the steering arm to port, and the steering casing stops pulling the valve spool to starboard. When the spring ~) movesthe valve spool to a "centered" position, hydraulic fluid is again routed past both cylinder outlets. Thesteering cylinder has an equal force at both ends and stops moving. The steering system is then back at the No Steering Input condition described previously.

[~] If the steering systemis not providing power assist, the operator maystill steer the boat. Turning the steering wheel to port causes the steering cable to pull the steering arm to starboard. This causes the cable casing to push the valve spool ® to port against the stop about 0.125 in. (3,18 mm). The steering cable then transmits the full manualeffort to pull the steering arm. The fluid ~.~ aheadof the piston is forced out of the cylinder thru outlet @into the valve, and thru return port ® back to the reservoir. Additional fluid is drawnout of the reservoir thru the pressure inlet (9 and (~) to the opposite side of piston ®. Moresteering effort is required since aN of the power required to steer the boat must be supplied by the operator, and additional force is required to movethe fluid through the system when the pumpis not operating.

STARBOARDSTARBOARD PORT PORT

Eng~ne/eng

8-7

/

/

Pump Removal E~I. Place an oil drain pan under pump.Disconnect high pressure hose (~) and return hose® at pump.Donot lose O-ring on pressurehosefitting. Securehoseendsin a raised position to prevent fluid draining from hoses. Capor tape ends of hoses to keep out dirt. Drain pumpcompletelybefore removing. [~] ~ [~] 2. Loosen pump bracket mounting screws and remove drive belt. 20497

® 3.0

Models

~]

¯ 4.3 and 5.7 Models ® 7.4, 8.2 Models ~] 3. Take out mounting screws and removepumpfrom engine.

Lg__l 4. Removepumppulley using a pulley remover, then remove mountingbracket. 23916A

Pumplnsta|lation [~1. Attach mountingbracket to pump.Attach pulley using a pulley installer. 2. Mountpumpbracket loosely on the engine. E~ 3. Makesure O-ring is in place and in goodcondition, then connect high pressurehosefitting (~). Tightenfitting to 15-26ft. Ibs. (20-35N*m). E~ 4. Connectreturn hose (~) to reservoir.Tighten hose clampto 12-17 in. Ibs. (1,4-2,0 N°m).

20495A

5. Fill pumpreservoir with VolvoPentapowertrim~tilt & steering fluid. Bleed pump,hoses, and valve by turning pulley clockwise(as viewedfrom front of engine)until reservoir no longer showsair bubbles.Keepreservoir filled while purging air from system. 6. Install drive belt andadjust belt tension as describedunderBelt Adjustmentin this section. Do not pry against pumpreservoir while tightening belt, 7. Bleedentire systemas outlined underPurgingAir FromSteering System.

8-8

20510

Engme/eng

HydraulicFluid TM PowerTrim/Tilt & Usean approvedpowersteering fluid such as DuraPlus SteeringFluid or GMFbwerSteeringFluid. If these fluids are not available, arty automatictransmission fluid labeled Dexronor DexronII maybe used.

CheckingFluid Level Eta1. Runengine and rotate steering wheel Iock4oqockfor a reasonably long period of time to warmup steering fluid, then shut engineoff. Remove reservoir filler capandcheckif fluid level is at "HOT"markon dipstick. E~] 2. if fluid level is k~w,add recommended hydraulic fluid to bring fluid up to "HOT"markon dipstick. Replacefiller cap. Eel Donot over-flit a cold reservoir. Fluid could overflow whensystem reaches operating temperature.

Purging Air FromSteering System Whensystem componentshave been serviced, pumpmust be refilled with fluid before engineis started. Performthe following steps to purgeair from the steering system.

28846

E~Ot--~Do not run pumpeven momentarilywithout fluid. Pumpwill be ruined or severely damaged. 1. With engine"OFF,"turn helmall the wayto port. Addpowersteering fluid to bring fluid level to "COLD" markon dipstick. 2. Start engine,run mornentarilyand shut off engine. Recheck fluid level ancl fill to "COLD"mark.Repeatthis step as necessaryuntil systemno Ior~gerrequiresadditionalfluid. 3. {Completepurging of air from systemby starting engineand turning wheel slowly lock-to-lock. Maintainfluid level abovepumpbodyin reservoir.

20509

4. Returningfluid with air in it will often be in the formof foamandwill have a light tan or red appearance. Maintainfluid level high enoughso foamis not drawninto pumpinlet. All air mustbe eliminated from fluid before normal steering action can be obtained. If excessivefoamaccumulatesin reservoir it must be removed,or let unit stand for an hour and repeat steps above. 5. After all air has beenpurged,return wheelto centeredposition. Continue to run enginefor several minutesand then shut engineoff. 31839

Eng,rie/eng

8=~

6. With engine"OFF"and with fluid at normaloperatiing temperature, recheckto makesure fluid level is at "HOT"markon the dipstick. 7. Watertest the boat to makesure the steering functions normallyand is free fromnoise.

Power Steering PumpBelt Adjustment [~ ~ ~ With engine stopped, the belt should be tight enough.so that it will deflect ¼" to V2"(6-13 mm)whenpressedwith the finger at the point indicated(~). tf the belt is too tight, excessivebelt wearcanoccur. If is too loose, slippage can occur, resulting in belt wearand poor power steering operation. Belt tension should be checkedafter 10 hours of service and every 50 hoursthereafter.

23910

PowerSteering PumpPulley Circulating PumpPuJley 1,4"- 1/2" (6-13 mm)Deflection Checkpowersteering pumpbelt tension (~) midwaybetweenthe circulating pumppulley (~) and the powersteering pumppulley (~. Retighten newbelt, or checkold belt after 10 hoursof service and every 50 hours thereafter. ~Whenadjusting a power steering pump belt, never pry against the pump reservoir or pull againstthe filler neck.

DR4933

3.0 Models |____Z____l ~ To increasebelt tension: - Loosennut on lower pivot bolt, and loosen screwon bracebehindpulley. Place 1/2" breaker bar into the square hole in the pumpmountingbracket, and pivot pumpawayfrom engine as shown.While maintaining pressure on pump,retighten all mountingscrews. Recheckbelt tension.

24278

4.3 and5.7 Models |4J [~]To increase bert tension: - Loosen pumpmounting bracket screws, insert a V2" breaker bar into the squarehole in the pumpmounting bracket, and pivot pumpawayfrom engine as shown. While maintaining pressureon pump,retighten all mountingscrews. Recheckbelt tension.

7.4 and8.2 Models E~ ~ ~ To increase belt tension: - Loosen mounting screws. Rotate bottom of pumpoutward by prying betweenthe harmonic balancer and the bottom tab of the powersteering pumpsupport bracket.

8-10

DR4935

20510 Er,g,ne./eng

© 16067

DR2959

20572

Steering Cylinder The steering cylinder assembly is a combination power cylinder and control valve. A piston rod clevis (~ provides the attachment to the steering arm and steering cable ram. The steering cable casing attaches to the threaded valve ®. Cylinder Removal D~ 1. Turn helmto port fuln lock position. Remove the cotter pin © and the steering cable pin @.

20606

2. Hold steering tube with wrench. Loosen steering cable anchor nut ® and punl steering cable out of valve. [~0~ 3. Removecotter pin, then pull pin ~ out of clevis and steering arm. [~ 4. Removeboth hose fittings @from the valve. Raise hose,,; and cover the endsto keep out dirt. Z~ Do not movecylinder rod in or out untiJ cylinder has been drained completely. A dangerousspray of fluid can discharge from the cylinder ports if the rod is movedin or out.

205O4

20583

Eng....... g

~ Safety

ReBated

8-1

1

®

20503

20580

20579

~J 5. Remove cotter pins (~) and loosen both anchor screws 3 until steering cylinder assembly can be removed. Cylinder Servicing [~ 1 Pry out steering pivot bushings@if they are to be replaced. If necessarythey maybe carefully drilled in two placeswith a ~/16in. (1,5 ram) drill bit and then removed. 2. Newbushingsshould be lubricated and pushedinto place. [~] 3. The cytinder rod should be wrappedwith heavy paper or pasteboard and held in a vise with Holder, P/N [email protected] removethe clevis (~, unscrewthe 19 mmIocknut (~.

20576

~ 4. To reinstall clevis, tighten piston rod Iocknut(~ to 23=28ft. ibs. (31-38 N-m). Cylinderinstallation [~ 1. lnstatf anchorscrews(~ flush with inside of inner transombracket. ~2. Apply Vo|vo Penta Grease P/N 828250-1 to both bushings.

31842

~] Filling the bushing pockets with grease can cause the screws to hydraulically lock and break the transomplate whentightened. ~ 3. Position steering cylinder assemblyon inner transombracket. ALign bushingsof steering cylinder with screws. Handstart both anchor screws to ensure alignment and engagementinto bushings. Tighten anchor screwsto 40-45ft. Ibs. (54-81N m). [~ ~ 4. Install cotter pins (~ through holes in transom bracket from transom side. Spreadendsof cotter pins to secure. (~ Do not movecylinder rod if cylinder containsany fluid. A dangerous spray of fluid maydischargefrom the ports.

20574

20573 Englne/eng

8-12

®

20504

31837

20570

E7==j 5. Connecthosesto cylinder. Start eachfitting by hand.Tighten pressurefitting @to 10-12ft. Ibs. (-4-16 N,m).Tightenreturn fitting (~ 15-17ft. Ibs. (2--23 N,m). ~ 6. Pull steering arm(~ into hydraulic cylinder clevis @.Align holes and install large pin ® from top of arm. Securelarge pin by installing andspreadingendsof cotter pin.

Cableinstallation ~ 1. Turn the steering wheeEto fully extend the steering cable ram

20506

to its maximum extension. Lubricatethe full length of the steering cable ram with Volvo Penta Grease, [~0~ 2. Retract steering cable ram (~ and insert ram through valve @. [~1~] 3. Hold steering cable anchor nut backon cable casing to makecertain the steering cable is completelyseatedin end of valve. [~2~4. Whileholding steering cable tight against valve, thread steering cable anchornut (~ onto valve until snug. [~ ~ 5. Hold cable tube with a 22 mmwrench on the flat @. Attach a crowfoot wrenchat 90° to a torque wrench® and tighten the steering cable anchornut to a torqueof 126 in. Ibs. (14 N.m).

