Volvo Penta 5.0GL, 5.7Gi, 5.0-5.7 GXi, 5.0 5.7 OSi, 5.7 OSXi Engine Workshop Manual_269597098 – PDF DOWNLOAD

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Volvo Penta 5.0GL, 5.7Gi, 5.0-5.7 GXi, 5.0 5.7 OSi, 5.7 OSXi Engine Workshop Manual_269597098 – PDF DOWNLOAD

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Volvo Penta 5.0GL, 5.7Gi, 5.05.7 GXi, 5.05.7 OSi, 5.7 OSXi Engine Workshop Manual_269597098

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Volvo Penta 5.0GL, 5.7Gi, 5.0-5.7 GXi, 5.0 5.7 OSi, 5.7 OSXi Engine Workshop Manual_269597098 – PDF DOWNLOAD

Good Service Practice:
Service required for stern drives is generally one of three kinds:
• Normal care and maintenance – which includes putting a
new stern 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
malfunction of some part of the engine. This includes engine
servicing procedures to keep the engine in prime operating
condition.
• Complete disassembly and overhaul – such as major service
or rebuilding a unit.
It is important to determine before disassembly just what the trouble
is and how to correct it quickly, with minimum expense to the owner.
When repairing an assembly, the most reliable way to ensure a good
job is to do a complete overhaul on that assembly, rather than just to
replace the bad part. Wear not readily apparent on other parts could
cause malfunction soon after the repair job. Repair kits and seal kits
General Information
4 VPA 7748089 English 09-2007
contain all the parts needed to ensure a complete repair, to eliminate
guesswork, and to save time.
Repair time can also be minimized by the use of special tools. Volvo
Penta special tools are designed to perform service procedures
unique to the product that cannot be completed using tools from other
sources. They also speed repair work to help achieve service flat
rate times. In some cases, the use of substitute tools can damage
the part.

TABLE OF CONTENTS:

Volvo Penta 5.0GL, 5.7Gi, 5.0-5.7 GXi, 5.0 5.7 OSi, 5.7 OSXi Engine Workshop Manual_269597098 – PDF DOWNLOAD

Model Identification 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 3
General Information 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 3
Engine – 5.0 & 5.7 Litre 29…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 3
Safety S1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 3
Model Identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 5
This workshop manual applies to the products listed in Service Bulletin 04-2-67 version 1 dated 08-2007. The unit that you are s……………………………………………………………………………………………………………………………… 5
All sterndrive system components must be matched for either single or dual engine installations. Failure to properly match engin……………………………………………………………………………………………………………………………… 5
4.3, 5.0, and 5.7 Gi, GXi, OSi, OSXi models……………………………………………………………………………………………………………………………………………………………………………………………………… 5
8.1 Gi, GXi, OSi models……………………………………………………………………………………………………………………………………………………………………………………………………………………….. 5
All GL models………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 5
General Information………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 7
Good Service Practice…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 7
Preparation for Service…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 8
Service Policy…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 8
Replacement Parts………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 8
Parts Catalogs…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 8
Special Service Tools…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 9
Product References, Illustrations & Specifications…………………………………………………………………………………………………………………………………………………………………………………………………… 9
Tuning the Engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 9
Engine Compression Testing…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 9
1. Visually inspect stern drive unit for leaks, missing parts or other obvious defects. Replace deteriorated parts…………………………………………………………………………………………………………………………………… 10
2. Compression check: Proper compression is essential for good engine performance. An engine with low or uneven compression cannot be properly tuned…………………………………………………………………………………………………….. 10
To Prevent Sparking…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 10
Test Conclusion………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 10
1. If compression improves considerably, the piston rings are at fault………………………………………………………………………………………………………………………………………………………………………….. 10
2. If compression does not improve, valves are sticking or seating poorly, or valve guides are worn………………………………………………………………………………………………………………………………………………… 10
3. If two adjacent cylinders indicate low compression pressures and squirting oil on the pistons does not increase the compressi………………………………………………………………………………………………………………………. 10
Compression Pressure Limit in PSI………………………………………………………………………………………………………………………………………………………………………………………………………………. 11
Ignition System Components…………………………………………………………………………………………………………………………………………………………………………………………………………………. 11
Fuel System Components…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 11
Intake Manifold Vacuum Testing…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 12
Test Procedures………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 12
1. Install a vacuum gauge to a good intake manifold source (usually at the PCV valve port), following the gauge manufacturer’s instructions. Start and warm up the engine………………………………………………………………………………….. 12
2. Observe the vacuum gauge while operating the engine over a range of engine speeds……………………………………………………………………………………………………………………………………………………………… 12
Test Results…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 12
1. A steady vacuum reading between 14 and 19in. Hg. (47-64 kPa) at idle indicates an engine in good mechanical condition……………………………………………………………………………………………………………………………… 12
2. A vacuum reading below 14 in. Hg. (47 kPa) at idle, indicates an engine that is not developing enough vacuum. Further testing for base mechanical problems is needed……………………………………………………………………………………. 12
3. Possible causes of low intake manifold vacuum are late ignition timing, low compression, poor engine sealing, leaks at vacuum lines and connections or bad MAP sensor…………………………………………………………………………………… 12
4. If the gauge fluctuates at idle, possible causes are sticking or leaking valves, or an ignition miss…………………………………………………………………………………………………………………………………………….. 12
5. If the gauge fluctuates at idle but smooths out as engine RPM increases, check for bad valves or camshaft………………………………………………………………………………………………………………………………………… 12
6. If the gauge fluctuates more with increases engine RPM, check for weak or broken valve springs, bad valves, ignition miss, or a leaking head gasket…………………………………………………………………………………………………… 12
7. If the vacuum gauge fluctuates regularly with each engine cycle, check for a bad valve…………………………………………………………………………………………………………………………………………………………. 12
8. If the vacuum reading drops steadily as engine RPM increases, check the exhaust system between the engine and vertical drive for restrictions………………………………………………………………………………………………………… 12
9. See table and chart below and on the following page for more information……………………………………………………………………………………………………………………………………………………………………… 13
Vacuum Gauge Readings…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 13
Gasoline Requirements…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 14
Gasoline Containing Alcohol……………………………………………………………………………………………………………………………………………………………………………………………………………………….. 14
Crankcase Oil……………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 15
Draining and Filling the Engine Crankcase……………………………………………………………………………………………………………………………………………………………………………………………………….. 15
Temperature Viscosity Recommendations…………………………………………………………………………………………………………………………………………………………………………………………………………… 16
Crankcase Capacities………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 16
Oil Filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 16
Canister type………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 16
Replaceable Element Type………………………………………………………………………………………………………………………………………………………………………………………………………………………. 17
Power Steering…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 17
Steering System Lubrication……………………………………………………………………………………………………………………………………………………………………………………………………………………. 17
Power Trim/Tilt Fluid Level……………………………………………………………………………………………………………………………………………………………………………………………………………………….. 17
Off-Season Storage……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 17
Limited Use………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 18
Storage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 18
Step 1. Prepare a storage mixture………………………………………………………………………………………………………………………………………………………………………………………………………………. 18
Step 2. Change Motor Oil and Oil Filter:………………………………………………………………………………………………………………………………………………………………………………………………………… 19
Step 3. Change Drive Lubricant:………………………………………………………………………………………………………………………………………………………………………………………………………………… 19
Step 4. Fog Engine:…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 19
Step 5. Drain Cooling System…………………………………………………………………………………………………………………………………………………………………………………………………………………… 19
Front……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 19
1. Disable ignition system See Engine Compression Testing on page 5…………………………………………………………………………………………………………………………………………………………………………….. 19
2. Remove inlet and outlet hoses from raw water pump and crank the engine with starter 1-2 revolutions……………………………………………………………………………………………………………………………………………… 19
3. Reconnect ignition system……………………………………………………………………………………………………………………………………………………………………………………………………………….. 20
Starboard……………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 20
4. Disconnect and drain large hose at circulation pump………………………………………………………………………………………………………………………………………………………………………………………… 20
Port………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 20
5. Remove exhaust manifold drain plug. Clear hole with a small wire to ensure complete drainage……………………………………………………………………………………………………………………………………………………. 20
6. Remove cap from engine flush hose and lower hose into bilge…………………………………………………………………………………………………………………………………………………………………………………. 20
Preparation for Boating After Storage………………………………………………………………………………………………………………………………………………………………………………………………………………. 20
1. Install all drain plugs. Install cooling hoses and clamps. Check condition of hoses, manifold end caps and clamps. Connect hoses to engine and tighten clamps securely. Install boat drain plug, if removed…………………………………………………….. 20
2. Remove the distributor cap and rotor. Wipe the inside of the distributor cap dry with a clean cloth and spray with Corrosion Spray. Replace the rotor and cap……………………………………………………………………………………………… 20
3. Clean the battery terminals. With the ignition switch in the “OFF” position, install the battery and attach the battery cables. Spray terminals with Corrosion Spray……………………………………………………………………………………….. 20
4. Open the fuel shut-off valve (if so equipped) and check all fuel line connections for leaks………………………………………………………………………………………………………………………………………………………… 20
5. Check the flame arrestor and clean if necessary. Reinstall, make sure all parts are in place and tighten nut securely…………………………………………………………………………………………………………………………………. 20
6. Make a thorough check of the boat and engine for loose or missing nuts and screws. Pump the bilge dry and air out the engine compartment………………………………………………………………………………………………………………… 20
7. Test run engine: Launch boat or use a flushing adaptor installed on Sterndrive……………………………………………………………………………………………………………………………………………………………………. 20
8. With engine compartment open, start the engine. Monitor the voltmeter, oil pressure and water temperature gauges frequently to be sure all systems are operating properly. Check for fuel, oil, and water leaks…………………………………………………. 20
Engine Break-in………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 21
First Two Hours………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 21
Next Eight Hours……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 21
Final Ten Hours………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 21
1. Check crankcase oil level frequently. Maintain oil level in safe range, between “add” and “full” marks on dipstick………………………………………………………………………………………………………………………………… 21
2. Watch oil pressure gauge. If gauge indication drops below the normal operating oil pressure range (See Engine Specifications ………………………………………………………………………………………………………………………. 22
3. Watch engine temperature indicator to be sure there is proper water circulation……………………………………………………………………………………………………………………………………………………………….. 22
Operation After Break-in………………………………………………………………………………………………………………………………………………………………………………………………………………………. 22
Submerged Engine or Water Ingestion in Cylinders…………………………………………………………………………………………………………………………………………………………………………………………………….. 22
1. Remove spark plugs immediately and crank engine to remove water from cylinders. Do not attempt to crank engine with water present in cylinders, internal engine damage will result…………………………………………………………………………… 22
2. Drain, flush and refill crankcase with new oil, See Draining and Filling the Engine Crankcase on page 11…………………………………………………………………………………………………………………………………………….. 22
3. Change oil filter, See Oil Filter on page 12………………………………………………………………………………………………………………………………………………………………………………………………….. 22
20-Hour Check……………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 23
1. Change engine oil and oil filter…………………………………………………………………………………………………………………………………………………………………………………………………………….. 23
2. Check power trim/tilt reservoir for proper fluid level…………………………………………………………………………………………………………………………………………………………………………………………. 23
3. Clean and inspect the ceramic filter located under the fuel pump………………………………………………………………………………………………………………………………………………………………………………… 23
4. Check flame arrestor for proper mounting……………………………………………………………………………………………………………………………………………………………………………………………………… 23
5. Start engine and check complete fuel system for leaks………………………………………………………………………………………………………………………………………………………………………………………….. 23
6. Lubricate steering cable ram with Volvo Penta grease P/N 828250. Check power steering pump reservoir for correct fluid level ………………………………………………………………………………………………………………………….. 23
7. Check shift system for proper adjustment and operation. Verify cable attachment clamp on pivot housing is fully seated and secure. Inspect cable anchor and cotter pin at shift linkage on stern drive for proper installation and free movement……………………. 23
8. Inspect exhaust system. Tighten all hose clamps, and check for leaks. Verify all clamps on exhaust and u-joint bellows are properly located and tightened…………………………………………………………………………………………………. 23
9. Check tension on drive belt…………………………………………………………………………………………………………………………………………………………………………………………………………………. 23
10. Check all engine mount screws, stern drive mounting nuts and transom shield mounting nuts for tightness…………………………………………………………………………………………………………………………………………….. 23
11. Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at this time will prevent the worsening of a minor problem and help ensure a trouble-free boating season……………………………………………………………. 23
12. Check oil level in Sterndrive and add as necessary with GL-5 Synthetic Gear Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W-90 (meeting or exceeding MIL-L-2105C or D, API GL-4 or 5) gear lubricant………………………………………………………. 23
13. Make sure engine can achieve maximum rated RPM with normal load………………………………………………………………………………………………………………………………………………………………………………… 23
Positive Closed Ventilation System…………………………………………………………………………………………………………………………………………………………………………………………………………………. 23
With Engine Idling……………………………………………………………………………………………………………………………………………………………………………………………………………………………. 24
1. Remove PCV valve from its mounting, but leave vacuum inlet side connected to hose. If the valve is functioning properly and n………………………………………………………………………………………………………………………. 24
2. Reinstall PCV valve, then remove crankcase air inlet hose at flame arrestor connection. Loosely hold a small piece of stiff p………………………………………………………………………………………………………………………. 24
With Engine Stopped…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 24
Servicing PCV Valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………… 24
Troubleshooting – System Isolation…………………………………………………………………………………………………………………………………………………………………………………………………………………. 24
System Isolation……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
1. Discharged or dead Battery………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
2. Loose or corroded connections……………………………………………………………………………………………………………………………………………………………………………………………………………. 25
3. Cranking System Troubleshooting Chart in the Electrical Ignition/ Fuel Service Manual………………………………………………………………………………………………………………………………………………………….. 25
1. Distributor Cap………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
2. Coil and spark plug leads……………………………………………………………………………………………………………………………………………………………………………………………………………….. 25
3. Ignition timing………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
4. Automatic spark advance…………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
5. Appropriate Ignition Troubleshooting Chart in the Electrical/Ignition/Fuel Service Manual………………………………………………………………………………………………………………………………………………………. 25
6. EFI Models: Refer to EFI Diagnostic Manual………………………………………………………………………………………………………………………………………………………………………………………………… 25
1. Fuel Tank, valves, and lines…………………………………………………………………………………………………………………………………………………………………………………………………………….. 25
2. Fuel pump and filter……………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
3. Carburetor and Filter…………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
4. Boat Fuel System Troubleshooting Chart……………………………………………………………………………………………………………………………………………………………………………………………………. 25
5. Carburetor Troubleshooting Chart…………………………………………………………………………………………………………………………………………………………………………………………………………. 25
6. Engine Fuel System Troubleshooting Chart………………………………………………………………………………………………………………………………………………………………………………………………….. 25
1. Compression……………………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
2. Ignition system………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
3. Fuel system and carburetor………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
4. Lubrication system……………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
5. Cooling System…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 25
6. Sterndrive and propeller………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
7. PCV Valve……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
8. Engine Troubleshooting Guides……………………………………………………………………………………………………………………………………………………………………………………………………………. 25
Engine Troubleshooting Guides……………………………………………………………………………………………………………………………………………………………………………………………………………………… 25
Engine Will Not Crank…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 26
Starter Circuit – Check:…………………………………………………………………………………………………………………………………………………………………………………………………………………… 26
Engine Cranks, But Will Not Start………………………………………………………………………………………………………………………………………………………………………………………………………………. 26
Ignition Circuit………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 26
Fuel System………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 27
Cylinder Compression………………………………………………………………………………………………………………………………………………………………………………………………………………………. 27
Hard Starting – Cold Engine……………………………………………………………………………………………………………………………………………………………………………………………………………………. 27
Has Engine Always Done This?……………………………………………………………………………………………………………………………………………………………………………………………………………….. 27
1. Carburetor choke operation and adjustment……………………………………………………………………………………………………………………………………………………………………………………………… 27
2. Fuel lines for obstructions………………………………………………………………………………………………………………………………………………………………………………………………………….. 27
3. For debris inside fuel tank………………………………………………………………………………………………………………………………………………………………………………………………………….. 27
4. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 27
Was Engine Not Used For A Long Time? (more than two months)……………………………………………………………………………………………………………………………………………………………………………………. 27
1. For clean external canister and carburetor fuel filters…………………………………………………………………………………………………………………………………………………………………………………. 27
2. Empty carburetor float bowl due to evaporation…………………………………………………………………………………………………………………………………………………………………………………………. 27
3. Water in fuel due to condensation…………………………………………………………………………………………………………………………………………………………………………………………………….. 27
4. Fuel quality deterioration…………………………………………………………………………………………………………………………………………………………………………………………………………… 27
5. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 28
Is This A New Condition?…………………………………………………………………………………………………………………………………………………………………………………………………………………… 28
1. Carburetor choke operation and adjustment……………………………………………………………………………………………………………………………………………………………………………………………… 28
2. Carburetor accelerator pump………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
3. Fuel system for leaks, dirt, or obstructions…………………………………………………………………………………………………………………………………………………………………………………………… 28
4. Engine timing and ignition system…………………………………………………………………………………………………………………………………………………………………………………………………….. 28
5. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 28
Hard Starting – Hot Engine…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
Has Engine Always Done This?……………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
1. Carburetor choke operation and adjustment……………………………………………………………………………………………………………………………………………………………………………………………… 28
2. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 28
Is This A New Condition?…………………………………………………………………………………………………………………………………………………………………………………………………………………… 28
1. Brand, type or octane of fuel………………………………………………………………………………………………………………………………………………………………………………………………………… 28
2. Spark plugs………………………………………………………………………………………………………………………………………………………………………………………………………………………… 28
3. Water in fuel………………………………………………………………………………………………………………………………………………………………………………………………………………………. 28
4. Condition of battery and cables………………………………………………………………………………………………………………………………………………………………………………………………………. 28
5. Starter motor for overheat damage…………………………………………………………………………………………………………………………………………………………………………………………………….. 28
Did Engine Refuse To Start After Being Run?………………………………………………………………………………………………………………………………………………………………………………………………….. 28
1. Ignition system primary circuit………………………………………………………………………………………………………………………………………………………………………………………………………. 28
2. Ignition coil(s)/ignition module……………………………………………………………………………………………………………………………………………………………………………………………………… 28
3. Engine timing………………………………………………………………………………………………………………………………………………………………………………………………………………………. 28
4. Carburetor choke operation and adjustment……………………………………………………………………………………………………………………………………………………………………………………………… 28
5. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 28
Engine Runs Rough…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
If At Slow Speed………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
1. Idle speed and idle mixture………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
2. Engine timing and spark plugs………………………………………………………………………………………………………………………………………………………………………………………………………… 28
3. Fuel pump pressure………………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
4. Water or contaminants in fuel………………………………………………………………………………………………………………………………………………………………………………………………………… 28
5. Carburetor or manifold vacuum leak……………………………………………………………………………………………………………………………………………………………………………………………………. 28
6. Internal carburetor fuel leak………………………………………………………………………………………………………………………………………………………………………………………………………… 29
7. See Electrical/Ignition/Fuel System Service Manual……………………………………………………………………………………………………………………………………………………………………………………… 29
If At High Speed………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 29
1. Air leak on suction side of fuel system……………………………………………………………………………………………………………………………………………………………………………………………….. 29
2. Too low octane fuel…………………………………………………………………………………………………………………………………………………………………………………………………………………. 29
3. Ignition system secondary circuit…………………………………………………………………………………………………………………………………………………………………………………………………….. 29
4. Engine timing………………………………………………………………………………………………………………………………………………………………………………………………………………………. 29
5. Wrong model or size carburetor, improper main jets or power valve, defective secondary fuel circuit, secondary vacuum diaphragm failure………………………………………………………………………………………………………….. 29
6. External canister and carburetor fuel filters………………………………………………………………………………………………………………………………………………………………………………………….. 29
7. Fuel pump pressure………………………………………………………………………………………………………………………………………………………………………………………………………………….. 29
8. Engine compression………………………………………………………………………………………………………………………………………………………………………………………………………………….. 29
9. Water or contaminants in fuel, water in cylinders………………………………………………………………………………………………………………………………………………………………………………………. 29
10. See General Information section and Electrical/Ignition/ Fuel System Service Manual……………………………………………………………………………………………………………………………………………………….. 29
Engine Noises and Vibrations…………………………………………………………………………………………………………………………………………………………………………………………………………………… 29
Valves – Hydraulic Lifters…………………………………………………………………………………………………………………………………………………………………………………………………………………. 29
1. Rapping only when starting (oil too heavy for prevailing weather, varnish on lifter, oil needs to be changed)…………………………………………………………………………………………………………………………………. 29
2. Intermittent rapping (leakage at lifter check ball)…………………………………………………………………………………………………………………………………………………………………………………….. 29
3. Idle noise (excessive leak down rate, faulty check ball seat)……………………………………………………………………………………………………………………………………………………………………………. 29
4. Generally noisy (excessive oil in crankcase, stuck lifter plunger)……………………………………………………………………………………………………………………………………………………………………….. 29
5. Loud noise at operating temperature (scored lifter plunger, fast leak down rate, oil viscosity too light for prevailing weather or operating temperatures)…………………………………………………………………………………………. 29
6. See appropriate Engine section……………………………………………………………………………………………………………………………………………………………………………………………………….. 29
Ignition System (Ping or Knock)…………………………………………………………………………………………………………………………………………………………………………………………………………….. 29
1. Improper tuning…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 29
2. Incorrect spark plug wire routing…………………………………………………………………………………………………………………………………………………………………………………………………….. 29
3. Use higher octane fuel………………………………………………………………………………………………………………………………………………………………………………………………………………. 29
4. See Electrical/Ignition/Fuel Service Manual……………………………………………………………………………………………………………………………………………………………………………………………. 29
Cooling System……………………………………………………………………………………………………………………………………………………………………………………………………………………………. 29
1. Supply pump………………………………………………………………………………………………………………………………………………………………………………………………………………………… 29
2. Loose belts, pulleys………………………………………………………………………………………………………………………………………………………………………………………………………………… 29
3. See Cooling System Manual……………………………………………………………………………………………………………………………………………………………………………………………………………. 29
Mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 29
1. Loose, broken or worn engine mounts…………………………………………………………………………………………………………………………………………………………………………………………………… 29
2. Loose lag screws holding mounts to stringer……………………………………………………………………………………………………………………………………………………………………………………………. 29
Crankshaft Balancer or Flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
1. Loose bolt(s)………………………………………………………………………………………………………………………………………………………………………………………………………………………. 30
Alternator……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
1. Loose pulley, worn bearings………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
2. Loose mounting bolts………………………………………………………………………………………………………………………………………………………………………………………………………………… 30
Sterndrive……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
1. Failed U-joints or gimbal bearing…………………………………………………………………………………………………………………………………………………………………………………………………….. 30
2. Damaged internal drive components…………………………………………………………………………………………………………………………………………………………………………………………………….. 30
3. Worn, bent or broken propeller hub or blades…………………………………………………………………………………………………………………………………………………………………………………………… 30
4. Loose, worn or damaged engine coupler…………………………………………………………………………………………………………………………………………………………………………………………………. 30
Engine Overheats……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 30
1. Actual engine temperature by verifying with an accurate thermometer at the thermostat housing…………………………………………………………………………………………………………………………………………………… 30
2. Gauge operation and wiring circuit……………………………………………………………………………………………………………………………………………………………………………………………………….. 30
3. Sending unit operation and wiring circuit…………………………………………………………………………………………………………………………………………………………………………………………………. 30
4. Supply pump, circulating pump and belt(s)…………………………………………………………………………………………………………………………………………………………………………………………………. 30
5. Water intake screens for blockage………………………………………………………………………………………………………………………………………………………………………………………………………… 30
6. Thermostat…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
7. Water supply hoses……………………………………………………………………………………………………………………………………………………………………………………………………………………… 30
8. Engine timing………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
9. Water leaks on pressure side of supply pump……………………………………………………………………………………………………………………………………………………………………………………………….. 30
10. Air leaks on suction side of supply pump including the transom shield and sterndrive………………………………………………………………………………………………………………………………………………………….. 30
11. Engine compression…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
Engine Dies Out………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 30
Loss Of, Or Out Of, Fuel…………………………………………………………………………………………………………………………………………………………………………………………………………………… 30
1. Fuel gauge operation and wiring………………………………………………………………………………………………………………………………………………………………………………………………………. 30
2. Fuel level in tank………………………………………………………………………………………………………………………………………………………………………………………………………………….. 30
3. Water or debris in fuel……………………………………………………………………………………………………………………………………………………………………………………………………………… 30
4. Fuel pickup tube and screen blockage………………………………………………………………………………………………………………………………………………………………………………………………….. 30
5. Fuel tank vent blockage……………………………………………………………………………………………………………………………………………………………………………………………………………… 30
6. Plugged external canister or carburetor fuel filters……………………………………………………………………………………………………………………………………………………………………………………. 30
7. Air leak on suction side of fuel system……………………………………………………………………………………………………………………………………………………………………………………………….. 30
8. Fuel leak on pressure side of fuel system……………………………………………………………………………………………………………………………………………………………………………………………… 30
9. Inoperative, restricted or incorrectly sized anti-siphon valve…………………………………………………………………………………………………………………………………………………………………………… 30
10. Boat fuel lines too small in diameter………………………………………………………………………………………………………………………………………………………………………………………………… 30
11. Fuel pump pressure and suction………………………………………………………………………………………………………………………………………………………………………………………………………. 30
12. Carburetor cleanliness and operation…………………………………………………………………………………………………………………………………………………………………………………………………. 31
13. See Electrical/Ignition/Fuel System Service Manual…………………………………………………………………………………………………………………………………………………………………………………….. 31
Loss Of Ignition………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 31
1. Primary and secondary ignition circuits……………………………………………………………………………………………………………………………………………………………………………………………….. 31
2. Ignition switch…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 31
3. Circuit breakers……………………………………………………………………………………………………………………………………………………………………………………………………………………. 31
4. Wiring between engine and dash……………………………………………………………………………………………………………………………………………………………………………………………………….. 31
5. Main engine harness wiring…………………………………………………………………………………………………………………………………………………………………………………………………………… 31
6. See Electrical/Ignition/Fuel Service Manual……………………………………………………………………………………………………………………………………………………………………………………………. 31
Engine Stops Or Dies Out Due To Seizure……………………………………………………………………………………………………………………………………………………………………………………………………… 31
1. Vertical drive for internal damage……………………………………………………………………………………………………………………………………………………………………………………………………. 31
2. Oil pressure gauge and crankcase oil level…………………………………………………………………………………………………………………………………………………………………………………………….. 31
3. Temperature gauge and cooling system operation…………………………………………………………………………………………………………………………………………………………………………………………. 31
4. Internal engine components as required………………………………………………………………………………………………………………………………………………………………………………………………… 31
Engine Won’t Reach Operating RPM……………………………………………………………………………………………………………………………………………………………………………………………………………. 31
1. Propeller pitch or diameter, damaged blades, slipping hub……………………………………………………………………………………………………………………………………………………………………………….. 31
2. Crankcase oil volume………………………………………………………………………………………………………………………………………………………………………………………………………………… 31
3. Marine growth on hull and drive………………………………………………………………………………………………………………………………………………………………………………………………………. 31
4. Fuel type or octane…………………………………………………………………………………………………………………………………………………………………………………………………………………. 31
5. Wrong Sterndrive gear ratio………………………………………………………………………………………………………………………………………………………………………………………………………….. 31
6. Operating at high altitude…………………………………………………………………………………………………………………………………………………………………………………………………………… 31
7. Restricted carburetor air intake……………………………………………………………………………………………………………………………………………………………………………………………………… 31
8. Restricted exhaust outlets in engine, transom bracket or drive…………………………………………………………………………………………………………………………………………………………………………… 31
9. Poor cylinder compression……………………………………………………………………………………………………………………………………………………………………………………………………………. 31
10. Carburetor size and type correct for engine…………………………………………………………………………………………………………………………………………………………………………………………… 31
11. Fuel pump pressure and vacuum……………………………………………………………………………………………………………………………………………………………………………………………………….. 31
12. Boat overloaded, or load improperly placed……………………………………………………………………………………………………………………………………………………………………………………………. 31
13. Engine overheating…………………………………………………………………………………………………………………………………………………………………………………………………………………. 31
14. Engine timing and ignition system operation…………………………………………………………………………………………………………………………………………………………………………………………… 31
15. Remote control cables and linkage for proper attachment and travel………………………………………………………………………………………………………………………………………………………………………. 31
Defective Engine Lubricating System…………………………………………………………………………………………………………………………………………………………………………………………………………….. 31
Engine Components…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 31
1. Clogged or incorrect oil filter………………………………………………………………………………………………………………………………………………………………………………………………………. 31
2. Worn oil pump gears, cover or shaft…………………………………………………………………………………………………………………………………………………………………………………………………… 31
3. Worn or collapsed oil pump relief valve spring, or foreign material caught on valve seat……………………………………………………………………………………………………………………………………………………. 32
4. Oil pump relief valve plunger loose in cover…………………………………………………………………………………………………………………………………………………………………………………………… 32
5. Damaged filter bypass grommet………………………………………………………………………………………………………………………………………………………………………………………………………… 32
6. Clogged oil pickup screen, broken tube or housing………………………………………………………………………………………………………………………………………………………………………………………. 32
7. Plugged crankshaft or blocked oil galleys……………………………………………………………………………………………………………………………………………………………………………………………… 32
8. Dirty or defective hydraulic lifters, clogged push rod passages………………………………………………………………………………………………………………………………………………………………………….. 32
9. Poor quality, incorrect viscosity or quantity of oil……………………………………………………………………………………………………………………………………………………………………………………. 32
10. Oil level too high – too much oil in the crankcase…………………………………………………………………………………………………………………………………………………………………………………….. 32
11. Incorrect hose routing on remote filter systems……………………………………………………………………………………………………………………………………………………………………………………….. 32
12. Water in crankcase oil from condensation, defective head gasket, oil cooler, or cracked manifold/block water passages…………………………………………………………………………………………………………………………. 32
Oil Pressure Warning System………………………………………………………………………………………………………………………………………………………………………………………………………………… 32
1. Oil gauge/warning horn operation and wiring……………………………………………………………………………………………………………………………………………………………………………………………. 32
2. Engine temperature………………………………………………………………………………………………………………………………………………………………………………………………………………….. 32
3. Oil pressure gauge and warning horn sender operation and wiring………………………………………………………………………………………………………………………………………………………………………….. 32
4. Oil level too high or too low, oil level should be within the “Safe” range on the dipstick………………………………………………………………………………………………………………………………………………….. 32
Low Battery Voltage After Short Storage…………………………………………………………………………………………………………………………………………………………………………………………………………. 32
Engine/Boat Components…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 32
1. All electrical accessories including ignition circuit off……………………………………………………………………………………………………………………………………………………………………………….. 32
2. Disconnect main battery negative cable from battery…………………………………………………………………………………………………………………………………………………………………………………….. 32
3. Connect ammeter or voltmeter in series between negative battery cable and negative battery post……………………………………………………………………………………………………………………………………………… 32
4. Disconnect main engine harness 10-Pin Connector………………………………………………………………………………………………………………………………………………………………………………………… 32
5. Repair or replace components as necessary……………………………………………………………………………………………………………………………………………………………………………………………… 32
Engine – 5.0 & 5.7 Litre……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 33
General Description………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 34
Cylinder Block……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 34
Cylinder Head………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 34
Camshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 35
Crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 35
Pistons and Connecting Rods……………………………………………………………………………………………………………………………………………………………………………………………………………………. 35
Lubrication………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 35
Tools and Shop Equipment………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 35
Accessories……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 35
Cleaning………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 36
Draining The Engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 37
Raw Water Cooled Engines………………………………………………………………………………………………………………………………………………………………………………………………………………………. 37
1. With the engine turned off, locate and open the engine drain petcocks located on both sides of the engine block…………………………………………………………………………………………………………………………………… 37
2. Remove drain plugs from exhaust manifolds. After the water has completely drained, reinstall the drain plugs and torque to 29 N.m (22 lb. ft.)……………………………………………………………………………………………………….. 38
3. Note the hose orientation on the raw water pump. Loosen the hose clamps and remove the hoses from the raw water pump………………………………………………………………………………………………………………………………. 38
4. Crank the engine briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump……………………………………………………………………………………………………………………………. 38
5. Loosen the hose clamp on the large diameter hose and remove it from the circulation pump……………………………………………………………………………………………………………………………………………………….. 38
6. Loosen the hose clamp on the lower fuel cell cooling line and remove hose from fuel cell. Allow water to drain from hose…………………………………………………………………………………………………………………………… 39
7. Reinstall all hoses and secure all clamps in the same orientation as removed………………………………………………………………………………………………………………………………………………………………….. 39
