Volvo Penta LK Models Engine Components Workshop Manual (432112593) - PDF DOWNLOAD

Safety

Warning

This Workshop ManualwUl alert you to certain proceduresthat must be donevery carefully, if you ignore this information, you could... ® injure yourself or peoplearoundyou ® Injure the boat operator, boat passengers,or people around the boat ® Damagethe Volvo Penta product or its systems Understandthe following symbols before proceeding: Safety Warning

Alerts you to the possibility of dangerand identifies informationthat will help preventinjuries.

Identifies informationthat will help prevent damageto machinery.

Appearsnext to information that controas correct assemblyand operation of the product.

This WorkshopManualis written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools.

This WorkshopManual tells you how to correctly maintain and service Volvo Penta products and systems. Whencorrectly serviced, the Volvo Penta product will be reliable and safe to operate.

WhenVolvo Penta special tools are called for, use them.

Wherementioned, the tools are required to perform the service procedure. if you use service proceduresor service tools that are not recommendedin this manual YOUALONEmust decide if your actions might injure people or damagethe Volvo Penta product.

General information

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

General Engine Mechanical - V6 and V8 Models ...........

3o0GS Engine ..........................................

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

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

5.7GSi Engines .......................................

7.4GL, Gi, GSi and 8.2 GSi Engines .....................

Steering

Systems .....................................

Throttle

and Shift

Control Systems ......................

Cooling Systems ......................................

Engine Removal and installation

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

Safety ................................................

© 1997 Volvo Penta of the Americas, Inc. All Rights reserved I-’ngme/eng

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This workshop manualis oneof a set of eight that coversVolvoPenta sterndrivemodels.All eight bookscanbe orderedas a set fromVolvoPenta Parts. OrderP/N7797360-0.

Individual workshop manuals coveringthesemodelsare also available. Order the following part numbers fromVolvoPentaParts. + P/N 7797361+8 Engine Components IncJudesinformationon Engineserviceandtroubleshooting;Engineremoval andinstallation; Steeringsystems;Throttle andShift Controlsystems;and Coolingsystems. +P/N 7797362-6 Electrical

& Ignition

System

Includesserviceandtroubleshootinginformationon Crankingsystems; Charging systems;Trim/Tilt electrical systems;Ignition systems;andEngine andInstrumentwiring diagrams. +P/N 7797363-4 Fuel System Includesserviceandtroubleshooting informationon all carburetor,MFIand TBI fuel systemsandrelated components. ° P/N 7797364-2 EFI Diagnostic Manual GM Containstroubleshooting procedures for air ElectronicFuel Injected GM modelsand related components. *P/N 7797365+9 PJX WaterJet Containsserviceinformationfor repair andoverhaulof the waterjetsystem. e P/N7797366-7 DPX- Workshop Manual Includesspecific informationfor repair andoverhaulof the DPX Sterndrive andXactTM steering systems. ,P/N 7797367-5 SX and DP-S Sterndrives and Transom Shield Includes information on Transom Shield, UpperGearUnit andLowerGear Unit service;DriveUnit removam andinstallation; Propellers;andTrim/Tilt hydraulicoperation. +P/N 7797368-3 SP and DP Workshop Manual includesUpperGearUnit andLowerGearUnit overhaulprocedures,installation andremoval.

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This Volvo Penta WorkshopManual CoversThe FoflowingVo0voPenta "LK" IViodels Engine 3.0 LmTER

4°3 LITER

30GSMLKD 30GSPLKD

3868646 3868647

7,4 LITER

43GLPLKD 43GSPLKD 43GiPLKDCE

3868618 3868619 3868620

5.7 UTER

74GLPLKD 74GiPLKDCE 74GSiPLKD

3868626 3868627 3868742

8.2 LITER

57GLPLKD 57GLPLKR 57GSPLKD 57GLiPLKDCE 57GiPLKDCE 57GSiPLKD 57GSiCPLKD

3868621 3868699 3868598 3868732 3868623 3868624 3868686

DP-S DP-S DP-S DP-S DP-S1 DP-S1 DP-S1 DP-S1

3868163 3868164 3868165 3868166 3868601 3868602 3868603 3868604

82GSiPLKD

3888743

TransomShield SX-Cl SX-CLT1 SX-ClAC SX-C2AC

3868404 3868432 3868515 3868820

Sterndrive SX-Cl SX-C1 SX-C1 SX-C1 SX-CT1 SX-RT1 SX-RT2 SX-C2 SXoC2 SX-C2 SX-C2 SX-C1 SX=RT1 SX-RT2

1.43:1 1.51:1 1.60:1 1.66:1 1.97:1 1.66:1 1.66:1 1.41:1 1.51:1 1.60:1 1.68:1 1.85:1 2.18:1 2.18:1

3868392 3868393 3868394 3868395 3868397 3868398 3888587 3868581 3868582 3868583 3868584 3868465 3868333 3868588

2.30:1 1.95:1 1.78:1 1.68:1 2:30:1 1.95:1 1.78:1 1.68:1

Jet Drive pJXoC PJX-Cl

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3868694 i 3868694

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DPX-S1 DPX-S1 DPX-S1

1.59:1 1.68:1 1.78:1

3868637 3868638 3868639

~®

¯

~

J

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B= -

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r-N0~ All sterndrive systems must be matchedfor either single or dual engineinstallations. Failure to properly matchengine, transombracket and sterndrive witl result in poor boat performance,and risk or damage to the engineandor drive becauseof incorrect drive gear ratio.

The model identification is located on the engine valve cover, and MUST correspondwith the transombracket and sterndrive numbersas listed in this document. ¯ Engine Model Number r~ [~ E~]

DRll4!

= Transom Bracket Model Number [~ ¯

Sterndrive Model Number

DR4282 7"

V I DR494,4

DR2058

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DR4957 Engmeseng

Section 1 General information Table of Contents Battery Cable Requirements ..................................

Belt Adjustments Alternator .................................................

Power Steering ............................................

Supply Pump..............................................

Belt Tension ...............................................

Compression Pressure Limit Chart ..............................

Conversion Charts Drill ......................................................

Metric ....................................................

Crankcase Oil ...............................................

Engine Break-in ..............................................

Engine Compression Testing ....................................

Engine Troubleshooting Guides ................................

Gasolines Containing Alcohol ..................................

Gasoline Requirements ....................................... intake Manifold VacuumTesting .................................

Introduction ..................................................

Volvo Penta Dealer Service - 20-Hour Check .......................

Off-Season Storage Preparations ................................

Oil Filter .....................................................

Periodic Maintenance Chart ...................................

Power Steering Fluid Level ....................................

PowerTrim/Tiit Fluid Level ......................................

Preparation for Boating After Storage ...........................

Steering System Lubrication ...................................

Submerged Engine ...........................................

Symbols ....................................................

Torque Specifications, General .................................

Troubleshooting - System isolation .............................

Tune-up Specifications ........................................

Tuning the Engine .............................................

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

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1 -39 1-25 1-26 f-25 1-24 1-7 1-41 1-40 1-11 1=21 1-5 1-28 1-10 1=10 1-8 1-2 1-23 1-13 1-12 1-43 1-13 1-13 1-20 1-13 1-23 %42 1-39 1-27 1-35 1=5

introduction This service manualcovers Volvo PentaSterndrive models.It is divided into sections concerning various systemsand assemblies. Refer to the Contents to locate the section covering the systemor assemblyrequiring service.

Eachsection title pagehasan additional listing that will describethe section’s contentsin moredetail. Besure to read the Safety Sectionat the end of this manual,and pay special attention to all safety warningsas they appearthroughoutthe text. Since modelsare subject to changeat any time, somephotos maynot depict actual product.

GoodService Practice Service required for Volvo PentaSterndrivesis generally one of three ki rids: Normal care andmaintenance - which includes putting a newstern drive into operation, storing engines,lubrication, and care under special operating conditions suchas salt water and cold weather.

Operatingmalfunctions- due to improper engine or drive mounting,propeller condition or size, boat condition, or the malfunctionof somepart of the engine. This includes engineservicing proceduresto keep the engine in prime operating condition. .

CompletedisassernbRyand overhaul - such as major service or rebuilding a unit.

It is important to determinebefore disassembJy just whatthe trouble is and howto correct it quickly, with minimum expenseto the owner.

Whenrepairing an assembly,the most reliable wayto ensure a goodjob is to do a completeoverhaulon that assembly,rather than just to replace the bad part. Wearnot readily apparenton other parts could cause malfunction soonafter the repair job. Repairkits andseal kits containall the parts neededto ensure a completerepair, to eliminate guesswork,and to save time.

Repair time can also be minimizedby the use of special tools. Volvo Penta specia~tools are designedto perform service proceduresuniqueto the product that cannotbe completedusing tools from other sources. Theyalso speedrepair workto help achieveservice flat rate times. In somecases,the use of substitute tools can damage the part. ~Do not operate engine out of water even momentarily. If operatedin test tank, use proper test wheel. Failure to do so can damage supply pump,overheat engine, or allow excessive engine RPM.

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Preparationfor Service Properpreparationis extremelyhelpful for efficient service work. A clean work area at the start of eachjob will minimizetools and parts becoming misplaced.Cleanan enginethat is excessivelydirty before workstarts.

Cleaningwill occasionally uncovertrouble sources.Obtain tools, instrumentsand parts neededfor the job before workis started. Interrupting a job to locate special too{s or repair kits is a needlessdelay.

Z~Useproper lifting and handling equipment. Workingon sterndrives without proper equipmentcan cause damageand personal injury.

Alwaysuse clean fresh fuel whentesting engines. Troublescan often be tracedto the useof old or dirty fuel.

Service Policy Whetherwithin or following the warranty period, Volvo Pentahas a constant interest in their products. nt is an VolvoPentapolicy to provide dealers with service knowledgeso they can give professional service demanded by today’s consumer.Volvo Penta Training Centers, Service Bulletins, Letters and Promotions,Special Tools and this Service Manualrepresentthe latest VolvoPentaeffort to assist dealers in giving consumersthe best and most promptservice possible.

This Service Manualcovers all phasesof servicing the Volvo PentaSterndrive unit. If a service questiondoesnot appearto be answered in this manual,you are invited to write or call the Volvo PentaService Department for additional help. Alwaysbe sure to havecompleteinformation available, including engine modelnumberand serial number.

Besure that you are familiar with the VolvoPentaWarranty.If you have any questions, write the Volvo PentaService Department.If other than genuine Volvo Penta replacementcomponentsor parts are used, Volvo Penta may refuse subsequentwarranty c~aimsinvolving that engine.

Whena brand-name product or specific tool is called for, anotheritem may be used. However,the substitute must haveequivalent characteristics, including type, strength, and material. Youmustdetermineif incorrect substitution could result in productmalfunctionandpersonalinjury to anyone. To avoid hazards, equivalent products which are used must meetall current u.s. coast GuardSafety Regulations and ABYCstandards.

ReplacementParts /~ Whenreplacement parts are required, always use genuine Volvo Pentaparts, or parts with equivalent characteristics, including type, strength, andmaterial. Failure to do so mayresult in productmalfunc= tion andpossible injury to the operator and/or passengers.

Parts Catalogs Parts Catalogsare a goodsourceof information for ordering parts. They are NOTa good source for disassemblyand reassemblyinformation of the engines, sterndrive, or related systems.Theexplodedviews in the Parts Catalogsare representationsand maynot reflect details of the actual assembly.TheWorkshopManualhas detailed information and is the ONLY source of disassemblyand reassebly information.

Special Service Tools Volvo Pentahas specially designedtools to simplify someof the disassemblyand assemblyoperations. Thesetools are illustrated in this Service Manual,in manycases in actual use. All Volvo Pentaspecial tools can be order from Volvo Penta GenuineParts. Individual purchasersof Service Manualsmust order Special Tools through an authorized dealer.

ProductReferences,illustrations & Specifications Volvo Penta of the Americas,Inc. reserves the right to makechangesat anytime, without notice, in specifications and modelsand also to discontinue models.Volvo Pentaalso reserves the right to changeany specifications or parts at any time without incurring any obligation to equip sameon modelsmanufactured prior to date of suchchange.All information, illustrations and specifications containedin this manualare basedon the tatest productinformationavailable at the time of printing.

All photographsand illustrations usedin this manuam maynot depict actual modelsor equipment,but are intended as representative views for reference only. The continuing accuracyof this manualcannot be guaranteed.

Z~ Safety

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Tuning The Engine Thepurposeof an engine tune-up is to restore powerand performancethat has beenlost through wear and deterioration of one or morecomponents.

In the normal operation of an engine, these changescan take place gradually at a numberof points. It is seldomadvisable to attempt improvement in performance by correcting one or two items only. Lasting results will be obtained by following a definite and thoroughprocedureof analysis and correcting all items affecting powerand performance.

Economical,dependableoperation can be ensuredif a complete tune up is performedonce every boating season,preferably at the beginning of the seasonwhenthe boat is brought out of off seasonstorage.

Components that affect powerand performancecan be divided into three groups: ® Componentsaffecting

compression

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

Engine CompressionTesting 1. CompressionCheck:Proper compressionis essential for good engine performance. An engine with low or unevencompressioncannot be properly tuned. /~Use extreme care around engine while running or cranking. Remove loose clothing and jewelry to prevent entanglementwith rotating pulleys anddrive belts. a. Runengine up to normal operating temperature.

N[N-o-te---] EnginemustNOTbe started and run without water for cooling.

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b. Removeany foreign matter from around spark plugs by blowing out with compressedair. c. Remove and inspect all spark plugs. Install thread-type compression gauge in spark plug hole. d. To Prevent Sparking: ¯ All ModelsExcept 5.7 GL, GSand 7.4 GL: Remove (grey) 2-wire connector, with purple and grey wires, at ignition coil. ¯ 5.7 GL and GS ModelsOnly: Removeboth distributor primary wires from the ignition coil Tapewire terminals to prevent accidental grounding. ® 7.4 GL Models Only: Remove14-wire connector at ignition module. e. With choke and/or throttle plates wide open, crank engine through at least four compressionstrokes.

Test Conclusion The indicated compression pressures are considered normal if the lowest reading cylinder is within 75%of the highest.

Example: If the highest pressure reading was 140 PSI, 75%of 140 is 105.

Therefore, any cylinder reading less than 105 PSi indicates an improperly seated valve, worn valve guides, piston, cylinder, or worn or broken piston rings. Any cylinder reading 105 PSI or greater is within specifications, and compressionis considered normal.

If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat compressionpressure check on the cylinders.

1. If compressionimproves considerabDy, the piston rings are at fault.

2. if compressiondoes not improve, valves are sticking or seating poorly, or valve guides are ,worn.

3. If two adjacent cylinders indicate low compressionpressures and squirting oil on the pistons does not increase the compression, the cause maybe a cylinder head gasket leak between the cylinders. This problem could allow engine oil and/or coolant to enter the cylinders.

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

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

Min 101 102 104 105 107 108 110 111 113 114

Max 154 156 158 160 182 184 168 168 170 172

Min 115 117 118 120 121 123 124 126 127 129

Max 174 176 178 180 182 184 186 188 190 192

Min 131 132 133 135 136 138 140 141 142 144

Max 194 196 198 2 00 202 204 206 2 08 210 212

Min 145 147 148 150 151 153 154 156 157 158

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

¯ SparkPlugs ¯ SparkPlug Leads ¯ Distributor Cap ® Rotor ® IgnitionCoil ¯ High TensionLeads ¯ Ignition Switch Circuit WiringandConnectors Electronic ControlModule

® FuelTankPickup and Screen * Fuel TankVent o Anti-SiphonValve (if equipped) ¯ Fuel,Octane and Quality ® Boat Fuel Lines andValves * ExternalEngineFuelFilter or Screen ® Fuel Pumpsand Lines ® Carburetor Fuel Filter or Screen ¯ CarburetorAdjustments ¯ Engine PCVVafve ¯ FlameArrestor ¯ PressureRegulatorandInjectors

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

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intake Manifold VacuumTests 1. mnstall a vacuum gaugeto a goodintake manifold source, following the gauge manufacturer’sinstructions. Start and warmup the engine.

2. Observethe vacuumgaugewhile operation the engine over a range of engine speeds.

3. A steady vacuumreading between18 and 22 in. Hg. (60,7 -- 74,3 kPa) at idle indicates an engine in goodmechanicalcondition.

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4. A vacuum reading below18 in. Hg. (60,7 kPa) at idle, indicates an enginethat is not developing enoughvacuum.Further testing for mechanicalproblemsis required.

Test Results 1. A steady vacuum reading between17 and 21 in. Hg. (60,7 -- 74,3 kPa) at idle indicates normal engine vacuum.

2. A vacuumreading below18 in Hg. (60,7 -- 74,3 kPa) at idle indicates an engine that is not developing enoughvacuum.Further testing for mechanicalproblemsis needed.

3. Possible causesof low vacuum are late ignition timing, low compression,poor engine sealing, leaks at vacuumline connections, or a bad MAPsensor.

5. Vacuumgaugefluctuates at idle but smoothsout as the engine RPMincreases, poorly seating valves, worncamshaft,or a sticking hydraulic lifter.

6. Vacuumgaugefluctuates morewith increases in engine RPM,check for weakor brokenvalve springs, poorly seatedvatves, ignition miss, or a leaking headgasket.

7. Vacuum gaugefluctuates with each engine cycle check for bad valve.

8. Vacuum reading drops steadily as RPM is increased, checkfor exhaustrestriction.

[2] NORMAL:Steady reading at 17-21 in. Hg. LATEIGNITIONTIMING:14-17 in. Hg. at idle.

LATEVALVE TIMING:8-15 in. Hg. at idle.

5

iNTAKELEAK: Low steady reading.

133 CONDITION: Drops to 2, then rises to 25 whenaccelerated rapidly.

B[]NORMAL I~] WORN PISTONRINGS:Dropsto 0, then rises to 22 whenaccelerated rapidly. [~] STICKINGVALVES:Normally steady, intemittently ticks downward 4 in. from highest reading.

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B"] LEAKING VALVE:Regular drop approximately2 in. from highest reading. ~==~ BURNED ORWARPED VALVE:Vacuumgauge fluctuates evenly with a downscale pulse approximately5 in. with each engine RPM at idle, checkfor a burnedor warpedvalve. ~__~0] WORN VALVEGUIDES:Vacuumgaugeoscillates valve guides for excessivewear.

approximately 4 in. Hg. Check

WEAK VALVE SPRINGS: Vacuumgaugegive violent or sharp oscillations RPMis increased, check for weakvalve springs. [~ IMPROPER IDLE MIXTURE:Vacuumgauge steadily Hg., checkand/or adjust the idle mixture.

floats

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as the

between 13 - 17 in.

~ EXHAUST RESTRICTION: Vacuumgauge gives a normal reading on engine start but drops to 0 as engine RPM is increased. Thevacuummayeventually rise to approximately16 in. Hg. Checkfor restrictions in the exhaustsystem.

1[~43 LEAKING HEAD GASKET: Vacuumgaugefloats between5 - 20 in. Hg., check for leaking headgasket.

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E,t~ SPARKPLUGGAPTOCLOSEOR DEFECTIVEPOINTS: Vacuum gauge gives a slight float between14 -. 16 in. Hg. checkfor defectiveignition points on engines equippedwith ignition points or small spark plug gap.

DRC6688

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Gasoline Requirements Volvo Penta engines are designed for maximum performanceusing gasoline with the following minimum octanespecifications: ® Anti-knock Index Number(AKI) ¯ Research Octane Number(RON) 4°3GL, GSAND5.7GL, GSModels: The ignition timing must be retarded if fuels are used with less than 86 AKI (90 RON)octane are used. Refer "Timing and Fuel Requirementsin the TuneUpSection of this manualfor details. When ignition timing is retarded, a slight decreasein performance can be expected. ~Use of gasoline with lower than 89 AKI (93 RON)octane in 4,3GL, GSand 5.7GL,GSmodels,without retarding ignition timing as specified, will result in serious damage to your engineand will void the engine warranty, All Other Models:Lower octane fuels, lower than 88 AKI (90 RON) octane, can be used. With the use of lower octanefuel, a slight decreasein power can be expected.

Every attempt should be madeto use unleaded fuel, however, some marinasonly sell fuel with lead additives, if unleadedfuel is unavailable,the substitution of leadedfuel for temporaryuse will not harmthe fuel system.

Premiumgrade fuels contain injector cleaners and other additives that protect the fuel system and provide optimumperformance.The use of premiumgrade fuels is strongly recommended.

Donot use leaded fuel in Certified Emissionengines. Leadedfuel will void the certification of emissions.

CarburetedModels:Useof lead-free or leaded gasoline is acceptable.

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

GasolinesContainingAlcohol Manygasolines being sold today contain alcohol. Twocommonlyused alcohol additives are Ethanol(ethyt aicohol) and Methanol(methyl alcohol).

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Seethe Operator’s Manualto determineif the boat’s fuel systemis compatible with alcohol blendedfuels. If it is, your enginemayusegasolines blended with no morethan 10%Ethanol (ethyl alcohol) meetingthe minF mumoctane specification. Do not use any gasoline whichcontains METHANOL (methyl alcohol). [~ Continued use of METHANOL (methyl alcohol) fuel will serious damage to the fuel system.

cause

If you use gasoline containing alcohol, be awareof the following: Theengine will operate leaner. This maycauseengine problemssuchas vapor lock, low speedstalling, or hard starting.

Alcohol blendedfuels attract and hold moisture. Moisture can causefuel tank corrosion. Inspect fuel tanks at least annually. Replacecorrodedor leaking fuel tanks. ® Frequently inspect non-metallic parts of fuel systemand replaceif excessivelystiff, deterioratedor leaking.

Fuel leakagecan contribute to a fire and/or explosion.