20606

[~4~] ,/~ 6. Align cable ram @with steering cylinder clevis ® and install small pin from top of clevis. Securesmall pin by installing and spreading endsof cotter pin. 7. !=ill systemwith fluid and removeall air. SeePurgingAir FromSteering System.

20605

Eng,ne/eng

8-13

20507

Lubrication ~] Z~ Every 60 days, grease the steering ram with Volvo Penta Grease P/N 828250-1 ~Dueto local conditions, it maybe necessary to lubricate engineat morefrequent intervals.

your

Hoses ~Do not start

engine with any power steering hose disconnected. 31837

The pumpoutput fitting has metric threads. Do not attach a hosewith SAEthreads to the pumpfitting, After connecting powersteering hoses, makesure that there’s ample clearance betweenthe hoses and drive belts and other components.Hoses installed out of position mayrub during operation and be damaged. If fluid return hoseis removedat pump,be sure to use a "wormdrive" clamp whenreinstalling it.

System Diagnosis Complaintsof faulty steering are frequently the resurt of problemsother than the steering cylinder assembtyor pump.Conditions such as hard or loose steering, or vibrations, are often related to suchfactors as the drive belt; pump andcylinder mounting;fluid level; or incorrect installation of the steering cable. Thesefactors should be checkedand corrected before disassemblingor replacing parts of the steering system. System Checks Manyfactors affect poweroperation of the steering system. Someof the most commonproblem areas are: = Fluid level. = Looseor worndrive belt, or oiFy belt. ¯ Steering cable jammedagainst somethingin boat at stern. ¯

Steering cable too short or steering cable too long.

o Loosely mountedcomponents. ® Loose pumppulley.

8-14

Engme/eng

After the problem has been found, determine the cause. For example,if the fluid level in the reservoir is foundto be low, refilP and bleed the system and check the entire hydraulic system for leaks. Just refilling the reservoir will makethe unit operate, but will not correct the condition that causedthe problem.

Trim Tab Adjustment Models With Power Steering EI~ Most power steering models are not equipped with trim tabs. If equipped,trim tab adjustmentis not required. Thetrim tab should be preset to dimension (~ 31/4 in. (83 ram), ° ® for left-hand rotation) and dimension© 21/4 in. (57 mini, (30° @fo: riqht-hand rotation). They should remain at this setting for all applications. If the trim tab is NOTset correctny, movetrim tab to the correct position. Tighten the trim tab screwto a torque of 34-16 ft. Ibs. 119°22N.m). Models Without Power Steering The boat maybe slightly easier to steer in one direction or the other due to steering forces or other reasons. To adjust, preset the trim to the dimensions above for models with power steering. Thencheck by running the boat in a straight line with a balanced load in an area where current and wind will not be a factor. To obtain equal steering effort, adjust the trim tab as follows: ~.L~ Safety Warning: Improper trim tab adjustment can cause difficult steering. 1. Turn the steering wheel in both directions to determine Lhe direction that requires the least amountof steering effort. 2. Loosenthe trim tab bolt and if tess steering effort is required to= port, movethe trim tab slightly to port. If less steering effort is: required to starboard, movethe trim tab slightly to starboard. Twin engine installations require both trim tabs be movedan equal amountin the samedirection. 3. For twin engine installations wheretrim tabs are used, set both trim tabs to the sameposition. 4. Retighten trim tab bolt and recheck steering effort in both directions. Repeatprocedureuntil steering effort is equal in both directions. 5. After final adjustment,retighten the trim tab screwto 14-16 ft. ibm;. (19-22N.m).

EnGr,~e/eng

~ Safety

Related

8-15

DR4931

Power Steering SystemDiagnosis Chart Possible Cause

Condition

Correction

SYSTEMNOISE: Pumpnoise "chirp="

Loosebelt.

Adjust belt tension to specification.

Belt squeal.

Loosebelt.

Adjust belt tension to specification.

"Hissing" sound.

Somenoise exists in all power steering systems. "Hiss"may be expected whenturning the steering wheel, particularly at low speed=

None; a slight "hiss" is normal and in no wayaffects steering.

RattJe

Pressure hose touching other parts of powerhead.

Adjust hose position.

Rattle or chuckle.

Steering system looseness.

Checkcable nut and cylinder pivot points for wear or looseness. Replace bushings if necessary.

Groan

Lowfluid level.

Find and repair leak. Fill reservoir and bleed system. Fill reservoir, find and repair leak. Check connections, bleed system.

Air in fluid. Growl

Excessive back pressure caused by hoserestriction,

Locate restriction and correct. Replace part if necessary.

Pumpgrowl.

Incorrect steering cable adjustment. Cable to boat interference,

Adjust cable per procedure. Eliminate interference.

Whine in pump.

Pumpshaft bearing scored.

Flush system, replace pump.

SYSTEMOPERATION: Excessive wheel kickback Steering cable attachment loose. or loose steering (not boat wander). Air in system. Steering wheel surges or jerks whenturning with engine running, especially during slow speed operation. Momentaryincrease in effort whenturning wheel fast to right or left.

Replace pin. Tighten steering cable anchor nut. Add fluid to pumpreservoir and bleed system. Checkall connections.

Loose pumpbelt.

Adjust tension to specification.

Air in fluid.

Fill reservoir, find andrepair leak. Bleed system. Replace pumpif defective.

Insufficient

pumppressure.

Pumpbelt slipping. Lowfluid level.

Tightenor replacebelt. If oily, fix leak. Fill reservoir and bleed system.

High internal leakage.

Replace pumpif defective.

8-16

CobrEng/eng

Condition Hard steering or lack of assist.

Correction

Possible Cause High internal leakage. (Power cylinder or pump.)

Replace pumpif defective. Replacecylinder if defective.

Cable jacket movementrestricted (bulkhead, fuel tank, jammed against inside of hull}.

Do not clamp cable tight near output end. Eliminate interference.

Loose pumpbelt.

Adjust belt tension to specification.

Lowfluid level in reservoir.

Fill to properlevel, if excessivelylow, checkall lines and joints for evidence of external leakage, torque to specs.

Lack of lubricant in lube points.

Lubricate, relubricate at proper intervals.

Excessivefriction in steering linkage.

Find reason for excessivefriction; relubricate or repair.

Cable has too tight a radius at output end.

Eliminate small radius.

Cabnemovementrestricted by tie straps, anchors, attached wires, etc.

Remove all cable anchors, tie straps, etc. on cable betweenlast bend and valve attachment point.

Insufficient fluid pressure.

Repmace pumpif defective.

Hard steering to starboard. Cable too long or movement restricted by bulkhead, etco

Replacecable, or eliminate restriction.

Hard steering to port.

Cable too short or movement restricted by bulkhead, etc.

Replacecable, or eliminate restriction.

Low fluid pressure due to restriction in hoses.

Checkfor kinks in hoses.

Removekink.

Foreign object stuck in hose.

Remove restricting hose.

object or replace

Low fluid pressure due to steering cylinder,

Pressure loss in cylinder due to worn Replace cylinder assembly. piston ring or scored housing bore.

Low fluid pressure due to steering pump.

Loosebelt.

Adjust tension to specification.

Lowfluid level.

Defective hoses.

Find and repair leak. Fill reservoir and bleed system. Fill reservoir, tighten fittings and hose clamps. Bleed system. Correct as necessary.

Pump worn or damaged

Flush system, replace pump.

Air in fluid and loss of fluid due to internal pumpleakage causing foaming and overflow.

Checkfor leak and correct. Bleed system. Keep fluid level up whenvery cold. Bf fluid level is correct and pump still foams, replace pump.

Air in fluid.

Foaming milky power steering fluid, low level and possible low pressure.

Col:,rEng/eng

8-1

7

External Leakage General Procedure 1. Wipesuspected area dry. 2. Checkfor over-filled reservoir. 3. Checkfor fluid aeration and overflow. 4. Checkhose connections - tighten if necessary. 5. Determineexact point of leakage. 6. Whenservice is required, replace component. Leakage Checks Although someleaks are easily found, seepagetype leaks maybe difficult to pinpoint. Locate seepageleaks as follows: 1. With the engine off, wipe the complete power steering system dry (pump, hoses, and connections). 2. Checkthe fluid level in the pumpreservoir and adjust as directed. 3. Start the engine and turn the steering wheel from stop=tostop several times. 4. Find the exact area of leakage. Easily Fixed Leaks 1. Loose clamp on pumpreturn hose. 2. Loosepumpor cylinder hosefitting, tf fittings are not cross-threaded, tighten to correct torque. See Torque Specifications. 3. Damaged O-ring on pumppressure fitting.

Replace O-ring.

4. External leakage of power cylinder. Replace power cylinder. 5. Leakageof fluid in cooling water. Replaceoil cooler. 6. Damageor cracked hose. Replace hose. if the return hose is removed,the clamp must be replaced with a wormdrive clamp. Replace leaky hoses.

@ ® DR3009

DR1443

PumpLeakage

2. Removefiller cap from pump reservoir and checkfluid level. Fill pumpreservoir to full mark an dipstick. Start engine, momentarily hold steering wheel against stop, and check connections at Tool J-5176 for leakage.

[7-] 1. An over-filled pumpreservoir can causea leak. Thefluid in the steering systemexpandsas it heats up during normal usage and fluid level rises in reservoir. Excessfluid is forced through the breather cap hole where it maybe sprayed over the engine by the drive belt. r T"I 2. install new()-ring. Tightenhosefitting (~)

3. Bleed system as outlined under Purging Air From Steering System. 4. Insert thermometer Kent-Moore Tool J-5421 into reservoir filler opening. Start the engineand movesteering wheel from stop-to-stop several times until thermometerindicates that hydraulic fluid has reached its normal operating temperature of approximately150° to 190° F (65° to 88° C).

to 15-26ft. Ibs. (20--32 N.m). If leakagepersists, replace pumpor hose as required. E~ 3. Check torque on fitting (~). Tighten 37-75ft. Ibs. (50-102N.m).If fitting is not loose, replace pump.

5. Checkfluid level; add fluid if required. When engine is at normal operating temperature, the pressure reading on the gauge (valve open) should be i’n the 50-100 PSi (345-690kPa) range. If pressure exceeds specifications, check the hosesfor restrictions.