Draining seawater from the Closed Cooling System…………………………………………………………………………………………………………………………………………………………………………………………………. 39
1. With the engine turned off locate and loosen the lower drain cap from the heat exchanger (1). After water has completely drained, retighten the lower drain cap of the heat exchanger to 18-30ft.lb. (25-41 Nm)……………………………………………… 39
2. Note the hose orientation on the raw water pump. Loosen the hose clamps and remove the hoses from the raw water pump. Crank t………………………………………………………………………………………………………………………. 39
3. Remove drain plugs from exhaust manifolds. Probe the drains with a wire to ensure rust particles have not blocked the drain. After water is completely drained, reinstall drain plugs and tighten securely………………………………………………….. 40
Engine Lubrication……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 40
4. Oil is drawn up through the oil pump screen and passes through the pump to the oil filter. The oil filter is a full-flow pape………………………………………………………………………………………………………………………….. 40
Exhaust Manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 41
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 41
1. Drain water from exhaust manifolds……………………………………………………………………………………………………………………………………………………………………………………………………….. 41
2. Disconnect water hose from manifold………………………………………………………………………………………………………………………………………………………………………………………………………. 41
3. Loosen upper exhaust hose clamps, then remove high rise elbow……………………………………………………………………………………………………………………………………………………………………………….. 41
4. Remove manifold attaching screws, then remove the manifold………………………………………………………………………………………………………………………………………………………………………………….. 41
Inspection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 41
1. Inspect for cracks……………………………………………………………………………………………………………………………………………………………………………………………………………………… 41
2. To pressure check manifold, use a plate such as pictured, and a new elbow gasket to seal water passage in manifold. Be sure t………………………………………………………………………………………………………………………. 41
Installation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 41
1. Clean mating surfaces on manifold and head. Install new exhaust gasket, then install manifold and secure with screws. Tighten screws to 20-26 ft. lb. (27-35 N.m)………………………………………………………………………………………. 41
2. Install a new gasket and high rise elbow to manifold. Tighten bolts to 12-18 ft. lb. (16-24 N.m)………………………………………………………………………………………………………………………………………………… 42
3. Clean the gasket mounting surfaces on both the riser and the manifold………………………………………………………………………………………………………………………………………………………………………… 42
4. Use spray on gasket remover to remove ALL traces of riser gasket. Heavy scrapping with tools on gasket surfaces may gouge surface, preventing proper seal……………………………………………………………………………………………… 42
5. Follow pre-cautions on can of gasket remover to prevent damage to paint on manifold, riser or engine…………………………………………………………………………………………………………………………………………….. 42
6. Use 80 grit sandpaper and a sanding block, or equivalent to smooth the gasket mounting surfaces on the riser and manifold………………………………………………………………………………………………………………………….. 42
7. Place gasket over mounting surface on manifold…………………………………………………………………………………………………………………………………………………………………………………………….. 43
8. Install riser, on to exhaust manifold…………………………………………………………………………………………………………………………………………………………………………………………………….. 43
9. Make sure gasket is properly placed………………………………………………………………………………………………………………………………………………………………………………………………………. 43
10. Install bolts and washers to secure riser………………………………………………………………………………………………………………………………………………………………………………………………… 43
11. Install any parts secured under bolts……………………………………………………………………………………………………………………………………………………………………………………………………. 43
12. Torque riser bolts in a crossing pattern to 40 Nm…………………………………………………………………………………………………………………………………………………………………………………………. 43
13. (30 ft. lb.). Make at least two passes to insure proper torque is reached……………………………………………………………………………………………………………………………………………………………………. 43
14. Install all other parts mounted to risers………………………………………………………………………………………………………………………………………………………………………………………………… 43
15. Install exhaust hose and secure with clamps………………………………………………………………………………………………………………………………………………………………………………………………. 43
16. Connect water hose and secure with clamp…………………………………………………………………………………………………………………………………………………………………………………………………. 43
17. Start engine and check for fuel leaks……………………………………………………………………………………………………………………………………………………………………………………………………. 43
Starter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 43
Remove………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 43
1. Disconnect power from the engine…………………………………………………………………………………………………………………………………………………………………………………………………………. 43
2. Remove battery cable (2) from solenoid extension nut……………………………………………………………………………………………………………………………………………………………………………………….. 43
3. Remove solenoid extension nut (4) and cover (3) from solenoid……………………………………………………………………………………………………………………………………………………………………………….. 43
4. Remove accessory wires from solenoid (5)………………………………………………………………………………………………………………………………………………………………………………………………….. 43
5. Remove start wire nut (6)……………………………………………………………………………………………………………………………………………………………………………………………………………….. 43
6. Remove start wire from solenoid start terminal (7)…………………………………………………………………………………………………………………………………………………………………………………………. 43
7. Remove starter mounting bolts……………………………………………………………………………………………………………………………………………………………………………………………………………. 44
8. Remove starter…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 44
Installation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 44
1. Hold stater against engine mounting pad with mounting holes aligned………………………………………………………………………………………………………………………………………………………………………….. 44
2. Install starter bolts and tighten to 41-49 Nm (30-36 ft.lb)…………………………………………………………………………………………………………………………………………………………………………………. 44
3. Connect accessory wires (5) to solenoid…………………………………………………………………………………………………………………………………………………………………………………………………… 44
4. Install solenoid extension nut (4) and washer on solenoid terminal. Tighten to 19 – 28 N.m (14 – 20 ft. lb.)……………………………………………………………………………………………………………………………………… 44
5. Install solenoid extension nut cover (3)………………………………………………………………………………………………………………………………………………………………………………………………….. 44
6. Connect battery cable (2) to solenoid extension nut………………………………………………………………………………………………………………………………………………………………………………………… 44
7. Install battery cable bolt (1) and washer. Tighten to 19 – 28 N.m (14 – 20 ft. lb.)……………………………………………………………………………………………………………………………………………………………. 44
8. Install start wire (7) on solenoid stud “S”……………………………………………………………………………………………………………………………………………………………………………………………….. 44
9. Install start wire nut (6) and washer. Tighten to 3 – 5 N.m (26 – 44 in. lb.)…………………………………………………………………………………………………………………………………………………………………. 44
10. Connect start wire to solenoid start terminal (1)…………………………………………………………………………………………………………………………………………………………………………………………. 44
11. On GL models, connect the purple wire to the solenoid “R” terminal in the same manner…………………………………………………………………………………………………………………………………………………………. 45
Intake Manifold………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 45
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 45
1. Disconnect power from engine…………………………………………………………………………………………………………………………………………………………………………………………………………….. 45
2. Drain water from engine block. See Draining The Engine on page 33……………………………………………………………………………………………………………………………………………………………………………. 45
3. If the engine has closed cooling installed, remove drain plugs from engine block. Catch the coolant from the engine and dispose of properly………………………………………………………………………………………………………….. 45
Disconnect:………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 45
4. Disconnect hoses from thermostat housing………………………………………………………………………………………………………………………………………………………………………………………………….. 45
5. Disconnect Throttle cable……………………………………………………………………………………………………………………………………………………………………………………………………………….. 45
a. Remove cotter pin (1) and washer (2) and remove throttle cable from throttle lever…………………………………………………………………………………………………………………………………………………………. 45
b. Loosen and remove anchor block bolt (3) and nut (4)…………………………………………………………………………………………………………………………………………………………………………………….. 45
c. Release cable block (5) and trunnion (6)………………………………………………………………………………………………………………………………………………………………………………………………. 45
6. Crankcase ventilation hose from rocker arm covers (both sides if applicable)………………………………………………………………………………………………………………………………………………………………….. 45
Remove:……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 45
1. Disconnect wire at temperature gauge sender unit and engine wiring harness from alternator……………………………………………………………………………………………………………………………………………………… 45
Remove Distributor, Gi and GXi Models…………………………………………………………………………………………………………………………………………………………………………………………………………… 46
1. Disconnect distributor high tension leads and ignition primary lead from distributor cap……………………………………………………………………………………………………………………………………………………….. 46
2. Remove the distributor cap bolts and discard………………………………………………………………………………………………………………………………………………………………………………………………. 46
3. Remove the distributor cap………………………………………………………………………………………………………………………………………………………………………………………………………………. 46
4. Mark the position of the rotor on the housing……………………………………………………………………………………………………………………………………………………………………………………………… 46
5. Scribe a line on distributor housing and intake manifold for reassembly in the same position……………………………………………………………………………………………………………………………………………………. 47
6. Loosen hold down clamp and remove the distributor………………………………………………………………………………………………………………………………………………………………………………………….. 47
7. Remove Distributor and discard Gasket…………………………………………………………………………………………………………………………………………………………………………………………………….. 47
8. Disconnect and remove alternator…………………………………………………………………………………………………………………………………………………………………………………………………………. 47
9. Remove Fuse box………………………………………………………………………………………………………………………………………………………………………………………………………………………… 47
10. Carburetor fuel line from carburetor and fuel pump or fuel lines from fuel rails. To disconnect fuel lines from fuel rail, see Quick Connect Fitting Service in EFI Diagnostic Workshop Manual……………………………………………………………. 47
11. Remove intake manifold attaching bolts. Lift manifold from engine. Discard front and rear seals and gaskets……………………………………………………………………………………………………………………………………… 48
Clean:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 48
Disassemble Intake Manifold (Gi, GXi, OSi, & OSXi)……………………………………………………………………………………………………………………………………………………………………………………………….. 48
12. Remove Flame arrestor and bracket……………………………………………………………………………………………………………………………………………………………………………………………………….. 48
13. Remove throttle body attaching studs…………………………………………………………………………………………………………………………………………………………………………………………………….. 48
14. Remove throttle body and gasket. Discard the gasket……………………………………………………………………………………………………………………………………………………………………………………….. 48
15. Remove Thermostat housing bolts…………………………………………………………………………………………………………………………………………………………………………………………………………. 49
16. Remove Thermostat housing and discard gasket……………………………………………………………………………………………………………………………………………………………………………………………… 49
17. Remove MAT/MAP sensor stud and remove sensor from manifold…………………………………………………………………………………………………………………………………………………………………………………. 49
18. Remove four retaining studs and remove fuel rail assembly………………………………………………………………………………………………………………………………………………………………………………….. 49
19. Remove upper intake manifold attaching bolts……………………………………………………………………………………………………………………………………………………………………………………………… 50
20. Remove upper intake manifold……………………………………………………………………………………………………………………………………………………………………………………………………………. 50
21. Remove and discard upper intake manifold to lower intake manifold gasket…………………………………………………………………………………………………………………………………………………………………….. 50
22. Remove impulse limiter…………………………………………………………………………………………………………………………………………………………………………………………………………………. 50
Clean and Inspect…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 50
1. Clean the upper intake manifold in cleaning solvent…………………………………………………………………………………………………………………………………………………………………………………….. 50
2. Dry with compressed air……………………………………………………………………………………………………………………………………………………………………………………………………………… 50
3. Clean the lower intake manifold in cleaning solvent…………………………………………………………………………………………………………………………………………………………………………………….. 50
4. Dry with compressed air……………………………………………………………………………………………………………………………………………………………………………………………………………… 50
Assemble Intake Manifold………………………………………………………………………………………………………………………………………………………………………………………………………………………. 51
1. If removed. coat the threads of the impulse limiter with sealing compound P/N 1141570………………………………………………………………………………………………………………………………………………………….. 51
2. Install impulse limiter into lower intake manifold and tighten to 14-19 N.m (10-14 ft. lb.)…………………………………………………………………………………………………………………………………………………….. 51
3. Place a NEW upper intake manifold gasket into the upper intake manifold gasket groove………………………………………………………………………………………………………………………………………………………….. 51
4. Place the upper intake onto the lower intake manifold………………………………………………………………………………………………………………………………………………………………………………………. 51
5. Install upper intake manifold bolts………………………………………………………………………………………………………………………………………………………………………………………………………. 51
6. Tighten the upper intake manifold bolts in two stages………………………………………………………………………………………………………………………………………………………………………………………. 51
7. Inspect O-rings on fuel injectors. Replace any damaged, cut, or missing O-rings……………………………………………………………………………………………………………………………………………………………….. 51
8. Install the fuel injectors into the lower intake manifold…………………………………………………………………………………………………………………………………………………………………………………… 51
9. Install the fuel rail retaining studs and tighten to……………………………………………………………………………………………………………………………………………………………………………………….. 51
Intake Manifold Installation…………………………………………………………………………………………………………………………………………………………………………………………………………………… 51
Install or Connect:……………………………………………………………………………………………………………………………………………………………………………………………………………………….. 52
1. Apply a 4.0 mm (0.157 in) patch of adhesive Volvo Penta P/N 1161277 or equivalent to the cylinder head side of the lower intake manifold gasket at each end………………………………………………………………………………………… 52
2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head…………………………………………………………………………. 52
3. Apply a 5.0 mm (0.197 in) bead of adhesive Volvo Penta P/N 1161277 or equivalent to the front top of the engine block………………………………………………………………………………………………………………………….. 52
4. Apply a 5.0 mm (0.197 in) bead of adhesive Volvo Penta P/N 1161277 or equivalent to the rear top of the engine block.Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket……………………………………………………. 52
5. Install the intake manifold assembly onto the engine block………………………………………………………………………………………………………………………………………………………………………………. 53
6. If reusing the fasteners, apply threadlock Volvo Penta P/N 1161053 or equivalent to the threads of the manifold bolts………………………………………………………………………………………………………………………….. 53
7. Install the manifold bolts…………………………………………………………………………………………………………………………………………………………………………………………………………… 53
Tighten:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 53
8. Tighten the intake manifold bolts…………………………………………………………………………………………………………………………………………………………………………………………………….. 53
a. Tighten the bolts in sequence (1-8) on the first pass to 3 N.m (27 lb. in)…………………………………………………………………………………………………………………………………………………………….. 53
b. Tighten the bolts in sequence (1-8) on the first pass to 12 N.m (106 lb. in)…………………………………………………………………………………………………………………………………………………………… 53
c. Tighten the bolts in sequence (1-8) on the first pass to 15 N.m (11 lb. ft.)…………………………………………………………………………………………………………………………………………………………… 53
9. Connect fuel lines to fuel rail. See Quick Connect Fitting Service on page 346 of EFI Diagnostic Workshop Manual 7742218……………………………………………………………………………………………………………………….. 53
Distributor Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………. 53
Gi and GXi models…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 54
1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer (1) are aligned with the tabs on the engine front cover (2) and the number 1 piston is at top dead center of the compression stroke………………………….. 54
2. If not already removed, remove and discard the distributor cap screws…………………………………………………………………………………………………………………………………………………………………….. 54
3. Remove the distributor cap…………………………………………………………………………………………………………………………………………………………………………………………………………… 54
4. Install NEW distributor gasket onto the distributor…………………………………………………………………………………………………………………………………………………………………………………….. 54
5. Align the indent hole on the distributor gear with the paint mark on the distributor housing………………………………………………………………………………………………………………………………………………… 55
6. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary…………………………………………………………………………………………………. 55
7. Align the flat (1) in the distributor housing toward the front of the engine………………………………………………………………………………………………………………………………………………………………. 55
8. Install the distributor and distributor clamp. The flat in the distributor housing must be pointing toward the front of the engine………………………………………………………………………………………………………………. 56
9. Once the distributor is fully seated, align the distributor rotor segment with the number 8 pointer (1) that is cast into the distributor base……………………………………………………………………………………………………. 56
10. Install the distributor clamp bolt. and Tighten the bolt to 25 N.m (18 lb. ft.)…………………………………………………………………………………………………………………………………………………………… 56
11. Install the distributor cap and NEW distributor cap bolts.Tighten the screws to 2.4 N.m (21 lb. in)…………………………………………………………………………………………………………………………………………. 57
12. Set timing, GL Models see Electrical Fuel and Ignition Workshop Manual. Gi and GXi Models see EFI Diagnostic Workshop Manual, On Board Repair……………………………………………………………………………………………………. 57
Alternator with mounting bracket……………………………………………………………………………………………………………………………………………………………………………………………………………. 57
13. Install distributor cap and high tension leads. See the General Information section in Electrical/Ignition/Fuel Service Manual for correct firing order and spark plug wire routing………………………………………………………………….. 57
14. Install oil pressure sending unit……………………………………………………………………………………………………………………………………………………………………………………………………. 57
Connect:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 57
15. All electrical connections. Apply black neoprene dip, or equivalent, on all exposed connections…………………………………………………………………………………………………………………………………………….. 57
16. Fuel lines to carburetor and fuel pump or throttle body and fuel pump/vapor separator……………………………………………………………………………………………………………………………………………………… 57
17. Throttle cable…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 57
18. All water hoses, and close all drain petcocks…………………………………………………………………………………………………………………………………………………………………………………………. 57
19. Both crankcase ventilation hoses…………………………………………………………………………………………………………………………………………………………………………………………………….. 57
20. Battery cables…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 57
21. Start engine. Check ignition timing, carburetor idle speed and mixture. Check for leaks……………………………………………………………………………………………………………………………………………………. 57
Rocker Arm Cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 58
Remove:……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
1. Valve rocker arm cover bolts…………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
2. Valve rocker arm cover………………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
3. Gasket………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
Clean:………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 58
a. Parts in solvent. Remove all sludge and varnish……………………………………………………………………………………………………………………………………………………………………………………………. 58
b. Old gaskets from the gasket surfaces……………………………………………………………………………………………………………………………………………………………………………………………………… 58
Inspect:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
a. Gasket flanges for bending or damage……………………………………………………………………………………………………………………………………………………………………………………………………… 58