CrankcaseOil WJ’~"l

|~ Initial factory fill is a high quality motoroil for APIServiceSG/CD. During the break-in period (20 hours), frequently checkthe oil level. Somewhathigher oil consumptionis normaluntil the piston rings are seated. The oil level should be maintainedin the safe range betweenthe Addand Full markson the dipstick. This range representsapproximately1 litre (1 quart).

If it is necessaryto addor changethe motoroil, use a quality oil with API service category SG/CDthat meets General Motors Standard GM6094-M. At the end of the break-in period (20 hours), changethe crankcaseoil and replace the oil filter. Refer to LubricationandInspectionChartfor recommended oil changeintervals. [ NO----O-~Theuse of multi-viscosity oils, suchas 10W-30 or 10W-40,is not recommended. [)raining and Filling the EngineCrankcase [)rain and refill ever occursfirst.

crankcaseevery 50 hours of operation or 8 months,which-

Z/~To prevent fire and explosion, always makesure engine compartmentis free of gasoline fumesbefore using any sparkproducingtools suchas the electric drill motorusedwith oil withdrawalpump kit.

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E~ ~[~ Check the motor oil frequently. Whenoil is to be changed,removedipstick and drawoil from crankcasethrough dipstick tube with a suction pump.Thedipstick tube is intendedto be usedfor drainageof the engineoil so it will not haveto be drairied into the bilge.

Fill the crankcaseto recommended capacity with a quality motoroil labeled for SAEservice category SGwhich meet General Motors Standard GM-6094-M. Oils conforming to this standard contain detergent andanti-wear additives that will prolongenginelife. Volvo Penta Dura PlusTMSynthetic Motor Oil P/N 3851230-7exceedsthis standard.

37904

Whenchangingmotoroil, select the viscosity that matchesthe temperature range in which the boat will be operated. Usethe sameviscosity whenaddingmotoroil, do not mix different viscosity oils.

Lowest Anticipated Temperature 32°F(0°C)andabove 0°F(-18°C) to 32°F(0°C) Below 0°F(-18°C)

SAE Viscosity Oil Recommended SAE30 SAE20W-20 SAE10W 34101

~,CAUTION: Donot fill abovefull mark. Overfilling resuEts in high operatingtemperatures,foamingthe oil (mixing air in the oil), loss power, and reducedengine life.

Crankcase Capacities

LessFilter

WithFilter

3.0GS

3.5qts.(3,3liters)

4.0qts.(3,8liters)

4.3GL,GS,Gi

4.0qts.(3,80iters)

4.5qts.(4,3liters)

5.7GL,GSGi and GSi

5.0qts. (4,7liters)

6.0qts. (5,7liters)

7.4GL,Gi, GSi

8.0qts. (7,5liters)

9.0qts.(8,5liters)

8.2GSi

8.0qts. (7,5liters)

9.0qts. (8,5liters)

DPX300

5.0qts. (4,7liters)

6.0qts.(5,7liters)

DPX385,DPX415, DPX500

8.0qts. (7,5liters)

9.0qts. (8,5liters)

Model

37210

%,

DR2497

Oil Filter ~ Replace the oil filter whenever the motoroil is changed.

Thisfilter is a self contained,screw-on type. Toremove, unscrew filter canister couterclockwise, remove anddrain residualoil into a suitablecontainer.

Dispose of the oil andfilter properly.When attachinga newfiltwer, be sure the gasketis lightly lubricatedwith freshmotoroil. handtightenonly, run engineto checkfor leaks. Donot run enginewithoutsupplyingcooling water. SeeTune-Up Specificationsfor modelandfilter requirements.

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PowerSteering Fluid Level E~ [~ Maintain the level with DuraPlusTMPowerTrim/Tilt & Steering Fluid. Approvedpowersteering fluids such as GMpowersteering fluid or DexronI1 automatictransmissionfluid can also be used. Donot overfill the pumpreservoir.

Steering SystemLubrication [~ [~ Every 60 days, grease the steering ram (~) with Volvo Penta Grease.

24074

PowerTrim/Tilt-Fluid Level I~ At the beginning of eachboating season,checkthe fluid level in the reservoir as follows: Z~Thetrim/tilt hydraulics are pressurizedwhenthe drive unit is in the downposition.Thedrive unit mustbe tilted full up to relieve hydraulicpressurebefore removing level/fill plug ~). Failure to tilt the drive unit to the full up positionbefore removing level/fill plug would resu|t in a hazardousspray of hydraulic oil. Cautionshouldalwaysbe taken whenremoving level/fill plug by placinga rag over the level/fill IPlUg to prevent residual pressurefromsprayingoil.

COA6781A

1 : Withthe drive unit tilted full up, slowlyandcarefully remove the level/fill ;)lug.

2. Checkthe fluid level. Thefluid shouldbe level with the bottomof the fill TMPower ~ole whenthe drive unit is at full tilt. If necessary,add DuraPlus Trim/Tilt & SteeringFluid. Replacethe level/fill plug andtighten securely.

Off-SeasonStorage Preparations Step 1. Condition Fuel System:

3253

TM MarineFuel Stabilizer to fuel system.Followinstructions AddDuraPlus for addingconditionerand runningengineas stated on the container. This will stabilize the fuel andpreventformationof varnishandgumin entire fuel system.Dothis before continuingwith the following procedures.

NoteModels equipped with 4 BBLcarburetors should be run under a toad at a high enoughthrottJe setting to circulate conditioner throughthe secondaryfloat bowl.

29819

19903

Step 2. ChangeMotorOil andOil Filter: Engineshouldfirst be operatedunderload until oil is thoroughly warmed up. If oil is allowedto warmup before draining, a morecompletedraining will be accomplished.In addition, accumulatedimpurities will be held in suspension by the oil and be removedduring draining operation.

Remove motoroil by siphoningit out of oil withdrawaltube.

Follow the procedureunder Draining and Filling the Engine Crankcase. ¯

Install a newoil filter oil.

and fill

crankcasewith recommended

Notet Vertical drive must be submerged in water or an accessoryflushing adaptor must be used while operating engine.

Whenusing a flushing adaptor, removepropeller before starting engine to preventaccidental contact with rotating propeller. ¯

Withvertical drive in full downposition, run engineat a fast idle for a few minutesto distribute cleanoil throughengine.

Shutoff engineandcheckoil level. Checkoil filter gasket for leaks. Addoil if necessary to bring oil level up to, but not over, the full mark.

Step 3. ChangeVertical Drive Lubricant: TMGL-5Synthetic GearLubricant. Refer Drain and refill with fresh DuraPlus to Vertical Drive Service Manual.

Step 4. Fog Engine:

Warmup engine to ensure fuel conditioner is throughout fuel system.UseV2pint (0,24 litre) of VolvoPentaFogging Oil P/N 4414651-810 oz. (355 ml) spray can to fog engine.

Remove flame arrestor from carburetor. Following instructions on container, bring engineup to a fast idle and slowly spray2/3 of the foggingoil into carburetor. Keep enginerunning while spraying fogging oil into carburetor throat.

Reduce throttle to idle andlet enginedie. Turn off ignition and replaceflame arrestor. Closefuel shutoff valve (if so equipped).

Safety Related

1 - 14

Engme/eng

Preparean engine"storagemixture" in an outboardsix gallon fule tank. it mustconsist of 5 gallons of fuel; 4 pints (84 oz.) FoggingOil; and1/3 cup TM MarineFuel Stabilizer. Mix these ingredients thor(2.5 oz.) DuraPlus ouglhlyo ¯

Disconnectboat fuel line at the enginefuel pump.Connect the "storage mixture" to the fuel pumpfitting. Runthe enine on the "storage mixture" for approximately5 minutesat 1500RPM.This will ensurethat all fuel systemand internal engine componenets are thoroughly protected. Shut off the engine before the "storage mixture" is used up.

~_ote~Donot run the engineout of fuel. TheeJectric fuel pumps will be damaged if allowedto run dry.

Step 5. Drain Cooling System: ~Ot~ Whendraining the engine cooling system, raise or lower the bos of the boat to position the enginein a horozontalplane. This will providefor completedrainageof the engineblock and exhaustmanifolds. If the bowof the boat is higher or lower than the stern, sore water maybe trappedin the engine block or exhaust manifolds, improperor incompletedraining may relult in freeze damage to the engine, manifolds,sterndrive or other componenets.Freeze damageis not covered under the Volvo Penta limited warranty.

Starboard (~) Disconnectand drain large hose at circulating pump. ~--~

Port

(~) Remove exhaust manifold petcock stem. Clear hole with a small wire ensure complete drainage.

23907

(~ Remove cylinder block petcock stem. Clear hole with a small wire to ensu re completedrainage.

23913

Engmeleng

1- 15

[~] Front Q Disconnect the small water by-pass hose at the top of the thermostat housing. [~

Rear

(~) Disconnect the water discharge hose. Lower to the rear the block. Blow out water by applying air to the by-pass hose.

42859

[~ Front (~) Disconnect and drain large hose at circulating pump. [~] Starboard Q Loosen clamp and remove hose.

Remove cylinder block petcock stem. Clear hole with a small wire to ensure complete drainage.

44195

Port Loosen clamp and remove hose. (~ Remove cylinder block petcock stem. Clear hole with a small wire to ensure complete drainage.

34093

34091

1-16

34102 Englne/eng

.n.e

LAoq"

gm

[~ Front Q Disconnect the smatl water by-pass hose at the top of the thermostat housing. []

Rear

~) Disconnect the water discharge hose. Lower to the rear of the block, BJowout water by applying air to the by-pass hose.

42859

[~ Front (~ Disconnect and drain large hose at circulating

pump.

Starboard ~) Loosen clamp and remove rubber hose. ~) Remove cylinder block petcock stem. Clear hole with a small wire to ensure complete drainage.

42862

Port (~ Loosen clamp and remove rubber hose.

0 Remove cylinder block petcock stem. Clear hole with a small wire to ensure complete drainage.

42861

Eng~r’le/er’pg

1 - 17

Front (~) Disconnectthe water bypasshoseat large diameterof checkvaEve. *

Drain or blow out valve and short hose to thermostat housing.

-

Drain or blow out long hoseto fuel resovoir.

42863

Front

®

Disconnectand drain the large hose at the circulation pump.

Starboard

®

Loosen clamp and remove rubber hose.

®

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

Port

®

Loosenclamp and reove rubber hose.

®

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

28283

28284

[] On Models equipped with oil coolers, removelowest water hose from cooler. If cooler is mountedhorizontally, removeone water hose ® from oil cooler, loosen mountingbolt (~), and tip oil cooler downward to drain.

[~ Loosen and slide hose clamps back. Removehoses from the rear of the raw-water pumpand drain. Crank the engine no morethan 2 seconds (DONOTSTART)to expel any water trapped in the raw-water pump.

ReinstaJl raw-water pumphoses.

Step 6. Drain Pivot Housing: Todrain cavity in pivot housing,tilt drive unit to the full tilt (up)position and removethe water drain plug © from the port side of the pivot housing.

Tilt the drive unit to the full downposition. Allowunit to drain. After unit has completelydrained, replace pivot housingplug. inspect drive unit water intake screenfor obstructions. [~ Failure to completly drain the cooling systemwill result in serious °damage to the engine, exhaust manifolds, and sterndrive whentempera ture go belowfreezing. If completedrainageis in doubt, checkdrain openingwith a small piece of wire.

33857

Step 7. Inspect sterndrive water pick-up for obstructions.

Step 8. Disconnectthe Battery andplace in storage. Whenstorage will be for a considerablelength of time, periodically rechargethe battery following the manufacturer’s recommendations= Step 9. SprayEntire Engine and Drive Unit With Volvo Penta TMCorrosionShield. Follow directions on the container.

DuraPlus 34087

Engme/eng

1-19

Preparation for BoatingAfter Storage 1. Install stemsandclose all drain petcocks.Install cooainghosesand clamps. Checkcondition of hoses, manifold end caps and clamps. Connect hosesto engineand tighten clampssecurely. Install boat drain plug, if removed.

2. Remove the distributor cap and rotor. Wipethe inside of the distributor ti Corrosion Shield P/N cap dry with a clean cloth and spray with DuraPlus 362002-8or equivalent. Replacethe rotor and cap.

3. Cleanthe battery terminals. Withthe ignition switch in the "OFF"position, install the battery and attach the battery cables. Sprayterminals with DuraPlusTMCorrosion Shield P/N 362002-8.

Z~4. Openthe fuel shut-off valve (if so equipped)and checkalt fuel line connectionsfor leaks. ~5. Checkthe flame arrestor and clean if necessary. Reinstall, make sure all parts are in place andtighten nut securely.

6. Makea thoroughcheck of the boat and engine for loose or missing nuts and screws. Pumpthe bilge dry and air out the engine compartment.

Z~ Safety Warning To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting engine, if the boat is not equippedwith a bilge blower, openengine cover or hatch prior to starting and leave openuntil after engineis running.

If operatingboat in water, tie boat securelyto dockto prevent forward or backwardmovement.

Whenusing a flushing adaptor, removethe propeller before starting engine to prevent accidental contact with rotating propel|or.

7. Test run engine: Launchboat or use a flushing adaptorinstalled on vertical drive. ~Do not start engine out of water unmessusing a flushing adaptor.

Alwaysturn water on before starting engine. Control water pressureas full water pressure maycause damageto supply pumpand engine. ~8. With engine compartmentopen, start the engine. Monitor the voltmeter, oil pressureand water temperaturegaugesfrequently to be sure all systemsare operating properly. Check for fuel, oil, andwaterleaks.

Safety Related

1-20

Engme/eng

EngineBreak-in All Volvo PentaSterndrive engineshave beenrun for a short period of time as a final test at the factory. Youmustfollow the EngineBreak-Inprocedure during the first 20 hours of operation to ensure maximum performanceand ~ongestenginelife. ~To ensure proper lubrication during the break-in period, do not removefactory break-in oil until after the 20-hourbreak-in is completed.

For the first five to ten minutesof operation, operateengineat a fast idle (above 1500 RPM).After engine has reachedoperating temperature, momentarilyreduce engine speed, then increase engine speed, .to assist break-in of rings and bearings.

During the remainingfirst two hoursof operation, accelerateto bring boat onto plane quickly and bring throttle backto maintaina planing attitude.

During this period, vary the enginespeedfrequently by accelerating to approximatelythree-fourths throttle for two to three minutes,then backto minimum planing speed. Maintain planing attitude to avoid excessiveengine load. r)o NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED PERIODSOFTIME DURING THE BREAK-IN PERIOD.

During next eight hours, continue to operate at approximately three-fourths throttle or less (minimumplaning speed). Occasionally reduce throttle to idle speed for a cooling period. During this eight hours of operation it is permissible to operate at full throttle for periods of less than two minutes.

DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGEDPERIODS OF TIME DURINGTHE BREAKqNPERIOD.

During the final ten hoursof break-in, after warmingengineto operating ’Iemperature,it is permissibleto operateat full throttle for five to ten minutes a| a time. Momentarilyreducethen increase engine speedto assist break-in of rings and bearings. Occasionallyreduceenginespeedto idle to provide cooling periods.

E.r,qlne/erlg

1-21

DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED PERIODSOF TiME DURINGTHE BREAK-IN PERIOD. During break-in period, be particularly running of engine, as follows:

observant during initial

1. Checkcrankcaseoil level frequently. Maintain oil level in safe range, between "add" and "full" marks on dipstick.

If you have a problem getting a good oil level reading on dipstick, rotate dipstick 180° in tube.

2. Watchoil pressure gauge. If indicator fluctuates wheneverboat attitude (i.e. turning, climbing on plane, etc=) is changed,it may be the oil pickup screen is not covered with oil. Checkcrankcase dipstick, and add oil to crankcase if required. DONOTOVERFILL. If oil level is correct andcondition still exists, checkfor possible gauge or oil pumpmalfunction.

Oil pressure will rise as RPMincreases, and fall as RPM decreases, in addition, cold oil witl generally showhigher oil pressure for any specific RPMthan hot oil. Both of these conditions reflect normal engine operation.

3. Watchengine temperature indicator to be sure there is proper water circulation.

Failure to follow the break-in procedure will engine warranty.

void the

At end of break-in period (20 hours), removemotor oil and replace oil filter. Fill crankcasewith recommended 4-cycle motor oil.

OperationAfter Break-in After break-in, the engine can be operated at any RPMfrom idle to full throttle. However,cruising at 3600 RPMor less saves fuel, reduces noise, and prolongs engine life.

Whenstarting a cold engine, always allow engine to warm up gradually. Never run engine at full throttle until engine is thoroughly warmedup. Be sure to check oil level frequently during the first 50 hours of operation, since oil consumptionwill be high until piston rings are properly seated.

1-22

Engme/eng

SubmergedEngine Remove engine from water as quickly as possible.

It is imperative that your dealer removeaHwater from the engineand immediatelyrePubricateair internal parts. All electrical devicesmustalso be dried and inspected for water damage.Delay in completing these actions mayallow extensive engine damage.

Frequently check engine compartmentfor gasoline fumesand excessive water accumulation;water depth in bilge should be kept well belowflywheel housing.

Volvo Penta Dealer Service = 20-Hour Check 1. Change engineoil and oil filter.

2. Checkfuel filter/water separator.

3. Checkpowertrim/tilt

reservoir for properfluid level.

4.3.0 GSOnly: Cleanand inspect the ceramicfilter pump.

located under the fuel

5. A|l ModelsExcept3.0 GS: Changefuel filter/water

separator.

~6. Check flame arrestor for proper mounting.

7. Start engineand checkcompletefuel systemfor leaks. ~8. Lubricate steering cable ram with Volvo Penta Grease P/N 8282501. On modelsequipped with power steering, check power steering pump :eservoir for correct fluid level. Failure to properlylubricate the steering systemcould Beadto loss of steering control. ~9. Checkshift system for proper adjustment and operation. ~10. Inspect exhaust system. Tighten all hose clamps, and check for leaks.

11. Checktension on all drive belts.

12. Checkall engine mountscrewsfor tightness.

13. Checkbase ignition timing. !4. CarburetedModels:Checkand adjust carburetor for correct idle mixture and idle RPM. 15. Checkfor defencies, malfunctions, signs of abuse,etc.

TM GL16.Checkoil level in sternddve and add as necessarywith DuraPlus 5 Synthetic GearLubricant.

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

Belt Tension o 3.0 GSModels o 4.3, 5.7, 7.4, and 8.2 Liter Models[~ o 3.0 GSNonpowersteering ModelsEE] o 4.3 PJX Models [~ O PowerSteering PumpBelt (~) AlternatorBelt Q Raw-waterPumpBelt [-1"1"=’~[~ With engine stopped, belts should be tight enoughso that it will deflect 1/~,, to 1/2" (6 - 13ram)whenpressedwith a finger the point indicated. Alternate method,use Volvo Pentaspecial tool 1159660-8 andtighten belts to 20 - 25 kg (44 - 55 Ibs.). If belts are too tight, excessivebelt andbearing wearcanoccur. If they are too noose,slippagecan occur, resulting in excessivebelt wear,poor circulation pump,raw-water pump,and or powersteering performance.

Tensionof a newbelt should be checkedafter 10 hours of service and every 50 hours thereafter.

©

1-24

Engme/eng

Alternator Belt Adjustment ¯

3.0 GS Models [~

¯

3.0 GS hiPS Models [~

e 4.3, &7 GL, GS, and Gi Models ~] e 4.3 PJX Models [~ ¯

7.4, 8.2 GL, Gi and GSi Models E~

LI) CrankshaftPulley (~) Circulating PumpPulley (3) Alternator Pulley (!) W’ to 1/2" (6 - 13 ram)Deflection (}) Raw-water PumpPulley

DR4933

\

EI~]===’~ Check alternator belt tension (~) midwaybetween the c, irculating pump pulley (~) andthe alternator pulley (~).

1. Loosenalternator mountingscrewsand nuts, pivot alternator awayfrom engineto increasebelt tension.

[}RC43344

;!. Whilemaintainingtension on alternator belt, tighten top screw,bottom screw and nut. Recheckbelt tension. [~ The belts used for the alternator, circulating pump,and power steering pumpare heavy-duty. DONOTreplace with automotive belts.

Raw-WaterPumpBelt Adjustment

Check raw-water pump belt tension midway between the cPculating pumppulley (~) and the raw-waterpumppulley (~).

21815

Loosenmounting bracket to raw-water pumpscrews, pry raw-water pump awayfrom engine to increase belt tension. While maintaining pressure on raw-water pump,retighten top and bottom screws. Recheckbelt tension.

O

Eog,,,o~o,U

1-25

®

DR4933

DRC43344

16067

PowerSteering PumpBelt Adjustment

e 3.0 GS Models [~ ¯ 4.3, 5.7, 7.4 and 8.2 Liter ModelsE~ (~ PowerSteering PumpPulley ® Circulating PumpPulley (~) ¼" to ½" (6 - 13 mm)Deflection [~ Improper power steering belt adjustment will powersteering assist, resulting in hard steering.

23910

cause a loss of

[~""~[~ Check power steering belt tension (~ midway between the circulating pumppulley (~) and the powersteering pumppulley

--[~ [~ To increase belt tension: Loosennut on lower pivot bolt, and loosen screw on brace behind pulley. Place a ½" breaker bar into the square hole in the pumpmountingbracket, and pivot pumpawayfrom engine as shown.While maintaining pressure on pump,retighten all mounting screws. Recheckbelt tension. Neverpry against the pump reservoir or pulJ ~ler neck.

~ To increase belt tension: Loosen pumpmounting bracket screws, insert a ½ in. breaker bar into square hole in the pumpmounting bracket, and pivot pumpawayfrom engine as shown. While maintaining pressure on pump,retighten a~l mountingscrews. Recheckbelt tension.