I~ 4. Check fluid level ©. If leakage persists wiith fluid at correct: levemand cap tight, replace cap or pump. Ell 5. Somenon-repairable pumpleakage areas are markedwith the oil-drop symbol. If leakage occurs in these areas, replace pump.

PumpPressure Test ~ 1. With engine off, disconnect high pressure (output) hose at pump. Use a spare pressure hose @to install Kent-Moore Tool J-5176 between pump and steering cylinder pressure hose (~. Gauge must be positioned between shut-off valve and pump. Connectsteering cylinder pressurehose to shut-off valve. Openshut-off va lye.

Z~ 6. Pumprelief valve pressure can be checked by momentarily closing the shutoff valve. Do not leave valve closed longer than it takes to read gauge; high hydraulic pressuresare developed. Relief valve pressure is approximately 1000-1100 PSI (6895-7584kPa). Replace pumpif fluid pressures or temperature do not meet specifications.

8-19

DR1451

DR~452

Cable Installation Problems The hydraulic valve reacts to steering cable casing movement. Total valve movementis about 1/4 inch. This small motion is sufficient to operate the vanveand direct hydraulic pressureto the appropriate side of the steering cylinder. Any restriction of movement of the steering cable casing at the stern of the boat will limit or restrict the movement of the valve and will result in hard steering in one or both directions.

_L

Whenreplacing the steering cable, the following points must be followed

for

proper

power steering

DR1453

system operation:

1. Do not install a cable that is too short. Inadequatelength will put tension on the cable casing, and cause binding of the steering cable. This will restrict valve movement,cause hard steering to port and a tendencyto self steer to starboard. [~ 2. Do not install a cable that is too long. Excessivelength will push on the cable casing, and cause binding of the steering cable. This will restrict valve movement,cause hard steering to starboard and a tendencyto self steer to port. 3. Donot position steering cable in a sharp bendof less than 6 in. radius. Tight bends will cause binding and limit control valve movement.This vviH contribute to hard or uneven steering, or rough steering wheel movement.

DR56,~

’ °

I (~

4. Do not jam anything against cable at the engine end. Do not bind cable against inside of boat or against fuel tanks, battery boxesor flotation blocks. Jamming the steering cable will restrict steering cable movementand cause hard steering. [~] 5. Do not interfere with or restrict steering cable movement through the last 90° of bendto the engine. Cableretainers, clips, clamps or tie straps should not be used in a mannerthat witl restrict the cable movement near the engine. Do not attach wiring harnessor control cables to this end of the steering cable.

DR5644

Do not restrict steering cable casingmovement. Any restriction of the cable also restricts the valve movement. This will limit or stop hydraulic assist, or mayhold the valve in one steering mode.

Z~ Safety Related

8-20

Engme/eng

FeedbackTo The Helm The steering system requires at least a little friction in the helm (and cable) to prevent hydrodynamic forces on the gearcase from feeding back and turning the steering wheel without the operator activating the powerassist system. This mayhappenon singne engine installations (or on twin engines having both drives rotating in the samedirection). Runthe boat in a straight line in opposite directions at normal cruising speed with the drive trimmed in both a "bow up" position and in a "bow down" position, in each trim position, momentarilyrelease the steering wheel to see if the wheel is turned by the gearcase, and in which direction.

If the steering wheel turns to both starboard and port, then helm friction must be increased slightly. This will allow the powersteering system to hold the desired steering position. EEl if the helm always turns in one direction (when it turns), it may be caused by steering cable that is too short, too long, or has restricted movement. See Cable Bnstallation Problems. Twin engine problems may be corrected by adjusting the tie bar for "toe-in" (~ or for "toe-out" (~ of the vertical drives.

Specifications PowerSteering PumpRelief Valve Pressure ....................

1000-1100psi (6895=7584kPa).

=TorqueSpecifications Component

Torque

Anchor Screw - Cylinder assy. to TransomPlate

40-45 ft. Ibs. (54-61 N.m)

Bolts - Power Steering PumpMounting Bracket

25 ft. Ibs. (34 N.m)

Bolts - Power Steering PumpMounting

25 ft. Ibs. (34 N.m)

Fitting-

37,-75 ft. Ibs. (50-102N-m)

Fitting

Power Steering Pump - Power Steering PumpHose

15,-26 ft. Ibs, (20-35N.m)

Fitting - Inlet Control Valve Hose

10.-12 ft. Ibs. (14-16N.m)

Fitting - Outlet Control Valve Hose

15-17ft. Ibs. (20-23 N.m)

Hose Clamps - Oil Cooler and Power Steering Pump

12-17in. Ibs. (1,4-2,0 N.m)

Jam Nut - Anchor Block

35-40ft. Ibs. (47-54 N.m)

Locknut - Piston Rod To Clevis

23,-28 ft. Ibs. (31-38N.m}

Nut - Steering Cable Anchor

120 in. Ibs. (14 N.m)

Screw - Trim Tab

14-16 ft. Ibs. (19-22 N.m)

Engme/eng

8-21

NOTES

Section 9 Throttle andShift Control Systems

Contents Throttle and Shift Control Systems............................. Shift andThrottle Cable Routing ............................... Installation of SAECablesto Engine/Drive...................... Shift Cableto Drive Unit installation ............................ Twin Engine SX ModelsOnly ................................. Throttle Cableto EngineInstallation ........................... CheckRemoteControl Shift Cable Stroke .......................

9-1 9-2 9-3 9-3 9-4 9.4 9-8

Materials Required

VolvoPentaGreaseP/N 828250-1 MolybdenumGrease

Z~ Safety Warnings Beforeworkingon anypart of the engineorrelated systems,read the section called Safetyat the endof this manual. Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfromthe battery beforeworkingon electrical systemto prew.~ntpossiblesparksor arcing in the enginecompartment. Beforestarting engineafter repair or maintenance procedures,alwaysmake sure enginecompartment is free of fuel vaporsto preventpossiblefire and explosion. Whenworkingon an enginethat is runningor being cranked,use extremecare to avoidgetting hands,fingers or clothing caughtin the alternator, power steering pump,supplypump,andcirculating pumpbelts, pulleys andother movingparts.

Engine/eng

9-1

Shift and Throttle Cable Routing 1. If the remotecontrol shift andthrottle cablesare installed in the remote controls, proceed to CheckRemoteControl Shift Cable Stroke. 2. If the remotecontrol shift andthrottle cableshavenot beeninstalled, the following procedurewill permit you to order the correct length remote control shirt andthrottle cables. 3. Measurethe proposedroute of the remotecontrol shift and throttle cables. All bendsmusthave a radius greater than 6 inches (15,2 cm). *

Remote control shift cable: Add(~)+~) plus 20 in. (50,8 cm), round up to next cable length.

/ T

= Remotecontrol throttle cable: Add(~)+(~)+@plus 4 (10,1 cm), (© is to center of throttle armpin). Roundup next cable length. ~-~ Whenremoving shift and throttle cables from the packing box, DO NOTbendthe cables tighter than a 6 inch radius.

®

___t_

-2

Englne/eng

®

®

\ 34045

34044

34041

installation of SAECablesto EnginelDrive Shift Cableto Drive Unit installation ~i"O-tel] Remote control shift and throttle cables mustbe SAEtype cables, f .~Ot~1. If the throttle cableis attachedto the throttle armand anchor block, removeit from both. Thethrottle cable mustbe disconnectedfrom the throttle armprior to shift cableinstallation and adjustmentto prevent "loading" the control boxand adverselyaffecting shift adjustments. 2. Notethe position of small seal (~) andlarge seat (~) on the shift cable. Remove and retain jam nut, small seal, and large seal from the shift cable.

34039

~]3. Apply a light coating of Volvo PentaGreaseto the end of the remote control shift cablecasing. Slide shift cablethroughshift cabletube until it appearson the outside of the transom. 4. For easeof installation of shift cable, turn drive unit to port. Reinstall the retained large seal ~) andsmall seal (~ onto the shift cablein the sameposition as notedin step 2. E4~] 5. Loosencable clamp screw © and pull clamp out. 34037

~=’J6. Slide shift cable throughpivot housingandfrive unit. E~ 7. Slide clampin fully, engagingthe shift cable anchorgroove. ,~,CAUTION:Tighten clamp screw securely.

34038

E~ [~ 8. Rotate shift lever to extendbellcrank @.Remove cotter pin, fiat washer,andanchorpin (~). 9. Threadanchorpin halfwayonto remotecontrol cable end. [~] 10. Rotateshift lever backto neutral detent position, then move remotecontrol handleto its neutral detentposition. Turnanchorpin IN or OUT until it alignswith centerof bellcrankslot (~. [~ ~ 11. Install fiat washerand cotter pin. Secureby spreading end of cotter pin Install jam nut @and tighten securely against cotter pin. E~ 12. Reinstaaa rear cover and secure with screws®. Tighten to 108 - 132in Ibs. (12 - 15 N.m). Twin EngineSX ModelsOnly 13. For left handrotation propei|ers: the control cable mustbe reversed at the remotecontrol.

Throttle Cableto Engineinstallation I-N--~ Moveremotecontrol handle to NEUTRAL detent position. Turn propeller shaft andshift into the FORWARD gear detent position, then pull HALFWAY BACKtowards NEUTRAL. This positions the control for proper throttle cableadjustment.Failure to follow this procedure canbindthe shift linkagein the control, andproduce "hardshifting." E~1. Atign internal boss(~ of trunnionwith throttle cable groove®. Presstrunnionon throttle cableuntil seated.