b. Rubber grommets and parts for deterioration……………………………………………………………………………………………………………………………………………………………………………………………….. 58
Installation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 58
1. New gasket…………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
2. Valve rocker arm cover………………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
3. Valve rocker arm cover bolts…………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
Tighten:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 58
1. Valve rocker arm cover bolts to 106 in. lb. (12 N.m)……………………………………………………………………………………………………………………………………………………………………………………….. 58
Valve Train……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
1. Remove rocker arms……………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
2. Remove pushrods and keep in order with the valve lifters and rocker arms……………………………………………………………………………………………………………………………………………………………………… 59
3. Remove valve lifter retainer bolts and valve guide retainer…………………………………………………………………………………………………………………………………………………………………………………. 59
4. Remove the valve guides and valve lifters…………………………………………………………………………………………………………………………………………………………………………………………………. 59
5. Remove the lifters one at a time using J 9290-01/J 3049 or equivalent and place them in an organizer rack………………………………………………………………………………………………………………………………………… 60
6. Store all reusable components in an exact order, so they may be reassembled in the same wear pattern location from which they were removed…………………………………………………………………………………………………………… 60
Clean:………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 60
1. Mark, sort and organize the components for assembly………………………………………………………………………………………………………………………………………………………………………………………… 60
2. Clean the components with cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………………… 60
3. Dry the components with compressed air……………………………………………………………………………………………………………………………………………………………………………………………………. 60
Inspect:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 60
4. Inspect the valve rocker arm components for the following:………………………………………………………………………………………………………………………………………………………………………………….. 60
5. Inspect the valve push rods for the following:…………………………………………………………………………………………………………………………………………………………………………………………….. 61
Valve Lifters and Guides Clean and Inspect………………………………………………………………………………………………………………………………………………………………………………………………………. 61
1. Mark, sort and organize the components for assembly………………………………………………………………………………………………………………………………………………………………………………………… 61
2. Clean the components with cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………………… 61
3. Dry the components with compressed air……………………………………………………………………………………………………………………………………………………………………………………………………. 61
4. Inspect the valve lifter pushrod guides (1) for excessive wear, cracks or damage………………………………………………………………………………………………………………………………………………………………. 61
5. Inspect the valve lifter guide retainer for wear, damage or stress cracking in the leg areas (2) and wear or damage in the bolt holes (3)……………………………………………………………………………………………………………. 61
6. Inspect the valve lifter for the following:……………………………………………………………………………………………………………………………………………………………………………………………….. 61
Installation……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 61
Valve Lifter Installation……………………………………………………………………………………………………………………………………………………………………………………………………………………… 62
1. Apply lubricant GM P/N 12345501 or equivalent to the valve lifter rollers…………………………………………………………………………………………………………………………………………………………………….. 62
2. Install the valve lifters……………………………………………………………………………………………………………………………………………………………………………………………………………….. 62
Valve Lifter Pushrod Guides……………………………………………………………………………………………………………………………………………………………………………………………………………………. 62
3. Install the valve lifter pushrod guides…………………………………………………………………………………………………………………………………………………………………………………………………… 62
4. Tighten the valve lifter pushrod guide bolts to 25 N.m (18 lb. ft.)………………………………………………………………………………………………………………………………………………………………………….. 62
Valve Push Rod……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 62
1. Install the valve pushrods………………………………………………………………………………………………………………………………………………………………………………………………………………. 62
Install Rocker Arm Assemblies………………………………………………………………………………………………………………………………………………………………………………………………………………….. 63
2. Install the following components:………………………………………………………………………………………………………………………………………………………………………………………………………… 63
Valve Lash Adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 63
1. Turn the valve rocker arm nuts clockwise until all of the valve lash is removed……………………………………………………………………………………………………………………………………………………………….. 63
2. Turn the crankshaft clockwise until the alignment mark on the crankshaft balancer is aligned with the notch in the engine front cover tab……………………………………………………………………………………………………………. 63
3. Look at the number 1 cylinder valves as the crankshaft balancer alignment mark approaches the notch in the engine front cover………………………………………………………………………………………………………………………. 63
4. With the engine in the number 1 cylinder firing position, adjust the exhaust valves for cylinder numbers 1, 3, 4, and 8 and the intake valves for cylinder numbers 1, 2, 5, and 7 using the following process:………………………………………………. 63
5. Turn the crankshaft clockwise 1 revolution until the alignment mark on the crankshaft balancer is aligned with the notch in the engine front cover tab………………………………………………………………………………………………… 64
6. With the engine in the number 6 cylinder firing position, adjust the exhaust valves for cylinder numbers 2, 5, 6 and 7 and the intake valve for cylinder numbers 3, 4, 6 and 8 using the following process:…………………………………………………. 64
Valve Rocker Arm Cover Installation…………………………………………………………………………………………………………………………………………………………………………………………………………….. 64
1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover…………………………………………………………………………………………………………………………………………………….. 64
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover…………………………………………………………………………………………………………………………………………………………… 64
3. Install the valve rocker arm cover onto the cylinder head…………………………………………………………………………………………………………………………………………………………………………………… 64
4. Install the valve rocker arm cover bolts………………………………………………………………………………………………………………………………………………………………………………………………….. 64
5. Tighten the valve rocker arm cover bolts to 12 N.m (106 lb. in)……………………………………………………………………………………………………………………………………………………………………………… 64
Cylinder Head……………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 64
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 64
1. Remove spark plugs……………………………………………………………………………………………………………………………………………………………………………………………………………………… 65
2. Remove cylinder head bolts………………………………………………………………………………………………………………………………………………………………………………………………………………. 65
3. Remove cylinder heads…………………………………………………………………………………………………………………………………………………………………………………………………………………… 65
4. Remove and discard head gaskets………………………………………………………………………………………………………………………………………………………………………………………………………….. 65
5. If required, remove the dowel pin (cylinder head locator)…………………………………………………………………………………………………………………………………………………………………………………… 66
Cylinder Head Disassemble and Recondition……………………………………………………………………………………………………………………………………………………………………………………………………….. 66
Disassemble:……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 66
1. Compress the springs with J 8062……………………………………………………………………………………………………………………………………………………………………………………………………… 66
2. Remove the valve stem keys (1)……………………………………………………………………………………………………………………………………………………………………………………………………….. 67
3. Remove the J 8062 from the cylinder head………………………………………………………………………………………………………………………………………………………………………………………………. 67
4. Remove the valve spring cap (2)………………………………………………………………………………………………………………………………………………………………………………………………………. 67
5. Remove the valve spring (3)………………………………………………………………………………………………………………………………………………………………………………………………………….. 67
6. Remove the valve stem oil seal (4)……………………………………………………………………………………………………………………………………………………………………………………………………. 67
7. Discard the valve stem oil seal………………………………………………………………………………………………………………………………………………………………………………………………………. 67
8. Remove the valve……………………………………………………………………………………………………………………………………………………………………………………………………………………. 67
Cylinder Head Clean and Inspect………………………………………………………………………………………………………………………………………………………………………………………………………………… 67
Clean:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 67
1. Clean the valve stems and cylinder heads on a buffing wheel……………………………………………………………………………………………………………………………………………………………………………… 67
2. Clean the following components in cleaning solvent:…………………………………………………………………………………………………………………………………………………………………………………….. 67
3. Dry the components with compressed air………………………………………………………………………………………………………………………………………………………………………………………………… 67
4. Use the J 8089 to clean the carbon from the cylinder head combustion chambers……………………………………………………………………………………………………………………………………………………………… 67
5. Inspect the cylinder head for the following:…………………………………………………………………………………………………………………………………………………………………………………………… 67
Inspect:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 68
6. Measure the cylinder head for warping with a straight edge and feeler gauge……………………………………………………………………………………………………………………………………………………………….. 68
Valve Spring Tension………………………………………………………………………………………………………………………………………………………………………………………………………………………. 68
1. Use the J 9666 in order to measure the valve spring…………………………………………………………………………………………………………………………………………………………………………………….. 68
Valve Spring Straightness……………………………………………………………………………………………………………………………………………………………………………………………………………………… 68
2. Inspect the valve springs for Straightness………………………………………………………………………………………………………………………………………………………………………………………………… 68
Valve Stems………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 69
3. Valve stems (1) with excessive valve guide (2) clearance must be repaired or the cylinder head replaced………………………………………………………………………………………………………………………………………….. 69
4. Measure the valve stem-to-guide clearance…………………………………………………………………………………………………………………………………………………………………………………………………. 69
a. Clamp the J 8001 on the exhaust port side of the cylinder head…………………………………………………………………………………………………………………………………………………………………………… 69
b. Position the dial indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will ca…………………………………………………………………………………………………………………… 69
c. Drop the valve head about 1.6 mm (0.063 in) off the valve seat…………………………………………………………………………………………………………………………………………………………………………… 69
d. Use light pressure and move the valve stem from side to side in order to obtain a valve stem-to-guide clearance reading………………………………………………………………………………………………………………………… 69
Valve Guide Reaming and Seat Grinding…………………………………………………………………………………………………………………………………………………………………………………………………………… 70
Measuring:……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 70
1. Measure the valve stem-to-guide clearance. See Cylinder Head Clean and Inspect on page 63…………………………………………………………………………………………………………………………………………………… 70
2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption……………………………………………………………………………………………………………………………………………………. 70
Reaming:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 71
3. Use the J 5830-3 in order to ream the exhaust valve guide in order to achieve the correct valve stem-to-guide clearance………………………………………………………………………………………………………………………… 71
4. Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves………………………………………………………………………………………………………………………… 71
Inspect………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 71
5. Inspect the valves for the following:…………………………………………………………………………………………………………………………………………………………………………………………………. 71
6. Inspect the valve contact surface for the following:……………………………………………………………………………………………………………………………………………………………………………………. 72
7. Reconditioning of the valves and valve seats:………………………………………………………………………………………………………………………………………………………………………………………….. 72
Valve Rocker Arm Stud Removal………………………………………………………………………………………………………………………………………………………………………………………………………………….. 72
1. Place the J 5802-01 over the valve rocker arm ball stud to be removed………………………………………………………………………………………………………………………………………………………………………… 73
2. Install a nu and a flat washer…………………………………………………………………………………………………………………………………………………………………………………………………………… 73
3. Rotate the clockwise t remove the valve rocker arm ball stud………………………………………………………………………………………………………………………………………………………………………………… 73
Valve Rocker Arm Stud Installation……………………………………………………………………………………………………………………………………………………………………………………………………………… 73
1. Ream the hole to the proper size for the replacement oversize valve rocker arm ball stud. Use J 5715 for 0.0762 mm (0.003 in) oversize valve rocker arm ball studs or J 6036 for 0.03302 mm (0.013 in) oversize valve rocker arm ball studs…………………….. 73
2. Apply lubricant GM P/N 1052271 or equivalent to the lower end (press-fit end) of the valve rocker arm ball stud…………………………………………………………………………………………………………………………………… 73
3. Use J 6880 and a hammer to install the valve rocker arm ball stud into place. The valve rocker arm ball stud is installed to proper depth when the J 6880 bottoms onto the cylinder head………………………………………………………………….. 74
Cylinder Head Assemble………………………………………………………………………………………………………………………………………………………………………………………………………………………… 74
Install Oil Seal……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 74
1. Assemble the valve into the proper valve guide…………………………………………………………………………………………………………………………………………………………………………………………….. 74
2. Select the proper valve stem oil seal for the specific valve guide…………………………………………………………………………………………………………………………………………………………………………… 74
3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil……………………………………………………………………………………………………………………………………………… 74
4. Assemble the valve stem oil seal onto the valve stem……………………………………………………………………………………………………………………………………………………………………………………….. 74
5. Install the valve stem oil seal onto the valve guide using the J- 42073. Tap the valve stem oil seal onto the valve guide until the J- 42073 bottoms against the valve spring seat……………………………………………………………………….. 75
6. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide………………………………………………………………………………………………………………………………………….. 75
Install Valve Spring………………………………………………………………………………………………………………………………………………………………………………………………………………………. 75
7. Install the valve spring (3)…………………………………………………………………………………………………………………………………………………………………………………………………………. 75
8. Install the valve spring cap (2) onto the valve spring (3) and over the valve stem…………………………………………………………………………………………………………………………………………………………. 75
9. Use the J 8062 in order to compress the valve springs…………………………………………………………………………………………………………………………………………………………………………………… 76
10. Install the valve stem keys…………………………………………………………………………………………………………………………………………………………………………………………………………. 76
a. Use grease in order to hold the valve stem keys in place while disconnecting the J 8062…………………………………………………………………………………………………………………………………………………. 76
b. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem……………………………………………………………………………………………………………………………………………… 76
c. Tap the end of the valve stem with a plastic-faced in order to seat the valve stem keys, if necessary…………………………………………………………………………………………………………………………………….. 76
Installation……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 76
1. Clean the cylinder head gasket surfaces on the engine block……………………………………………………………………………………………………………………………………………………………………………… 76
2. Inspect the dowel pins (cylinder head locators) for proper installation…………………………………………………………………………………………………………………………………………………………………… 76
3. Clean the cylinder head gasket surfaces on the cylinder heads……………………………………………………………………………………………………………………………………………………………………………. 76
4. Install NEW cylinder head gaskets in position over the locator pins………………………………………………………………………………………………………………………………………………………………………. 76
5. Install the cylinder head onto the cylinder block. Guide the cylinder head carefully into position over the locator pins and the cylinder head gasket……………………………………………………………………………………………… 77
6. Apply sealant 1141570 or equivalent to the threads of the cylinder head bolts……………………………………………………………………………………………………………………………………………………………… 77
7. Install the cylinder head bolts finger tight…………………………………………………………………………………………………………………………………………………………………………………………… 77
Tighten:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 77
1. First step, 30 N.m (22 ft. lb.)………………………………………………………………………………………………………………………………………………………………………………………………………. 77
2. Final step use special tool J 36660 and tighten as follows;……………………………………………………………………………………………………………………………………………………………………………… 77
a. Tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the final step sequence to 75 degrees………………………………………………………………………………………………………………………………………………. 77
b. Tighten the middle length bolts (14 and 17) on the final step sequence to 65 degrees……………………………………………………………………………………………………………………………………………………. 77
c. Tighten the short length bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the final step sequence to 55 degrees…………………………………………………………………………………………………………………………………… 77
3. Install New spark plugs adjusted to the proper gap……………………………………………………………………………………………………………………………………………………………………………………… 77
4. Install Rocker Arm Cover. See Rocker Arm Cover on page 54……………………………………………………………………………………………………………………………………………………………………………….. 77
Oil Pan and OIl Pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 78
1. Drain oil from engine. See Draining The Engine on page 33………………………………………………………………………………………………………………………………………………………………………………………. 78
2. Remove engine from boat. See Removal and Installation Workshop Manual……………………………………………………………………………………………………………………………………………………………………………. 78
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 78
3. Disconnect and remove the dipstick tube . Discard the O-rings (1) and seals (2)……………………………………………………………………………………………………………………………………………………………….. 78
4. Remove the oil pan bolts and nuts………………………………………………………………………………………………………………………………………………………………………………………………………… 78
5. Remove the oil pan……………………………………………………………………………………………………………………………………………………………………………………………………………………… 78
6. Remove and discard the oil pan gasket…………………………………………………………………………………………………………………………………………………………………………………………………….. 79
Oil Pan Clean and Inspect……………………………………………………………………………………………………………………………………………………………………………………………………………………… 79
1. Clean the oil pan baffle in cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………………. 79
2. Dry the oil pan and the oil pan baffle with compressed air………………………………………………………………………………………………………………………………………………………………………………….. 79
3. Inspect the oil………………………………………………………………………………………………………………………………………………………………………………………………………………………… 79
Oil Pump Removal………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 80
1. Remove the nuts (6) and the crankshaft oil deflector (2)………………………………………………………………………………………………………………………………………………………………………………… 80
2. Remove the oil pump bolt (1)…………………………………………………………………………………………………………………………………………………………………………………………………………. 80
3. Remove the oil pump (3), the oil pump driveshaft (5) and the oil pump driveshaft retainer (4)……………………………………………………………………………………………………………………………………………….. 80
4. Separate the oil pump (3), the oil pump driveshaft (5) and the oil pump driveshaft retainer (4)……………………………………………………………………………………………………………………………………………… 80
5. Discard the oil pump driveshaft retainer………………………………………………………………………………………………………………………………………………………………………………………………. 80
6. Inspect the pins (oil pump locator) for damage, and replace if required…………………………………………………………………………………………………………………………………………………………………… 80
Oil Pump Disassemble………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 81
1. Remove the oil pump driveshaft and retainer……………………………………………………………………………………………………………………………………………………………………………………………….. 81
2. Remove oil pump screen (if necessary)…………………………………………………………………………………………………………………………………………………………………………………………………….. 81
3. Remove the oil pump cover bolts………………………………………………………………………………………………………………………………………………………………………………………………………….. 81
4. Remove the oil pump cover……………………………………………………………………………………………………………………………………………………………………………………………………………….. 82