Neverpry against the pump reservoir or pull filler neck.

24278

19901

2[~ [_~ To increase belt tension: Loosen pumpmounting bracket screws. With a long pry-bar, pry against corner of timing chain cover and tab on pumpmountingbracket. While maintaining pressure on bracket, tighten screw closest to tab. Tighten the remainingscrews. Recheckbelt tension.

1-26

Engmefeng

"rroubieshooting- SystemIsolation ]’he following is to help you isolate a malfunction of one or possibly several systems.After determining which systemsare related to the malfunction, refer to the individual systemtroubUeshootingcharts to isonate the specific cause.

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

1. Discharged or dead battery 2. Loose or corroded connections 3. CrankingSystemTroubleshootingChart in the = Electrical Service Manual Must havegood spark at spark plugs, if not, checkthe:

Engine Does Not r Run

Ignition System

1. Distributor cap and rotor 2. Coil and spark plug leads 3. Ignition timing 4. Automatic spark advance 5. Appropriate ignition Troubleshooting Chart in the ignition Service Manual 6. EFI Modelsrefer to Diagnostic Service Manual L

EFI Models: Refer to Diagnostic Service Manual Non-EF! Models: Carburetor accelerator pumpshould squirt fuel into venturi whenthrottle is advanced.If not, check the: Fuel System

1. Fuel tank, valves, and lines 2. Fuel pumpand filter 3. Carburetor and filter Checkthe following"

Engine Runs Improperly

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

Engine Troubleshooting Guides EFi EnginesOnly: Refer to EFI DiagnosticService Manual.

These guides were written to help you trace the symptomsof the trouble to the source,-without having to read through and prove every possibility. Muchof the information here will be familiar to well informed mechanics.

Also, manyfactors will seeminsignificant but whenyou think of it, usually the toughest problemto troubleshoot is causedby the smallest error. The greatest aid to solving a service problem is information. Start gathering information from the boat operator andwrite it on his job card or workticket. Find out pertinent facts, such as: ¯ Whendid this trouble start? ® Howwas the boat loaded? ¯ Did the trouble occur suddenly, or start gradually?

AnaUyze this information and try to matchit to similar situations you have experienced in the past. Keepin mind the fundamental rules: 1. COMPRESSION - Mixture inducted into pressed.

cylinder

and com-

2. SPARK - Proper intensity at the proper time.

3. FUEL-Proper mixture of air and fuel.

Theseare very old rules, but necessaryfor the engine to run. Use these charts and the service information they refer to. Do not try to remembertolerances, settings, measurements,etc., as they are written in the service manual.Leaveyour mindfree to analyze the problem.

Following is a list of the troubleshooting guides which maybe found on the pages indicated.

Title

Page

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

1. Engine Will Not Crank ..........................

2. Engine Cranks, But Will Not Start .................

3. Hard Starting - Cold Engine ......................

4. Hard Starting - Hot Engine ......................

5. Engine Runs Rough ............................

6. Engine Noises and Vibrations ....................

7. Engine Overheats .............................

8. Engine Dies Out ...............................

9. Engine Won’t Reach Operating RPM...............

10. Defective Engine Lubricating System ..............

11. Low Battery Voltage After Short Storage ...........

1-28

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

Eng.ne/eng

EngineWill Not Crank

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

EngineCranks, But Will Not Start ¯ |

Q

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

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

0 "

e

0 "

0

*

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

~.g,..../,.~,

1-29

HardStarting - Cold Engine Ask these questions first: o

e

¯ ¯ ¯ ¯

=A

o

Beo

-

-

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

e For clean externat canister and carburetor fuel filters e Empty carburetor float bowl due to evaporation e Water in fuel due to condensation ¯ Fuel quality deterioration e See Fuel System Service Manual * ~-

o

o

o

°-

¯ Carburetor choke operation and adjustment ® Carburetor accelerator pump ¯ Fuel systemfor leaks, dirt, or obstructions ¯ Engine timing and ignition system ¯ See Electricai/|gnition and Fuel SystemService Manuals

Hard Starting - Hot Engine Ask these questions first:

¯ Carburetor choke operation and adjustment o See Fuel System Service Manual

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

o - "-

" o

.

A = ~.

o "

- -

¯ Ignition systemprimary circuit e Ignition coil/ignition module ¯ Engine timing e Carburetor choke operation and adjustment e See Electrical/Ignition and Fuel SystemService Manuals

1-30

Eng,ne/eng

Engine Runs Rough

¯ Idle speed and idle mixture ¯ Engine timing and spark plugs ¯ Fuel pump pressure e Water or contaminants in fueP o Carburetor or manifold vacuumleak o Internal carburetor fuel leak ¯ See Fuel SystemService Manual

¯ Air leak on suction side of fuel system ¯ Too low octane fuel ¯ Ignition system secondarycircuit ¯ Engine timing e Wrongmodel or size carburetor, improper main jets or powervalve, defective secondaryfuel circuit, secondary vacuumdiaphragm failure o External canister and carburetor fuel filters ¯ Fuel pump pressure ¯ Engine compression ¯ Water or contaminantsin fuel, water in cylinders ¯ See Generalinformationsection and Electrical/Ignition and Fuel SystemService Manuals

EngineNoises and Vibrations

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

E ngune/eng

1-31

EngineNoises and Vibrations, Cont.

e Improper tuning o Incorrect spark plug wire routing o Use higher octane fuel e See Electrical/Ignition Service Manual

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

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

® Loosebolt(s)

® Loose pulley, worn bearings ® Loose mounting bolts

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

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

1-32

Eng,ne/eng

Engine Dies Out o

0

0

O

0

-

-

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

e o

®

-

e Primary and secondaryignition circuits e Ignition switch ® Circuit breakers ® Wiring between engine and dash ¯ Main engine harness wiring ® See Electrical/ignition Service Manual

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

Engine Won’t ReachOperating RPM- Check: ¯ Fuel type or octane ¯ Propeller pitch or diameter, damagedblades, slipping hub ¯ Crankcase oil volume ¯ Marine growth on hull and drive o Wrongvertical drive gear ratio e Operating at high altitude ® Restricted carburetor air intake ¯ Restricted exhaust outlets in engine, transombracket or drive ® Poor cylinder compression ¯ Carburetor size and type correct for engine ¯ Fuel pump pressure and vacuum ¯ Boat overloaded, or load improperly placed ¯ Engine overheating ¯ Engine timing and ignition system operation ¯ Remotecontror cables and linkage for proper attachment and travel

E ng,ne/eng

1-33

Defective Engine Lubricating System

e Cloggedor incorrect oil filter o Wornoil pumpgears, cover or shaft o Wornor collapsed oil pumprelief valve spring, or foreign material caught on valve seat ¯ Oil pumprelief valve plunger loose in cover e Damagedfilter bypass grommet e Clogged oil pickup screen, broken tube or housing o Plugged crankshaft or blocked oil galleys o Dirty or defective hydraulic lifters, clogged push rod passages ¯ Poor quality, incorrect viscosity or quantity of oil ¯ mncorrect hose routing on remote filter systems ¯ Water in crankcaseoit from condensation, defective head gasket, oil cooler, or cracked manifold/block water passages Oj

= *

’=

¯

®

" I1| __

=

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

Low

Battery

Voltage

After

Short

Storage,

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

1-34

Eng,ne/eng

Tune-upSpecifications

~=

--

_

EngineFiring Order 3.0 liter ...................................................

4.3 liter ...............................................

5.7 liter ............................................

7.4 and 8.2 liter ......................................

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

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

Fuel Injecected Models ...................

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

CrankcaseCapacities Model

Eoo,oe/oog

LessFilter

WithFilter

3.0GS

3.5qts. (3,3 liters)

4.0qts. (3,8 liters)

4.3GL, GS, Gi

4.0 qts. (3,8 liters)

4.5qts. (4,3 liters)

5.7GL, GSGi and GSi

5.0qts. (4,7 liters)

6.0 qts. (5,7 liters)

7.4GL, Gi, GSi

8.0qts. (7,5 liters)

9.0 qts. (8,5 liters)

8.2GSi

8.0qts. (7,5 liters)

9.0 qts. (8,5 liters)

DPX300

5.0qts. (4,7 liters)

6.0qts. (5,7 liters)

IDPX385, DPX415, DPX500

8.0 qts. (7,5 liters)

g.0 qts. (&5 liters)

1 "35

Tune-upSpecifications mdle* and Operating RPM 3.0 GS Idle .....................................

WOT ..................................

4.3 GL

650-750 RPM 4200-4600 RPM

Idle .....................................

WOT ..................................

4.3 GS

550-650 RPM 4200-4600 RPM

Idle .....................................

WOT ..................................

4.3 Gi

550-650 RPM 4400-4800 RPM

Idle ............................

WOT ..................................

5.7 GL

600 RPM- Not Adjustable 4400-4800 RPM

Idle .....................................

WOT ..................................

5.7 GS

550-650 RPM 4200-4600 RPM

Idle .....................................

WOT ..................................

5.7 Gi

550-650 RPM 4200-4600 RPM

Idle ............................

WOT ..................................

5.7 GSi

600 RPM- Not Adjustable 4200-4600 RPM

Idle ............................

WOT ..................................

7.4 GL

600 RPM- Not Adjustable 4600-5000 RPM

Idle .....................................

WOT.......................................

7.4 Gi

550-650 RPM 4200-4600

Idle ............................

WOT.......................................

7.4 GSi

600 RPM- Not Adjustable 4200-4800

tdie ............................

WOT .......................................

8.2 GSi Idle ............................

WOT .................................

600 RPM- Not Adjustable 4800-5200 600 RPM- Not Adjustable 4600 - 5000 RPM

* In ForwardGear WOT= Wide OpenThrottle

1-36

Englne/eng

Tune-upSpecifications

Oil Pressure - All Models

I

800 RPM.............................

2000 RPM............................

103-207kPa(15-30 psi)t 276-414kPa (40-60 psi)J

Timingand Fuel Requirements 3.0 GS .........................

0° TDC- w/87 AKI or higher Volvo Penta 885163-6shunt required

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

6° BTDC- w/89 AKI or higher 1 ° BTDC- w/87 AKI Volvo Penta 885163-6shunt required

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

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

5.7 GL, GS ...................

8° BTDC - w/86 AKI or higher

5.7 Gi, GSi ....................

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

7.4 GL .........................

10° BTDC- NormAdjustable w/86 AKI or higher

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

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

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

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

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

10° BTDC - w/87 AK~or higher Service Moderequired

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

10° BTDC- w/87 AKaor higher Service Moderequired

All timingset at idle RPM

E nglne/eng

1-37

Tune-upSpecifications Spark Plugs 3.0 GS Spark Plug .....................

VP-3851857-7,AC-MR43LTS, CH-RS12YC Gap .............................................

0.045"(1,143mr’n) Torque .............................................

20ft. lb. (27Nm) 4.3 GL, GS, Gi Spark Plugs ....................

VP-3856756-0,AC-MR43LTS, CH-RS12YC Gap .............................................

0.045" (1,143 mm) Torque .............................................

20ft. lb. (27Nm) 5.7 GL Spark Plugs .....................

VP-3851859-3,AC-MR43T,CH-RV15YC4 Gap ...............................................

0.035" (0.89mm) Torque .............................................

20ft. lb. (27Nm) 5.7 Gi Spark Plugs .....................

VP-3851862-1,AC-R43TS,CH-FW15YC4 Gap .............................................

0.045"(1,143turn) Torque .............................................

20ft. lb. (27Nm) 5.TGSi Spark Plugs ....................

VP-3856756-0,AC-MR43LTS, CH-RS12¥C Gap.............................................

0.045" (1,143 mm) Torque .............................................

20ft. lb. (27Nm) 7.4 GL Spark Plugs .....................

VP-3851861-9,AC-MR43T,CH-RV15YC4 0.045" (1,143 mm) Gap.............................................

Torque .............................................

20ft. lb. (27Nm) 7.4 Gi Spark Plugs .....................

VP-3851862-1,AC-R43TS,CH-RV15YC4 Gap.............................................

0.045" (1,143 mm) Torque .............................................

20ft. lb. (27Nm) 7.4 GSi Spark Plugs .....................

VP-3851861-9,AC-MR43T,CH-RV15YC4 Gap.............................................

0.045" (1,143 mm) Torque .............................................

20ft. lb. (27Nm) 8.2 GSi Spark Plugs .....................

VP=3851861-9,AC-MR43T,CH-RV15YC4 Gap.............................................

0.045" (1,143 mm) Torque .............................................

20ft. lb. (27Nm) VP= Volvo Penta

CH= Champion

AC= ACDelco

1-38

Engme/eng

Generaltorque Secifications Thefollowing specifications are for nut and screwsizes not having specific torque recommendations.

Screw Size

Ft. Lb.

In. Lb.

Nm

Screw Size

Ft. tLb.

In. lb.

Nm

No. 6

9.7 - 14

1,1 - 1,6

M-6

6-9

72-108

8-12

No. 8

19.4 - 24.7

2,2 - 2,8

M-8

14-21

168-252

19-28

No. 10

2- 3

25 - 35

3- 4

M-10

28-40

336-480

38-54

No. 12

3- 4

35 - 45

4- 5

M-12

50-71

600-852

68-96

1/4-20

5- 7

60 - 80

6,8 - 9,5

M-14

80-"14

960-1368

108-155

5/18-18

12 - 14

144 - 168

14 - 16

3/8-16

20 - 25

240 - 300

24 - 27

7/I6-14

32-40

384-480

43 - 54

Pound-inches x 0.11298 = NewtonMeters N=m Pound-feet x 1.3558 = NewtonMeters N®m

Battery Cable Requirements Thebattery should be mountedas close to the engineas practical to cut downon battery cable lengths. Follow the recommendationsbelow. ® 0-10feet

1 AWG

10-15 feet 2.0 AWG ® 15-20 feet 4/0 AWG ~ These specifications do not apply to aluminumbattery cables. Volvo Penta does not recommendthe use of aluminumbattery cables. //~To prevent the possibility of fire or explosion, do not substitute automotiveparts for the following marine components: starter, alternator, distributor andrelated ignition parts, spark plug leads, solenoids, carburetor (and related parts), fuel pumpor fuel filter canister. Thesecomponents havebeenspecifically designedto meet U.S. CoastGuardregulationsno to emit fuel vaporsor to causeignition of fuel vaporsin the bilge.

I_:ngme/eng

~ Safety Related

1-39

METRIC CONVERSIONCHART

inches feet yards miles inches

X 25.4 X 0.3048 X 0.9144 X 1,6093 X 2.54

= millimetres (ram) = metres (m) = metres (m) = kilometres (kin) = centimetres (cm)

foot-pounds camories Btu watt-hours kilowatt - hrs e

2 inches

= millimetres 2 2) (mm 2) = centimetres2 (cm = metres2 2) (m = metres2 2) (m = hectares (104 2) (ha) = kilometres2 2) (km

2 inches 2 feet 2 yards acres

X 645.16 X 6.452 X 0.0929 X 0.8361 X 0~4047

2 miles

X 2.590

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

X 16387 = millimetres 3 3) (ram X 16.387 = centimetres3 3) (cm X 0.01639 = litres (I) X 0.94635 = litres (I) X 3.7854 = Ditres(I) X 28.317 = nitres (I) 3) X 0.02832 = metres3 (m X 29.57 = milliLitres (ml) X 0.7646 = metres3 3) (m

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

X 28.35 = grams (g) X 0.4536 = kilograms (kg) X 907.18 = kilograms (kg) X 0.90718 = metric tons (t)

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

2 feet/see

2 inches/sec

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

X 0.3048 = metres/sec ~ 2) (m/S X 0.0254 = metres/sec 2 2) (m/S

X 1.3558 X 4.187 X 1055 X 3500 X 3.600 A D

e

miles/gal

= joules (j) = joumes(j) = joules (j) = joules (j) = megajoules (M J) 0

= e

X 0°42514= kilometres/litre

(kin/I)

Note: 235.2/(mi/gal) = litres/100 235.2/(litres/100 kin) = m[/gal

m footcandles

X 10,76

2) = lumens/rnetre2 (Im/m

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

X 3.377 = kilopascals (kPa) X 6.895 = kilopascals (kPa) X 0.2488 = ki~opascals (,kPa) X 100 = kilopascals (kPa) X 47.88 = pascals (Pa)

horsepower ft-lbf/min

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

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

pound-inches pound-feet

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

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

X 1.6093 = kilometres/hour (km/h) X 0.3048 = metres/sec (m/s) X 0.27778 = metres/sec (m/s) X 0.4470 = metres/sec (m/s)

1 "40

Engme/eng

Drill Size Conversion Chart SHOWINGMILLIMETER SIZES, FRACTIONALAND DECIMALINCH SIZES ANDNUMBERDRILL SIZES Milli- Dec. Frac- Numo MilliDec. FracMeter Equiv. tional Meter Equiv. tional ber .t .0039 .15 .0059 .2 .0079 .25 .0098 .3 .0118 ....

0135 .35 .0138 ....

0415 .39 ,0156 .4 .0157 ....

0160 .45 ,0177 ....

0180 .5 .0197 ....

0200 ....

0210 .55 .0217 ....

0225 .6 .0236 ....

0240 ....

0250 .65 .0256 ....

0260 ....

0280 .7 .0276 ....

0292 .75 .0295 ....

0310 .79 .0312 .8 .0315 ....

0320 ....

0330 .85 .0335 ....

0350 .9 .0354 ....

0360 ....

0370 .95 .0374 ....

0380 ....

0390 1.0 ,0394 ....

0400 ....

0410 1,05 .0413 ....

0420 ....

0430 1.1 .0433 1.15 .0452 ....

0465 1.19 .0469 1.2 .0472 1.25 .0492 1.3 .0512 ....

0520 1.35 .0513 ....

0550 1.4 .0551 1.45 .0570 t.5 .0591 ....

0595 1.55 .0610 1.59 .0625 1.6 .0629 ....

0635 1.65 .0649 1.7 .0669 ....

0670

80 144

79 ...

78 77 76 75 74 73 72 71 70 69

½2

68 ...

67 66 65 64 63 62 61 60 59 58 57 56

%4

55 54

53 ¼6

.., 52 51

1.75 .0689 ....

0700 1.8 .0709 1.85 .0728 .0730 1.9 .0748 ,... .0760 1.95 .0767 1.98 .0781 ....

0785 2.0 .0787 2.05 .0807 ....

0810 ....

0820 2.1 .0827 2.15 .0846 ....

0860 2.2 .0866 2.25 .0855 ....

0890 2.3 .0905 2.35 .0925 ....

0935 2.38 .0937 2.4 ,0945 ....

0960 2.45 .0964 ....

0980 2.5 .0984 ....

0995 ....

1015 2.6 .1024 ....

1040 2.7 .1083 ....

1065 2.75 .1082 2.78 .1094 ....

1100 2.8 .1102 ....

1110 ....

1130 2~9 .1141 ....

1160 3.0 .1181 ....

1200 3.1 .1220 3.18 .1250 3.2 .1260 3.25 .1279 .1285 3.3 .1299 3.4 .1338 ....

1360 3.5 .1378 ....

1405 3.57 .1406 3.6 .1417 ....

1440 3.7 .1457 ....

1470 3.75 .1476 ....

1495 3.8 .1496 ....

1520 3.9 .1535 ....

1540 3.97 .1562

Num- MilliDec. Frac- Num- MilliDec. Fraco Nurn- MdliDec. Fracber Meter Equiv. tional ber Meter Equiv. tional Meter Equiv. tional ber

50 49 48 %4 47 46 45 44 43

%2

42 .,.

41 40 39 38 37 36

%4 35 34 33 32 31 %

...

30 29

%4

28 ...

27 26 25 24

%z

23 ...

....

1570 22 4.0 .1575 21 ....

1590 ....

1610 20 4.1 .1614 4.2 .1654 ....

1660 19 4.25 .1673 4.3 .1693 ....

1695 18 4.37 .1719 ~4 ....

1730 1"7" 4.4 .1732 ....

1770 16 4.5 .1771 ....

1800 15 4.6 .1811 14 ....

1820 13 }4.7 .1850 4.75 .1870 4.76 .1875 ¾6 t’2’ 4.8 .1890 ....

1910 tl 4.9 .1929 ....

1935 10 ....

1960 9 5.0 .1968 ....

1990 8 5.1 .2008 ....

2010 7 5.16 .2031 13/64 $o ....

2040 6 5.2 .2047 ....

2055 5 5.25 .2067 5.3 .2086 .2090 4 5.4 .2126 ....

2130 3 5.5 .2165 5.56 .2187 %2 ...

5.6 .2205 ....

2210 2 5,7 .2244 5.75 .2263 ....

2280 1 5.8 .2283 5.9 .2323 ....

2340 A 5.95 .2344 W64 ... .2362 6.0 ....

2380 B 6.1 .2401 ....

2420 C 6,2 ,2441 6.25 .2460 D 6.3 .2480 E 6.35 .2500 V4 6,4 .2520 6.5 .2559 .2570 F 6.6 .2598 ....

2610 G 6.7 .2638 6.75 .2657 1%4 .., 6.75 .2657 ....

2660 H

6.8 .2677 6.9 .2716 I ....

2720 7.0 .2756 ....

2770 J 7.1 .2795 ....

2811 K 7.14 .2812 9/32 ...

7.2 .2835 7.25 .2854 7.3 .2874 ....

2900 L 7.4 .2913 ....

2950 M 7.5 .2953 7.54 .2968 19/64 ...

7.6 .2992 ....

3020 N 7.7 .3031 7.75 .3051 7.8 ,3071 7.9 .3110 7,94 .3125 ~8 ...

8,0 3150 ....

3160 0 8,1 .3189 8.2 ,3228 ....