®

EEl ® 9- 4

Engine/eng

F~ Lm~V_.~.~_J CarburetedModelsOnly: Engineanchorbracket mayhavetwo sets of anchorblock holes. Thetop set (marked)is for the 4Vcarburetor models,andthe bottomset is for the 2V carburetedmodels. [8~ ~ 2. Install openend © of trunnion in anchorblock. Install screw (A~ in anchorblock(~) andposition throttle cableassembly in selected of holes. Nut @must be against the anchorbracket, tighten securely. [~ Z~ 3. Throttle arm connector Q must have a minimumof 9 fu, turns or 1A in. (6.4ram)of throttle cable threadengagement. Install throttle armconnectoronto the throttle cable. Pull connectorforwardto remove all free play fromthe throttle cable, thenturn the connector in until holealignswith the top throttle lever pin. Thetop throttle leverpin is for "Pull-to-Open"throttle operation. E~if throttle armconnectorhole cannotbe adjusted to align with the throttle arm,checkfor propercableinstallation in remotecontrol. [~ ~ 4. Install connectoronto appropriatethrottle lever pin. Install washerand cotter pin @, and secure by spreading end of cotter pin. Tighten Iocknut ® against connector. o 7.4 Gi Models [~] . 7.4GSi, 8.2GSi, DPX385,and DPX415[~

~:ngine/eng

9=5

NOTES

Engine/eng

9-6

NOTES

9-7

CheckRemoteControl Shift Cable Stroke Control cable should "PULL" for forward gear. r’~ 1. Moveremote control handle into the forward gear, wide open throttle position. Pull out cable core wire to removeend play. Mark cable core wire at end of casing. 2. Return remote control shift handle to the neutral detent position. Measureand record the distance betweenmark (~) and end of casing. This dimensionis the shift cable stroke for forward gear.

36560

I~ 3. Mark cable core wire at end of casing with control in the neutral detent position. I-4] 4. Movethe remote control handle into the reverse gear, wide open throttle position. Pushin on cable core wire to remove end play. Measureand record the distance between mark ® and end of casing. This dimensionis the shift cable stroke for reverse gear. e The distance between forward and neutral must be no less than 11/4 in. (31,8 turn) andno greater than 13/8 in. (35,0 rnrn). e The distance between neutral and reverse must be no less than 11/4 in. (31,8 ram) and no greater than 1%in. (35,0 turn).

36561

Checkyour remotecontrol installation instructions, if your measurements are not within these specifications. Makesure the cables are attached correctly inside the control box before continuing. All control boxes must meet these minimumand maximum specifications in order for the shift systemto function properly. Should it becomenecessary to remove or replace the remote control cables, the attachment at the engine and vertical drive is very important. Follow these steps for removal and installation of remotecontrol cables.

36562

36563

//~ Safety Related

9-8

Engine/ertg

Section 10 Cooling System Table of Contents Components Circulating Pump - Engine ..................... Hoses,Clamps andDrainPlugs............ Manifold andElbows .............................. Thermostat ............................................... Raw Water Pump ..................................... Description ................................................ Draining EngineBlock or Exhaust Manifold........ Pivot Housing .......................................... Power Steering Coolers ......................... Supply Pump ........................................... Thermostat Replacement ....................... Troubleshooting Isolating Problem ...................................... Possibilities to Consider .......................... Problem Checkpoints ............................... QuiztheCustomer ....................................

10-18 10-17 10-18 10-17 10-19 10-2 10-20 10-23 10-22 10-19 10-23

Water Flow Diagrams DriveUnit andTransom Bracket ............. 10-8 3.0GS ..........................................................10-9 4.3GL, and GS ......................................... 10-10 4.3Gi .........................................................10-11 5.0GL and5.7GS ..................................... 10-12 5.0Gi and5.7GSi ...................................... 10-13 7.4Gi,7.4GSi and8.2GSi ........................ 10-14 V-6 and V-8 Carbureted Closed Cooling System ....................................... 10-15 V-6 and V-8 EFi ClosedCooling System ..................................................... 10-16

10-4 10-4 10-6 10-3

Safety Warnings Beforeworkingon anypart of the engine, readthe section called Safety at the endof this manual. Unlessinstructed otherwise,alwaysdisconnect:the battery cablesfrom the battery beforeworkingon electrical systemto preventpossible sparksor arcing in the enginecompartment. Beforestarting engineafter repair or maintenance procedures,always makesure enginecompartment is free of fuel vaporsto preventpossible fire andexplosion. When workingon an enginethat is running or being cranked,use extremecare to avoidgetting hands,fingers or clothing caughtin the alternator, powersteering pump,supplypump,andcirculating pump belts, pulleys andother movingparts.

Engir~/eng

1O-1

U

Description Water is supplied to the engine by meansof an impeller type pump (supply pump). The water supply pump is mounted on the engine. Water supplied to the engine is circulated in the engine by meansof a centrifugal type pump(circulating pump). The supply pump used on aH models is a self priming impelUer type pump, mounted on the engine and belt driven. During low speed operation the impeller functions as a positive displacement pump. At higher speeds it functions as a combination centrifugal and positive displacement pump.

All Models: The circulating pumpis mountedon the front of the cyainder block, it has a pulley bolted to the pumpshaft hub at its forward end. This in turn is driven by meansof a belt from the crankshaft pulley. The pumpshaft and bearing assembly is pressed in the water pumphousing. The bearing is permanently lubricated during manufactureand sealed to prevent loss of lubricant and entry of dirt. Thepumpis sealed against coolant leakage by a non-adjustable sean assembly pressed into the pumpcover. Cooling water for the engine is picked up at the water intakes on both sides of the lower gearcase. Water is pulled upward thru the Jower gearcaseuntil it enters a water tube that transfers it to the upper gear housing.

The shape of the housing and liner cause an eccentric action of the impeller blades during engine operation. During periods of high speed operation, the resistance of the water on its way through the pumpis sufficient to prevent the ends of the impeller blades from making contact and following the inside perimeter of the pump housing. The blades merely flex in toward the center of the impeller to perform as a combination centrifugal and positive displacement pump.

’1 0-2

Water is pulled through the upper gear housing water passage where it meets a nipple and hose attached to the pivot housing. Water is routed through the transom mount assembly to a tube that’s mountedon the inside of the gimbal housing. From this tube the water is drawnthrough a supply hose that’s connectedto the inside nipple of the supply pump. Water exits the outside nipple of the supply pump under pressure and carried through a hose to the inlet nipple of the thermostat housing.

Engine/eng

All Models: The water is now carried downward through the thermostat housing where it enters the flexible hosewlnich attaches to the inlet pipe of the circulating pump.This inlet pipe is a part of the pumpcover and feeds the coolant into a low pressure area located at the axis of the impeller. Vaneson the rotathlg impeller cause the coolant to be thrown outwardand into the cylinder block.

In the event the engine cooling water is cold, as in first starting up, the thermostatwill be closed and will not allow any of the water to pass through for eventual discharge overboard, hstead, the water will be carried via the flexible hose back to the circulating pumpfor recirculation within the block. While the water within the block is recirculating, the supply pumpis pumping water to the block.

The cooling water flows rearward through the water jacket which surrounds each cylinder and extends below the lower limit of piston ring traveH. After flowing the full length of the cylinder b;ock, the water is forced upward through two passagesand into the cylinder head(s). The water now flows forward in the cylinder head(s) cool the combustion chamberareas.

Since this water is not able to enter the cylinder block, it is necessary to provide a method of discharge. This is provided by the bypass passage within the thermostat housing, if this were not provided, the resulting water pressure would be enoughto force the thermostat off its seat, resulting in a greatly increased warm-upperiod.

At the forward end of the cylinder head(s), the water enters the thermostat housing, ff the water within the block is sufficiently warmedup, the thermostat will be open and a portion of the water will be pumpedupward past the thermostat. The remainder will be returned via the flexible hose to the water pumpfor recirculation within the powerhead. The water which ,was pumpedupward past the thermostat will enter the hose(s) connectedto the thermostat housing outlet(s) and travel to the manifold(s). At this point the water flows rearward through the manifold passages and into the high-rise elbow. All of the water that enters the high-rise elbow is mixed with the exhaust gases prior to entering the exhaust pipe(s} and hose(s). This mixture of exhaust gases and water then enters the exhaust passages of the gimbal housing, pivot housing and vertical drive whereit is discharged under water.

Englne/eng

Cooling SystemTroubleshooting 1. Quiz Customerfor the Foliowing information: a. How old is unit, how many hours of operation? (Wear and corrosion.) b. Howlong has problem existed? {Gradual or sudden.) Whatwere the operating conditions prior to problem?(Fresh or salt water, silty or sandy water.) Wihat previous repairs and service have been madeon unit? (Tune-ups, impeller replacement, etc.) e. At what RPIVI does problem occur? (Low, high.)

10-3

2. Possibilities To Consider: a. Temperature GaugeMalfunction. ¯ improper or defective sender unit ¯ Malfunctioning gauge- Checkground wire - substitute good gauge. b. Engine Water Circulation PumpMalfunction. ¯ Loosealternator belt ¯ Impeller vanes worn - replace pump. ¯ Impeller shaft seamfailure - replace pump. c. Water Intake ScreensBJocked. d. Ventilation - Marinegrowthon keel, hull deformities, etc. e. Ignition Timing ¯ Running with retarded timing - Checktiming. 3. Isolating CoolingProblem:

a. Procedure- Replace water hose between thermostat housing and the supply pumpwith clear plastic hose. Operateunit in test tank or boat in water at RPMat which overheat occurs. [~ If operating unit in test tank, run motor in neutral. Some test tanks maynot have sufficient water volumeto allow running engine in gear without creating turbulence. This can be picked up by the water intake and misconstrued as evidence of a cooling problem. b. Results and Conclusions - No bubbles in hose, air/ exhaust is not entering cooling water. Bubblesin hose, air/exhaust is entering cooling water. c.Check for - Defective lower gearcase water tube guide and seals; damagedwater tube grommet; leaking water passagecover gasket or adaptor-to-gear housing gasket.

10-4

Engine/erie

a.

b,

Procedure- Disconnect water suppDyhose from transonq bracket at thermostat housing. Operateengine at specified idle RPM.Hold end of hose level with the top of the flame arrestor. Resultsand Conclusions - A 1 inch (2,5 cm) head of water discharge, water supply is good. If less than 1/2 inch (1.2 cm), look for source of water loss. Checkfor - Blocked intake screens; damagedimpeller housing O-ring or impeller plate gasket; broken or worn impeller; defective pivot housing water passageO-ring or water drain screw seal; loose pivot housing-to-gimbal housing water hose clamps.

|ii|~]|i|[oT.’i~Ini~||ilr,[oi~o]il

-

overheatingor slowwarm-up:

a. Procedure- Operate engine until indicated temperature exceeds 160° . Touch hoses between thermostat and exhaust manifolds. b.Results and Conclusions- Hoses cold, thermostat is stuck closed. Hoseswarmor hot, thermostat is good. c. Checkfor -- Thermostatstuck open or closed, defective thermostat O-ring, correct thermostat style for engine type, clear thermostat housing bypass passage. |~JL,~=l-m[~.~ll[ml:~.[,_~r~ (water in cylinders):

I - overheating or hard starting

a. Procedure.- Allow engine to cool. Replacewater hose(s) between thermostat housing and exhaust manifold(s) with clear plastic hose. Operate unit at RPMat which overheat occurs. b,

Results and Conclusions - No bubbles evident, head gaskets not leaking. Bubblesevident, head gaskets leaking. Checkfor - Cylinder compression using appropriate tester, water in engineoil, water in cylinders, spark plugs wet with water.