5. Remove the oil pump drive gear and the oil pump driven gear…………………………………………………………………………………………………………………………………………………………………………………. 82
6. Match mark the gears for reassembly………………………………………………………………………………………………………………………………………………………………………………………………………. 82
7. Remove the oil pressure relief valve retaining pin (1)……………………………………………………………………………………………………………………………………………………………………………………… 82
8. Remove the oil pressure relief spring (2)…………………………………………………………………………………………………………………………………………………………………………………………………. 82
9. Remove the oil pump pressure relief valve (3)……………………………………………………………………………………………………………………………………………………………………………………………… 82
Oil Pump Clean and Inspect…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 82
1. Clean the oil pump components in cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………….. 82
2. Dry the components with compressed air……………………………………………………………………………………………………………………………………………………………………………………………………. 82
3. Inspect the oil pump for the following conditions:…………………………………………………………………………………………………………………………………………………………………………………………. 82
4. If the oil pump is to be reused, install a NEW oil pump pressure relief valve spring…………………………………………………………………………………………………………………………………………………………… 83
5. During oil pump installation, install a NEW oil pump driveshaft retainer……………………………………………………………………………………………………………………………………………………………………… 83
Oil Pump Assemble…………………………………………………………………………………………………………………………………………………………………………………………………………………………. 83
1. Apply clean engine oil GM P/N 12345610 or equivalent to the oil pump pressure relief valve, oil pump pressure relief valve spring and oil pump body……………………………………………………………………………………………….. 83
2. Install the following items:…………………………………………………………………………………………………………………………………………………………………………………………………………. 83
a. The oil pump pressure relief valve………………………………………………………………………………………………………………………………………………………………………………………………… 83
b. The oil pump pressure relief valve spring………………………………………………………………………………………………………………………………………………………………………………………….. 83
c. The oil pump pressure relief valve spring straight pin………………………………………………………………………………………………………………………………………………………………………………. 83
3. Apply clean engine oil GM P/N 12345610 or equivalent to the oil pump drive gear, the oil pump driven gear and the oil pump body internal surfaces…………………………………………………………………………………………………. 83
4. Install the oil pump drive gear and the oil pump driven gear into the oil pump body………………………………………………………………………………………………………………………………………………………… 83
a. Align the match marks on the oil pump drive and driven gears…………………………………………………………………………………………………………………………………………………………………………. 83
b. Install the smooth side of the oil pump drive and driven gears toward the oil pump cover………………………………………………………………………………………………………………………………………………… 83
5. Install the pump cover………………………………………………………………………………………………………………………………………………………………………………………………………………. 84
6. Install the oil pump cover bolts. Tighten the bolts to 12 N.m (106 lb. in)………………………………………………………………………………………………………………………………………………………………… 84
7. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand…………………………………………………………………………………………………………………………………………………. 84
8. Install the oil pump screen………………………………………………………………………………………………………………………………………………………………………………………………………….. 84
a. If removed, replace the oil pump screen……………………………………………………………………………………………………………………………………………………………………………………………. 84
b. The oil pump screen must have a good press fit into the oil pump body…………………………………………………………………………………………………………………………………………………………………. 84
c. Mount the oil pump in a soft jawed vise……………………………………………………………………………………………………………………………………………………………………………………………. 84
d. Apply sealant 1141570 or equivalent to the end of the oil pump screen pipe…………………………………………………………………………………………………………………………………………………………….. 84
e. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body…………………………………………………………………………………………………………………………………………… 84
9. The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed…………………………………………………………………………………………………………………………………………. 84
Oil Pump, Pump Screen and Deflector Installation……………………………………………………………………………………………………………………………………………………………………………………………… 84
1. Inspect for properly installed pins (oil pump locator)………………………………………………………………………………………………………………………………………………………………………………….. 84
2. Assemble the oil pump (3), the oil pump driveshaft (5) and a NEW oil pump driveshaft retainer (4)……………………………………………………………………………………………………………………………………………. 85
3. Install the oil pump (3). Position the oil pump onto the pins……………………………………………………………………………………………………………………………………………………………………………. 85
4. Install the crankshaft oil deflector (2) and the nuts (6)……………………………………………………………………………………………………………………………………………………………………………….. 85
5. Install the bolt (1) attaching the oil pump to the rear crankshaft bearing cap…………………………………………………………………………………………………………………………………………………………….. 85
Tighten………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 85
Oil Pan Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………. 85
1. Install the oil pan studs into the engine block if removed………………………………………………………………………………………………………………………………………………………………………………. 85
Tighten………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 85
2. Tighten the oil pan studs to 6 N.m (53 lb. in)……………………………………………………………………………………………………………………………………………………………………………………… 85
3. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive Volvo Penta P/N 1161277 or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces………………………… 86
4. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive Volvo Penta P/N 1161277 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces……………. 86
5. Install the NEW oil pan gasket into the groove in the oil pan………………………………………………………………………………………………………………………………………………………………………… 86
6. Install the oil pan onto the engine block………………………………………………………………………………………………………………………………………………………………………………………….. 87
7. Slide the oil pan back against a suitable straight edge……………………………………………………………………………………………………………………………………………………………………………… 87
8. Using new seals and O-rings, install the dipstick tube. Tighten bolt to 25 N.m (18 ft. lb.)……………………………………………………………………………………………………………………………………………… 87
Water Pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 88
GXi…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 88
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 88
1. Release tension on the bent tensioner and remove the serpentine belt from the water pump pulley…………………………………………………………………………………………………………………………………………………. 88
2. Remove the bolts and the water pump pulley using the J41240 or suitable substitute…………………………………………………………………………………………………………………………………………………………….. 88
3. Remove the water pump bolts……………………………………………………………………………………………………………………………………………………………………………………………………………… 88
4. Remove the water pump…………………………………………………………………………………………………………………………………………………………………………………………………………………… 88
5. Remove and discard the water pump gaskets…………………………………………………………………………………………………………………………………………………………………………………………………. 88
Inspection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 88
Installation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 89
1. If reusing the fasteners, apply sealant 1141570 or equivalent to the threads of the water pump bolts…………………………………………………………………………………………………………………………………………….. 89
2. Clean any residual gasket material from cooling ports on the engine. If reusing the circulation pump, clean any residual gasket material from the face of the mounting ports…………………………………………………………………………….. 89
3. Install the water pump and the NEW water pump gaskets………………………………………………………………………………………………………………………………………………………………………………………. 89
4. Install the water pump bolts and tighten to 45 N.m (33 lb. ft.)……………………………………………………………………………………………………………………………………………………………………………… 89
5. Install the fan and water pump pulley and bolts using the J41240 or suitable substitute………………………………………………………………………………………………………………………………………………………… 89
6. Tighten the and water pump pulley bolts to 25 N.m (18 lb. ft.)………………………………………………………………………………………………………………………………………………………………………………. 89
7. Release the belt tensioner and reinstall the serpentine belt………………………………………………………………………………………………………………………………………………………………………………… 89
GL………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 90
Remove…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 90
1. Loosen power steering pump nut……………………………………………………………………………………………………………………………………………………………………………………………………….. 90
2. Loosen power steering pump bolt………………………………………………………………………………………………………………………………………………………………………………………………………. 90
3. Loosen power steering pump pivot nut………………………………………………………………………………………………………………………………………………………………………………………………….. 90
4. Pull up on power steering pump belt to loosen belt tension and remove the belt…………………………………………………………………………………………………………………………………………………………….. 90
5. Loosen alternator pivot bolt…………………………………………………………………………………………………………………………………………………………………………………………………………. 91
6. Loosen alternator belt tension bolt…………………………………………………………………………………………………………………………………………………………………………………………………… 91
7. Pull on alternator belt to loosen the alternator and remove the belt……………………………………………………………………………………………………………………………………………………………………… 91
8. Remove the bolts and the fan and water pump pulley using the J41240………………………………………………………………………………………………………………………………………………………………………. 91
9. Remove the water pump bolts………………………………………………………………………………………………………………………………………………………………………………………………………….. 91
10. Remove the water pump………………………………………………………………………………………………………………………………………………………………………………………………………………. 91
11. Remove the water pump gaskets……………………………………………………………………………………………………………………………………………………………………………………………………….. 91
12. Discard the water pump gaskets………………………………………………………………………………………………………………………………………………………………………………………………………. 91
Water Pump Installation……………………………………………………………………………………………………………………………………………………………………………………………………………………….. 92
1. If reusing the fasteners, apply sealant 1141570 or equivalent to the threads of the water pump bolts…………………………………………………………………………………………………………………………………………….. 92
2. Install the water pump and the NEW water pump gaskets………………………………………………………………………………………………………………………………………………………………………………………. 92
3. Install the water pump bolts. Tighten the water pump bolts to 45 N.m (33 lb. ft.)……………………………………………………………………………………………………………………………………………………………… 92
4. Install the fan and water pump pulley and bolts using the J41240. Tighten the fan and water pump pulley bolts to 25 N.m (18 lb. ft.)………………………………………………………………………………………………………………… 92
5. Install Alternator belt…………………………………………………………………………………………………………………………………………………………………………………………………………………. 92
6. Tighten alternator belt to 33,6 ± 2,7 N (75 ± 10 lb.) or 6,4 mm (¹ in.) deflection with light pressure on belt. Check belt tension midway between the water pump pulley and the alternator pulley (2)………………………………………………………. 92
7. Install power steering pump belt…………………………………………………………………………………………………………………………………………………………………………………………………………. 92
8. Tighten power steering belt to 33,6 ± 2,7 N (75 ± 10 lb.) or 6,4 mm (¹ in.) deflection with light pressure on belt. Check belt tension midway between the water pump pulley and the power steering pump pulley (1)…………………………………………… 92
Crankshaft Balancer………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 93
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 93
1. Disconnect hoses from raw water pump……………………………………………………………………………………………………………………………………………………………………………………………………… 93
2. Remove raw water pump retaining bolts and remove the pump…………………………………………………………………………………………………………………………………………………………………………………… 93
3. Remove water pump stay bracket…………………………………………………………………………………………………………………………………………………………………………………………………………… 93
4. Remove the crankshaft balancer bolt and washer…………………………………………………………………………………………………………………………………………………………………………………………….. 94
5. Use the J23523-F in order to remove the crankshaft balancer…………………………………………………………………………………………………………………………………………………………………………………. 94
a. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten the bolts to 25 N.m (18 lb. ft.)………………………………………………………………………………………………………………………………….. 94
b. Install the J 23523-F forcing screw into the plate……………………………………………………………………………………………………………………………………………………………………………………… 94
c. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer…………………………………………………………………………………………………………………………………………………….. 94
6. Remove the J23523-F from the crankshaft balancer…………………………………………………………………………………………………………………………………………………………………………………………… 94
Crankshaft Balancer Inspect……………………………………………………………………………………………………………………………………………………………………………………………………………………. 94
1. Clean the crankshaft balancer in cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………….. 94
2. Dry the crankshaft balancer with compressed air……………………………………………………………………………………………………………………………………………………………………………………………. 94
3. Inspect the crankshaft balancer for the following:…………………………………………………………………………………………………………………………………………………………………………………………. 94
Crankshaft Balancer Installation……………………………………………………………………………………………………………………………………………………………………………………………………………….. 94
1. Apply a small amount of adhesive Volvo Penta P/N 1161277 or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint………………………………………………………………………….. 95
2. Align the keyway of the crankshaft balancer with the crankshaft balancer key………………………………………………………………………………………………………………………………………………………………….. 95
3. Install the crankshaft balancer onto the end of the crankshaft………………………………………………………………………………………………………………………………………………………………………………. 95
4. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft……………………………………………………………………………………………………………………………………………………………….. 95
a. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten the J23523-F plate bolts to 25 N.m (18 lb. ft.)…………………………………………………………………………………………………………. 95
b. Install the J 23523-F screw into the end for the crankshaft……………………………………………………………………………………………………………………………………………………………………………… 95
c. Install the J 23523-F bearing, the washer and the nut onto the J 23523-F screw…………………………………………………………………………………………………………………………………………………………….. 95
d. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring……………………………………………………………………………………………………. 95
5. Remove the J23523-F…………………………………………………………………………………………………………………………………………………………………………………………………………………….. 95
6. Install the balancer bolt, lock washer, and centering washer. Tighten the balancer bolt to 58 N.m (43 lb. ft.)……………………………………………………………………………………………………………………………………. 95
7. Install the water pump stay bracket………………………………………………………………………………………………………………………………………………………………………………………………………. 96
8. Install raw water pump and pulley. Tighten bolts to 33-39 N.m (25-29 ft. lb.)…………………………………………………………………………………………………………………………………………………………………. 96
9. Install water pump retaining bracket……………………………………………………………………………………………………………………………………………………………………………………………………… 96
10. Install water hoses in the correct orientation and tighten clamps…………………………………………………………………………………………………………………………………………………………………………… 96
Engine Front Cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 96
Removal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 97
1. Remove the crankshaft position sensor bolt………………………………………………………………………………………………………………………………………………………………………………………………… 97
2. Remove the crankshaft position sensor…………………………………………………………………………………………………………………………………………………………………………………………………….. 97
3. Remove and discard the crankshaft position sensor seal (O- ring)…………………………………………………………………………………………………………………………………………………………………………….. 97
4. Remove engine front cover bolts and front cover……………………………………………………………………………………………………………………………………………………………………………………………. 97
Engine Front Cover Installation………………………………………………………………………………………………………………………………………………………………………………………………………………… 98
1. Install the NEW engine front cover……………………………………………………………………………………………………………………………………………………………………………………………………….. 98
2. Install the engine front cover bolts and tighten to 12 N.m (106 lb. in)………………………………………………………………………………………………………………………………………………………………………. 98
3. Lubricate the NEW crankshaft position sensor seal (O-ring) with clean engine oil………………………………………………………………………………………………………………………………………………………………. 98
4. Install the NEW crankshaft position sensor seal (O-ring) onto the crankshaft position sensor……………………………………………………………………………………………………………………………………………………. 98
5. Install the crankshaft position sensor until fully seated into the engine front cover………………………………………………………………………………………………………………………………………………………….. 98
6. Install the crankshaft position sensor bolt and tighten to 9 N.m (80 lb. in)………………………………………………………………………………………………………………………………………………………………….. 98
7. Install oil pan, Oil Pan and OIl Pump on page 74 ………………………………………………………………………………………………………………………………………………………………………………………….. 98
8. Install crankshaft balancer, Crankshaft Balancer on page 89 ………………………………………………………………………………………………………………………………………………………………………………… 98
9. Install engine circulation pump, Water Pump on page 84 …………………………………………………………………………………………………………………………………………………………………………………….. 98
10. Install engine in boat, see Engine Removal and Installation Workshop Manual………………………………………………………………………………………………………………………………………………………………….. 98
Timing Chain and Sprocket……………………………………………………………………………………………………………………………………………………………………………………………………………………… 98
Removal………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 98
1. Remove engine front cover. See Engine Front Cover on page 92…………………………………………………………………………………………………………………………………………………………………………….. 99
2. Remove the crankshaft position sensor reluctor ring…………………………………………………………………………………………………………………………………………………………………………………….. 99
3. Check the camshaft timing chain free play……………………………………………………………………………………………………………………………………………………………………………………………… 99
a. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2)……………………………………………………………………………………………………………………………. 99
b. Measure the free play on the slack side (3) of the camshaft timing chain. If the camshaft timing chain can be moved side to side in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly….. 99
4. Remove the camshaft sprocket bolts……………………………………………………………………………………………………………………………………………………………………………………………………. 99
5. Remove the camshaft sprocket and the camshaft timing chain………………………………………………………………………………………………………………………………………………………………………………. 99
6. Remove the crankshaft sprocket using the J 5825-A……………………………………………………………………………………………………………………………………………………………………………………….100
7. Remove the crankshaft balancer key…………………………………………………………………………………………………………………………………………………………………………………………………….100
Inspection………………………………………………………………………………………………………………………………………………………………………………………………………………………………..100
1. Clean the components with cleaning solvent……………………………………………………………………………………………………………………………………………………………………………………………..100
2. Dry the components with compressed air…………………………………………………………………………………………………………………………………………………………………………………………………100
3. Inspect the camshaft timing chain for binding or wear……………………………………………………………………………………………………………………………………………………………………………………100
4. Inspect the camshaft sprocket and the crankshaft sprocket for the following:……………………………………………………………………………………………………………………………………………………………….101
5. Inspect the crankshaft balancer key (1), the keyway (2) and the threaded hole (3) for damage…………………………………………………………………………………………………………………………………………………101
6. Repair or replace the crankshaft as necessary…………………………………………………………………………………………………………………………………………………………………………………………..101
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………101
1. Install the crankshaft balancer key into the crankshaft keyway……………………………………………………………………………………………………………………………………………………………………………101
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key……………………………………………………………………………………………………………………………………………………………….102
3. Use the J 5590 to install the crankshaft sprocket……………………………………………………………………………………………………………………………………………………………………………………….102
4. Rotate the crankshaft until the crankshaft sprocket is at the 12 o’clock position…………………………………………………………………………………………………………………………………………………………..102
5. Install the camshaft sprocket and the camshaft timing chain………………………………………………………………………………………………………………………………………………………………………………102
6. Install the camshaft sprocket bolts and tighten to 25 N.m (18 lb. ft.)…………………………………………………………………………………………………………………………………………………………………….102