3230 P 8.25 3248 8,3 3268 8.33 .328t 2%4 ...

8.4 .3307 ....

3320 Q 8.5 .3346 8.6 .3386 ....

3390 R 8.7 .3425 8.73 .3437 1½2 ...

8.75 .3445 8.8 .3465 ....

3480 S 8.9 .3504 9.0 .3543 ....

3580 T 9.1 .3583 9.13 .3594 2%4 ...

9.2 .3622 9.25 .3641 9.3 .3661 ....

3680 U 9.4 .3701 9.5 .3740 9.53 .3750 % ... ....

3770 V 9.6 .3780 9.7 .3819 9.75 .3838 9.8 .3858 ....

3860 W 9.9 .3839 9.92 .3906 25/64 ...

10.0 .3937 ....

3970 X ....

4040 Y ...

10.32 .4062 13/32 ....

4130 Z 10.5 .4134

10.72 .42t9 2%4 ll.0 .4330 11.11 .4375 %6 11.5 .4528 I1.51 .4531 ~/~ ll.91 .4687 1%2 I2.0 .4724 12.30 .4843 3~4 12.5 .4921 12,7 .5000 ½ 13.0 .5118 13,10 .5156 33/64 13.49 .5312 ~½2 13.5 .5315 13.89 .5469 3%4 14.0 .5512 14.29 .5624 ~6 14.5 .5709 14.68 .5781 3%4 15.0 .5906 ~15.08 .5937 ~%z i15.48 .6094 3%4 15.5 .6102 !15.88 .6250 % 16.0 .6299 16.27 .6406 4~4 16.5 .6496 16.67 .6562 2%2 17.0 .6693 17,06 .6719 4%4 17.46 .6875 1¼e 17.5 .6890 17.86 .7031 4%4 18.0 .7087 18.26 .7187 2%2 18.5 .7283 18.65 .7344 47/64 19.0 .7480 19.05 .7500 ¾ 19.45 .7656 4%4 19.5 .7677 19.84 .7812 z%2 20.0 .7874 20.24 .7969 s%4 20.5 .8071 20.64 .8125 ~¾6 21.0 .8268 21.04 .8218 s%4 21.43 .8437 2%2 21.5 .8465 21.83 .8594 5%4 22.0 .8661 22.23 .8750 % 22.5 .8858 22.62 .8906 sT/~ 23.0 .9055 23.02 .9062 2%2 23.42 .9219 s%4 23.5 .9252 23.81 .9375 ~6 24.0 .9449 124.21 .9531 6~4 24.5 .9646 24.61 .9687 3½2 25.0 .9843 25.03 .9844 6~4 25.4 1.0000 1 DR2949-ENG

Symbols Certain symbolsor combinations of symbolsmayappearon your VolvoPentaSterndriveor on their accessories.It is very importantthat youunderstand their meaning or purpose.If anysymboa is not clearly understood, seeyour Dealer.

"Safety Warning" Symbols

Poisonous /\

,, BeCareful ® Follow instructions

Fire Hazard

Contents Under Pressure E "Position indicator" Symbols

Raise

Shift Positions NEUTRAL

0

4--

Lower

FORWARD

"Condition"

f

Hour Meter Voltmeter

Symbols

o Voltmeter ¯ Ammeter

(~ Oil Filter

Water Temperature

REVERSE

Tachometer (~ Fue,

~ Emergency Stop ~1~(~.

Oil

Filter Pressure

"instructional" Symbols

1-42

Englne/eng

Perodic MaintenanceChart itemsmarked//~ SafetyWarning are safetyrelatedservicepointsto preventmechanical failures, fire andexplosion.

Make surethe safetyrelatedserviceis performed at thesepointsandat the intervalsspecified,

Service Point

Every 25 Hours or as Specified

Al~rnator Belt, Powersteering pL~npbelt

Every 50 Hours or a Specified

Recommendations

Checkbelt for tension and deterioraUon

Adjustto specifications. Replace deteriorated bells. Keepspare on board

FlameArrestor

Checkfor damageto gdll area.

Mustbe firn~y attached.

Seasonallycleanand inspect.

If damaged, replace w~thspecified Damaged unitmay allow backfire VoFvoPentapadsIfdirty, clean in flame to enter engine compartment, solvent, air dry beforeinstallation

Crankcase

Checkoil lewt daily.

Dramand refill every 50 hoursor every 6 months, whicheveroccurs ~Iret.

SeeSpecilications

Engine Alignment

Seasonally

Check engine alignment

Oil Fdter

Replace

See Specilicatio~.

Every 50 Hours or a Specified

Recommendations

Power Steering Pump

Checkresovmrfiu=d level

UseDuraPlusTM PowerTrtm/’Sll & SteeringFlutd

Steering Cable Ram

Lubricate every 50 hours or every 60 days, wh=chevercomesfirst

Use Volvo Penta Grease PIN 828250-1

Service PAnt

Every 25 Hours or as Specified

I Service Point

Every 25 Hours or as Specified

Every 50 Hours or a Specifiecl

Recommendations

Engine

Checkfor leaks. Checkbelts for correct tenston

Seasonallycheckfor hose deterioration. Checksupply pump operatEonRepair as required

Drain afar operationin freezing temperatures,or during seasonal lay-up. Tigh~nconnectJorls Replacesupply pumpevery 2 years.

Seasonallycheck for hose deterlorabon,

Dratnafter operationin freezing temperatures,or during seasonal lay-up.

TransomShteld

Sterndrlve

Engmeleng

Checkwater pickup screens for obstructtons

~ Safety Related

Drain after operationin freezing temperatures, or during seasonal lay-up

1-43

PerodicMaintenance Chart - Continued

Every 5(} Hours or a Specified

Recommendations

Service Point

Every 25 Hours or as Specified

Control Linkage

Checkoperation, checkadjusb’nent andlubricate

Shif~ Sys~m

Checkfor smoothshifting inb and out of gear.

Seasonallyor every 100 hours, checkcable for properrouting and operation

Replaceshift cable if necessary

Service Point

Every 25 Hours or as Specified

Every 50 Hours or a Specified

Recommendations

Bilge Area

Checkfor gas fLrnes and leaks

Repair or replace defectk, e componenets

Hull

Check for madnegrowth

Clean boat bottom.

Adjust as required. UseVolvo Penta Grease P/N 828250-1

Preparation for boating season Safety Equipment

See Preparation for Boating.

Checkremot~control and emergency stop switch, if insta{led, for proper operabon

Trailer (if applicable)

Z~ Safety Related

All boat safety equipmentshould be Be sure U S.C.G. required checkedfor condition ar~ proper equipment aboard (check Coast Guardregulations). operation.

Seasonally repack wheel bearings

1-44

Use Marine E/P ~VTeel beafng grease.

Englne/eng

Section 2 General Engine IVlechanical V6 and V8 Models Table of Contents Assembling Piston and Connecting Rod ¯ ¯ 2-10 Camshaft Bearings .........................

2-13 Bearing installation ................

2-14 Searing Removal ..................

2-13 Cleaning and inspection .............

2-13 Measurements ....................

2-14 Cleanliness and Care ..................

2-2 Crankshaft and Connecting Rod Bearings 2-18 Cleaning and inspection .............

2-18 Connecting Rod Side Clearance .......

2-21 Crankshaft End Play ................

2-21 Crankshaft Runout .................

2-21 Measuring Bearing C0earance .........

2-19 Cylinder Bores .......................

2-4 Boring ...........................

2-6 Honing ...........................

2=7 Measuring Taper and Out-of-Round .....

2-4 Reconditioning .....................

2-5 Removing Ridge ....................

2-6

2-15 Cylinder Head .......................

Assembly .........................

2-18 Cleaning and Inspection .............

2-15 Disassembly .......................

2-15 Cylinder Head(cont.}.

Reaming Valve GuKJes ..............

2-17 Repair ...........................

2-17 VaUve Grinding ....................

2-17 Valve Seat Grinding ................

2-17 2-4 Engine Gaskets, Replacing .............

2-2 General Description ...................

2-8 Piston and Connecting Rod .............

2-9 Measuring Piston to Pin Clearance .......

Piston Rings AssembFy ........................

2-12 inspecting ........................

2-12 2-11 installing Piston Rings ................

2-10 Piston Selection ......................

RTVSealer / Anaerobic Gasket ERiminator ¯ 2-2 2-23 Special Tools .......................

2-22 Thread Repair ......................

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual.

Alwaysuse the correct fastener in the proper location. Whenyou repOace a fastener, use ONLYthe exact part number for that application. The text will call out those fasteners that require repnacementafter removal. Thetext will also call out the fasteners that require thread lockers or thread sealant.

UNLESSOTHERWISE SPECIFIED, do not use supp0ement coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clampingforce, and may damagethe fastener.

Whenyou insta01 fasteners, use the correct tightening sequence and tightening specifications. Following these instructions can help you avoid damageto parts and systems.

F-ng,,~,e/eng

2-1

General Description The engine repair information described in this section explains how to clean, inspect, and measurecertain engine components.

Use this section along with the proper engine repair section for the correct disassembly and assembly procedures. Engine specifications are found in the back of each engine repair section and will be referred to often in this section.

Cleanliness and Care An engine is a combination of manymachined, honed, polished, and lapped surfaces with very close tolerances. Whenevervalve train, cylinder head, crankshaft, piston, and connecting rod componentsare removedfor service, they should be installed in their original location.

Anytime the flame arrestor is removed, the intake opening must be covered. This will protect against the entrance of foreign material which could follow the intake passageinto the cylinder and cause extensive damagewhenthe engine is started.

Whenany internal engine parts are serviced, care and cleanliness are important. Apply a Hberal coating of engine oil to friction areas during assembly to protect and lubricate the surfaces during initial operation.

Throughout this section, it should be understood that proper cleaning and protection of machinedsurfaces and friction areas is part of the repair procedure. This is considered standard shop practice evenif not specifically stated.

Use of RTVSealer and Anaerobic Gasket Eliminator Twotypes of sealants are commonlyused in the engines covered by this manual. These are RTV sealer and anaerobic "gasket eliminator" sealer.

It is important that these sealers be applied properJy and in the proper paace to prevent oil leaks. THETWOTYPESOF SEALER ARE NOT iNTERCHANGEABLE. Use the sealer recommended in the procedure.

RTV (Room Temperature Vulcanizing) sealer is used where a non-rigid part is assembled to a rigid part.

Commonexamples are oil pans and valve rocker arm covers.

0

Anaerobic gasket eliminator hardens in the absence of air. This sealer is used wheretwo rigid parts (such as castings) are assembledtogether. Whentwo rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using gasket eliminator.

Using RTV Sealer 1. Do not use Rrv in areas where extreme temperatures are expected, such as exhaust manifold or head gaskets, or where gasket eliminator is specified.

2. Use a rubber mallet to separate componentssealed with RTV. Bumpthe part sideways to shear the RTVsealer. Bumpingshould be done at bends or reinforced areas to prevent distortion of parts. RTVis weaker in shear (lateral) strength than in tensile (vertical) strength.

Attempting to pry or pull componentsapart mayresult in damageto the part.

3. Removeall gasket material from the part using a plastic or wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N 79040, or Permatex brand "Gasket Remover", P/N 4MA, or equivalent. Follow all safety recommendationsand directions that are on the can. Do not use any other methodor technique to removegasket material from a part.

Do not use abrasive pads, sand paper or power tools to clean gasket surfaces. These methods of cleaning can damage the part. Abrasivepadsalso producea fine grit that the oil filter cannot removefrom the oil. This grit is abrasive and haJs been knownto cause internal engine damage.

4. Apply RTVto one of the clean surfaces. Use a bead size as specified in the procedure. Runthe beadto the inside of any bolt holes. Do not allow the sealer in any blind threaded holes, as it may prevent the bolt from seating properly or cause damage whenthe bolt is tightened.

5. Assemblecomponentswhile RTVis still Do not wait for RTVto skin over.

wet (within 3 minutes).

6. Torquebolts to specifications. Donot overtighten.

Using AnaerobicGasket Eliminator 1. Removeall gasket material from the part using a plastic or wood scraper. Use Loctite brand "Chisel Gasket Remover", P/N 79040, or Permatex brand "Gasket Remover", P/N 4MA, or equivalent. Follow all safety recommendationsand directions that are on the can. Do not use any other methodor technique to removegasket material from a part.

Do not use abrasive pads, sand paper or power tools to clean gasket surfaces. These methods of cleaning can damage the part= Abrasivepadsalso producea fine grit that the oil filter cannot removefrom the oil. This grit is abrasive and has been knownto cause internal engine damage.

Engme/eng

2-3

2. Apply a continuous bead of gasket eliminator to one flange.

Surfaces to be resealed must be clean and dry.

3. Spread the bead evenly with your finger to get a uniform coating on the complete flange.

4. Assembleparts in the normal mannerand torque immediately ecifications.

~

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

@ DRC6507

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

Cylinder Bores MeasuringCylinder Bore Taper and Out-of-Round [~ Tool Required: J 8087 Cylinder Bore Gauge ®

If one or more cylinder bores are rough, scored or worn beyondlimits, it will be necessary to smoothor true up such bores to fit newpistons.

@

No attempt should be madeto cut downoversize pistons to fit cylinder bores as this will destroy the surface treatment and affect the weight. The smallest possible oversize service pistons should be used and the cylinder bores should be honed to size for proper clearances.

1. Refer to EngineSpecifications in the proper engine repair section for cylinder bore tolerances.

2. Depressplunger on tool 0.03 in. (0,76 mm)or until tool enters cylinder bore. [~ 3. Center the gaugein the cylinder and turn the dial to "0".

Z~ Safety Related

2-4

Engmeieng

I~ 4. Carefully work the gauge up and down the cylinder to determinetaper and turn it to different points aroundthe cylinder wall to determine the out-of-round condition. Measurethe bore both parallel to and at right angles to the engine centerline.

Measureat the top, middle, and bottom of the bore and note the readings.

5. Recondition the cylinder bore as necessary. Refer to Cylinder BoreReconditioning in this section.

Cylinder Bore Reconditioning [~

DRC6508

Measure:

1. Cylinder bore for out-of-round and taper. r2~ 2. Wearat the top of the bore (~ and the bottom ®. Refer to EngineSpecifications in the proper engine repair section for cylinder bore tolerances.

E.3~] Cylinder bores can be measuredby setting the cylinder gaugedial at zero in the cylinder at the point of desired measurement. Lock the dial indicator at zero before removingit from the cylinder, and measureacross the gauge contact points with an outside micrometer, with the gauge at the samezero setting when removedfrom the cylinder.

If cylinder bore taper or wearexceedspecification, the cylinders must be bored and honed to the smallest oversize. Refer to EngineSpecifications in the proper repair section.

Fine vertical scratches madeby ring endswill not, by themselves, cause excessive oil consumption; therefore, honing to remove them is unnecessary. nt; the bore is glazed but otherwise serviceabne, break the glaze lightly with a honeand replace the piston rings. Refer to Honingin tl3is section.

It: honing is not required, the cylinder bores should be cleaned ,with a hot water and detergent wash.Apply clean engine oil to the Ibore after cleaning.

[- RgH3e/ref]g

2-5

DRC6509

RemovingCylinder Bore Ridge [~ Tool Required: J 24270 Ridge Reamer [~ Important: Do NOT remove excessive material from the cylinder bore. Excessive removal of material mayrequire cylinder boring to the next oversize.

1. Rotate the crankshaft until the piston is at BDC. 2. Place a cloth on top of the piston. [~ 3. Perform the cutting operation with a J 24270 ridge reamer.

Refer to the manufacturer’s instructions before using J 24270.

4. Remove J 24270and rotate the crankshaft until the piston is at TDC. 5. Remove the cloth and cuttings.

6. Repeatthis procedure for each piston.

Boring [~ important: Refer to Engine Specifications in the proper engine repair section for additional information.

1. Before the honing or reboring operation is started, measureall new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline. Somepistons must be measuredat a specified distance from the piston crown. Refer to the proper section for additional instructions. Then select the smallest piston for the first fitting. The slight variation usually found betweenpistons in a set mayprovide for correction in case the first piston is fitted too loose.

2. Before using any type of boring bar, the top of the cylinder block should be filed to removeany dirt or burrs. This is very important, if not checked, the boring bar may be tilted which wouldresult in the rebored cylinder wall not being at right angles to the crankshaft.

3. The instructions furnished by the manufacturer of the equipment being used shoundbe carefully followed.

4. Whenreboring cylinders, all crankshaft bearing caps mustbe in p~ace and tightened to the proper torque to avoid distortion of bores in the final assembly.

2-6

Englne/eng

5. Whentaking the final cut with a boring bar, leave 0.001 in.

(0,025 mm)on the diameter for finish honing to give the required position to the cylinder clearance specifications. (The honing or boring operation must be done carefully so the specified clearance betweenpistons, rings, and cylinder bores is maintained).

Honing 1. Whenhoning the cylinders, follow the hone manufacturer’s recommendationsfor use, cleaning, and lubrication during honing. Use only cUean, sharp stones of the proper grade for the amountof material to be removed.Dull, dirty stones cut unevenly and generate excessive heat. Whenusing coarse or medium grade stones, use care to leave sufficient metal so that all stone marks maybe removedwith the fine stones used for finishing to provide proper clearance.

2. Occasionally, during the honing operation, the cylinder bore should be thoroughly cleaned, and the piston selected for the individual cylinder checkedfor correct fit.

3. Whenhoning to eliminate taper in the cylinder, makefull strokes of the hone in the cylinder. Also check measurementat the top, middle, and bottom of the bore repeatedly. [~ Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been honed to the correct size. The piston can be easily distorted through careless handling.

4. Whenfinish honing a cylinder bore to fit a piston, movethe hone up and down at a sufficient speed to obtain very fine uniform surface finish marks in a cross-hatch pattern at the specified angJe(45 to 65 degrees).

5. The finish marks should be clean but not sharp, free from embeddedparticles and torn or folded metal.

6. By measuring the piston to be installed at the sizing point specified in the proper section, and adding the average of the clearance specification, the finish hone cylinder measurement ,can be determined. It is important that both the block and piston be measured at normal room temperature.

7. Refer to Engine Specifications :section.

in the proper engine repair

’8. it is of the greatest importancethat refinished cylinder bores ,~re trued up to haveless than the specified out-of-round or taper.

Eachbore must be final honedto removeall stone or cutter marks and provide a smooth surface.

E ng,ne/eng

2-7

9. After final honingand before the piston is checkedfor fit, clean the bores with hot water and detergent. Scrubwith a stiff bristle brush and rinse thoroughly with hot water. It is essential that a good cleaning operation be performed. If any of the abrasive material is allowed to remainin the cylinder bores, it will wearthe newrings, cylinder bores, and bearings lubricated by the contaminated oil. After washing, the dry bore should be brushed clean with a power-driven fiber brush.

10. Refer to Engine Specifications section.

in the proper engine repair

11. Permanentlymark the piston for the cylinder to which it has beenfitted.

DRC6511

J 24086-C 12. Apply clean engine oil to each bore to prevent rusting.

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

Set

Disassemble: 1. Piston rings, in most cases the rings should be discarded and replaced with new rings at assembly.

2. Connectingrod bearings. If the bearings are to be reused, place them in a rack so they maybe reinstalled with the original connecting rod and cap. [~ 3. Piston pin. a. Place the piston/connecting rod on support fixture 24086-C. Makesure the connecting rod is fully supported. b. Place remover J 24086-Con the support fixture.

J

DRC6515

c. Press out the piston pin.

2-8

Engme/eng

Cleaning and inspection [~-----’~ Clean:Piston ¯ Removeall varnish and carbon deposits. DO NOTUSEA WIRE BRUSH. ¯ Use an approved cleaning solution to remove carbon build-up0 e Removethe carbon from the ring grooves. Use a ring groove cleaning tool. ¯ Oil-control ring groove holes.

L~ Inspect: 1. Piston pin bore and connecting rod bore for scuffing and burrs.

2. Connecting rod for cracks, nicks, etc. If a suitable jig is available, check the connecting rod for a bent or twisted condition.

3. Connectingrod bearings for scratches or deep pitting. zL Piston for: ¯ ¯ ¯ ¯ ¯

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

MeasuringPiston Pin to Piston Clearance [~

Measure:

[_3~ 1. Piston pin diameter. Checkagainst Engine Specifications in the proper engine repair section.

DRC6512

.2. Piston pin to piston clearance. ~] a. Measurethe piston pin hole diameter. b. Subtract the piston pin diameter from the piston pin hole diameter to obtain the clearance.

L

c. Replacethe piston and piston pin if the clearance exceeds specifications. Thepiston and piston pin are a matchedset and not available separately.

Englne/eng

2-9

........

i

, ,r

DRC6513

Piston Selection Check the used piston to cylinder bore clearance.

Measure: r~ 1. Cylinder bore diameter. Use a telescoping bore gauge, located 2.56 in. (65 ram) belowthe top of the cylinder bore.

2. Piston diameter. Measurethe piston skirt at a right angle to the piston pin, at the centerline of the piston pin.

DRC6507

3. Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance.

4. Refer to EngineSpecifications in the proper engine repair section to determine if piston clearance is within the acceptable range.

If the usedpiston is not acceptable, determineif a newpiston will fit the cylinder bore. if a newpiston doesnot bring the clearance within tolerances, the cylinder bore must be reconditioned. Mark the piston to identify the cylinder for whichit wasfitted.

Assembling the Piston and Connecting Rod [~ Tool Required" J 24086-C Piston Pin Removaland Installation Set

DRC6514

J 24086-C

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

DRC6515

2-10

Eng=ne/eng

c. Install the pin guide. Hold the piston and connecting rod together. Be sure to use the proper pin guide. Refer to the instructions supplied with the tool.