Problem Checkpoints: Numbersrefer to Cooling System Flow Diagrams. O Intake Screen - Blocked with debris. (~ Water Tube Guide and Seal - Improperly sealed. ® Water Tube - Plugged with debris. Grommet- Deteriorated, improperly seated. (~ Upper Gear Housing - Debris blocking damaged.

passage, freeze

(~)Pivot Housing Seal - Damaged,out of position, sealed. O Nipple O-ring - Out of position, aged.

improperly

improperly sealed, dam-

(~) Nipple - Blockedby debris, freeze cracked. (~)Water Hose and Clamps - Clamps loose, hose collapsed or leaking. (~ TransomMount Water Tube - Blocked by debris. Supply Pump(Engine Mounted) - Failed seal, corroded bad bearings, eroded impeller, leaking mounting gaskets or backing plate. Thermostat Housing - Corroded, restricted, ket.

or leaking gas-

I~) Thermostat - Defective thermostat, or wrong type for engine; improperly seated or damagedO-ring. Belts - Loose, or worn and slipping. Circulating Pump(Engine) - Failed seal, corroded or bad bearings, eroded impeller, leaking mounting gaskets or backing plate.

10-6

EngmeJeng

~} Cylinder Block Water Passages- Corrosion, slag, blocked passages,or leaking core plugs. Cylinder Head- Corrosion, slag, blocked passagesor leaking gaskets. ExhaustManifold, Elbows,Gaskets, and Hoses- Gasketsimproperly installed; corrosion, sand, or sJag in manifold and elbows; hosescollapsed, burnedthrough, or Jeaking. ExhaustPipe and Seal - Improperlysealed or installed, leaking. Bellows, Clamp,and Retainer - LoosecJamp,detachedor torn bellows. {~ PowerSteering Cooler - Restricted, or crackedand leaking. Intake Manifold- Crackedcasting, or leaking gasket(s). []

EngineOil Cooler - Restricted, or crackedand leaking.

[]

7.4Gi, GSi, and 8.2GSi Models: CheckValve - Water By-passHose- Pluggedwith debris.

In addition, check: ¯

Ignition Timing

¯

BoatHull - Condition of hull, marinegrowth, or underhulJequipment.

[~Ot~ Fittings protruding through hull maycause air bubble streams which can be picked up by the lower gearcaseand mixed with incoming cooling water to causean overheat condition.

Englne/eng

10-7

(~) Water (~)To Thermostat Housing ©Return From Exhaust Pipe (~ Exhaust and Water Out

@

®

Vertical Drive and TransomBracket A[[ Models DR6252 1 0-8

Eng,ne/eng

C

Warm water Bypass Cold Water Exhaust Water

21

A

e er in driv Wat Stern from

11 9

9

13 18

12 9

19 9

17

22

18 Cold Engine

12

C 16

15 B Warm Engine

14

3.0GS Models

D GR970388

Engine/eng

10-9

C

Warm water Bypass Cold Water Exhaust Water

A

11 21

9 9 9

18 9 13

12

22

9

19 17

B

15

C 16

D GR970389

14

4.3GL and GS Models 10-10

Engine/eng

C

Warm water Bypass Cold Water Exhaust Water

A

11 9

21

9

9 18 9 13

12

22

9

19 17

15 B

C 16 14 Engine/eng

4.3Gi Models 10-11

D GR970390

Warm water Bypass Cold Water Exhaust Water

C

A

11 21

9

9 18 9

12 13 22 19 17

9 15 B

14

C

16 D

GR970392

5.0GL and 5.7GS Models 10-12

Engine/eng

C

Warm water Bypass Cold Water Exhaust Water

A

11 21

9

9

9 18

12

13 22

19

17

9 B

15 14

C 16 D GR970391

5.0Gi and 5.7GSi Models Engine/eng

10-13

Warm water Bypass Cold Water Exhaust Water

C

A

9

24

9

21

9

21 18 12 9 13 22 19

17

9 15

B

14 C

16 D

GR970393

7.4Gi, 7.4GSi and 8.2GSi Models 10-14

Engine/eng

Warm water Bypass Cold Water Exhaust Water Raw Water Air Vent

C

A

11 21 9

9 9 18

9 13

12

9

19

22 9

17

16 14

GR970433

15

V6 and V8 Carbureted Models with Closed Cooling System Engine/eng

10-15

C

Warm water Bypass Cold Water Exhaust Water Raw Water Air Vent

A

9

24

9

21 21

18

13

9 19 12 22 17

9 14 16 GR970437

15

V6 and V8 EFI Models with Closed Cooling System 10-16

Engine/eng

Cooling System Components For all models.Nospecialtools required. ~nspectionProcedure:Examineall external cooling systemcomponents for Veaks,wear,deterioration, anddamage. Checkall connections for tightness. Inspecthosesfor cracks,checkingor deterioration. Repair Procedure:Repairor replace as required. E~ Water supply hoses used for replacement must conform to S.A.E. 20R3,class D-2.

¯

All ModelsExcept7.4Gi, GSi and8.2GSi:A 180° F (71 ° C) thermostatis standard.

¯

7.4Gi, GSiand 8.2GSiModels:A 140° F (60° C) thermostatis standard.

¯ All modelswith closedcooling systems:A ° I-- (70° C)is standard. 158 InspectionProcedure: Checkfor properrating andstyle, corrosion, restricted movement, or brokenspring.

Test ProcedureA.Models Except 7.4G , Gsi a.d8.2Gsi: Immerse the thermostatanda thermometer in a container of water. Heat ° F. and should water. Thermostat should start to openbetween157-163 opento 5/32 in. (3,96 ram)minimum ~) at ° F. ~ Test Procedure: 7.4 Gi, GSi and 8.2GSi: Immersethe thermosta! anda thermometer in a containerof water. Heatwater. Thermostat should ° F. andshouldopento 5/32 in. (3,96 mm) start to openbetween 138-142 minimum (~ at 162° F. ¯ 3.0 GSModelsr-~ ¯ All V-6 and V-8 Models[~ Repair Procedure:None,replace unit.

For all models.Nospecial tools required. inspectionProcedure:Pressure check componentsfor leaks. Disassembleand inspect for corrosion or accumulationof foreign materia I. Repair Procedure:Rodout any accumulationof foreign matter built up in water passages.If evidence of porosity betweenwater passagesand exhaustchambersor exterior is found, replace component.Install new gaskets on reassembly.

For all models.Nospecial tools required. InspectionProcedure:Makesure belt tension is correct. With the engine running, observethe rotation of the circulating pumppulley. If the pulley does not run true it can causeexcessivedrive belt wear and damage to the circuaatingpump itself. If the leakageof water occursat the circulating pumpwhile the engineis in operation, the pumpmaybe loosely mountedto the engine, the shaft seal in front of the pumpmaybe bad, the backing plate gasket maybe defective, or the circulating pumpmountinggaskets are leaking. If the aboveinspections do not detect any defect, the pumpmustbe removedand inspected for internal corrosion, blockage, or damage.Inspect impe{lerfor erosion. Repair Procedure: None, replace the pump. ~ Volvo Penta marine engines have a special circulating water pump with stainless steel components and a special marine shaft seal assembly. Donot replace with an automotivewater pump.

1 O-18

Eng,ne/eng

Removal 1. Drain engine, refer to DrainingEngineBlockor ExhaustManifold. E~2. Loosen hose clamps and remove hoses from supply pump. E~ The inside hose (~) is the inlet hose. 3. Loosenpumpto bracket mountingscrews~) and removedrive belt. Removemounting screws and remove pumpassembly.

45330

impeller Removal E~ 1. Removethe three screws © securing the end cover. [~]2. Removeand discard gasket. [] 3. Graspimpeller securely and pull from housing. C~eaningand inspection 1. Cleanall parts with solvent andblow dry thoroughly. 42864

2. Remove any old gasket from end cover and housing. C~eansealing surfaces. 3. Inspect impelrer housingand camfor wear, and housingfor cracks and distortion causedby freezing. Replaceif necessary.Donot removecamif not required. 4. mnspectend cover; checkimpeller contact surfacefor wear, scoring, or distortion causedby freezing. Replaceif necessary. 5. Inspectimpeller; if bladesare set in a bent position, cracked,or broken, or showflat instead of roundededgeson the housingcontact surfaces, replacethe impeller.

39149

6. Checkbearings for smoothoperation.

39150

10-19

39151 Englne/eng

39152

39155

impeller installation - V-6 andV=8Models 1. Apply a light coat of VolvoPentaGreaseP/N 828250-1to impeller surfaces,install impelleruntil flush with surface. [~2. install

newgasket without sealant.

[~ 3. Install end cover and secure with screws. Tighten screwssecurely. Installation ~] 1. Orient pumpassemblyto the pumpbracket with the camscrew (~) up. mnstall mountingscrewsand belt. Refer to Supply PumpBelt Adjust= ment in the General information Section.