7. Install the camshaft sprocket with the alignment mark at the 6 o’clock position…………………………………………………………………………………………………………………………………………………………….102
8. Install the crankshaft position sensor reluctor ring…………………………………………………………………………………………………………………………………………………………………………………….103
a. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft…………………………………………………………………………………………………………………………103
b. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket………………………………………………………………………………………..103
9. Install front cover. See Engine Front Cover on page 92…………………………………………………………………………………………………………………………………………………………………………………..103
Camshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………103
Remove……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….103
1. Remove timing chain and sprockets, Timing Chain and Sprocket on page 94 ………………………………………………………………………………………………………………………………………………………………………103
2. Remove intake manifold, Intake Manifold on page 41………………………………………………………………………………………………………………………………………………………………………………………….103
3. Remove valve lifters, Valve Train on page 54……………………………………………………………………………………………………………………………………………………………………………………………….103
4. Remove the camshaft retainer bolts and retainer…………………………………………………………………………………………………………………………………………………………………………………………….103
5. Remove the engine camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………….103
a. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes………………………………………………………………………………………………………………………………………………………..103
b. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings……………………………………………………………………………………………………………………………………….103
c. Remove the bolts from the front of the engine camshaft…………………………………………………………………………………………………………………………………………………………………………………..103
Inspect………………………………………………………………………………………………………………………………………………………………………………………………………………………………………103
1. Clean the engine camshaft in cleaning solvent………………………………………………………………………………………………………………………………………………………………………………………………103
2. Dry the engine camshaft with compressed air………………………………………………………………………………………………………………………………………………………………………………………………..104
3. Inspect the camshaft retainer plate for damage……………………………………………………………………………………………………………………………………………………………………………………………..104
4. Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores………………………………………………………………………………………………………………………………………………………104
5. Inspect the camshaft bearings for excessive wear or scoring………………………………………………………………………………………………………………………………………………………………………………….104
6. Inspect the engine camshaft for the following:……………………………………………………………………………………………………………………………………………………………………………………………..104
7. Measure the engine camshaft journals with a micrometer………………………………………………………………………………………………………………………………………………………………………………………104
8. Measure for a bent engine camshaft or excessive engine camshaft run-out using the J 7872………………………………………………………………………………………………………………………………………………………..104
a. Mount the engine camshaft in a suitable stand between centers…………………………………………………………………………………………………………………………………………………………………………….104
b. Use the J 7872 in order to check the intermediate engine camshaft journals…………………………………………………………………………………………………………………………………………………………………104
9. Measure the engine camshaft lobe lift using the J 7872………………………………………………………………………………………………………………………………………………………………………………………104
a. Place the engine camshaft on the V-blocks………………………………………………………………………………………………………………………………………………………………………………………………104
b. Use the J 7872 in order to measure the engine camshaft lobe lift………………………………………………………………………………………………………………………………………………………………………….104
10. Replace the engine camshaft if the engine camshaft lobe lift is not within specifications. Refer to Engine Mechanical Specifications………………………………………………………………………………………………………………..104
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………….105
1. Apply clean engine oil GM P/N 12345610 or equivalent, or engine oil supplement GM P/N 1052367 or equivalent to the following components:……………………………………………………………………………………………………………..105
2. Install three 5/16-18 x 4.0 in. bolts into the engine camshaft front bolt holes………………………………………………………………………………………………………………………………………………………………..105
3. Use the bolts as a handle in order to install the engine camshaft…………………………………………………………………………………………………………………………………………………………………………….105
4. Remove the 3 bolts from the front of the engine camshaft…………………………………………………………………………………………………………………………………………………………………………………….105
5. Install the timing chain and sprockets, See Timing Chain and Sprocket on page 94……………………………………………………………………………………………………………………………………………………………….105
6. Install the valve lifters, Valve Train on page 54 ………………………………………………………………………………………………………………………………………………………………………………………….105
7. Install the intake manifold, See Intake Manifold on page 41………………………………………………………………………………………………………………………………………………………………………………….105
Camshaft Bearings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………105
Remove……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….105
1. Remove camshaft, See Camshaft on page 99…………………………………………………………………………………………………………………………………………………………………………………………………..105
2. Select the cone (1), the handle (10), the expanding driver (4-8), the washer (2 or 3) and the expander assembly (15) from the J 33049………………………………………………………………………………………………………………..105
3. Assemble the J 33049…………………………………………………………………………………………………………………………………………………………………………………………………………………….105
4. Remove the camshaft inner bearings #2, #3 and #4……………………………………………………………………………………………………………………………………………………………………………………………106
a. Insert the J 33049 through the front of the engine block and into the camshaft inner bearing #2………………………………………………………………………………………………………………………………………………106
b. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….106
c. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049……………………………………………………………………………………………………………………………………………………106
d. Drive the camshaft inner bearing #2 from the camshaft inner bearing bore #2………………………………………………………………………………………………………………………………………………………………..106
e. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….106
f. Remove the camshaft inner bearing #2 from the J 33049 expander assembly……………………………………………………………………………………………………………………………………………………………………106
g. Insert the J 33049 expander assembly into the camshaft inner bearing #3……………………………………………………………………………………………………………………………………………………………………106
h. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….106
i. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049……………………………………………………………………………………………………………………………………………………106
j. Drive the camshaft inner bearing #3 from the camshaft inner bearing bore #3………………………………………………………………………………………………………………………………………………………………..106
k. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….106
l. Remove the camshaft inner bearing #3 from the J 33049 expander assembly……………………………………………………………………………………………………………………………………………………………………106
m. Insert the J 33049 expander assembly into the camshaft inner bearing #4……………………………………………………………………………………………………………………………………………………………………106
n. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….106
o. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049……………………………………………………………………………………………………………………………………………………106
p. Drive the camshaft inner bearing #4 from the camshaft inner bearing bore #4………………………………………………………………………………………………………………………………………………………………..106
q. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….106
r. Remove the camshaft inner bearing #4 from the J 33049 expander assembly……………………………………………………………………………………………………………………………………………………………………106
5. Remove the J 33049 from the engine block…………………………………………………………………………………………………………………………………………………………………………………………………..106
6. Remove the camshaft outer bearings #1 and #5……………………………………………………………………………………………………………………………………………………………………………………………….107
a. Insert the J 33049 into the camshaft outer bearing #1……………………………………………………………………………………………………………………………………………………………………………………107
b. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….107
c. Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1………………………………………………………………………………………………………………………………………………………………..107
d. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….107
e. Remove the camshaft outer bearing #1 from the J 33049 expander assembly……………………………………………………………………………………………………………………………………………………………………107
f. Remove the J 33049 from the engine block……………………………………………………………………………………………………………………………………………………………………………………………….107
g. Insert the J 33049 expander assembly into the camshaft outer bearing #5……………………………………………………………………………………………………………………………………………………………………107
h. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….107
i. Drive the camshaft outer bearing #5 from the camshaft outer bearing bore #5………………………………………………………………………………………………………………………………………………………………..107
j. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….107
k. Remove the camshaft outer bearing #5 from the J 33049 expander assembly……………………………………………………………………………………………………………………………………………………………………107
7. Remove the J 33049 from the engine block…………………………………………………………………………………………………………………………………………………………………………………………………..107
8. Discard the camshaft bearings…………………………………………………………………………………………………………………………………………………………………………………………………………….107
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………….107
1. Select the handle (10), the expanding driver (4-8), the washer (2 or 3) and the expander assembly (15) from the J 33049…………………………………………………………………………………………………………………………….107
2. Assemble the J 33049…………………………………………………………………………………………………………………………………………………………………………………………………………………….107
3. Install the NEW camshaft outer bearings #5 and #1…………………………………………………………………………………………………………………………………………………………………………………………..108
a. Install the NEW camshaft outer bearing #4 onto the J33049 expander assembly………………………………………………………………………………………………………………………………………………………………..108
b. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….108
c. Align the camshaft outer bearing #5 lubrication hole with the oil gallery hole in the camshaft outer bearing bore #5 at the rear of the engine block……………………………………………………………………………………………….108
d. Drive the camshaft outer bearing #5 into the camshaft outer bearing bore #5 at the rear of the engine block……………………………………………………………………………………………………………………………………108
e. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….108
f. Remove the camshaft outer bearing #5 from the J33049 expander assembly…………………………………………………………………………………………………………………………………………………………………….108
g. Install the NEW camshaft outer bearing #1 onto the J33049 expander assembly………………………………………………………………………………………………………………………………………………………………..108
h. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….108
i. Align the camshaft outer bearing #1 lubrication hole with the oil gallery hole in the camshaft outer bearing bore #1 at the front of the engine block………………………………………………………………………………………………108
j. Drive the camshaft outer bearing #1 into the camshaft outer bearing bore #1 at the front of the engine block…………………………………………………………………………………………………………………………………..108
k. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….108
l. Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #3 and the camshaft inner bearing bore #4………………………………………………………………….108
4. Install the NEW camshaft inner bearings #4, #3 and #2……………………………………………………………………………………………………………………………………………………………………………………….108
a. Install the NEW camshaft inner bearing #4 onto the J33049 expander assembly………………………………………………………………………………………………………………………………………………………………..108
b. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….108
c. Align the camshaft inner bearing #4 lubrication hole with the oil gallery hole in the camshaft inner bearing bore #4 of the engine block………………………………………………………………………………………………………….108
d. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049…………………………………………………………………………………………………………………………………………….108
e. Drive the camshaft inner bearing #4 into the camshaft inner bearing bore #4………………………………………………………………………………………………………………………………………………………………..108
f. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….108
g. Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #3 and the camshaft inner bearing bore #2……………………………………………………………………………………..109
h. Install the NEW camshaft inner bearing #3 onto the J33049 expander assembly………………………………………………………………………………………………………………………………………………………………..109
i. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….109
j. Align the camshaft inner bearing #3 lubrication hole with the oil gallery hole in the camshaft inner bearing bore #3 of the engine block………………………………………………………………………………………………………….109
k. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049…………………………………………………………………………………………………………………………………………….109
l. Drive the camshaft inner bearing #3 into the camshaft inner bearing bore #3………………………………………………………………………………………………………………………………………………………………..109
m. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….109
n. Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #2 and the camshaft outer bearing bore #1……………………………………………………………………………………..109
o. Install the NEW camshaft inner bearing #2 onto the J33049 expander assembly………………………………………………………………………………………………………………………………………………………………..109
p. Tighten the J 33049 expander assembly nut until snug…………………………………………………………………………………………………………………………………………………………………………………….109
q. Align the camshaft inner bearing #2 lubrication hole with the oil gallery hole in the camshaft inner bearing bore #2 of the engine block………………………………………………………………………………………………………….109
r. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049…………………………………………………………………………………………………………………………………………….109
s. Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2………………………………………………………………………………………………………………………………………………………………..109
t. Loosen the J 33049 expander assembly nut……………………………………………………………………………………………………………………………………………………………………………………………….109
5. Install camshaft, See Camshaft on page 99………………………………………………………………………………………………………………………………………………………………………………………………….109
Piston, Connecting Rod, and Bearings………………………………………………………………………………………………………………………………………………………………………………………………………………..109
1. Remove engine from boat. See Removal and Installation Workshop Manual…………………………………………………………………………………………………………………………………………………………………………….109
2. Remove cylinder heads. See Cylinder Head on page 60…………………………………………………………………………………………………………………………………………………………………………………………….109
3. Remove oil pan. See Oil Pan and OIl Pump on page 74…………………………………………………………………………………………………………………………………………………………………………………………….109
4. Use the J 24270 in order to remove the cylinder ring ridge………………………………………………………………………………………………………………………………………………………………………………………110
a. Turn the crankshaft until the piston is at the bottom of the stroke…………………………………………………………………………………………………………………………………………………………………………..110
b. Place a cloth on top of the piston………………………………………………………………………………………………………………………………………………………………………………………………………..110
c. Use the J 24270 to remove all of the cylinder ring ridge…………………………………………………………………………………………………………………………………………………………………………………….110
d. Turn the crankshaft so the piston is at the top of the stroke………………………………………………………………………………………………………………………………………………………………………………..110
e. Remove the cloth………………………………………………………………………………………………………………………………………………………………………………………………………………………..110
f. Remove the cutting debris………………………………………………………………………………………………………………………………………………………………………………………………………………..110
5. Remove the connecting rod nuts……………………………………………………………………………………………………………………………………………………………………………………………………………….110
6. Remove the connecting rod cap………………………………………………………………………………………………………………………………………………………………………………………………………………..110
7. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block……………………………………………………………………………………………………………….110
8. Remove the connecting rod bearings……………………………………………………………………………………………………………………………………………………………………………………………………………111
a. Keep the connecting rod bearings with the original connecting rod and connecting rod cap………………………………………………………………………………………………………………………………………………………..111
b. Wipe the oil from the connecting rod bearings………………………………………………………………………………………………………………………………………………………………………………………………111
c. Wipe the oil from the crankpin……………………………………………………………………………………………………………………………………………………………………………………………………………111
Piston and Connecting Rod Disassemble……………………………………………………………………………………………………………………………………………………………………………………………………………111
1. Remove the piston rings from the pistons…………………………………………………………………………………………………………………………………………………………………………………………………..111
2. Press the piston pin from the connecting rod using the J 24086- C…………………………………………………………………………………………………………………………………………………………………………….112
3. The piston pin has an interference fit into the connecting rod, and is full floating in the piston……………………………………………………………………………………………………………………………………………….112
4. Mark separate, and organize the parts for assembly………………………………………………………………………………………………………………………………………………………………………………………….112
Clean and Inspect……………………………………………………………………………………………………………………………………………………………………………………………………………………………..112
1. Clean the piston and connecting rod in solvent……………………………………………………………………………………………………………………………………………………………………………………………..112
2. Dry the components with compressed air…………………………………………………………………………………………………………………………………………………………………………………………………….112
3. Clean the piston oil lubrication holes and slots……………………………………………………………………………………………………………………………………………………………………………………………113
4. Inspect the piston for the following:……………………………………………………………………………………………………………………………………………………………………………………………………..113
5. Inspect the piston pin for scoring, wear or other damage…………………………………………………………………………………………………………………………………………………………………………………….113
6. Measure the piston ring-to-piston ring groove side clearance…………………………………………………………………………………………………………………………………………………………………………………113
d. Insert the edge of the piston ring into the piston ring groove……………………………………………………………………………………………………………………………………………………………………………113
e. Roll the piston ring completely around the piston……………………………………………………………………………………………………………………………………………………………………………………….113
7. Measure the piston ring side clearance with a feeler gauge…………………………………………………………………………………………………………………………………………………………………………………..113
8. If the side clearance is too small, try another piston ring set………………………………………………………………………………………………………………………………………………………………………………113
9. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly………………………………………………………………………………………………………………………………….113
10. To determine the proper piston ring side clearance, Engine Specifications 5.0 Litre on page 139 ………………………………………………………………………………………………………………………………………………..113
11. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin…………………………………………………………………………………………………………………………………………………………113
12. To determine piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore……………………………………………………………………………………………………………………………………………..114
13. To determine the piston pin-to-bore clearance, subtract the piston pin diameter from the piston pin bore diameter. Engine Specifications 5.0 Litre on page 139…………………………………………………………………………………………114
14. Measure the piston with a micrometer at a right angle to the piston pin bore, measure the piston at 11 mm (0.433 in) from the bottom of the skirt. Engine Specifications 5.0 Litre on page 139 ……………………………………………………………114
15. If the piston is not within specifications, replace the piston and pin as an assembly………………………………………………………………………………………………………………………………………………………….114
16. Inspect the connecting rod for an out-of-round bearing bore. Engine Specifications 5.0 Litre on page 139 ………………………………………………………………………………………………………………………………………..114
17. Inspect the connecting rod for twisting…………………………………………………………………………………………………………………………………………………………………………………………………..115
18. Inspect the connecting rod for damage to the bearing cap and bolt threads…………………………………………………………………………………………………………………………………………………………………….115
19. Measure the piston compression ring end gap……………………………………………………………………………………………………………………………………………………………………………………………….115
20. Place the compression ring into the cylinder bore………………………………………………………………………………………………………………………………………………………………………………………….115
a. Push the compression ring into the cylinder bore to approximately 6.5 mm (0.25 in) above the ring travel. The ring must be square to the cylinder wall……………………………………………………………………………………………..115