2. Piston pin: a. Insert the piston pin into the piston pin hole. [~ b. Place the assembly on the support fixture. ~] c. Adjust the piston pin installer (J 24086-C)to the correct length, using the letter-number scale on the installer adjuster.

This is necessaryto ensure the piston pin is pressed into the piston to the correct depth. Refer to the instructions supplied with the tool for the proper setting. d. Lock the adjuster in pnacewith the lock ring. [~_~ After the installer hub bottoms on the support assembly, do not exceed5000 PSI (35,000 kPa) pressure, as this could cause damageto the tool. e. Place the adjuster in the supportfixture. Pressthe piston pin into place (until the adjustable installer bottomsin the support fixture). f. Removethe piston and connecting rod assembly from the tool and check the piston for freedom of movementon the piston pin.

installing the Piston Rings [~ Measure: L=4~ Ring end gap as follows: 1. Select rings comparablein size to the piston being used.

2. Slip compressionring into the cylinder bore.

3. Usepiston to square ring in cylinder wall.

L=4~ Insert piston without rings upside down and guide the compressionring into the cylinder bore until ring is downabout t.499 in. (38,1 mm)below ring travel.

L=4~ 4. Spaceor gap betweenthe ends of the ring with a feeler gauge.

En£1me/eng

2-11

DRC6516

5. Refer to EngineSpecifications in the proper engine repair section for correct gap.

6. If the gap betweenthe ends of the ring is not as specified, removethe ring and try another for fit. [~ inspect: Ring fit as follows: 1. Fit eachcompressionring to the piston on which it is going to be used.

10755

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

E~ Assemble: Refer to Piston Assemblyin the proper engine repair section.

All compressionrings are markedon the upper side of the ring.

Wheninstalling the compression rings, makesure the MARKED SiDE iS TOWARD THE TOP OF THE PISTON. The oil control rings are 3-piece assemblies, consisting of two rails and an expander. o Expander ¯ Lower rail ¯ Upper rail ¯ Lower compression ring ¯ Upper compression ring Flex all rings to makesure they are free. if binding occurs at any point the cause should be determined. If binding is causedby the ring groove,correct it by dressingthe groovewith a fine cut file. If binding is causedby a distorted ring, try a newring. e Ring gaps must be 180 degrees apart o Rail gaps must be 180 degrees apart

2-12

Engme/eng

I~

Measure:

[2=7 1. Ring clearance. Use a feeler gauge.

2. Comparewith Engine Specifications in the proper engine repair section.

CamshaftBearings Camshaft Bearing Removal Disassemble:

DRC6517

-3-’] Tool Required: J 33049 Camshaft Bearing Removal and L hlstallation Set

J33049

1. Rear camshaft plug. [_-3~E] 2. All camshaftbearings. UseJ 33049. a. Insert the tool with the correct collet into the camshaft bearing you want to replace. b. Turn the tool until the collet has tightened in the bearing. c. Push the center cone against the bnock and into the first bearing bore to center the tool. d. Drive the bearing from the block. e. Repeat this procedure to remove the remaining inner camshaft bearings. Note that the rear bearing must be removedfrom the front of the block and the front bearing should be removed from the rear. This allows the tool to remain centered.

Cleaning and inspection [=~--~ Clean: ¯ Camshaftbearing bores in the block. [i*~

inspect: ¯ Camshaftbearingsfor scratches, pits, or loose fit in their bores. Replace the camshaft bearings if necessary. ¯ Camshaftlobes and journals for scratches, pitting, scoring, and wear. Minor irregularities maybe cleaned up with emerycloth.

Er,gine/eng

2-1

3

DRC6518

Camshaft Measurements Tool Required: J 7872 Dial Indicator or Equivalent new

important: Wheneverthe camshaft needs to be replaced, a set of valve roller lifters mustalso be installed.

Measure:

m

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

DRC6519

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

CamshaftBearing Installation Tool Required: Installation Set

J 33049 Camshaft Bearing Removal and

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

DRC6520

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

Assemble: EEl 1. Rear camshaft bearings. Drive the bearings into place using J 33049from front of engine.

EEl important: Make sure the camshaft bearing lubrication hole (or holes) align with the oil gatlery hole (or holes) in block. Onsomeengines, the oil holes maybe difficult to see.

Verify the holes are lined up.

DRC65’m8

[~E] 2. Front camshaft bearing using tool J 33049.

EEl important: Make sure the camshaft bearing lubrication hole (or holes) align with the oil hole (or holes) in the block.

2-14

Engune/eng

~’3~ 3. Inner camshaft bearings using J 33049. Reverseof removal procedure.

4. Camshaftrear plug. a. Coat a new camshaft plug with GMSealer, P/N 12345493,or equivalent. b. Install the plug. The pnug must be installed deep enoughin camshaft bore. Refer to the proper engine repair section for camshaftplug installation.

Cylinder Head E"~] Disassemble: ’Valves and components.Refer to the proper engine repair section.

Cleaning and Inspection E4~ Tools Required: J 8089 Wire Brush r~

Clean:

[==4~ 1. Carbon from the combustion chambers, using J 8089.

DR3123

2. Valve stems and heads on a wire wheel. :3. Carbonand old gasket from the cylinder head gasket surface. [_5~ 4. Valve guides using a valve guide cleaner. [~ Inspect: 1.. Cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the coolant chamber. Gasket surfaces should be free of damage.

2. Valves for burning, pitting, or warpage. Grind or replace as needed. Refer to Valve Grinding in this section. Checkthe valve stems for scoring or excessive wear. Stemsmust not be bent.

3. Valve rocker arm studs for wear, damage,or improper fit.

4. Valve seats for pitting needed.

or other damage.Grind or reface as

5. Rotators (if used}.. Therotators should rotate smoothlywithout binding.

Englne/eng

2-15

DR3124

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

Measure:

[~"~[~ Tools Required: J 8001 Dial Indicator or equivalent J 9666 Valve Spring Tester 1. Valve stem to guide bore clearance.

Excessive valve stem to guide bore clearance will cause excessive oil consumption and maydamagecomponents,insufficient clearance will result in noisy and sticky functioning of the valve and interfere with engine smoothness.

DRC6521

a, Clampa dial indicator J 8001 or equivalent on one side of the cylinder headvalve rocker arm cover gasket rail. [~ b. Observe dial indicator movementwhile moving valve from side to side (crosswise to the head}. The dial indicator measurementmust be taken just above the valve guide bore. c. Drop the valve head about 0.063 in. (1,6 ram) off the valve seat. d. Movethe stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to reamthe valve guide bores for oversize valves as outlined later.

DR2101

2. Valve spring tension, using J 9666 or equivalent. [~ a. Compressthe valve springs to the specified height.

Check valve spring height in Engine Specifications in the proper engine repair section. Valve springs should be replaced if not within specification. [~ b. Valve spring length. Replace the valve spring if valve spring length exceedsspecifications. Refer to Engine Specifications in the proper engine repair section.

DR3122

DRC6522

2-16

Er,gme/eng

Repair Valve Grinding Pitted valves must be refaced to the proper angle. Valve stems that show excessive wear, or valves that are warped excessively must be replaced. Whenan excessively warpedvalve head is refaced, a sharp or thin valve margin mayresult because of the amount of metal that must be removed. Undersize valve margins lead to breakage, burning, or preignition due to heat localizing on this edge. Refer to EngineSpecifications in the proper engine repair section.

Several different types of equipmentare available for refacing valves. The manufacturer’s instructions for howto use the equipment should be carefully followed to achieve proper results. Refer to Engine Specifications in the proper engine repair section for valve face angle specifications.

07

NEW VALVE

WORN VALVE

21[}4 VALVE TIP 2(}5 I~EY GROOVE 2(}6 $,TEM-LEAST WORN SECTION

207 STEM=MOSTWORN SECTION 2O8 FACE 209 IVIARG[N

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

DRC6523

Another important factor is the cooling of the valve head. Good contact betweeneach valve and its seat ensures that heat will be carried awayproperly. :Several different types of equipmentare available for resurfacing valve seats. Carefully follow the recommendationsof the manufacturer of the equipmentbeing used to attain proper results.

Regardlessof what type of equipmentis used, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the pilot in the guide. Refer to EngineSpecifications in the proper enginerepair section for valve seat angle specifications.

ReamingVanve Guides "The valve guides used in engines covered by this manual are simply holes bored into the cylinder head. The valve guides are not replaceable.

If the valve stem-to-bore clearance as previously measuredis excessive, the valve guides should be reamedand a valve with an oversize stem installed. Oversize valves are available. Refer to EngineSpecifications in the proper engine repair section.

[6~] Select a reamer that will provide a straight, through the entire length of the valve guide.

Eng...... g

2-17

clean bore

DRC6524

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

Measure:

Valve spring installed height of eachvalve spring as follows: E~ 1. Valve installed height using a narrow thin scale. A cutaway scale ~) maybe helpful. ~] 2. Spring seat in the cylinder head to the top of the valve spring cap.

DRC6667

~] 3. Certain engine applications use valve spring shims to adjust valve spring installed height. If measurement® exceeds the amountshownin EngineSpecifications in the proper engine repair section, install valve spring seat shimsof sufficient thickness (between the spring and cylinder head) to obtain desired measurement.NEVER shim the spring so as to give an installed height under the specified amount.

Crankshaft and Connecting Rod Bearings DRC6668

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

2-18

Eng,ne/eqg

Crankshaft bearings for scoring or other damage. In general, the lower crankshaft bearings (except the #1 bearing) showthe greatest wear and distress from fatigue. Uponinspection, if a lower crankshaft bearing is suitable for reuse, it can be assumedthat the upper crankshaft bearing is also satisfactory, ff a lower crankshaft bearing shows evidence of wear or damage,both the upper and lower crankshaft bearings must be replaced.

MeasuringBearing Clearance Crankshaft bearings are of the precision insert type and do not use shims for adjustment. If clearances are excessive, newupper and Jower bearings will be required. Service bearings are available in standard size and undersize. Refer to Crankshaft and BearingInstallation in the proper engine repair section.

Selective fitting of crankshaft bearings are necessaryin production to obtain close tolerances. For example, you may find one-half of a standard crankshaft bearing with one-half of an undersize crankshaft bearing.

To determine the correct replacement bearing size, the bearing clearance must be measuredaccurately. Either of the following two methods may be used, however, the micrometer method gives morereliable results and is preferred.

Micrometer Method ~] 1. Measurethe crankshaft journal diameter with a micrometer in several places, approximateJy90 degrees apart, and average the measurements.

2. Computetaper and runout. Refer to Engine Specifications in the proper engine repair section for allowable limits.

3. Install block.

crankshaft bearings into the crankshaft cap and engine

4. Install crankshaft caps and bolts. Tighten bolts to the Torque Specifications in the proper engine repair section.

5. Bearing inside diameter (I.D.) using an inside micrometer= 6. Comparecrankshaft bearing clearance specifications using EngineSpecifications in the proper engine repair section.

"7. If bearing clearancesexceedsspecifications, install newcrankshaft bearings. a. Measureinside diameter with an inside micrometer. Place the micrometerat go degreesto the split line of the crankshaft bearing.

[ ng{ne/eng

2-19

DRC6525

b. Subtract journal diameter from bearing inside diameter to obtain bearing clearance. Refer to EngineSpecifications in the proper engine repair section for bearing inside clearance.

Replaceor repair the crankshaft if clearance exceedsspecifications.

Plastic GaugeMethod [~ 1, Install

all crankshaft bearings and crankshaft into block.

E~ Install the crankshaft bearing caps and torque them to specifications.

Removethe bearing caps and check the amount the gauging plastic has been compressed. Gauging plastic may adhere to either the crankshaft bearing or crankshaft journal.

DRC6526

2. Onthe edge of the gauging plastic envelope there is a graduated scale. Without removing the gauging plastic, measure its compressedwidth (at the widest point).

3. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearanceindicating taper, tow spot or other irregularity of the bearing or journal.

4. Normally crankshaft bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround 0.001 in. (0,0254 mm)maximum journal, be sure to fit the maximum diameterof the journal. If the bearing is fitted to the minimumdiameter and the journal is excessively out-of-round, interference betweenthe bearing and the journal will result in rapid bearing failure.

DRC6527

5. If the bearing clearanceis ,within specifications, the bearing is satisfactory. If the clearanceis not within specifications, replace the bearing. Always replace both upper and lower bearings as a unit.

6. A standard or undersize bearing combination mayresult in the proper clearance. If the proper bearing clearance cannot be achieved using standard or undersize bearings, it will be necessary to replace the crankshaft.

Crankshaft bearings must not be shimmed, scraped or filed. Donot touch the bearing surface with bare fingers. Skin oil and acids will etch the bearing surface.

7. Remove the flattened gaging plastic.

8. Measureremaining journals.

2-20

Englne,’eng

Crankshaft Runout Tools Required: J 7872 Magnetic Base Dial Indicator MeasureCrankshaft: [~ 1. Mount the crankshaft in V-blocks at crankshaft journals 1 and 5. [~ 2. Position a d{an indicator pointer on the center mainbearing and rotate crankshaft.

DRC6528

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

ConnectingRod Side Clearance Measure: [’~ Connecting rod side clearance. Refer to Engine Specifications in the proper engine repair section for clearance.

Crankshaft End Play [~

DRC6529

Measure:

Crankshaft end play, as follows: 1. Firmly thrust the end of the crankshaft first rearward then forward. This will line up the rear crankshaft bearing and crankshaft thrust surfaces.

2. With crankshaft wedgedforward, measureat the front end of the crankshaft bearing(thrust side) with a feeler gauge.Refer EngineSpecifications in the proper engine repair section for crankshaft end play clearance.

3. if correct end play cannot be obtained, be certain that the correct size crankshaft bearing has been installed. Someproduction engines mayuse crankshaft bearings that are wider across the thrust faces than standard size bearings. Refer to Engine Specifications in the proper engine repair section for available bearing sizes.

IEngmo/eng

2-21

DRC6530

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

Thread

Repair

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

out,

DRC6572

Z~ Wear safety glasses to avoid eye damage.

1. Determinesize, pitch, and depth of damaged thread. If neces, adjust stop collars on cutting tool and tap to required depth.

~

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

[~ 2. Drill

out damagedthread. Clean out chips.

[-~ 3. Lubricate tap with night engine oil. thread.

Tap hole. Clean the

DRC6573

important: Avoid buildup of chips. Back out the tap every few turns and removechips. [~ 4. Threadthe thread insert onto the mandrelof the installer.

Engagethe tang of the insert onto the end of the mandrel. [~ 5. Lubricate the insert with light installing in aluminum)and install.

E~ important: Whencorrectly installed, flush to one turn below the surface.

engine oil (except when the insert

should be

DRC6574

8. If the tang of the insert doesnot break off ,whenbackingout the installer, breakthe tang off with a drift.

DRC6575

2-22

Engme/eng

J 33049 J 8087 J 24086=C DRC6576

DRC6577

DRC6579

SpecialTools Cylinder Bore Gauge [~

Piston Pin Replacer Set

[~

Camshaft Bearing Remover/ installer DRC6580

Wire Brush [~]

Dial indicator Valve Spring Tester J 8601

Ridge Reamer

DRC6578

J 9666 DRC6581

J 24270 Englne/eng

2-23

DRC6582

Notes .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... ..........................................................................................

Section 3 3.0 GS Engines Table of Contents Camshaft ..........................

Camshaft Bearings ..................

Circulating Pump....................

Connecting Rod Bearings .............

Crankshaft .........................

Crankshaft Bearings .................

Cylinder Block ......................

Cylinder Head Assembly ..............

Distributor Lower Bearing .............

Engine Coupler Replacement ...........

Engine Specifications .................

Exhaust (Flapper) Valve Replacement....

Exhaust Hose Replacement ............

Front Engine Mount ..................

Height Adjustment .................

3-14 3-16 3-32 3-19 3-18 3-20 3-27 3-8 3-31 3-40 3-42 3-39 3-38 3-35 3-37

General Motors Tool,’; .................

3-2 High-Rise Exhaust Elbow Replacement. ¯. 3-37 Hydraulic Valve Lifter .................

3-4 Intake/Exhaust Manifold ..............

3-3 Oil Filter Bypass Valve ................

3-35 3-32 Oil Pan Replacement .................

Oil Pump ..........................

3-33 Oil Seal Replacement, Rear Main Bearing 3-23 Oil Seal Retainer Replacement .........

3-23 3-25 Piston Rings ........................

Piston and Connecting Rod ............

3-23 Timing Gear Cover ...................

3-12 3-45 Torque Specifications .................

Valve Lash Adjustment ...............

3-5 Valve Spring and Sea| Repair ...........

3-6

Before removing cooling system hoses, it maybe necessary to removeboat from water to prevent flooding boat.

Safety Warnings Before working on any part of the engine, read the secth~n called Safety at the end of this manual.

Un|ess instructed otherwise, always disconnect the battery cables from the battery before working on electrical system to prevent possible sparks or arcing in the engine compartment, Before starting engine after repair or maintenanceprocedures, always makesure engine compartmentis free of fuel vapors to prevent possible fire and explosion.

Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the aHternator, power steering, supply pumpand circulating pumpbelts, pulleys and other moving parts.

Eng,ne/eng

3-1

General Motors Tools Item

Part Number

Air Line Adaptor ...........................................

Bolt Guide Set ...........................................

CamLobe Lift Indicator .......................................

Camshaft Bearing Removerand Installer ......................

Carbon Remover Brush ......................................

Crankshaft Gear Installer .....................................

Cylinder Bore Checker .......................................

Distributor Bearing Installer ...................................

Distributor Bearing Remover................................

Piston Pin Tool .............................................

Piston Ring Tool ............................................

Rear Crankshaft Seal Installer ................................

Rocker Arm Stud Hole Reamer(0.003 Oversize) ..................

Rocker Arm Stud Hole Reamer(0.013 Oversize) ..................

Rocker Arm Stud Installer .....................................

Rocker Arm Stud Remover .................................

Timing Cover Tool ..........................................

Valve Guide Cleaner .........................................

Valve Guide Reamer Set ...................................

Valve Seal Tester ...........................................

Valve Spring Compressor .................. ; ..................

Valve Spring Compressor .....................................

Valve Spring Tester ..........................................

Vibration Damperand Crankshaft Gear Remover................

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

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

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

3-2

Engme/eng

Intake/Exhaust Manifold

[

Removal Z~ 1. Disconnect battery cables at battery. Removethrottle cable from anchor block and actuating bracket.

2. Drain water from block and exhaust manifold (see Coeling SystemSectien in this manual).

3. Removecarburetor from intake manifold. Follow the instructions in Fuel SystemsService Manual.

45329

[~ 4. Disconnect water hose (~) running between manifold end cap and thermostat housing.

5. Removealternator

and mounting bracket ®.

[~] 6. Loosen upper hose clamps © securing exhaust hose to high rise elbow. Loosen and remove screws and lock washers @ securing elbow to manifold and removethe throttle linkage plate and elbow.

7. Removefour bolts, two nuts and lock washers securing manifold to cylinder head, then pull manifold off of head. Discard gasket.

45375

8. Clean all gasket surfaces of cylinder head and manifold and check for cracks on the manifold casting.

Installation 1. Position a newgasket over the manifold studs on the head. Use a gasket sealer if leakage has occurred. Carefully install the manifold in position making sure that the gasket is correctly placed.

2. Install nuts, bolts and washerswhile holding the manifold in place. Tighten bolts and nuts finger tight, then alternately tighten to 20-25 ft. Ibs. (27-34 N-m),working from the center towards the ends.

3. Apply gasket sealer to a newelbow gasket and place it on the manifold. Pushthe elbow into the exhaust hose, then install the elbow, throttle linkage plate, lock washers, and screws. Tighten the screwsto 12-14 ft. Ibs. (16-19 N.m).

4. Install carburetor using a newmountinggasket following the instructions in Fuel SystemsService Manual. Install water hose from thermostat housing to manifold @.

Fngine/eng

~ Safety Related

3-3

34727

[~ 5. Install alternator with mounting bracket @. Tighten screws ® to 26-30 ft. Ibs. (35-41 N-m).. Reset belt tension folrowing the procedures found in the General Unformationsec= tion of this manual. Tighten the alternator screws@to 28-30 ft.

Ibs. (35-41 N.m).

Z~ 6. Reconnect throttle cable to anchor block and actuating bracket. Securewith cotter pin.

Z~ 7. Connectbattery cabaes. Start engine and check for fuel leaks.

45376

HydraulicValve Lifter RemovaU 1. With air hose and cloths, clean dirt from cylinder head and adjacent parts to avoid getting dirt into engine. It is extremely important that no dirt gets into the valve lifters.

2. Disconnectventilation hose, fuel line, and fuel pumpoverflow hose. Removecircuit breaker bracket. Removerocker arm cover.

22477

3. Loosenrocker arm nuts and pivot the rocker arms free of the push rods.

4. Disconnect spark plug wires at plugs. Remove high tension lead from coil Removeboth connectors from coil. Removecoil and mounting bracket from cylinder head° [~ 5. Removeboth connectors at distributor. Take off cap, note distributor rotor position and removedistributor. (Mark distributor housingand block ,with chalk at point of rotor.}

ROTATING- NORMAL,OK - NOT ROTATING

6. Fromrear of block, take out screwsthat mountthe shift bracket assembly and move bracket away from push rod cover.

7. Removepush rod cover and gasket.

8. Remove pushrods and lift out valve lifters that require service.

Place lifters in a woodenblock having numberedholes, or use other suitable meansof identifying them according to original position in the engine.

9. If less than a completeset of lifters is being removed,immediately disassembleand inspect one or two for presence of dirt or varnish, ff lifters contain dirt or varnish, it is advisableto replace all lifters. Otherwise,it will be satisfactory to service only those lifters that are not operating properly.