42865

2. Attach the inlet hoseto the inside nipple andthe outlet hoseto the outside nipple. Tighten hose clampssecurely.

Draining EngineBlock or ExhaustManifold Someservice work performed on the engine block and exhaust manifold mayrequire the comptetedrainage of those components. 3.0

Modens

1. Remove the long supply hose at thermostat housing (~. Lowerit alongsidethe cylinder block and drain it completely. 2. Disconnect and drain large hose ® at water pump. 3. Remove the drain plugs from cylinder block port side ~) and exhaustmanifold (~. Clear holes with a small wire to ensure complete drainage. 23907

23913 Eng,ne/eng

~0-20

4.3 Gi Models L~ 1. Disconnectthe small water bypasshose@at the top of the thermostathousing. ~L~2. Disconnecttl~e water dischargehose® at the port side exhaust elbownipple. Lowerthe hosebelowthe level of the vaporseparator. Blow out anytrappedwaterin the vaporseparatorandlines by applyingair to the bypasshose. AH4.3 Models 10204

[~ 1. Remove the long water supply hoseat the thermostathousing @.Lower it alongsidethe engineblock anddrain completely. ET~2. Disconnectand drain the large hoseat the circulation waterpump

@. E~ 3. Remove the drain plugs (~ from the port and starboard exhaust manifolds. Remove drain plugs ® on the port andstarboardside of the engineblock. Clear holes with a small wire to ensurecompletedrainage. 5.0Gi and 5.7GSi Models [[~ 1. Disconnectthe small water bypasshose@at the top of the thermostathousing. L~ 2. Disconnectthe water dischargehose® at the port side exhaust elbownippfe. Lowerthe hosebelowthe level of the vaporseparator.Blow out anytrappedwaterin the vaporseparatorandlines by applyingair to the bypasshose. All 5.7 Models 1. Remove the tong water supplyhoseat the thermostathousing0. Lowerit alongsideblock anddrain completely. [_4_~_2. Disconnect anddrain the large hoseat the circulating waterpump

@.

1020-5

Fngine/eng

10-21

1021-6

42863

All 5,7 Models (continued) [~ 3. Remove plug ® at rear of eachexhaust manifold, and remove drain piugs (~ on both sides of the cylinder block, Clearholes with a small wire to ensurec0mpletedrainage. All 7.4 and 8.2 Models [~ 1. Remove the long water supply hoseat the thermostat housing ~). Lowerit alongsideblockanddrain it completely. [~ 2. Disconnectand drain the large hoseat the water pump(~),

1021o9

[~ ~ 3. Remove hose (~ at front of each port and starboard exhaustmanifold, and removedrain plugs ® on both sides of the cylinder block. Clear holeswith a small wire to ensurecomplete drainage. 7.4 Gi, GSi and 8.2GSi Models DE] Drain the small water by-passhose@betweenfuel reservoir andthe top of thermostathousing.Disconnecthoseat the reservoir side of the checkvalve. Blowout waterin both directions. ~nspect checkvalve for debris, then reassemble.

Draining PowerSteering Coolers [~] Remove the lowest water hosefrom the powersteering oil cooler. If cooler is mounted horizontally, removeonewater hose® from the cooler, loosencooler mountingbolt and tip cooler downward to drain.

Draining Supply Pump [~1. Loosenand slide hose clampsback. Remove hoses from the rear of pumpanddrain. 2. Crank the engine no morethan 2 seconds(DONOTSTART) expel anywater trapped in waterpump.Reattachhoses.

10-22

1021-10

34087

45332

45333

Draining Pivot Housing EI~ 1. Tilt vertical drive to the full tilt up position and removethe water drain plug @from the port side of the pivot housing. 2. Tilt the verticaR drive to the full tilt downposition. Allow unit to drain. After unit has completely drained, replace pivot housing plug. Failure to ensure complete drainage of the cooling system mayresult in serious damageto the engine and/or drive unit if temperature should drop below freezing.

45334

Thermostat RepUacement 3.0 GS Models E2~ 1. Removeall

hoses ® from the thermostat housing.

E3~] 2. Remove the=, engine coolant temperature sender nut, lead and washers @from the sender. 45335

L~ 3. Loosen the alternator adjusting screw. Removescrew securing alternator bracket @to the thermostat housing. Pivot the bracket out of the way. E~ 4. Removetwo screws (~ securing thermostat housing to the cylinder head, Renqovethe housing from the head. Clean all gasket surfaces. E6=-] 5. Removethermostat O-ring ® and thermostat @from the housing.

® 45354

10-23

Engme/eng

t/L 45355

45356

45357

[~ [~] 6. Install thermostat ~ into the thermostat housing with the pointed end ® facing into the housing. Place the O-ring ® into position in the O-ring groove to retain the thermostat. [~ 7. Place a newgasket (~ into position at the front of the head. No sealer is required with this gasket. [~ 8. Install the thermostat housing into position and secure with two screws ~. Tighten the screws to 12-16 ft. Ibs. (16-22 N.m).

45358

[~ 9. Install the alternator bracket on the engine. Set alternator bett tension following the procedures in the General Information section. Tighten both screwsQ to 26-30 ft. Ibs. (35-41 N.m), [~] 10. Attach the engine coonant temperature sender washers, lead and nut © to the sender. Tighten the nut securely. 11. Install all hoses ® and secure with clamps. Tighten the clamps securely. 45345

Englne/eng

10-24

V=6 and V-8 Models [1~] ~]1 Removeall water hoses from the thermostat housing. ® Carburetor Models: four hoses ~) [~ " EFt Models: five

hoses ~ [~

2. Note position of lifting eye @.Remove two screws(~ then remove lifting eye andthermostathousing. 28546

L’~ 3. Thethermostat(g) is held in place by an O-ring. Pry the O-ring out of its groove,then lift the thermostatout of the housing. 4. Discard the housing gasket and O-ring. Thoroughlyclean the housing and manifold gasket surfaces. E4~5. PLacethe thermostat in the housing. Thetemperaturesensing element(3 mustface you wheninstalled. Install a newO-ring to seal thermostatin housing.Makesure O-ring is completelyseatedin its groow,=. E,.~ 6. Coat both sides of a newgasket with Volvo Penta GasketSealing Compound P/N 1161231-4and place it on the manifold. Position thermoslat housingand lifting eye; on engineadapteras notedin Step2. Install two lock washersand [email protected] the screwsto 20-25 ft. Ibs. (27-34 N.m).

38259

7. Connectthe water supply hose to nipple ® and tighten hose clamp securely. Connectthe three remainingwater hosesand tighten hose clampssecurely. Makesure lifting eye @is positioned as shown. [~ If the water supply hose is attached to the wrongnipple, the engine will overheat. 28548

10-25

28547 Engme/eng

NOTES

10-26

Section 11 EngineRemoval andinstallation

Table of Contents

Engine Alignment ................................................. Installation ................................................ Removal .................................................. Determining MinimumEngine Height ......................... Engine Mounts, Rear ........................................ Exhaust Pipe Replacement ...................................

11-7 11-6 11-2 11-12 11-11 11-6

Volvo PentaSpecial TooRs PIN 3851083-0 3850609-3

Description Volvo Penta Alignment Tool Volvo Penta Drive Handle

Sealants, Lubricants and Adhesives Volvo Penta Grease 3M adhesive or equivalent Gasket Sealing Compound

Z~ Safety Warnings BeforE.= beginning work in this section, read Safety chapter at end of this manual. Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommendand describe in these instructions are effective methodsto be followed wheninstalling Volvo Penta sterndrive products. Someof these methodsrequire the use of tools specially designed for the purpose. The special tools should be used when and as recommended.

Englne/eng

1 1-1

Engine Removal Before removing engine, check engine height. See Determining Minimum Engine Height. Check engine clearance between front of engine and engine compartmentbulkhead prior to starting work° If clearance is less than 8 in. (15,2 cm), the vertical drive must be removed disengageU-joint shaft from engine coupler. See Vertical Drive and TransomBracket Service Manual Whenengine clearance is more than 6 in. (15,2 cm), the engine can be pulled forward to disengage the U-joint shaft from the flywheel coupler, and be removedfrom the engine compartment.

22703

The vertical drive can remain installed only if engine removaldoes not require re-alignment of the engine. If the engine mounts, boat stringers, or engine coupler are being repaired or replaced, removethe vertical drive for engine alignment. Z~ To prevent possible fire and explosioncausedby ignition of fuel vapors which may be present in the engine compartment, removethe positive and negative cables from the battery. 22704

DisconnectBattery Z~ AHswitches must be in the "OFF"position prier to disconnecting the red (positive) and black {negative) cables from battery. This will safeguard against permanentdamage to electrical components. Disconnect PowerSteering Lines [~ 1. Disconnect both power steering lines cylinder.

at the steering

[~ ~ 2. If original steering line connector, P/N 914728, is available, useit to [ink both steering lines together. If Connectoris not used, cover both steering cylinder openingsand line fittings to prevent fluid loss and entry of contaminants. Tie lines onto engine higher than power steering pumpto prevent damageand loss of oil during engine removal.

22706

Disconnect Fuel Supply [~ Z~ Disconnectboat fuel line at the fuel filter of fuel line and inlet opening.

inlet.

Seal end

DisconnectElectrical Cables 1. Disconnectthe plastic two-wire trim/tilt

2913

motor connector

®.

11-2

38277 Eng,ne/eng

[6~] 2. Remove wire retainer (~ andunplugrubbertwo-wiretrim/tilt connector.Cut tie strap © securingsendercable, if required.

sender

[~ 3. Unscrewclamp@and disconnectlarge rubber instrument cable connector(~). Unplugrubberthree-wiretrim/tilt cableconnector T’hrottJe Cab|eDisconnection [i~ Prior to disconnectingthe remotecontrol throttle cabre, note wheter you havea "Push=To-Open" or "Pull-To-Open"throttle armattachment. ~ ~ 1. Remove cotter pin and flat washer@from throttle arm.

24288

~ ~ 2. Loosenanchor retainer nut (~) and rotate retainer (~ away fromcable trunnion. Remove throttle cable fromthrottle armandanchor bracket. , All Models(except 7.4Gi, GSi and 8.2GSi) E~ ,

7.4Gi, Models

E~

.

7.4GSiand8.2GSi Modeas

[~

33727

DisconnectExhaustHose- 3.0 Models [~ 1. Loosen four hose clamps. [~ 2. For ease of moving hose, lubricate exhaust pipe. I~ 3. To free exhaust hose from elbow, pry or twist hose. Slide hose down onto exhaust pipe. DisconnectExhaustHose- All V-6 and V-8 Models E~ 1. Loosen four clamps ® on lower exhaust hose. For ease of moving lower hose, lubricate exhaust pipe.

6361

[~ 2. To free lower hose from intermediate pipe, pry or twist hose. Slide hose down onto exhaust pipe ®.