b. Use a feeler gauge in order to measure the end gap………………………………………………………………………………………………………………………………………………………………………………………115
c. Select another size ring set if the end gap exceeds specifications. Engine Specifications 5.0 Litre on page 139 ……………………………………………………………………………………………………………………………….115
Piston Selection………………………………………………………………………………………………………………………………………………………………………………………………………………………………115
1. Use the J 8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore and 90 degrees to the crankshaft centerline……………………………………………………………………………115
2. Measure the J 8087 with a micrometer and record the reading………………………………………………………………………………………………………………………………………………………………………………….116
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt……………………………………………………………………………………………………………….116
4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. Engine Specifications 5.0 Litre on page 139 ………………………………………………………………………………………………116
5. If the proper clearance cannot be obtained, then select another piston and measure the clearances………………………………………………………………………………………………………………………………………………..116
6. If the proper fit cannot be obtained, the cylinder bore may require honing or boring……………………………………………………………………………………………………………………………………………………………116
7. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder………………………………………………………………………………………………….116
Piston and Connecting Rod Assemble…………………………………………………………………………………………………………………………………………………………………………………………………………..116
1. Install the piston pin and connecting rod assembly………………………………………………………………………………………………………………………………………………………………………………………116
a. Lubricate the piston pin bores with clean engine oil…………………………………………………………………………………………………………………………………………………………………………………117
b. Use a torch and apply MILD heat to the piston pin end of the connecting rod…………………………………………………………………………………………………………………………………………………………….117
c. Use the J 24086-C in order to press the piston pin into the piston and connecting rod assembly……………………………………………………………………………………………………………………………………………117
d. Inspect for the proper installation of the piston and piston pin. The piston must move freely on the piston pin with no binding or interference………………………………………………………………………………………………..117
2. Install the piston rings onto the piston……………………………………………………………………………………………………………………………………………………………………………………………….117
a. Install the oil control piston ring spacer………………………………………………………………………………………………………………………………………………………………………………………….117
b. Install the lower oil control piston ring…………………………………………………………………………………………………………………………………………………………………………………………..117
c. Install the upper oil control piston ring…………………………………………………………………………………………………………………………………………………………………………………………..117
d. Install the lower compression piston ring…………………………………………………………………………………………………………………………………………………………………………………………..117
e. Install the upper compression piston ring…………………………………………………………………………………………………………………………………………………………………………………………..117
3. Space the compression piston ring end gaps 120 degrees apart……………………………………………………………………………………………………………………………………………………………………………..117
4. Space the oil control piston ring end gaps a minimum of 90 degrees apart…………………………………………………………………………………………………………………………………………………………………..117
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………118
1. Apply clean engine oil to the following components:……………………………………………………………………………………………………………………………………………………………………………………..118
2. Install the J 5239 onto the connecting rod bolts………………………………………………………………………………………………………………………………………………………………………………………..118
3. Install the J 8037 onto the piston and compress the piston rings………………………………………………………………………………………………………………………………………………………………………….118
4. Install the piston and connecting rod assembly, with the J 8037 into the proper cylinder bore………………………………………………………………………………………………………………………………………………..118
5. Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle………………………………………………………………………………………………………………………………………………119
a. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore……………………………………………………………………………………………………………………………….119
b. Use the J 5239 in order to guide the connecting rod onto the crankshaft journal…………………………………………………………………………………………………………………………………………………………119
6. Remove the J 5239……………………………………………………………………………………………………………………………………………………………………………………………………………………119
7. Install the connecting rod caps, bearings and nuts………………………………………………………………………………………………………………………………………………………………………………………119
a. Tighten the nuts evenly on the first pass to 27 N.m (20 ft. lb.)………………………………………………………………………………………………………………………………………………………………………119
b. Use the J 36660 or an equivalent angle torque meter to tighten the nuts on the final pass an additional 70 degrees………………………………………………………………………………………………………………………….119
8. After the piston and connecting rod assemblies have been installed, then lightly tap each connecting rod assembly (parallel to the crank pin) in order to ensure that the connecting rods have side clearance…………………………………………….120
9. Use a feeler gauge or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15-0.44 mm (0.006- 0.017 in)…………………………………………………………120
10. Install oil pan, Oil Pan and OIl Pump on page 74……………………………………………………………………………………………………………………………………………………………………………………….120
11. Install cylinder heads, Cylinder Head on page 60 ………………………………………………………………………………………………………………………………………………………………………………………120
12. Install engine in boat, Engine Specifications 5.0 Litre on page 139………………………………………………………………………………………………………………………………………………………………………120
Engine Coupler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………120
Removal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………120
1. Remove engine from boat, Engine Specifications 5.0 Litre on page 139 …………………………………………………………………………………………………………………………………………………………………………120
2. Take out screws holding flywheel housing cover, then slide out cover………………………………………………………………………………………………………………………………………………………………………….120
3. Remove nut, lock washer, and ground leads from ground stud and coil bracket. Remove inner nut, lock washer and washer………………………………………………………………………………………………………………………………120
4. Remove nut, lock washer, and ground leads from ground stud and power steering cooler bolt……………………………………………………………………………………………………………………………………………………….121
5. Unscrew remaining flywheel housing bolts, lock washers and washers. Note position of clamps so they can be installed in original position…………………………………………………………………………………………………………….121
6. Lift flywheel housing off engine block and set aside………………………………………………………………………………………………………………………………………………………………………………………..121
7. Unscrew six locknuts, then pull coupler off flywheel………………………………………………………………………………………………………………………………………………………………………………………..121
Inspection……………………………………………………………………………………………………………………………………………………………………………………………………………………………………121
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………….122
1. Slide coupler onto crankshaft studs. Install new locknuts……………………………………………………………………………………………………………………………………………………………………………………122
2. Tighten nuts in sequence. Use a crowfoot wrench and tighten nuts to 40-45 ft. lb. (54-61 N.m)……………………………………………………………………………………………………………………………………………………122
3. Install flywheel housing. Place clamps in their original positions, and attache coil bracket and power steering cooler. Tighten screws to 38-49 N.m (28-36 ft. lb.)……………………………………………………………………………………..122
4. Place washer, lock washer and nut on ground stud. Tighten inner nut to 47-54 N.m (35-40 ft. lb.) Attach electrical leads to ground stud. Install lock washer and tighten outer nut securely. Install ground stud hardware on opposite side of block………………122
5. Slide flywheel cover into place. Install screws and tighten them to 7-9 N.m (60-84 in. lb.)……………………………………………………………………………………………………………………………………………………..123
6. Install engine, see Engine Installation and Removal Workshop Manual…………………………………………………………………………………………………………………………………………………………………………..123
Flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………123
Removal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………123
1. Engine coupler, Engine Coupler on page 116…………………………………………………………………………………………………………………………………………………………………………………………………123
2. Remove flywheel from crankshaft studs……………………………………………………………………………………………………………………………………………………………………………………………………..123
3. Note the position of any flywheel weights for assembly (if applicable)………………………………………………………………………………………………………………………………………………………………………..123
Inspection……………………………………………………………………………………………………………………………………………………………………………………………………………………………………124
4. Inspect the engine flywheel for the following:……………………………………………………………………………………………………………………………………………………………………………………………..124
5. The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel…………………………………………………………………………………………124
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………….124
6. Install flywheel on crankshaft studs………………………………………………………………………………………………………………………………………………………………………………………………………124
7. Install engine coupler, Engine Coupler on page 116 …………………………………………………………………………………………………………………………………………………………………………………………124
Crankshaft Rear Oil Seal and Housing………………………………………………………………………………………………………………………………………………………………………………………………………………..124
Remove……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….124
1. Remove engine from boat. See Engine Removal and Installation Workshop Manual…………………………………………………………………………………………………………………………………………………………………..124
2. Remove engine coupler, See Engine Coupler on page 116……………………………………………………………………………………………………………………………………………………………………………………….124
3. Remove flywheel, See Flywheel on page 119………………………………………………………………………………………………………………………………………………………………………………………………….124
4. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing………………………………………………………………………………………………………………………………………………………………….124
5. Discard the crankshaft rear oil seal………………………………………………………………………………………………………………………………………………………………………………………………………124
6. Remove the crankshaft rear oil seal housing nut and bolts……………………………………………………………………………………………………………………………………………………………………………………125
7. Remove the crankshaft rear oil seal housing………………………………………………………………………………………………………………………………………………………………………………………………..125
8. Remove the crankshaft rear oil seal housing gasket………………………………………………………………………………………………………………………………………………………………………………………….125
9. Discard the crankshaft rear oil seal housing gasket…………………………………………………………………………………………………………………………………………………………………………………………125
10. If necessary, remove the spring type pin………………………………………………………………………………………………………………………………………………………………………………………………….125
Installation………………………………………………………………………………………………………………………………………………………………………………………………………………………………….125
1. Install the crankshaft rear oil seal housing retainer stud and tighten to 6 N.m (53 lb. in)……………………………………………………………………………………………………………………………………………………..125
2. Install the NEW crankshaft rear oil seal housing gasket……………………………………………………………………………………………………………………………………………………………………………………..125
3. Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud……………………………………………………………………………………………………………………………………………..126
4. Install the crankshaft rear oil seal housing nut and bolts. Tighten nut and bolts to 12 N.m (106 lb. in)………………………………………………………………………………………………………………………………………….126
5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing……………………………………………………………………………………………………………………………………….126
6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange………………………………………………………………………………………………………………………………..126
7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin…………………………………………………………………………………………………………………………………………….126
8. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface………………………………………………………………………………………………………………………………………………………….126
9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal……………………………………………………………………………………………………………………………………………………..126
10. Remove the sleeve from the crankshaft rear oil seal………………………………………………………………………………………………………………………………………………………………………………………..126
11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal…………………………………………………………………………………………………………………………………..126
12. Install the crankshaft rear oil seal onto the J 35621-B…………………………………………………………………………………………………………………………………………………………………………………….126
13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug………………………………………………………………………………………………………………………………………………..126
14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing…………………………………………………………………………………………………………………………………………..126
a. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing……………………………………………………………………………………………..126
b. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal……………………………………………………………………………………………………………………………………….126
15. Remove the J 35621-B from the crankshaft………………………………………………………………………………………………………………………………………………………………………………………………….126
16. Wipe off any excess engine oil with a clean rag……………………………………………………………………………………………………………………………………………………………………………………………126
17. Install oil pan if removed. See Oil Pan and OIl Pump on page 74……………………………………………………………………………………………………………………………………………………………………………..126
18. Install flywheel. See Flywheel on page 119………………………………………………………………………………………………………………………………………………………………………………………………..127
19. Install engine coupler. See Engine Coupler on page 116……………………………………………………………………………………………………………………………………………………………………………………..127
20. Install engine in boat. See Engine Specifications 5.0 Litre on page 139………………………………………………………………………………………………………………………………………………………………………127
Crankshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….127
Remove……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….127
1. Remove engine from boat. See Removal and Installation Workshop Manual…………………………………………………………………………………………………………………………………………………………………………127
2. Remove cylinder heads. See Cylinder Head on page 60…………………………………………………………………………………………………………………………………………………………………………………………127
3. Remove oil pan. See Oil Pan and OIl Pump on page 74…………………………………………………………………………………………………………………………………………………………………………………………127
4. Remove pistons and connecting rods. See Piston, Connecting Rod, and Bearings on page 105………………………………………………………………………………………………………………………………………………………..127
5. Remove timing chain and sprocket. See Timing Chain and Sprocket on page 94…………………………………………………………………………………………………………………………………………………………………….127
6. Remove starter. See Starter on page 39…………………………………………………………………………………………………………………………………………………………………………………………………….127
7. Remove engine coupler. See Engine Coupler on page 116……………………………………………………………………………………………………………………………………………………………………………………….127
8. Mark or identify the crankshaft bearing cap locations, direction and positions for assembly……………………………………………………………………………………………………………………………………………………..127
9. Remove the crankshaft bearing cap bolts……………………………………………………………………………………………………………………………………………………………………………………………………127
10. Remove the crankshaft bearing caps……………………………………………………………………………………………………………………………………………………………………………………………………….127
11. Remove the crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………..127
12. Remove the crankshaft bearings from the crankshaft bearing caps……………………………………………………………………………………………………………………………………………………………………………..128
13. Remove the crankshaft bearings from the engine block……………………………………………………………………………………………………………………………………………………………………………………….128
Crankshaft and Bearings Clean and Inspect………………………………………………………………………………………………………………………………………………………………………………………………………..128
1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages………………………………………………………………………………………………………………………………………………..128
2. Dry the crankshaft with compressed air…………………………………………………………………………………………………………………………………………………………………………………………………….128
3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth…………………………………………………………………………………………………………………………………………..128
4. Dry the crankshaft bearings with compressed air…………………………………………………………………………………………………………………………………………………………………………………………….128
5. Inspect the crankshaft for the following:………………………………………………………………………………………………………………………………………………………………………………………………….129
6. Inspect the crankshaft balancer key (1), the keyway (2) and the threaded hole (3) for damage. Repair or replace the crankshaft as necessary…………………………………………………………………………………………………………..129
7. Measure the crank pins for out-of-round and taper. Engine Specifications 5.0 Litre on page 139 ………………………………………………………………………………………………………………………………………………….129
8. Use a suitable support to support the crankshaft on the front and rear journals………………………………………………………………………………………………………………………………………………………………..129
9. Use the J 7872 in order to measure the crankshaft journal run out. The crankshaft run out should not exceed 0.025 mm (0.0010 in)…………………………………………………………………………………………………………………….129
10. Measure the crankshaft end play………………………………………………………………………………………………………………………………………………………………………………………………………….130
a. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance. Refer to Engine Mechanical Specifications…………………………………………………………..130
b. If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed. Engine Specifications 5.0 Litre on page 139 ………………………………………………………………………………………..130
c. Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one bearing cap at a time, until the tight crankshaft bearing is located…………………130
11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue…………………………………………………………………………………………………………………..130
12. Inspect the crankshaft bearings for excessive scoring or discoloration……………………………………………………………………………………………………………………………………………………………………….130
13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material………………………………………………………………………………………………………………………………………………..130
14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings…………………………………………………………………………………………………………………………….131
Bearing Clearance Measuring Procedures…………………………………………………………………………………………………………………………………………………………………………………………………………..131
Micrometer Method for Crankshaft Bearings………………………………………………………………………………………………………………………………………………………………………………………………………..131
1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements………………………………………………………………………………………………………..131
2. Determine the taper and the out-of-round of the crankshaft journal. See Engine Specifications 5.0 Litre on page 139………………………………………………………………………………………………………………………………..131
3. Install the crankshaft bearings into the engine block……………………………………………………………………………………………………………………………………………………………………………………….131
4. Install the crankshaft bearings into the crankshaft bearing caps……………………………………………………………………………………………………………………………………………………………………………..132
5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block……………………………………………………………………………………….132
6. Install the crankshaft bearing cap bolts…………………………………………………………………………………………………………………………………………………………………………………………………..132
a. Tighten the crankshaft bearing cap bolts and the crankshaft bearing cap studs on the first pass to 20 N.m (15 lb. ft.)………………………………………………………………………………………………………………………….132
b. Tighten the crankshaft bearing cap bolts and the crankshaft bearing cap studs on the final pass an additional 73 degrees using the J 36660 angle torque meter……………………………………………………………………………………….132
7. Measure the bearing inside diameter (ID) at two points 90 degrees apart. Average the measurements………………………………………………………………………………………………………………………………………………..132
8. In order to determine the bearing clearance, subtract the average journal diameter from the average bearing inside diameter…………………………………………………………………………………………………………………………132
9. Compare the crankshaft bearing clearance to the specifications. See Engine Specifications 5.0 Litre on page 139……………………………………………………………………………………………………………………………………132
10. If the crankshaft bearing clearances exceeds specifications, install the new crankshaft bearings as follows:……………………………………………………………………………………………………………………………………..132
a. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer………………………………………………………………………………………………………………………………………132
b. Compare the crankshaft bearing clearance to the specifications. See Engine Specifications 5.0 Litre on page 139………………………………………………………………………………………………………………………………..132
11. Replace or repair the crankshaft if the proper clearances cannot be obtained………………………………………………………………………………………………………………………………………………………………….132
Measuring Crankshaft Bearing Clearances (Plastic Gauge Method)………………………………………………………………………………………………………………………………………………………………………………….132