GALLED - SHOULDBE REPLACED- SOFT, WORN

86000Q

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

Z~ Safety Related

3-4

EngJne/eng

Installation lifter

Before installing any newlifters, with Molykoteor its equivalent.

coat the bottom of each

1. Install valve lifters in cylinder block. If anynewlifters or a new camshaft has been installed, an additive containing EP nubricant such as GMEngine Oil Supplement must be added to the crankcaseoil for break-in.

2. Install pushrods onto lifters new gasket.

and install pushrod cover with a

3. Install distributor (position rotor to markon housingandblock).

Install coil and bracket. Connectboth connectorsto coil. Install distributor cap and attach spark plug and coil wires. Connectboth connectorsto distributor.

4. Install shift bracket assembly.

5. Pivot rocker arms in place and turn adjusting nuts the amount necessaryto eliminate lash.

Valve Lash Adjustment Adjust valve lash whenlifter

is on basecircle of camas follows:

1. Remove distributor cap and crank engine until distributor rotor points to numberone cylinder terminal. In this position the piston in numberone cylinder is at top center on compressionstroke.

Both lifters are on base circle of cam and both valves can be adjusted.

E~ 2. Turn adjusting nut until all lash is removedfrom valve train. This can be determined by checking push rod side play by hand while turning nut slowly. At this point, turn adjusting nut one moreturn to pDacethe lifter plunger in center of its travel.

3. Follow steps 1 and 2 for each cylinder following firing order sequenceand adjust remaining valve one cylinder at a time. No further adjustment is necessary.

Donot attempt to turn the adjusting nut one full turn while the engine is operating. Adjustmentin this mannerwill not allow the lifters to bleed down.This wouldresult in valve train damage, probably bent push rods. For those whoprefer to adjust the valve lash while the engine is running, the preferred methodwould be to find the "zero lash" point as described aboveand then slowly turn the adjusting nut 1/4 turn. Wait for the lifter to bleed down (several enginerevolutions) and again turn adjusting nut 1/4 turn.

Continuethis adjust-and-wait cycle until nut is one completeturn down from "zero lash" point. Repeat sequence on remaining valves.

860001

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

circuit

breaker bracket. Connectcrankcaseventilation

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

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

Cylinder Head Assembly The condition of the cylinder head and valve mechanismsignificantly determines the power, performance and economyof the valve-in-head engine. Extreme care should be exercised when conditioning the cylinder head and valves. Maintain correct valve stem to guide clearance, correctly grind valves and valve seats, and properly adjust valves.

Removal 1. Removeintake and exhaust manifold as described under heading intake/Exhaust Manifomd.

2. Disconnect coolant hoses at thermostat housing. Disconnect spark plug wires and removespark plugs.

3. Disconnect fuel line retaining clips at thermostat housing and cylinder head. Disconnect wire harness from the temperature sending unit, leaving harness clear of clips on rocker arm cover.

Removethermostat housing assembly from front of cylinder head. Disconnect fueR line at the fuel pumpand remove° 4. Removethe rocker arm cover. Next, back off the rocker arm nuts and pivot the rocker arms to clear the push rods. Remove the push rods.

860{)02

5= Remove the ignition coil and bracket.

6. Removethe cylinder head bolts, cylinder head, and gasket.

Place the cylinder head on two blocks of woodto prevent damage to the head.

Disassembly [~ 1. Removerocker arms nuts, ball seats and rocker arms. Use tool J-8062, compressthe valve springs and removevalve stem keys. Release the spring compressor tool and remove exhaust valve rotator or intake valve cap, shield, spring and seals.

Z~ Safety Related

3-6

Engine;eng

2. Removevalves from bottom of cylinder head and place them in a rack in their proper sequenceso they can be assembledin their original positions Cleaning 1. Clean all carbon from combustion chambers and valve ports using tool J-8089. Inspect the cylinder headfor cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber. Clean carbon deposits from head gasket mating surfaces. ~] 2. Thoroughly clean the valve guides using tool J-8101.

Clean all carbon and sludge from push rods and rocker arms.

3. Clean valve stems and heads on a buffing wheel. Inspect the valve for burned head, worn seat, cracked faces, or damaged stems.

4. Washall parts in cleaning solvent and dry them thoroughly.

Checkfit of valve stemsin their respective bores.

E~] 5. Measurevalve stern clearance as follows: Clampa dial indicator on one side of the cylinder headrocker armcover gasket rail, locating the indicator so that movementof the valve stem from side to side (crosswise to the head) will cause a direct movementof the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide. With the valve head droppedabout 1/16 in. offthe valve seat; movethe stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceedsspecifications it will be necessaryto reamvalve guides for oversize valves as outlined= Excessive valve stem to bore clearance will cause lack of power, oil consumption, rough idling and noisy valves, and may cause valve breakage.Insufficient clearance will result in noisy and sticky functioning of the valves and disturb engine smoothness of operation, intake and exhaust valve stem to bore clearance should be 0o001-0.0027 in. (0,025-0,007 mm). By using micrometer and a suitable hole gauge, check the diameter of the valve stem in three places; top, center and bottom. Insert hole gauge in valve guide bore, measuring at the center. Subtract highest reading of valve stem diameter from valve guide bore center diameter to obtain valve to valve guide clearance. If clearance is not within limits use next oversize valve and ream bore to fit using suitable reamer.

860004

t

[~ 6. Checkvalve spring tension with tool J-8056 spring tester.

860005

Onall models, springs should be compressed to 121/s2 in. at which height it should check 78-86 pounds (35,5-39,0 kg). Weak springs affect power and economy and should be replaced if below 70 pounds. (31,8 kg)

Engme/eng

3-7

860006

7. Checkvalve lifters for free fit in block. Theendthat contactsthe camshaft should be smooth. If this surface is worn or rough, the lifter should be replaced. If lifter is damaged,check the corresponding camshaft lobe for damage.

Repair 1. Valve GuideBore: Valves with oversize stems are available for inlet and exhaust valves in the following sizes: 0.0003 in., 0.015 in., and 0.030 in.

Use the 11/32 in. diameter reamer sizes from reamer tool set J-5830-02 which are: J-4822 standard; J-5830-1,0.003 in oversize, J-5830-2, 0.015 in. oversize and J-5830-3, 0.030 in. oversize to reamthe bores for the newvalves.

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

a.

860007

oversize stud without reaming

Remove old stud by placing tool J-5802-01 over the stud. mnstall nut and fiat washer, and removestud by turning nut. b. Reamhole for oversize stud. Usetool J-5715for 0.003 in. oversize and tool J-6036 for 0.013 in. oversize.

C, Coat press-fit

area of stud with a hypoid axle lubricant.

Install new stud using tool J-8880. Tool should bottom on head.

3. Valve Seats" Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the powerand performancebuilt into it.

Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve headwill be properly carried away.

86O0O8

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

3-8

860009

Engme/eng

Regardless of what type of equipment is used, however, it is essential that valve guides be free from carbon or dirt to ensure proper centering of pilot in the guide. a. lnstall expanding piBot in the valve guide bore and expandpiJot by tightening nut on top of pilot. b. Place roughing stone or forming stone over pilot and just clean up the valve seat. Usea 46° stone for both the inlet and exhaust valve seats.

Removeroughing stone or forming stone from pi~ot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smoothfinish. d. Narrowdownthe valve seats to the proper width for the intake and exhaust. See Engine Specifications. °This operation [s done by grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head care= fully to remove all chips and grindings from above operations.

[5~ ~ Valve seats should be concentric to within 0.002 in. total indicator reading.

4. Valves: Valvesthat are pitted can be refaced to the proper angle, ensuring correct relation between the head and stem on a valve refacing machine. Valve stems which showexcessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be groundon part or alJ of the valve headdue to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this knife edge. If the edgeof the valve headis less than 1/32 in. thick after grinding, replace the valve.

If necessary, dress the valve refacing machinegrinding °wheelto makesure it is smoothand true. Set chuckat 45 mark for grinding valves. b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheel by movingthe lever to the left. d.

Engme/eng

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

3-9

860010

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

@

f. Removevalve from chuck and place stem in "V" block.

Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem.

I~ Only the extreme end of the valve stem is hardened to resist wear. Donot grind end of stern excessively. g. After cleaning valve face and cylinder headvalve seat of grinding particles, makepencil marksabout 1/4 in. apart across the valve face, place the vaBve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve.

860012

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

860013

Assembly r-~ 1. Starting with number one cylinder, place the exhaust valve in the port, and place the valve spring (~ and cap ® in position. Place spring and cap on exhaust valves. Then, using tool J-8062, compressthe spring and install the oil seal © and valve keys @.See that the seal is flat and not twisted in the valve stem groove and that the keys seat properly in the valve stem groove. [~ Place vabve springs in position toward the cylinder head.

with the closed coil

end

2. Assemblethe remaining valve, valve springs, spring caps, oil seals and valve keys in the cylinder head using tool J-8062. Check seals by placing a vacuumcup over valve stem and cap, squeeze vacuumcup to makesure no oil leaks past oil seal.

860014

[~ 3. Check the installed height of the valve springs using a narrow, thin scale to measurefrom the top of the shim or spring seat in the head, to the top of the valve spring shield. If this is found in excess of 12s/s2 in., install a valve spring seat shim, approximately 1/16 in. thick. At no time should the spring be shimmed to give an installed height of less than 121/32 inch.

If springs are to be changedwith cylinder head installed, refer to Valve Spring and Seal Repair, in 5.7 GL, GSand Gi Engine Section.

3-10

860015

EngMe/eng

Installation 1. Thegasket surfaces of both the headand the block must be clean and free of any foreign matter, andfree of nicks or heavyscratches.

REAR

2. Cylinder headbolt threads in the block mustbe cleanedas well as the threadson the cylinder headbolts. Dirt will affect bolt torque.

[3~ 3. Place a newcylinder headgasket in position over the dowelpins in the cylinder block. Onengineswith a steel gasket coat both sides of a new gasket with a thin, even coat of Volvo Penta Gasket Sealing Compound P/N i 161231-4.Toomuchsealer will hold the beadsof the gasket awayfrom the I:)mockor head. [~ The 3.0 Litre engine has a special marine head gasket. Do not substitute an automotiveheadgasket. [__4~_4. Carefully guide cylinder headinto place over dowelpins andgasket.

Coat threads of cylinder headbolts with PermatexNo. 2 P/N 910032.install the bolts and run themdownto the block. [~ 5. Tighten the cylinder headbolts, with a torque wrench,in three progressive steps following the sequenceshown. ¯ Step 1 -35ft. Ibs. (47 N m) ¯ Step 2 - 85 ft. Ibs. (88 N.m) - Step 3 - 95 ft. Ibs. (129 N.m) 8. Install valve push rods downthrough openingsin the cylinder headand seat themin lifter sockets. iE~ 7. install rocker arms,balls and nuts and tighten rocker armnuts until all pushrod play is takenup.

8. Install thermostathousingusing a newgasket. Attach coolant hoses.

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

FRONT 860016

10. Install coil and connectboth connectorsto coil. Connectwire to temperature sendingunit.

1 t. Cleanmanifoldgasket surfaces and install newgasket over manifold studs. Position manifoldand slide it into place over the studs, makingsure it seats against the gasket. Install bolts and nuts and tighten as described under heading Intake/Exhaust Manifold.

ErJgine/eng

3-11

860017

12. Adjust valve lash as outlined under heading Valve Lash Adjustment.Install rocker arm cover and gasket. Tighten screws to 65 in. Ibs. (7,3 N.m). t3. Connectthrottle linkage and adjust.

14. Connectfuel line and overflow hoseto carburetor and install fuel line support clamps(two). Cleanand install flame arrestor.

Z~ 15. Start engine and check for fuel, cooUant, and exhaust leaks.

Timing Gear Cover Removam 1. Drain coolant from block and exhaust manifold.

Z~ 2. Securely support engine and removefront engine mount.

3. Removealternator and power steering belts. Next remove harmonic balancer and pulley assembly from pulley hub. r~ 4. Install puller tool J-6978-Eto pulley hub with three 3/8-24 x 2 in. bolts and removehub. Removepuller tool.

5. Removecirculating

860019

pumppulley.

6. Removecrankcase oil drain tube cap and withdraw oil with a suction pump. Disconnect oil drain tube and removeoil pan.

7. Removetiming gear cover attaching screws. Removecover and gasket.

Oil SeamReplacement 1. After removingtiming gear cover, pry oil seal out of cover from front with a large screwdriver.

2. Install newlip seal with lip (openside of seal) facing inside of cover, and drive or press seal into place with tool J-23042.

868020

Oil Nozzle Replacement [~ Removeold nozzle with pliers. Drive new nozzle in place using a suitable light plastic or rubber hammer.

Z~ Safety Related

3-12

860021 Engme/eng

Timing Gear Cover Installation 1. Clean gasket surface on block and cover.

2= Install centering tool J-23042over end of crankshaft.

3. Coat both sides of a newgasket with a light grease, and stick gasket in position on block.

[4~ 4. Place cover over centering tool and install cover screws.

Tighten screws to 80 in= Ibs. (9 N.m) and removecentering tool.

860022

5. install oil pan using newgaskets. Tighten 1/4-20 inch screwsto 80 in. Ibs. (9 N.m). Tighten5/16-18 inch screwsto 165in Ibs. (18,6 N.m).

6. Connectoil drain tube to oil pan.

it

HarmonicBalancerInstallation i-5~ E~] 1. Coat oil seal contact area on harmonicbalancer with engine oil. Position hub over crankshaft and key, and start hub into position with a mallet. Using tool J-5590, drive hub onto crankshaft until it bottomsagainst crankshaft gear. ~ Crankshaft extends slightly through hub and a hollow tool i,,~ necessaryto drive hub completely into bottomedposition.

E~ 2. There are two 3/8 in. holes and one s/16 in. hole that must be matchedon hut) in order to properly position timing mark. :3, Install circulating pumppulley. ,4. Install alternator specifications.

and power steering belts and adjust to

5. Install front engine mount.

860023

If

~J’~ ,~ .Z "t /

’ J

& Fill engine crankcasewith proper amountof oil.

7° Lakeor tank test unit and checkfor leaks.

6 860024

En,geneleng

3-13

Camshaft MeasuringCamshaftLift [~E] Removeboth connectors from ignition

coil.

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

of each

1. Removevalve cover and rocker arms. i~ 2. Position indicator with ball socket adapter (Tool J-8520) push rod.

3. Rotate crankshaft slowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position.

4. Set diaa indicator on zero. Rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, untiB the pushrod is in the fully raised position.

5. Comparethe total lift recorded from the diaP indicator with specifications. Thecorrect lift is 0.253 inch - 0.005 inch (6,426 0,127 mm).

6. Continueto rotate the crankshaft until the indicator reads zero.

This will be a check on the accuracy of the original indicator reading.

860026

7. If camshaft readings for all lobes are within specifications, removedial indicator assembly, install and adjust valve mechanism.

Removal 1. Withdraw oil from crankcase. Drain coolant from block and exhaust manifold.

2. Removevalve cover and gasket. Loosen valve rocker arm nuts and pivot rocker arms clear of push rods.

3. After noting position of rotor, removedistributor.

4. Removecoil, valvelifters.

side cover, and gasket. Removepush rods and

5. Remove crankshaft pulley and hub. Disconnect oil drain tube.

Removeoil pan and timing gear cover. [~ 6. Removetwo camshaft thrust through holes in camshaft gear.

plate screws by working

3-14

860027

Engme/eng

7. Removethe camshaft and gear assembly by pulling through the front of the block.

L~ Support shaft carefully damagecamshaft bearings.

it

out

when removing so as not to

"]’he camshaft has three bearings, all with the samejournal diameter of 1.8692 in. to 1.8682 in. (4,7478 to 4,7452 cm). These dimensions should be checked with a micrometer for an out-ofround condition. If the journals exceed 0.001 in. (0,025 mm) out-of-round, the camshaft should be replaced= ]’he camshaft should also be checked for alignment. The best methodis by use of "V" blocks and a dial indicator. The dial indicator will indicate the exact amountthat the camshaftis out of true. If it is out morethan 0.002 in. (0,051 mm)dial indicator reading, the camshaft should be replaced. Whenchecking, the high reading of the dial indicator indicates the high point of the ,,;haft. Examinethe camshaft bearings and if any bearing needs replacement, replace aim bearings.

Gear and Thrust Plate [=-3~] If the inspection indicated that the camshaft,gear and thrust plate were in good condition, the camshaft end play should be checked.This clearance should be 0.001 in. to 0.005 in. (0,025 to 0,127 mm).

D, isassembly [=-4~ If the inspection indicated that the shaft, gear or plate should be replaced, the gear must be removedfrom the shaft, Support the camshaft gear and press shaft out of gear. [~o-~ Thrust plate must be positioned so that woodruff key in ,;Ihaft doesnot damage it whenshaft is pressedout of gear. Also, support the hub of the gear or the gear will be seriously damaged.

Assembly To assemblecamshaft gear, thrust plate and gear spacer ring to camshaft, proceed as follows: 1. Firmly support shaft at back of front journal in an arbor press.

Place gear spacer ring and thrust plate over end of shaft, and install woodruff key in shaft keyway.

2. Install camshaftgear and press it onto the shaft until it bottoms against the gear spacer ring. Theend clearanceof the thrust plate ,,~hould be 0.001-0.005in. (0,025-0,127 ram)

E ngine/eng

3-15

86O028

r

Camshaft

Bearings

Camshaftbearings can be replaced while the engine is disassembled for overhaul, or without complete disassembly of the engine after camshaft and flywheel have been removed. Operation is easier if crankshaft is also removed. See Crankshaft in this section.

1. With camshaft and flywheel removed,drive out expansion plug for rear cambearing by driving from inside.

860030

2. Position bearing pilot in inner bearing. Instal[ nut on puller screw far enoughso puller screw can be threaded into pilot while nut extends out front of block.

3. Install removersection onto puller screw, and then install screw through cambore and thread it into pilot. [~ 4. Using two wrenches, hold screw shaft and turn puller nut to removebearing. [~ 5. Removepilot from shaft and install on drive handle with shoulder to handle. Drive out front and rear bearings from outside to inside of bnock. installation Inner bearing should be installed first bearing with screw shaft.

to prevent damagingend

860031

Bearing O.D.’s for number one and number two are 1.999-2.001 in. (5,077-5,083 cm) and numberthree is 2.009-2.011 in. (5,103-5,108cm).

1. Remove handle from pilot. Install

inner bearing on pilot.

2. Position inner bearing and pilot to rear of inner bearing bore.

Install screwshaft (with removeradapter on it} through the block from front of engineinto pilot.

3. Align oil hole on bearing with oil hole from oil gallery. Snug puller nut against adapter. [~ 4. Using two wrenches, hold screw shaft and turn puller nut to pull bearing into place.

Oil hole is on top side of bearing and cannot be seen during installation. First align bearing oil hole with oil hole in bore, and mark opposite side of bearing and block at bore to easily index oil hole during installation.

3-16

860032

Engme/eng

5,. Attach drive h~mdle to pilot, bearing on pilot.

then place new number one

-2--j 6. Align oil hole on bearingwith oil hole from oil gallery and I,drive bearing in from front of engine.

I:~ ~ The front bearing must be driven approximately 1/8 in. behindfront of cylinder block to uncoveroil hole to timing gear oil nozzle.

7. Repeatstep (5) and (6) aboveto drive rear bearing into position from rear of block.

L]~ Rear bearing installed rear cambearing bore.

8. Install

860033

position is flush with inner edge of

a newexpansionplug at rear bearing.

CamshaftInstallation I. If crankshaft has beenremoved,install it at this time. Follow procedures under the tithe Crankshaft in this section. If a new camshaft is to be installed, coat cam lobes with G.M. Super Engine Oil Supplement(G.M. P/N 1051858)and add rest of can crankcaseoil.

860034

2. Install the camshaftassemblyin the engineblock, being careful not to damagebearings or cam.

[-5~ 3. Turn crankshaft and camshaft so that the valve timing marks on the gear teeth will line up, then push camshaft into position. Install camshaftthrust plate to block screwsand tighten them to 72-90 in. Ibs. (8-10 N.m).

[-6~] 4. Checkcamshaft and crankshaft gear runout with a dial indicator. The camshaft gear runout should not exceed 0.004 in. ((I,102 mm)and the crankshaft gear runout should not exceed 0.003 in. (0,076 mm).

860035

5. ff gear runout is excessive, the gear wiJ~ have to be removed, aind any burrs cleaned from the shaft or the gear replaced.

E.7~] 6. Checkthe backlash betweenthe timing gear teeth with a narrow feeler gaugeor dial indicator. The backlash should not be less than 0.004 in. (0,102 mm)nor morethan 0.006 in. (0,152 ram).

7,, Install timing gear cover with newgaskets. Install oil pan with newgaskets and sealer. Connectoil drain tube.

860036

8, Install harmonicbalancer as described under title Coverin this section.

Timing Gear

9. Install valve lifters and pushrods. Install side cover with a new gasket and sealer. Attach coil and wires, tnstall distributor, positioning rotor to reference mark.

10. Pivot rocker arms over push rods. Adjust valve lash as outlined under heading Valve Lash Adjustment.

11. Add oil to engine. Install the alternator and powersteering belts, then adjust tension. Checkand adjust timing.

Crankshaft Removaland Installation 1. Removemain bearing caps and connecting rod caps and lift crankshaft out of cylinder block. Pushpistons to top of bores.

2. Inspect the crankshaft: Main bearing journals are ground to 2.2983-2.2993 in. (5,83775,8402 cm).

Crankpin journals are ground to 2.099-2.100 in. (5,331-5,334 cm).

These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in.