6362

6363

17370

11-4

17371 Eng,ne/eng

Disconnect Water Hose Loosen clamp and pult bracket water tube.

water supply hose off transom

Separate Engine Mounts ~-~ Z~ 1. Attach a hoist to lifting brackets of engine. Hoist must havea lifting capacity of at least 1500Ibs. (680 kg). ES~2. Removeand retain both lock nuts © and both flat washers ~ from rear engine mounts. L-~ [~] 3. Removeand retain mo u nts.

lag screws from front

22698

engine

® 3.0 Models ® All V-6 and V-8 Models 4. ffvertical drive wasremoved,lift engine out of engine compartment. If vertical drive was not removed,lift engine slightly and pull it forward to disengageU-joint shaft and flywheel coupler. With U-joint shaft clear of flywheel coupler, lift engine out of compartment.

31444

12211

2888

En;lme/eng

1 1-5

2933

Exhaust Pipe Replacement Removal 1. Remove engine following previous procedure. [~ 2. Removeand retain four exhaust pipe screws. Remove exhaust pipe and discard seal (~. Cleanall material from transomshield and exhaust pipe seal surfaces.

NoteExhaust pipe mountingholes have locking Hefi-CoiP inserts. Do not clean screwholes with a thread tapping tool, otherwiselocking feature will be destroyedandHeft-Coil will haveto be replaced.

?.2780

mnstalmatien 1 Coat a newseal with 3Madhesiveor equivalent and place in transomshield groove (~. [~ 2. Apply VomvePenta Gasket Sealing Compound P/N 1161231-4to the four exhaust pipe mounting screws @. 3. Secureexhaustpipe (~) to transomshield with four screws.Tighten to 20-25 ft. Ibs. (27-34 N.m). Slide exhausthosesand caamps (~ onto exhaust pipes if they were removed.

15048

4. install engine.

EngineInstallation Engine Mount Attachment 1. Lowerengine into engine compartment: If drive unit wasnot removedand engine crankshaft wasnot rotated, engageU-jo nt shaft with engine coupler and slide engine back onto rear mounts.If coupler and Ujoint shaft will not align, either the engineor U-joint shaft will haveto be rotated to allow engagement.If engine mountheight was disturbed, engine must be realigned as describedlater. L.~

¯

15047

If drive unit has beenremoved,lower engine onto rear mounts.

[~ 2. nnstall flat washers~ into recesses of engine bracket and secure engineto mountwith lock nuts (~). Tightenlock nuts to 28-30ft. Ibs. (38-40 N,m).

11-6

12212

12211

E,~,n~on~

L_Vj ~ 3. install securely.

forward engine mountUagscrews and tighten them

. 3.0 Models E~ , AJJ V-6 and V-8 Models E~ If the sterndrive wasnot removed,go to ExhaustHoseAttachment.If the; stemdrive was removed, continue with Engine Alignment section.

EngineAlignment

2988

~-_N~Correct enginealignmentis essential to long enginedrivetrain life. The front engine mountsmayneed adjustment UPor DOWN to produce correct engine alignment. UseVolvo Penta Alignment Tool P/N 3851083-0 with Volvo Penta Drive HandleP/N 3850609-3to check engine alignment.

1. Slide aJignmenttool ~) throughdriveshaft gimbal bearing (~. The alignmenttool must slide throughthe gimbal bearing and into engine couplerwith ease. If the alignmenttool binds going into enginecoupler, makesure the gimbal bearing is properly aligned. If gimbal bearing alignmentis correct, the front enginemountsmust be adjusted either UPor DOWN, as required, until alignmenttoomslides easily in and out of engine coupler.

2933

DE] [~ 2. To changeengine height, tighten or loosen nuts @and ® as required. See respective engine section, Front MountHeight Adjustment. *

3.0 Mode|s E~

¯ All V-6 and V-8 Models [~ 3. After correct alignment has beenmade,the front mount(s)must tightened to maintainalignment.

34068

3.0 Models- While holding one nut with an open-endwrench, tighten the second adjustingnut to a torqueof t 15-140ft. Ibs. (156-190 N®m). V-6 and V-8 ModeJs- While holding one nut with an open-endwrench,tighten the secondadjusting nut to 100-120ft. Ibs. (136-163 N®m).

Eo~,o~/ong

1 1-7

#

......!;,¯ 2972

2953

Connect Exhaust Hose [~ 3.0 Models- Slide exhaust hose (~) up onto high-rise exhaust elbow

®. [~ V-6 and V-8 Models - Push lower hoses © up onto intermediate exhaust pipes (~. E~ Position and tighten all hose clampssecurely betweenribs of exhaust hose(s) as shown. Z~ DONOTinstall hose clamps in expandedarea (~) of hose(s). Coolingwill be restricted and engine damage will occur, ConnectThrottle Cabme [~ Determine whether you have a "pull-to-open" or "push-to-open" remotecontrol throttle cable. Position remotecontrol handlein neutral, propeller shouldrotate freely. Turn propeller shaft andshift into the forward gear detent position, then pu~l handle HALFWAY BACKtowards NEUTRAL. This positions the control for properthrottle adjustment.Failure to follow this procedurecanresult in "hard shifting" out of neutral. E~ 1. Align internal bosses® of trunnion with throttle cable groove @. Presstrunnion on throttle cable until seated.

~7372A

[~ ~ 4.3 GL and GS Models Only: Engine anchor bracket may havetwo sets of anchorblock holes. Thetop set (~ is for GSmodelsonly. The bottom set (~ is for GLmodelsonly. [~ ~ 2. Install openend @of trunnion in anchor block. Instalt screw in anchorblock and position throttle cable assemblyin selected set of holes. Nut mustbe against the anchorbracket, tighten it securely. ~] ~ 3. Throttle arm connector ® must have a minimumof 9 full turns or 1,~ in. of throttBecable threadengagement. Install throttle arm connectoronto the throttle cable. Pull connectorforward ® to removeall end play from throttle cable, then turn the connectorin until hote aligns with the "pull-to open"(~ throttle armstud.

17370A

®

~lf throttle arm connector hole cannot be adjusted to align with the throttle arm, checkfor propercable installation in the remotecontrol box.

34751

®

11-8

DR4977 Engmelerlg

DR4978

DR4979

22698

~ 4. install connectoronto throttle arm. Install washerandcotter pin (~, and spreadcotter pin prongs.Tightenjam nut @against connector. El~_~For throttle andshift cable adjustmentprocedures,see Throttle and Shift Control Sy.,~temssection. Water HoseInstallation E~ 1. Slide hose damp® onto water inlet hose. Lightly lubricate inside of water inlet hose and push hose onto water inlet tube @.

15864

E~9~3 2. if inlet hoseis not installed properly, undersideof hosemaycollapse. Checkundersideof hosefor proper installation and adjust hoseas required. Tighten hose clampsecurely. ~ Failure to install water inlet hose correctly can result in engine damage from blockageof water circulation. PowerSteering Line installation 1, Remove tape or protective cover from small hydraulic hosefitting (or unscrewsteering line connector)and small steering cylinder opening.

22702

rlo-~ 2. install smallhosefitting into steeringcylinder andtighten to 10-12ft. Ibs. (14-16 N®m). 3. Remove tape or protective cover from large hydraulic hosefitting large steering cylinder opening.

and

~--~4. install large hosefitting into steering cylinder andtighten to 15-17fl. Ibs. (20-23N.m).

22701

Encjtne/eng

11-9

Electrical Cabie Connections E~1. Connectplastic two=wireplug of engineharnessto two-wirereceptacle @of trim/tilt motor.Connectors shouldlock together. ~2. Connectrubbertwo-wire trim/tilt senderplug to two-wire receptacle of instrumentharness.Secureconnectorswith wire retainer andcable with a tie strap @. 3. Routethe instrumentcable plug to join enginecablereceptacleon engine. ~ Ensure cable is routed to prevent cutting or chafing on any sharpor hot object. This could resumtin an electricaJ short, and contribute to fire and explosion in the engine compartment. ~] 4. Apply a light coat of Volvo PentaGreaseP/N 828250-1around large engineplug @. [~ 5. Slide hoseclampover large enginereceptacle. Align the two large terminals on plug and receptacle ® and press together. Slide hosedamp over receptacleandtighten securely. Z~6. Modelswith Starter Solenoids: Position the red cable protec= tor over solenoid terminal. ~7. All switches must be in the "OFF" position prior to connecting the battery cablesto the battery. Besure polarity is observed; positive (+) cableto the positive terminal, andnegative(--) cableto negativeterminal.

1 1 - 10

Engine/eng

ConnectFuel Supply L~ Attachboat’s fiJel supplyhoseto fuel filter canister. Tighten connectionsecurelyo Checkfor fuea leaks whentesting engine, and repair any leaks that mightoccur.

Rear Engine Mounts Removaa 11. Remove engine as previously described in this section. ES~2= Unscrewtwo screws and washers, then Pift bly off transomplate.

6678

mount assem-

Disassembly Hold square nut and remove screw. Mount assembly will break downinto componentsshown. Pay particular attention to the two mountwashers; their thickness, their shape (concave or flat), and their position in the assembly (above or below the rubber mount). 16348

Assembly ~--~ 1. Slide lower washer ® onto mount bolt; makesure you choose the correct washer (as determined during the mount disassembly)for this position, insert bolt into bottom(flat) side rubber mount assembly, and install remaining washer and square nut. Do not tighten nut at this time. if top and bottomwashersare not installed in their original positions, mount maytransmit excessive engine vibrations into boat and cause undesirable operating conditions. 2. -Pdrn mount assembly upside downand clamp square nut in vise. Rotate rubber mount until mountingholes are positioned at 90° to any side of square nut. Hold mountin this position and tighten center bolt to 44-52 ft. Ibs. (60-71 N.m).

6880

~ot~ ff 90° relationship between nut and mounting holes is not maintained, slot of engine mount pad cannot engagerear mount during installation. Installation ~’ 1. Place mount assembly on transom plate. Install two screws and washers, and tighten them to 20-25 ft. Ibs. (27-34 N~m).

6677

~--~ 2. Install engine as previously described in this section. Makesure mount pad slot engagessquare nut. Install both flat washersand lock nuts, then tighten lock nuts to 28-30 ft. Ibs. (38-41 N.m).