1. Install the crankshaft bearings into the engine block……………………………………………………………………………………………………………………………………………………………………………………132
2. Install the crankshaft……………………………………………………………………………………………………………………………………………………………………………………………………………….133
3. Install the gauging plastic the full width of the journal………………………………………………………………………………………………………………………………………………………………………………..133
4. Install the crankshaft bearings into the crankshaft bearing caps………………………………………………………………………………………………………………………………………………………………………….133
5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block……………………………………………………………………………………134
6. Install the crankshaft bearing cap bolts……………………………………………………………………………………………………………………………………………………………………………………………….134
a. Tighten the crankshaft bearing cap bolts on the first pass to 20 N.m (15 lb. ft.)……………………………………………………………………………………………………………………………………………………….134
b. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660……………………………………………………………………………………………………………………………………..134
7. Remove the crankshaft bearing cap bolts………………………………………………………………………………………………………………………………………………………………………………………………..134
8. Remove the crankshaft bearing caps. The gauging plastic may adhere to either the crankshaft-bearing journal or the crankshaft-bearing surface……………………………………………………………………………………………………..134
9. Without removing the gauging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope………………………………………………………………………………………..134
10. Remove the flattened gauging plastic………………………………………………………………………………………………………………………………………………………………………………………………….134
11. Measure the remaining crankshaft bearing journals………………………………………………………………………………………………………………………………………………………………………………………134
Crankshaft and Bearings Installation…………………………………………………………………………………………………………………………………………………………………………………………………………135
1. Install the crankshaft bearings into the engine block……………………………………………………………………………………………………………………………………………………………………………………135
2. Apply clean engine oil to the crankshaft bearings……………………………………………………………………………………………………………………………………………………………………………………….135
3. Apply clean engine oil to the crankshaft bearing journals………………………………………………………………………………………………………………………………………………………………………………..135
4. Install the crankshaft……………………………………………………………………………………………………………………………………………………………………………………………………………….135
5. Install the crankshaft bearings into the crankshaft bearing caps………………………………………………………………………………………………………………………………………………………………………….135
6. Apply clean engine oil to the crankshaft bearings……………………………………………………………………………………………………………………………………………………………………………………….135
7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block…………………………………………………………………………………….136
8. Install the crankshaft bearing cap bolts and the crankshaft bearing cap studs………………………………………………………………………………………………………………………………………………………………136
9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps…………………………………………………………………………………………………………………………136
10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings…………………………………………………………………………………………………………………………………………….136
11. Look to ensure that the crankshaft bearing caps are fully seated in the engine block crankshaft bearing cap channel and that the crankshaft bearing caps are centered on the engine block bulkheads…………………………………………………….136
12. Tighten the crankshaft bearing cap bolts………………………………………………………………………………………………………………………………………………………………………………………………136
a. Tighten the crankshaft bearing cap bolts on the first pass to 20 N.m (15 lb. ft.)……………………………………………………………………………………………………………………………………………………….136
b. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660……………………………………………………………………………………………………………………………………..136
13. Measure the crankshaft end play………………………………………………………………………………………………………………………………………………………………………………………………………136
a. Firmly thrust the crankshaft rearward, and then forward………………………………………………………………………………………………………………………………………………………………………………136
b. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance. Crankshaft end play 0.05-0.20 mm (0.002-0.008 in)…………………………………………..136
14. Rotate the crankshaft in order to check for binding…………………………………………………………………………………………………………………………………………………………………………………….136
15. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding……………………………………………………………………………..136
16. Install pistons and connecting rods. See Piston, Connecting Rod, and Bearings on page 105…………………………………………………………………………………………………………………………………………………..136
17. Install cylinder heads. See Cylinder Head on page 60……………………………………………………………………………………………………………………………………………………………………………………136
18. Install intake manifold. See Intake Manifold on page 41…………………………………………………………………………………………………………………………………………………………………………………136
19. Install oil pan. See Oil Pan and OIl Pump on page 74……………………………………………………………………………………………………………………………………………………………………………………136
20. Install timing chain and sprocket. See Timing Chain and Sprocket on page 94……………………………………………………………………………………………………………………………………………………………….136
21. Install flywheel. See Flywheel on page 119…………………………………………………………………………………………………………………………………………………………………………………………….137
22. Install engine coupler. See Engine Coupler on page 116………………………………………………………………………………………………………………………………………………………………………………….137
23. Install starter. See Starter on page 39……………………………………………………………………………………………………………………………………………………………………………………………….137
24. Install engine in boat. See Removal and Installation Workshop Manual……………………………………………………………………………………………………………………………………………………………………..137
Recondition Engine Block…………………………………………………………………………………………………………………………………………………………………………………………………………………………..137
Engine Block Plug……………………………………………………………………………………………………………………………………………………………………………………………………………………………..137
Removal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..137
1. Remove the engine oil pressure sensor and fitting……………………………………………………………………………………………………………………………………………………………………………………….137
2. Remove the dowel straight pins (if required)……………………………………………………………………………………………………………………………………………………………………………………………137
3. Remove the S type pin………………………………………………………………………………………………………………………………………………………………………………………………………………..137
4. Remove the square socket plugs (engine block oil gallery) from the rear of the engine block………………………………………………………………………………………………………………………………………………….138
5. Remove the left side rear and left rear top engine block oil gallery plugs…………………………………………………………………………………………………………………………………………………………………138
6. Remove the expansion cup plug (camshaft rear bearing hole) and discard…………………………………………………………………………………………………………………………………………………………………….138
7. Remove the engine block oil gallery plugs (front) from the engine block and discard…………………………………………………………………………………………………………………………………………………………138
8. Remove the spring type S pin (crankshaft rear oil seal housing locator if required)…………………………………………………………………………………………………………………………………………………………139
9. Remove the engine block core hole plugs………………………………………………………………………………………………………………………………………………………………………………………………..139
a. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket……………………………………………………………………………………………………………………………………………139
b. Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket…………………………………………………………………………………………………………………………………………….139
c. Discard the engine block core hole plugs……………………………………………………………………………………………………………………………………………………………………………………………139
Engine Block Clean and inspect………………………………………………………………………………………………………………………………………………………………………………………………………………….140
1. Clean all the remaining sealing or gasket material from the sealing surfaces…………………………………………………………………………………………………………………………………………………………………..140
2. Clean the engine block with cleaning solvent……………………………………………………………………………………………………………………………………………………………………………………………….140
3. Flush the engine block with clean water or steam……………………………………………………………………………………………………………………………………………………………………………………………140
4. Clean the cylinder bores…………………………………………………………………………………………………………………………………………………………………………………………………………………140
5. Clean the oil galleries and the oil passages……………………………………………………………………………………………………………………………………………………………………………………………….140
6. Clean the scale and the deposits from the coolant passages…………………………………………………………………………………………………………………………………………………………………………………..140
7. Clean the engine block cylinder head bolt holes…………………………………………………………………………………………………………………………………………………………………………………………….140
8. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil………………………………………………………………………………………………………………………………….140
9. Inspect the following areas:……………………………………………………………………………………………………………………………………………………………………………………………………………..140
10. Measure the cylinder bores for taper and out-of-round………………………………………………………………………………………………………………………………………………………………………………………141
a. Depress the plunger on the J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore……………………………………………………………………………………………………………………………………………….141
b. Center the J 8087 in the cylinder bore and turn the indicator dial to 0……………………………………………………………………………………………………………………………………………………………………141
c. Move the J 8087 up and down the cylinder bore to determine the cylinder bore taper. See Engine Specifications 5.0 Litre on page 139………………………………………………………………………………………………………………141
d. Turn the J 8087 to different points around the cylinder bore to determine the cylinder bore out-of-round condition. Engine Specifications 5.0 Litre on page 139……………………………………………………………………………………..141
Cylinder Boring and Honing……………………………………………………………………………………………………………………………………………………………………………………………………………………..141
Honing Procedure…………………………………………………………………………………………………………………………………………………………………………………………………………………………..141
1. When honing the cylinder bores, follow the manufacturer’s recommendations for equipment use, cleaning and lubrication…………………………………………………………………………………………………………………………..141
2. During the honing operation, thoroughly check the cylinder bore…………………………………………………………………………………………………………………………………………………………………………..141
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore…………………………………………………………………………………………………………………………………141
4. Repeatedly check the measurement at the top, the middle and the bottom of the cylinder bore………………………………………………………………………………………………………………………………………………….141
5. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined………………………………………………………………..141
6. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements………………………………………………………………………………………………………………….141
7. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent…………………………………………………………………………………………………………………………..141
a. Scrub the cylinder bores with a stiff bristle brush………………………………………………………………………………………………………………………………………………………………………………….142
b. Rinse the cylinder bores thoroughly with clean hot water……………………………………………………………………………………………………………………………………………………………………………..142
c. Dry the cylinder bores with a clean rag…………………………………………………………………………………………………………………………………………………………………………………………….142
d. Do not allow any abrasive material to remain in the cylinder bores…………………………………………………………………………………………………………………………………………………………………….142
8. Perform final measurements of the piston and the cylinder bore……………………………………………………………………………………………………………………………………………………………………………142
9. Permanently mark the top of the piston for the specified cylinder to which it has been fitted………………………………………………………………………………………………………………………………………………..142
10. Apply clean engine oil to each cylinder bore in order to prevent rusting………………………………………………………………………………………………………………………………………………………………….142
Boring Procedure………………………………………………………………………………………………………………………………………………………………………………………………………………………………142
1. Before starting the honing or boring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline…………………………………………………………………………………..142
2. Thoroughly clean the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar…………………………………………………………………………………………………………………………….142
3. Follow the instructions furnished by the manufacturer regarding the use of the boring equipment………………………………………………………………………………………………………………………………………………….142
4. When boring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction…………………………………………………………………………………………………………………………..142
5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly………………………………………………………………………………………………………142
6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This……………………………………………………………………………………………………………………….142
Engine Specifications 5.0 Litre…………………………………………………………………………………………………………………………………………………………………………………………………………………….143
Engine Mechanical Specifications 5.0 litre……………………………………………………………………………………………………………………………………………………………………………………………………….143
Engine Specifications 5.7 Litre…………………………………………………………………………………………………………………………………………………………………………………………………………………….147
Engine Mechanical Specifications 5.7 litre……………………………………………………………………………………………………………………………………………………………………………………………………….147
Fastener Tightening Specifications………………………………………………………………………………………………………………………………………………………………………………………………………………….151
Fastener Tightening Specifications………………………………………………………………………………………………………………………………………………………………………………………………………………151
Sealants, Adhesives and Lubricants………………………………………………………………………………………………………………………………………………………………………………………………………………….154
Sealants, Adhesives and Lubricants………………………………………………………………………………………………………………………………………………………………………………………………………………154
Tune Up Specifications…………………………………………………………………………………………………………………………………………………………………………………………………………………………….154
Tune Up Specifications 5.0GL, 5.7GL……………………………………………………………………………………………………………………………………………………………………………………………………………..154
Tune Up Specifications 5.0GXi, 5.0OSi, 5.7Gi, 5.7OSi, 5.7GXi, 5.7OSXi……………………………………………………………………………………………………………………………………………………………………………….155
Special Tools…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
J 3049-A……………………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
Valve Lifter Remover…………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
J 7872……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Magnetic Base Dial Indicator……………………………………………………………………………………………………………………………………………………………………………………………………………………156
J 5239……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Connecting Rod Bolt Guide Set…………………………………………………………………………………………………………………………………………………………………………………………………………………..156
J 8001……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Dial Indicator………………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
J 5590……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Crankshaft Gear Installer………………………………………………………………………………………………………………………………………………………………………………………………………………………156
J 8037……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Piston Ring Compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………156
J 5825-A……………………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
Crankshaft Gear Remover………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
J 8062……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
Valve spring compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………..156
(head off the engine)………………………………………………………………………………………………………………………………………………………………………………………………………………………….156
J 5830-02…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Valve Guide Reamer Set…………………………………………………………………………………………………………………………………………………………………………………………………………………………157
J 8087……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Cylinder Bore Gauge……………………………………………………………………………………………………………………………………………………………………………………………………………………………157
J 8089……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Carbon removing brush………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
J 24086-C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Piston Pin Remover/Installer Set………………………………………………………………………………………………………………………………………………………………………………………………………………..157
J 9666……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Valve Spring Tester……………………………………………………………………………………………………………………………………………………………………………………………………………………………157
J 24270………………………………………………………………………………………………………………………………………………………………………………………………………………………………………157
Ridge Reamer………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
J 21882………………………………………………………………………………………………………………………………………………………………………………………………………………………………………157
Oil Suction Pipe Installer……………………………………………………………………………………………………………………………………………………………………………………………………………………..157
J 33049………………………………………………………………………………………………………………………………………………………………………………………………………………………………………157
Camshaft Bearing………………………………………………………………………………………………………………………………………………………………………………………………………………………………157
Service Kit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..157
J 23523-F…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Balancer Remover and Installer………………………………………………………………………………………………………………………………………………………………………………………………………………….157
J 35621-B…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….157
Crankshaft Rear Oil Seal Installer………………………………………………………………………………………………………………………………………………………………………………………………………………157
J 36660………………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
Electronic Torque……………………………………………………………………………………………………………………………………………………………………………………………………………………………..158
Angle Meter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..158
J 8520……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….158
Camshaft Lobe Lift Indicator……………………………………………………………………………………………………………………………………………………………………………………………………………………158
J 5802-01…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….158
Rocker Arm Stud Remover………………………………………………………………………………………………………………………………………………………………………………………………………………………..158
J 41240………………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
Fan Clutch Remover and…………………………………………………………………………………………………………………………………………………………………………………………………………………………158
Installer…………………………………………………………………………………………………………………………………………………………………………………………………………………………………….158
J 42073………………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
Valve Stem Seal Installer………………………………………………………………………………………………………………………………………………………………………………………………………………………158
J 23738-A Vacuum pump………………………………………………………………………………………………………………………………………………………………………………………………………………………….158
J 6880……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….158
Rocker Arm Stud Installer………………………………………………………………………………………………………………………………………………………………………………………………………………………158
o……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
J 28428-E…………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
High Intensity Black……………………………………………………………………………………………………………………………………………………………………………………………………………………….158
Light Kit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………158
J 38606…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..159
Valve spring compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………….159
(head on the engine)……………………………………………………………………………………………………………………………………………………………………………………………………………………….159
J 35468…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..159
Engine Front Cover Aligner and Oil Seal Installer……………………………………………………………………………………………………………………………………………………………………………………………..159
J 3936-03…………………………………………………………………………………………………………………………………………………………………………………………………………………………………159
Piston Ring Groove Cleaner………………………………………………………………………………………………………………………………………………………………………………………………………………….159
J 5892-D………………………………………………………………………………………………………………………………………………………………………………………………………………………………….159
Valve Spring Compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………….159
J 5715 or J 6036…………………………………………………………………………………………………………………………………………………………………………………………………………………………..159
Reamer……………………………………………………………………………………………………………………………………………………………………………………………………………………………………159
J 22794…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..159
Spark Plug Port Adapter…………………………………………………………………………………………………………………………………………………………………………………………………………………….159
Volvo Penta Special Tool……………………………………………………………………………………………………………………………………………………………………………………………………………………159
888863……………………………………………………………………………………………………………………………………………………………………………………………………………………………………159
Distributor hold down tool………………………………………………………………………………………………………………………………………………………………………………………………………………….159
J 43276…………………………………………………………………………………………………………………………………………………………………………………………………………………………………..159
Clutch Pilot Bearing……………………………………………………………………………………………………………………………………………………………………………………………………………………….159
Remover……………………………………………………………………………………………………………………………………………………………………………………………………