(0,025 mm) out-of-round or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings.

The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the front center and rear center journals using a dial indicator. The runout limit of eachof these journals is 0.002 in. (0,051 mm).If the runout exceeds 0.002 in. (0,051 ram), the crankshaft must repaired or replaced.

3. Removerear main bearing oil seal.

4. Remove old bearings from cylinder block and caps. Install bearings in the cylinder block and caps.

new

Main bearings with oil holes are the upper halves of the bearings and are inserted between the crankshaft and cylinder block.

5. Oil crankshaft journals and carefully place the crankshaft in the bearings.

3-18

Engme/eng

6. Install all bearing caps and bolts. Tighten all mainbearing cap bolts, except the rear mainbearing, to 60-70 ft. Ibs. (81-95 N.m).

Whentightening rear main bearing cap, tighten bolts to 10-12 ft.

Ibs. (14-16 N.m) first, then tap end of crankshaft rearward with lead hammer(this witB locate bearing cap and bearing). Thentap crankshaft forward (this will line up both upper and lower crankshaft bearing thrust surfaces). Proceedwith final tightening of rear mainbearing cap bolts to 60-70 fto Ibs. (81-95 N-m).

7. Checkmain bearing clearance and crankshaft end play. Install new rear bearing oil seal. Install connecting rod bearings and caps.

Connecting Rod Bearings Connecting rod bearings are available in standard sizes and u~ndersizesof 0.001 in., 0.002 in., 0.010 in. and0.020 in. (0,025, 0,051, 0,254, 0,508 mm). These bearings are not shimmedand when clearances becomeexcessive the next undersize bearing should be used.

E~ Do not file

rod or rod caps.

Removaland Inspection 1. Withdrawoil, disconnect oil drain tube and removeoil pan.

2. Removethe connecting rod bearing cap. Wipe bearing and crankpin clean of oil. [~.1~ 3. Place a piece of Plastigagegaugingplastic the full width of the bearing on crankpin (parallel to the crankshaft).

860037

4. Reinstall the bearing cap and evenly tighten the retaining nuts to 35 ft. Ibs. (47 N.m).

[-t.~o-’~ Donot turn crankshaft with the gaugingplastic installed. ["2=-] 5. Removethe bearing cap and, without removing the gauging plastic, check its width at the widest point with the Plastigage scale. [=N~ If the crankpin is out-of-round be sure to fit the bearing to file maximum diameter of the crankpin. If the flattened plastic is Blot uniform from end to end in its width, the crankpin or bearing is tapered, has a low spot or someother irregularity.

Checkthe c’rankpin with a micrometer for taper if the flattened gauging plastic indicates morethan 0.001 in. (0,025 mm)difference.

860038

Eng ...... g

3-19

6. ffthe reading is not over 0.0009 in. (0,0229 mm)or not less than 0.0014 in. (0,0356 mm)the fit is satisfactory. If however, the clearances are not within these limits, repaace the bearing with the proper undersize bearing. [~ The bearings are not adjustable and no attempt should be madeto adjust by filing or shimmingthe bearing caps.

Installation Newbearing clearance should be 0.00085-0°00135 in. (0,021590,03429 ram).

1. Rotate the crankshaft after bearing adjustment to be sure the bearings are not too tight.

Ell 2. Check connecting rod end clearance between connecting rod cap and side of crankpin. See Engine Specifications for clearance.

3. Install oil pan with newgaskets and seals. Connectoil drain tube. Refill with engineoil.

860039

Crankshaft Bearings The main bearings are of the precision insert type and do not utilize shims for adjustment. If the clearances are found to be excessive, a new standard or oversize bearing, both upper and Jowerhalves, will be required.

If, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirements will be determined by bearing clearance.

The clearance may be checked by using PRastigage gauging plastic. Whenone bearing is being checked, all the other main bearing caps must be in place and tightened to specifications.

The main bearings used as service replacement are of high quality with close tolerances of fit and will not require line reaming on installations.

The close dimensional tolerances ensure an equalized bearing surface at all points on the crankshaft whenreplaced in sets. !~ Main bearings crankshaft.

may be replaced

without

removing the

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

3-20

Engme.’eng

2. Removethe spark plugs.

3. Removecap on main bearing requiring replacement and removebearing from cap. Install a main bearing removing and installing tool in the oil hole in the crankshaft.

I~ Use tool J-6098-01. If such a tool is not available, a cotter pin maybe bent as required to do the job.

4. Rotate the crankshaft clockwise as viewedfrom the front of the engine. This will roll upper bearing out of engine. !5. Oil newupper bearing and insert plain (unnotched)end of the bearing betweencrankshaft and indented or notched side. Rotate the bearing into place.

6. Install new bearing in bearing cap. The rear main bearing journal has no oil hole drilling. To removethe upper bearing half proceed as follows after cap is removed: a. Use a small drift punch and hammerto start the bearing rotating out of block. b. Usea pair of pliers to hold the bearing thrust surface to the oil sginger, and rotate the crankshaft to pull bearing out.

C.

d.

To install start the bearing (side not notched} into notched side of block by hand, then use pliers as before to turn bearing half into place.

The last 1/4 in. movement maybe doneby holding just the slinger with pliers (taped jaws) or tap in place with a drift punch.

7. Check bearing clearance per paragraph below.

Main Bearing Clearance Plastigage gaugingplastic is a wa×-Iike plastic material which will compress evenly between the bearing and journal surfaces without damagingeither surface. To obtain the most accurate results with gauging plastic, certain precautions should be observed, ff the engine is upside down, the crankshaft wiln rest on tlhe upper bearings and it can be assumed that the total clearance can be measuredbetween the cap bearing and journal. t’_l~ To ensure the proper seating of the crankshaft, the rear main bearing oil seal should be removedand all bearing cap bolts should be at their specified torque. In addition, preparatory to ,checking fit of bearings, the surface of the crankshaft journal and bearing should be wiped clean of oil.

1. Starting with the rear main bearing, removebearing cap.

I]~ Wipe oil from journal gaugingplastic.

E.n, gine!eng

and bearing cap before applying

3-21

860040

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

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

3. Install the bearing cap and evenly tighten the retaining bolts to 60-70ft. Ibs. (81-95 N.m).

4. Removebearing cap. The flattened gauging plastic will be found adhering to either the bearing or journal. On the edge of gauging plastic packing envelope there is a graduated scale measuring in thousandths of an inch.

l "\

8e0o41

i~ 5. Without removing the gauging plastic, check its compressed width (at the widest point) with the graduations on the gauging plastic envelope.

Normally, main bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround journal be sure to fit to the maximumdiameter of the journal. If the bearing is fitted to the minimumdiameter of the journal, and the journal is out-of-round 0.001 in. (0,025 mm) more, interference betweenthe bearing and journal will result in rapid bearing failure. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating a taper, low spot, or other irregularity of the bearing or journal. Be sure to check the journal with a micrometer if the flattened gauging plastic indicates more than 0.001 in. (0,025 mm)difference.

6. If the bearing clearance is not over 0.0035 in. (0,0889 ram) (worn) or 0.003 in. (0,076 mm)(new), or hess than 0.001 in. mm),the bearing is satisfactory. If the clearance is not within these limits replace the bearing.

If a newbearing cap is being installed and clearanceis less than 0.001 in. (0,025 mm), check for burrs or nicks; if none are found then install shims as required.

7. A 0.002 in. (0,051 ram) undersize bearing may produce the proper clearance. If not, it wilJ be necessary to regrind the crankshaft journal for use with the next undersize bearing. [~ Bearings are available in standard sizes and various undersizes. See your parts catalog.

8. Oil newbearings with engine oil prior to installing end caps.

Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to see that there is no excessive drag.

3-22

Englne/eng

[3--7 9. Checkthe end play by forcing the crankshaft to its extreme front position. Checkat the front side of the rear main bearing with a feeler gauge. This clearance should be from 0.002-0.006in.

(0,051-0,152 ram).

110. Install a newrear mainbearing oil seal in the cylinder block and main bearing oil cap as described beBow.

Rear Main Bearing Oil Seal Replacement [~ Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft sealing surface.

[4~ 1.Insert a screwdriver into the notches provided in the seal retainer and pry the seal out. Take care not to damagethe crankshaft sealing surface.

860043

2. Inspect chamferon crankshaft for grit, loose rust, and burrs.

Clean seal running surface on the crankshaft with a non-abrasive ,cleaner. h-5~ 3. Lubricate the inner and outer diameter of new seal with ,engine oil. Install the seal on J-35621. Position J-35621against the crankshaft. Threadthe attaching screws into the tapped holes in the crankshaft.

4. Tighten screwssecurely. This will ensure the seal is installed :squarely over the crankshaft. Turn handle until it bottoms then remove J-35621.

Oil Seal Retainer Replacement 1. RemoveFlywheel and oil pan. Removescrews, nuts and seal retainer. Removegasket.

DR1878

;2. Remove rear crankcaseoil seal as previously stated and clean gasket surfaces on block and seal retainer. [~o-’~ Wheneverseal retainer is removed,a new retainer gasket and rear crankshaft oil seal mustbe installed.

3. Attach gasket to block. No sealer is required, install seal retainer, screwsand nuts. Tighten to 135 in. Ibs. (15,3 N-m).

4. Install oil pan. install rear crankshaft oil seal as outlined previously. Install flywheel.

DR1879

Piston and Connecting Rod Piston and Rod Removal I, Withdrawcrankcaseoil. Disconnect oil drain tube. Remove oil pan.

2. Drain coolant from block and exhaust manifold, then remove cylinder head.

En~,ne/e.g

3-23

3. Removeany ridge and/or deposits from the upper end of the cylinder bores with a ridge reamer.

Movepiston to the bottomof its travel and place a cloth on top of piston to collect the cuttings. After ridge and/or deposits are removed,turn crankshaftuntil piston is at the top of its stroke and carefully removecloth with the cuttings.

4. Checkconnecting rods and pistons for cylinder numberidentification and if necessary, mark them.

5. Removeconnecting rod cap nuts and caps. Push the rods away from the crankshaft and install caps and nuts loosely to their respective rods.

6. Push piston and rod assemblies awayfrom crankshaft and out of the cylinders.

It will be necessary to turn the crankshaft slightly to disconnect someof the rods and push them out of the cylinder.

Piston and Rod Disassembly 1. Install pilot of piston pin removingand installing tool J-24086 on piston pin.

2. Install piston and connecting rod assembly on support and place assemblyin an arbor press. Press pin out of connecting rod.

3. Removeassembly from press. Removepiston pin from support and removetool from piston and rod.

4. Piston pins are a matchedfit to the piston and not available separately. Piston pins will not becomeloose enoughto cause a knock or tapping until after prolonged use. In such cases a new piston and pin assembayshould be installed.

Piston pins should be capable of supporting their ownweight in either pin boss whencoated with light engine oil at 60° F. Higher or lower temperatures will cause false indications. Pistons and pins are serviced as assemblies.

Checkfit of usedpiston pins. Usea dial bore gaugeor telescoping snap gaugefor the bore, and a micrometerfor the pin. Wearlimit on piston pin is production clearance plus 0.001 in. (0,025 ram).

Replace piston and pin assemblyif wear is excessive.

86OO45

Cneaningand Inspection Clean varnish from piston skirts and pins with a cleaning solvent.

DONOTWIREBRUSHTHEPISTONSKIRT. Clean the ring grooves with a groove cleaner, and makesure oil ring holes and slots are clean.

3-24

Engme/eng

Inspect the piston for cracked ring lands, skirts or pin bosses, wavyworn ring lands, scuffed or damaged skirts, or eroded areas at top of the piston. Replace pistons that are damagedor otherwise showsigns of excessive wear.

Piston and Rod Assembly 1. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin.

2. Position connectingrod in its respective piston so that flange or heavy side of rod at the bearing end will be towards front of piston (cast depressionin top of piston head).

3. ~nstall piston pin @on installer pilot @in support (~.

® and pilot spring @and

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

5. Place support on arbor press, start pin into piston and press on installer until pin pilot bottoms.

6. Removeinstaller and support assembly from piston and connecting rod assembly. Check piston pin for freedom of movement in piston bore.

Piston Rings Piston rings are furnished in standard sizes as well as several oversizes. See your parts catalog.

Oil contron rings used on all engines consist of two segments (rails) and a spacer.

Compression rings in all engines are the deepsection twist type, 0.0775-0.0780 in. (1,969-1,981 mm)wide.

This type compressionring takes its name, twist type, from its installed position which is cocked or twisted. It assumesand maintains this position for life becausethe upper edge of its diameter is chamfered, making the ring unbalanced in cross section.

J~ All compression rings are marked with the letter "GM" cast in the upper side of the ring. Wheninstalling compression rings, makesure the side marked"GM" is toward the top of the piston.

1. Removepiston rings by expanding them and sliding them off ’the ends of the piston. Tool No. J-8037 is available for this purpose.

Englne/eng

3-25

i@©® 860047

2. Checkpiston ring groovesby carefully removingall particles of carbon. Also check for burrs or nicks that might cause rings to hang up.

Installation 1. Select rings comparablein size to the piston being used° It is important that each ring be fitted to its individual cylinder for proper gap spacing and to its individual piston and groove for proper clearance.

2. Slip the ring in the cylinder bore; then, using the head of a piston, press the ring down into the cylinder bore about two inches. [~= Using a piston in this way will pDacethe ring square with the cylinder walls. [~ 3. Checkthe space or gap betweenthe ends of the ring with a feeler gauge.

4. ff the gap betweenthe endsof the ring is belowspecifications, removethe ring and try another for fit.

860848

5. Fit eachring separatelyto the cyninder in whichit is going to be used.

6. Newpistons, rings and cylinder bores wear considerably during seating and gaps widen quickly; however, engine operation will not becomeseriously affected if ring gapsdo not become greaterthat 1/32 in. [~ 7. Slip the outer surface of the compression ring into the piston ring groove. Roll the ring entirely around the groove to makesure that the ring is free and does not bind in the groove at any point. If binding occurs, the cause shouId be determinedand removedby carefully dressing ,with a fine cut file. However,if the binding is causedby a distorted ring, install a newring.

,,\

8. install the oil ring spacerin the oil ring grooveand positLongap in Line with piston hole. HoLdspacerendsbutted and install steel rail on top side of spacer. Position gap at least one inch to left of spacer gap, then install second rail on lower side of spacer.

Position gap at least one inch to right of spacer gap. g. Flex the oil ring assemblyin its grooveto makesure ring is free and doesnot bind in the grooveat any point. If binding occurs, the cause should be determined and removedby carefully dressing with a fine cut file. However, if the binding is caused by a distorted ring, install a newring°

3-26

860050

Englne/eng

[] 10. Proper clearance of the piston ring in its piston ring groove is very important in maintaining engine performance and in preventing excessive oil consumption.Therefore, whenfitting newrings, the clearances betweenthe top and bottom surfaces of the ring grooves should be inspected.

EEl 11. The compression rings should be fitted clearance is 0.0020-0.0035in. (0,051-0,089 ram).

so that the

12. Assemblethe rings to the pistons as they are fitted and makea final test of the ring fit in the groovesby repeating the fitting procedure given above.

Expanderends must not align with the ring gap.

Piston and Rodinstallation 1. Lightly coat pistons, rings and cylinder walls with light engine oil.

2. With bearing caps removed, install bearing cap bolts.

tool J-6305-01 on

[~] 3. Install each piston in its respective bore, using tool J-8037 on each assembly. The side of the piston with the cast depressionin the headshould be to the front of the cylinder block and the oil hole on connecting rod toward the camshaft side of the engine. Guide the connecting rod bearing into place on the crankshaft journals with the long deta[t of tool J-6305-01. Use J-8037 to compresspiston rings.

4= Oil bearings and install bearing caps. Install cap retaining screws and nuts. Tighten nuts to 35 ft. Ibs. (47 N.m). Checkthe bearing clearance as described previously.

5. Install oil pan gaskets, seals and oil pan. SeeOiUPan. Connect oil drain tube.

860051

6. Install cylinder head gasket and head. See Cylinder Head |nstallation.

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

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

860052

I-:ngme!eng

3-27

[~ 2. Checkthe cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator (use Tool J-8087). Set the gaugeso that the thrust pin must be forced in about 1/4 in. to enter gaugein cylinder bore.

Center gauge in cylinder and turn dian to "O". Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine the out-ofround condition. If cylinders were found to have morethan 0.002 in. (0,051 mm)out-of-round, boring wi[[ be necessary.

Repair The performanceof the following operations is contingent upon engine condition at time of repair.

If the cylinder block inspection indicated that the block was suitabne for continued use except for out-of-round or tapered cylinders, they can be conditioned by honing, or boring and honing.

860053

if the cylinders were found to haveless than 0.005 in. (0,127 mm) taper or wear, they can be conditioned with a honeand fitted with 0.001 in. (0,025 mm)oversize pistons. A cylinder bore of less than 0.005 in. (0,127 mm)wear or taper maynot entirely clean up when fitted to a 0.001 in. (0,025 mm)oversize piston. If it is desired entirely cneanup the bore in these cases, it winl be necessaryto rebore for an oversize piston. If morethan 0.005 in. taper or wear exists, they should be bored and honed to the smalUestoversize that will permit completeresurfacing of all cylinders.

Piston Selection Replacement pistons are available in two sizes, see the appropriate parts catalog for part numbers.Thesize identification of the piston is markedin ink on the piston top.

To determine the correct size of piston needed, measure the cylinder bore with a telescope gauge and micrometer, and subtract the base cylinder bore diameter, 4.000 in. (10,160 cm) from the measureddiameter. Next locate this dimension on the Piston Selection Chart. The numbershownon the chart in the box above the dimension is the marking on the piston which should be used.

3-28

Engme/eng

Example"’A": Cylinder Bore Measurement Base Cylinder Bore Diameter

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

Difference

0.002 in. (0,051 ram)

4.000 in. (10,160 cm)

The numberin the box above 0.002 (0,051 ram) in is $7. Therefore, in this case a 0.001 in. (0,025 mm)oversize piston marked would be used.

Example"B": Cylinder Bore Measurement Base Cylinder Bore Diameter

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

Difference

0.032 in. (0,813 ram)

4.000 in. (10,160 cm)

The numberin the box above0.032 in. (0,813 ram) is 4. in this example, a 0.030 in. (0,762 mm)oversize piston marked4 would be used.

SERVICE PISTON MARKING

"~-

o

o

.

II

d

.d o.

o

.

.

o

~.

.

DR4649

13oring 1. Before using any type boring bar, the top of the cylinder block should be dressed to remove any dirt or burrs. This is very important. Otherwise, the boring bar maybe tilted which would result in the reboredcylinder wall not being at right angles to the crankshaft.

2. The piston to be fitted should be checkedwith a micrometer, measuringjust below the lower ring groove and at right angles to the piston pin. The cylinder should be bored to the samediameter as the piston and honed to give a clearance of 0.0025-0.0035in.

(0,064-0,089 mm).

3. The instructions furnished by the manufacturer of the equipment being used should be carefully followed.

Eng,,e/o,~

3-29

Honingand Piston Fit 3. Whenthe cylinders are to be honedonly for use of a standard piston or for final finishing after they havebeenreboredto within 0.002 in. (0,051 mm)of the desired size, they should be finished with a hone. Roughstones maybe usedat first and fine stones for the final operation.

2. Place the honeinto a cylinder bore and expandthe stones until the honecan just be turned by hand. Connecta 1/2 in. (0,217 mm) electric drill to the hone and drive hone at drill speed while moving hone up and down entire length of cylinder until hone begins to run free. During this operation a niberal amountof kerosene should be used as a cutting fluid to keep the stones of the hone cUean. Move hone slowly up and down with rough stones, but movehone up and downrapidly enoughwith the fine stones to producea final bore finish of very fine surface scratches in a cross-hatch pattern of approximately 45° to 60°. The marks should be clean but not sharp, and free from embedded particles or torn or folded metal.

3. Expandthe stones against the cylinder bore and repeat the honing operation until the desired bore diameter is obtained.

4. Occasionally during the honing operation, the cylinder bore shound be thoroughly cleaned and the piston selected for the individual cylinder checkedfor correct fit.

5. Checkfit

of the aluminumpistons in the following manner:

| ThoroughLy clean cylinder to removeall grit particles. a.

bores with soap and hot water

Measure the cylinder bore diameter with a telescope gauge and micrometer 21/2 inches (6,35 cm) from top cylinder bore at 90° from crankshaft axis.

b. Next measurethe diameter of the piston skirt just below the lower ring groove and at right angles to the piston pin.

C.

d,

e.

If the difference is greater than the maximum allowable (see Boring, step 2}, try another piston or lightly honethe cylinder bore to obtain the proper fit.

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

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

3-30

Eng,ne/eng

Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been bored to correct size. This type piston can be distorted through careless handling.

8. Thoroughly clean the cylinder bores with hot water and soap.

Scrubwell with a stiff bristle brush and rinse thoroughly with hot water. It is extremely essential that a good cneaningoperation be performed. If any of the abrasive material is allowed to remain in the cylinder bores, it will rapidly wearthe newrings and cylinder bores. In addition, the bearing will be lubricated by the contaminated oil The bores should be swabbedseveral times with light engine oil and a clean cloth and then wipedwith a clean dry cloth.

Cylinder should not be cleaned with kerosene or gasoline. Clean the remainder of the cylinder block to removethe excessmaterial spread during the honing operation.

860054

Distributor LowerBearing Thedistributor lower bearing is a bronze bushing pressedinto the lower side of the engineblock. Its upper inside diameterpilots the distributor shaft, and the outside diameter extending below the block pilots the oil pump.

Someengines have a thrust washer at the upper end of the bushing bore. The thrust washer, where used, maybe replaced at the sametime the bushing is replaced.