E.g,.e~ng

1 1-11

12212

®

Determining MinimumEngine Height [~ 1. To determine minimum engine height, use a level (~) placed on top of the transom, measurefrom bottom of level to top of elbow (~) and record distance= [~ 2. Measurefrom bottom of level to static record distance.

water line © and

[~ 3. Subtract dimension (~) from dimension © and record result. See engine height requirements below: ¯ 3.9 Models - Measurement © minus ~) should not be less than g in. (22,8 cm). ® V-6 Models - Measurement © minus (~ should not be less than 13 in. (33 cm). ¯ V-8 Models - Measurement © minus ~) should not be less than 14 in. (35,6 cm). 4. Whenengine installations do net meet these specifications, an exhaust elbow high-rise kit must be installed. An installation that permits water to enter the engine through the exhaust manifolds(s) wilJ not be covered by warranty, unless damageis due to defective part(s).

11-12

Engine/eng

Safety Section

Part A Marine Products and Safety of People Who Use Them . . . . . . . . . Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . .

S-2 S-3 S-4 S-5 S-7

Part B Marine Products and Safety of People Who Fix Them . . . . . . . . Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety

S-1

S-11 S-11 S-12 S-13 S-14

Part A - Marine Products and safety of People Who Use Them

Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure... Product User is informed. . . Products are safe and reliable. . . It's up to you, the People who. . . Install accessories. . . Service and Maintain the boat. . . Service and maintain the sterndrive. . . . . . to keep the products safe and reliable. This section talks about safe boating and how you can help keep it safe. Some things you may know . . . but others you may not.

First! A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.

Do Not Substitute Fasteners

They look the same, but . . . are they? The Same Size? The Same Strength? The Same Material? The Same Type? Standard or Metric Thread?

Don't substitute unless you know they are the same in all characteristics. Second! Special locking screws and nuts are often used to attach steering, and remote control components to the sterndrive. When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with other parts When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and control cables, plus related parts. Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.

S-2

Safety

Sterndrive Shift System

The Shift System starts here at the remote control lever. . .

. . . and ends here at the propeller.

What's Most Important? When the control lever is in Forward, Neutral or Reverse position . .

. . . Shift mechanism must match control lever position.

What Could Happen? If . . . Neutral

If . . . Forward

Forward or Reverse Reverse

. . . Propeller is still powered (turning) unknown to operator, or engine will start in gear, boat will move unexpectedly.

. . . boat will move opposite to direction intended by operator.

How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . . Read, understand and follow manufacturers instructions. Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure propeller does what the operator wants and nothing else. Safety

S-3

Sterndrive Throttle Control System

The throttle Control System starts here and the remote control lever . . . . . . and ends here on the engine.

What's Most Important?

When the control lever is moved from Forward (or Reverse) to Neutral . . .

. . . engine speed must slow to idle RPM and allow operator to shift into Neutral.

Operator must be able to stop propeller. What Could Happen? If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control of boat.

How Can Loss of Throttle Control be Minimized? In pre-delivery inspection and when servicing . . . Read, understand, and follow manufacturers instructions. Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure engine throttle response is smooth. Make sure full throttle operating RPM can be reached so operator won't overload engine

S-4

Safety

Sterndrive Steering System

The Steering System starts here at the helm . . .

What's Most Important? The Steering System . . .

. . . and ends here at the propeller on the sterndrive

must be installed properly must be adjusted properly must be lubricated

What Could Happen? . . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator may be thrown into water and could be hit.

. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic. . . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of boat control.

Safety

S-5

How Can Loss of Steering Control be Minimized? In predelivery inspection and when servicing

use steering components which meet marine industry (BIA/ABYC) standards . . . Read, understand, and follow manufacturer's instructions. Assemble parts and make adjustments carefully . . . Closely follow the warnings marked with ... Keep parts moving freely . . . lubricate parts as soon as shown in manuals Use bolts, nuts, and washers supplied with steering attachment kits

When power assisted or mechanical steering systems are used, check to uncover possible trouble! Cable housing in this area must not be restricted

Steering components must not bind

Why? Unit may go to full turn without turning steering wheel (Power assist models)

Why? Possible jamming of steering system.

Engine stringer must not interfere with power steering pump and pulley

Maintain proper belt tension. Power steering parts and push/pull cable must be free to move in order to actuate power steering valve when operator turns steering wheel

Check for damaged parts . . . impacts to the sterndrive like this

or this . . . or ? ? ? can put stress on steering components. Look for . . . Cracked parts Bent parts Loose fasteners

Replace damaged parts. If weakened, parts could fail later . . . on the water . . . when least expected. S-6

Safety

Sterndrive Fuel and Electrical Systems

The electrical System begins here at the battery . . . . . . and ends here at the carburetor or fuel injectors

The fuel system starts here at the fuel tank . . .

. . . and ends here on the engine.

What's Important? Fuel leakage must be prevented. Electric sparks must not happen.

What Could Happen? Gasoline can explode and/ or burn easily: When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire connection, or a damaged or deteriorated electrical component.

How Can Fire and Explosion Be Minimized? Read, understand and follow manufacturers instructions. Closely follow the warnings marked with

...

Do not substitute fuel or electrical parts with other parts which may look the same. These parts are designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and explosion. If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write to . . . ------------------------National Technical Information Service Springfield, Virginia 22161

. . . and ask for copies of: (1) Electrical System Compliance Guideline (AD/A-049-638) (2) Fuel System Compliance Guideline (AD/A-047-767) These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explosions. Safety

S-7

Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard requirements. Most automotive parts do not, especially electrical components that must meet ignition protection requirements of the U.S. Coast Guard regulations. When nonmetallic parts look to be in poor shape . . . replace them!

Wires Cracked!

Torn Boots!

Cracked Fuel Lines! Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . . It's time for replacement BEFORE sparks and/or fuel leaks occur. Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires (to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with either of these CRITICAL safety related systems. When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.

STOP

If you smell gasoline in the engine compartment . . . find its source and stop the leakage.

S-8

Safety

Follow "Starting Procedure" outlined in the operator's manual. Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble. Backfire flame arrestor must be in place and securely attached to the air intake.

Do not alter the backfire flame arrestor. If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compartment. If fumes are present in compartment, fire and explosion could result.

Safety

S-9

Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about it . . . it takes time! Reading and understanding instructions. Reading and understanding warnings marked with

...

Putting parts together correctly . . . Making correct adjustments . . . Testing you work.

and making sure Worn or damaged parts are replaced, Replaced parts are like originals . . . in every way. Customer is told of things which need attention . . .

But do you really want the alternative?

S-10

Safety

Part B - Marine Products and Safety of People* Who Fix Them

Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you? Mechanics can be hurt while . . . Servicing boats Servicing sterndrives Troubleshooting problems Testing their work Some items you'll know . . . others you may not.

When Lifting Engines If hoist is poor shape . . . or too small for the job Engine may drop suddenly

DR3471

DR3469

Make sure shop aids have extra capacity — and keep them in good repair!

When Running Engine with Engine Compartment Cover Removed The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember: Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands, arms, belts can be caught by moving belts or spinning pulleys Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into moving parts. Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electrical part, near the propeller, etc.) *Mechanics, technicians, backyard do-it-yourselfers.

Safety

S-11

Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly! When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated areas.

Eyes Need help

Grinding

Sprayed Cleaners, Paints

End of Cables

Acid

Chiseling (steel on steel) (Tip: Use plastic or brass type hammers. They don't chip off as easily as steel hammers.)

Handling Lead Acid Batteries

If spilled or splashed on any part of body..

Wash with lots of water. . .

If solution gets into eyes. . . Wash. . . and see a Doctor, fast!

Charging Lead Acid Batteries Attach and remove these cables with charger unplugged from 110 volt wall socket. (Prevents shocks if the charger is defective.) Observe correct polarity when connecting these charger leads. Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. . . Make sure vents are open. If clogged, pressure inside may build. . . battery may explode.

S-12

Safety

Never yank cables off battery posts. . . it's a sure way to make lots of sparks. . .surrounded by battery gas

Battery gas is explosive! While charging or discharging, remember. . .

No Smoking No Flames No Sparks

After Charging. . .

Don't check battery condition by placing metal objects across posts.

Shut off charger Remove charger plug from wall socket Then. . .

You're sure to make sparks and serious burns are possible.

Take charger cable off battery posts

Gasoline! Handle With Care When you smell any odor of gasoline, explosion is possible Gasoline fumes are heavier than air and will sink to the lowest point in the boat or room, and will stay there. . . waiting Gasoline explodes easily and violently when mixed with air

If the air around you is quiet . . . the pilot light in the heater may ignite the heavy fumes before your nose ever smells the fumes . .

5 Parts Gasoline 100 Parts Air

What Can you Do?

Store in sturdy, sealed gas can . . .and . . . keep outside Safety

Store properly . . . Fill portable tanks outside boat to prevent spillage in boat Use fuel for fuel . . . not for a solvent If fumes are smelled (in shop, basement, garage), immediately: Put out open flames, cigarettes, sparking devices Wipe up spill or leak; get towels, rags outside fast Check lowest area for fumes; open doors or windows

S-13

Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled. Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ????????? How many of these are in your area?

Hazardous Products

Read the container label. It tells you . . . "How, and where, to use," "How to give First Aid," and have "recommended" first aid materials on hand- should an emergency arise "How to dispose of can," Remember: Little children are very curious and will try to taste everything, so . . . Keep containers away from children

. . . yummmmmmmmmmm

S-14

Safety

VOLVOPENTAMODELiDENTiFiCATiON Engine Modelidentification is located on the engine valve cover for four cylinder (in-line) models, on the inside of the port valve cover for V6 & V8 models, or on the Thick Film Ignition (TFI} module bracket for Ford fuel injection models. The identification numbersmust correspond with the transom shield and drive unit numbers. See below.

E]

Engine Model Number(GL, GS, and Gi Models) Engine Model Number

SX MODELS: E] r~

Transom Shield Model Number Drive Unit Model Number

DP & DPX MODELS:

Nunber plate for drive unit andtransomshield. Onlyfields 2 and3 are filled for transom shield.

1 3

[

1

1. Product Designation 2. Model Number 3. Serial Number 4. ReductionRatio

4

07-1998

1300 Volvo Penta Drive Chesapeake, Virginia 23320 U.S.A.

7797451

Volvo Penta of the Americas, Inc.

English

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