The lower bushing will ordinarily require only a clearance or wear check during engine overhaul. Whendistributor shaft-to-bushing clearance exceeds0.0035 in. (0,0889 ram) the bushing should replaced as follows with oil pumpand distributor removed: 1. Install tool J-9534-01 into bushing and ’using a slide hammer, remove the bushing.

Z~ Protect your eyes from fragments. Wearsafety glasses when striking these tools, handles, drivers, etc. Tool end maymushroomafter being repeatedly struck. Always grind off any rolled edges before using tool. Use soft face hammerswhenever possible.

2. Using a drift up through bushing bore, drive thrust washer (if installed) out of bore and removefrom block.

3. Clean bushing bore in block and check for burrs or damage.

4. If thrust washer was removed, start new washer in position in bore and drive into place using tool J-9534-01.

5. Usingtool J-9535with driver-bolt in driver handle, install driver into newbushing from large inside diameter.

860055

[~ 6. Place bushingand driver on block and drive the bushingin position.

Depthis determinedby toot bottomingagainst the block.

7. Remove tool from bushing. It is possible that the bushingwith minimum I.D. will collapseenough, duringinstallation, to slightly seize the installer arbor. If this happens,removeinstaller tool using slide hammer in driver bolt hole of driver handle. ~This will not damagethe bushing and the tool is designed for this purpose,shouldit occur.

Circunating Pump Removal 1. Openpetcocks on port side and drain coolant from block and exhaust manifold. Disconnectwater hose from circulating pump.

2. Loosenfour screwsholding circulating pumppulley to circulating pump.

3. Loosenalternator bracket bolts and removealternator belt. Remove circulating pumppulley and bolts. Unscrewbotts and removethe circulating pumpfrom the engine. ~Pult the pumpstraight out of the block first, impeller.

860057

to avoid damageto

Inspection If the seal is leaking replacethe pump.if the bearingis roughor allows excessivesidewaysmovement of the shaft, replace the pump.If the impelter has excessive erosion replace the pump.

Installation [ N~_.~t~This pumphas a special shaft and bearing assemblyand a special seal assemblyintended for marine service. Donot substitute with an automotive pump.

1. Apply VoVvoPenta Gasket Sealing Compound P/N t 181231-4to a new pumpto block gasket. Install pumpassemblyon cylinder block and tighten bolts securely.

2. Install circulating pump pulley. Attachalternator belt andadjust. Referto Generalinformationsection for specifications.

3. Connectcoolant hosesto circulating pump.Lake or tank test unit and checkfor leaks.

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

3-32

Eng,ne/eng

2. Removeoil gasket.

withdrawal tube. Removescrews, oil

pan and

Installation 1. Thoroughlyclean all gasket sealing surfaces. Apply RTVsealer to the front and rear of the block.

2. Install gasketon the block. Install oil pan. TightenI/,x20 screws to 80 in. Ibs. (9 N.m)ands/10x18screwsto 165 in. Ibs. (18,6 N.m).

Install oil drain tube andfill crankcasewith engineoil.

Oil Pump IN The oil pumpconsists of two gears(~ and a pressure relief valve ® enclosed in a two-piece housing ©. The pumpis driven from the distributor driveshaft which in turn is driven by a helix gear on the camshaft.

The oil pumpis flange mountedto the cylinder block with two bolts, and piloted on the outside of the lower distributor bronze bearing. Oil pressure passes through an opening in the mounting flange to the cylinder block, then into the full flow oil filter. The pumpcover is equipped with the pressure regulator valve that regulates oil pressure at approximately 40-60 PSI (135,1-202,6 kPa} at 2000 RPM.The pumpintake is of the fixed screen type. A meshscreen @filters out small particles of dirt and sludge which maybe present.

I~ A baffle incorporated on the intake screen has been designed to eliminate pressure loss due to suddensurging stops, turns, and acceleration.

In the event that a screen becomes plugged a steel grommet opens and bypasses oil to the pump.

Removaland Disassembly 1. Withdrawoil. Disconnect oil withdrawal tube. Remove screws, oil pan and gasket.Removeoil withdrawal tube fitting from oil pan.

2. Removeoil pickup tube clamp bolt= Removetwo flange mounting bolts. Removepump and screen as an assembly.

3. Remove four cover attaching screws, cover, gasket, idler gear, and drive gear and shaft.

4. Remove pressure regulator valve and valve parts. If necessary, removeoil pumpsuction pipe and screen by pulling from pump housing.

Engme:eng

3-33

860058

Do not disturb oil pickup pipe on screen. This pipe is located at assembly.

5. Washall parts in cleaning solvent and dry using compressed air. inspection Should any of the folaowing conditions be found during inspection operations, the defective parts should be repnaced.

1. Inspect pumpbody for cracks and excessive wear. Inspect oil pumpgears for excessive wear or damage.

2. Checkshaft for loosenessin the housing. Checkinside of cover for wearthat would permit oil to neak past the endsof gears.

3. Checkthe oil pick-up screen for damageto screen or relief grommet.

4. Checkpressure regunator valve plunger for fit

in cover.

Assemblyand Installation 1. Place drive gear and shaft in pumpbody. Install idler gear so that smoothside of gear will be toward the cover.

2. Install a new pumpto cover gasket to ensure correct end clearance of the gears.

3. Install suction pipe and screen assembly to pumpbody and install cover and attaching screws. Tighten screwsto 65-75in. Ibs. (7-8 N.m) and check to see that shaft turns freely.

4. Instalt regulator valve plunger, spring, retainer and pin.

5. Align oil pumpdriveshaft slot to matchwith distributor tang.

Install oil pumpto baock, positioning flange over distributor lower bushing. Use no gasket.

Oil pumpshould slide easily into place. If not, removeand relocate slot or determine other problem.

8. Attach and tighten oil pickup tube clamp.

7. Install oil pan using newgaskets and seals.

8. Install withdrawal tube fitting to pan; leave screwloose.

Orient fitting and attach withdrawal tube. Then tighten both fitting screwand flare nut to 15-18ft. Ibs. (20-24 N.m).

9. Fill crankcasewith oil.

3-34

Englne/eng

Oil Filter BypassValve mnspection Removethe oil fiiter and check the spring and fiber valve for operation. Checkfor a cracked or broken valve.

Replacement If replacementis necessary: 1. Removethe vaive by prying it out with a screwdriver.

2888

2. Install a newvalve and seat it by tapping into place using a 9/16 in. thin wall deep socket and hammer.

3. Install oil filter

accordingto manufacturer’sinstructions.

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

34732

Z~ 2. Lift enginewith hoist capableof lifting at least 1000 lb.

(454 kg) minimum capacity hoist to allow removalof front mount and bracket. [~3. Remove four mount screws and lock washers. Remove front engine mount and spacer (port side) from engine.

Disassembly ~] ~ Prior to disassembly of front mount assembly, measure distance between large washer on bracket and small washer on lower mount and record for reference during reassembly.

16367

[~ 1. Put wrench on flat of trim adjustment shaft and socket on top nut, and removeengine bracket and spacer.

22657

Engme/eng

3-35

16383

22658

16351

22654

[~ 2. Removetwo bolts from engine bracket and removerubber mount assembly. [~ 3. Removelower nut and washer on shaft and remove shaft from lower mount. [~ 4. Upon complete disassembly, check pieces and replace where necessary.

Reassembay ,~ 1. Place one nut and washer on trim shaft, then set trim adjustment shaft in lower mount. Rnstall remaining washer, and screwon lower nut. Makesure at neast three shaft threadsextend throughnut, Tighten nuts finger tight, do not tighten at this time=

16383

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

22653

installation [~] 1. Attach engine bracket and port side spacer to the engine with two long bolts and lock washers (port side} and two short bolts and lock washers(starboard side}. Tighten long port side bolts to 48-56 ft. Ibs. (65-76 N.m)and starboard bolts to 32-40ft.

Ibs= (43-54 N.m). ~] ~ 2. To reset engine height to original position, refer to measurementpoints and dimension recorded in Step 4 of Removal. Loosen nuts to adjust shaft and mount position to desired height. Hoadone nut and tighten the other to 115-140 ft. Ibs. (156-190 N.m).

3-36

18382

34731 Engine~ng

[~ ~ 3. Install

lag screws and tighten securely.

Front MountHeight Adjustment [~1. Supportenginewith a heist capableof lifting at least 1 (}00 lb.

(454 kg).

Ii]

eoveothcres,ro ,oer.on, oon .

3. Loosennuts securing lower mountto trim shaft. Reposition lower mount to desiredposition, then retighten lowermountnuts to 115-140ft. Ibs. (156-190 N m).

16367

Z~ 4. install two lag screwsin lower mountandtighten securely.

High-Rise Exhaust Elbow Replacement Removal 1. Loosenall four hose clamps. Lubricate exhaustpipe with a soapywater solution, and slide hosedownoff exhaustelbow.

2. Loosenhose clamp and disconnect cooling hose from inside of exhaust elbow. Thenremovehose fitting.

2972

[~3. Removethe two screws - and swing anchor bracket out of the way.

Thenremovethe two nuts and lock washers(id. [~14. Loosenthe elbowwith a soft hammer, then lift Removeand discard the elbow gasket.

it off the manifold.

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

2888

34729

22649

2. Mount the elbow on the manifold. {nstall the throttle anchor bracket, and secure with the two screws (~ and the two nuts and lock washers®.Tighten all four to 12-14 ft. Ibs. (16-19 N.m). Slide the exhaust hose all the way onto the elbow.

3. Install hosefitting hose.

on the inside of elbowand connect cooling

E~ 4. Position the upper clamps in the top two channeBs and tighten them securely. Position the two lower clamps in the channensand tighten them securely.

5. Reconnectthrottle cable to carburetor and throttle linkage plate. Securewith cotter pin.

34728

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

procedure in

2, Removeclamps and slide hose off exhaust pipe.

34727

mnstamlation E~ ~ One end of exhaust hose has two ribs © around the circumference. Position this end up when installing hose to ensure secure attachment.

I. Place two No. 64 hose clamps over exhaust pipe if they were removed.

E~] 2. For ease of installation Uubricate inside diameter of hose with a soapy water solution, and slide hose all the way onto exhaust pipe. Place two No. 64 clamps around top section of hose.

22647

3. Complete hose and high-rise elbow installation folnowing procedure in High-Rise Exhaust EBbowReplacement

3-38

22646 Englne/eng

Exhaust(Flapper)Valve Replacernent Removal 1. Theexhaustvaneis at the upperendof the exhaustpipe. Remove exhaustelbowandexhausthose. [~ 2. Usinga small drift or punch@, pushthe exhaustvalve pin (~ out of the exhaustpipe. [~ 3. Remove pin andvalve. Pushout two rubber bushings.

6373

installation 1. Apply3M~ ScotchGrip RubberAdhesive1300 to two newrubber bushingsandpushinto exhaustpipe.

E~ [~ 2. Lightly lubricate exhaustvalve pin with oil. Positionvalve in exhaustpipe with long side of valve down.Pushpin throughbushingand exhaustvalve until flush with bothsidesof pipe. Checkexhaustvalvefor freedomof movement. ~lf the valve is not positionedproperly(long lip down),it will restrict exhaustflow andfail to preventwaterfrombackingup into exhaustsystem.

Boat performance could be adverselyaffected, andmajorpowerhead damagecould occur

6375A

3. Install exhausthoseandelbow.

6376

6377

Englne/eng

3-39

6378

20034

6676

6675

Engine Coupler Replacement RemovaR 1. Removeengine from boat following Removaland Instagatien section.

instructions

in Engine

Jf coupler is being replaced due to coupler failure (rubber hub of splined hub), check engine alignment after installing new coupler. See Engine Alignment in Engine Removaland InstalJatien section.

67~0

2. Cut tie strap holding flywheel housing drain hose to starter motor. [~ 3. Take out screws holding flywheel housing cover @, then slide out cover.

4. Removenut, lock washer, and ground leads from ground stud. Removeinner nut, lock washer and washer. Removesimilar ground stud hardware on opposite side of block.

5. Removescrews and ,washers holding 10 pin connector and relay, and movebracket aside.

6712

6. Unscrewremaining flywheel housing bonts, lock washers and washers. Note position of clamps so they can be installed in original position. [~ 7. Lift

flywheel housing off engine block and set aside.

8. Unscrewsix Iocknuts, then pull coupler off flywheel.

6714

3-40

Eng~ne/eng

Installation [6"~ 1. Slide coupler onto crankshaftstuds. Install Iocknuts. Usea crowfoot wrenchandtighten nuts to 50-55ft, lb. (54-61N-m)applied in a "star" sequence.Repeat torque procedure once more.

[7~ 2. Install flywheel housing.Placeclampsin their originat positions, and attach 10 pin connectorandrelay bracket. Tighten screwsto 28-36ft. Ibs. (.38-49 N®m).

Z/~3. Place washer, lock washerand nut on groundstud. Tighten inner nut to 35-40ft. Ibs. (47-54N®m).

Attachelectrical leadsto groundstud. install lock washerand tighten outer nut securely. Install groundstud hardwareon oppositeside of block.

6711A

C8~4. Slide flywheel cover up into place. Install screwsand tighten themto 60-84in. Ibs. (7-9 Nom).

L’~ 5. Attach flywheel housingdrain hose(~ to starter motor with tie strap.

6. Install enginein boatfollowinginstructionsin EngineRemoval and #lstallation section.

2OO34

14704

Engme/eng

~ Safety Related

3-41

EngineSpecifications 1. General Specifications Type- No. of Cylinder .....................

Bore and Stroke ..........................

Piston Displacement .......................

Cylinder No. (front to rear} ..................

Firing Order .............................

Compression Ratio ........................

Thermostat Opens at ......................

Full Throttle Operating Range ...............

4- In-line 4.000in. x 3.60 in.

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

2. EngineDimensions,Fits and Adjustments Pistons: Type ................................

CUearanceLimit at Top Land ..............

Clearance Limit at Skirt ..................

Compression Ring Groove Depth ..........

Oil Ring Groove Depth ..................

Piston Rings: Compression Ring Material .........................

Type ............................

Coating - Upper Ring ...............

Coating - Lower Ring ...............

Width ...........................

Gap ............................

Oil ring Material .........................

Type ............................

Coating (rail) .....................

Width (Piston Groove) ..............

Gap (Ring) .......................

Width (Ring) ......................

Expanders .......................

Piston Pins: Length ..............................

Diameter .............................

Clearance in Piston (new) ................

Wear Limit in Piston ....................

Clearance in Rod .......................

Flat Head 0.0255- 0.0345in.

0,0025- 0.0035in.

0.209 - 0.211 in.

0.190 - 0.199 in.

Cast iron Radius Face (Upper) Tape Face (Lower) Molybdenum Wear Resistant 0.0775 - 0.0780in.

0.010 - 0.020 in. (Upper) 0.013 - 0.025 in. (Lower) Flat Spring Steel Multi-piece Rail Expander and Spacer Chrome 0.188 - 0.189 in.

0.015 - 0.055 in.

0.154 - 0.160 in.

One-Piece Expander-Spacer

2.990 - 3.010 in.

0.9270 - 0.9273 in.

0,0003 - 0.0004 in, 0.001 in.

0.0008- 0.0021 in.

3-42

Engme/eng

EngineSpecifications Connecting Rods: Material .............................

Length CL to CL .......................

Connecting Rod Bearing Material .........................

Effective Length ...................

Clearance ........................

End Play .........................

Drop Forged SteeJ 5.700 in.

M400 0.792 - 0.822 in.

0.00085- 0.00135in.

0.008 - 0.015 in.

Crankshaft: Material .............................

End Play .............................

End Thrust Taken By ....................

Crankpin Journal Diameter ...............

Main Bearing Type ............................

Journal Diameter ..................

Length ..........................

Clearance ........................

Nodular Cast Iron 0.002- 0.006in.

Rear Main Bearing 2.099- 2.100in.

Precision Removable 2.2983- 2.2993in.

0.822in. (rear) 0.830 in. (others) 0.0003- 0.0029in.

Camshaft: Camshaft Bearing Material .........................

Steel BackedBabbitt Journal Diameter x Bearing Length .... 1.8692in. x .860 in.

Bearing Outer Diameter - Nos. 1 and 2 . 1.999 - 2.001 in.

Bearing Outer Diameter - No. 3 .......

2.009 - 2.011 in.

Type of Drive .........................

Gear Crankshaft Gear Material ................

Helical Cut Nodular Cast Iron Camshaft Gear Material .................

Helical Cut Bakelite and Fabric Composition Lobe Lift .............................

0.253in. ___0.005in.

Valve Systems: Lifter Type ...........................

Rocker Arm Ratio ......................

Valve Lash Adjustment = Intake and Exhaust (hot) ............

Valve Face Angle ......................

Valve Seat Angle .......................

Stemto Guide Clearance intake Valve ......................

Stemto Guide Clearance Exhaust Valve ....................

RecommendedValve Seat Width intake ...........................

Exhaust .........................

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

0.0010 - 0.0027 in.

1/32in. to 1.~6in.

1/16in. to 3/32in.

EngineSpecifications Valve Systems(cont.): Outer Valve Spring Free Length ................................

Outer Valve Spring Pressure Lb. @In .........................................

Engine Lubrication:

2.08 in.

78-86 @1.66 in.

Type Oil Pump...............................................

Normal Oil Pressure ...........................

Crankcase Capacity .......................

Oil Grade Recommended: Service SG-Meeting GMSpec 6094

Gear 40-60 PSI @ 2000 RPM 31/2qts. (4 qts. with newfilter)

32° R and Above ...........................................

0° R to 32° F ..........................................

Below 0° F ...............................................

SAE 30 SAE 20W-20 SAE 10W

Werecommend DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil which is specially formulated for heavy duty marine TM SAE use. DuraPlus 30 HeavyDuty Synthetic Motor Oil provides superior anti-wear qualities, especially important during prolongedhigh speedoperation. It also neutralizes acids createdin all internal combustion engines.This motor oil is formulatedto offer superior protection against corrosion and to resist oxidation andhigh temperaturesludgeformation. ~Theuse of multi-viscosity oils is not recommended.

Disregard any reference to multi-viscosity engine. Suchreference is intended for automotiveuse only, not marineuse.

Fuel Grade Recommendation............

3-44

oil printed on

See GeneralInformation section

Engme/eng

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

( FT. LBS.1 [IN. LB$.I

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

Er,g,ne/eng

10-14 26-30 72-90 13-17 135 20 12-14 28-36 48-56 32-40 15-18 26-30 3O-36 16-19 13-17 12-16 -

3-45

60-84 80 165 65-75 80 65

14-19 35-41 8-10 18-23 15,3 27 16-19 38-49 7-9 65-76 43-54 9 18,6 7-8 20-24 35-41 41-49 22-26 t8-23 16-22 9 7,3

TorqueSpecifications- (Cont.) [ FT, LBS.]

I IN. LBS.J

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

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

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

35 65 95 20-25 60-70 10-12 60-70

47 88 129 27-34 81-95

=

110-120

FlameArrestor to Carburetor Flywheel and Coupler PowerSteering PumpBracket

10-15 13-15

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

15-18 10-14 18-22 2O

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

65-80 a

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

Oneturn after contact

3-46

20-24 14-19 24-30 27

Engme/eng

Section 4 4.3 GL, GS and Gi Engine

Table of Contents Accessories .........................

Balance Shaft ......................

Baiancer, Crankshaft .................

Camshaft ..........................

Cleaning ...........................

Circulating Pump....................

Crankshaft and Bearings ..............

Cylinder Block ......................

Cylinder Head ......................

Engine Coupler Replacement ...............

Draining ..........................

Front Cover .......................

Front Mount ......................

Lubrication ........................

Fxhaust (Flapper) Valve Replacement .........

Manifold ..........................

High-Rise Elbow Replacement ........

Hose Replacement .................

4-4 4-23 4-15 4-22 4-4 4-34 4-30 4-31 4-12 4-40 4-4 4-20 4-35 4-5 4=39 4-6 4-37 4-38

General Description .................... intake Manifold ....................... intermediate Pipe Replacement .........

Oil Pan ............................

Oil Pump ..........................

Pistons and Connecting Rods ..........

Rear Oil Seal, Crankshaft ..............

Rear Oil Seal Housing ................

Rocker Arm Cover .....................

Rocker Arm Stud Replacement .........

Special Tools - GM....................

Specifications Engine ...........................

Torque ...........................

Timing Chain and Sprockets ...........

Tooms and Shop Equipment .............

Valve Train ..........................

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual.

Alwaysuse the correct fastener in the proper location. Whenyou replace a fastener, use ONLYthe exact part number for that application. The text wUl call out those fasteners that require replacementafter removal, Thetext wi|l also call out the fasteners that require thread lockers or thread sealant.

UNLESSOTHERWISE SPECIFIED, do not use supplement coatings (paints, greases, or other corrosion inhibitorsl on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damagethe fastener.

Whenyou install fasteners, use the correct tightening sequence and tightening specifications. Following these instructions can help you avoid damageto parts and systems=

I:nglne/eng

4-1

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

General Description EngineConstruction The 4.3L engine is a liquid-cooled 90 degree V6 type with overheadvalves, a balance shaft, and cast-iron block and cylinder heads.

Cylinder B|ock Thecylinder block has 6 cylinders arrangedin a "’V" shapewith 3 cylinders in each bank. Starting at the front of the engine, cylinders in the right bank are numbered1-3-5 and cyJinders in the left bank are numbered2-4-6 (when viewed from the front).

Thefiring order of the cylinders is 1-6-5-4-3-2. Thecylinders are encircled by coolant jackets.

Cylinder Heads The cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is located betweenthe valves in the side of the cylinder head. The valve guides are integral and the valve rocker arms are retained on individual threaded studs.

Crankshaft The crankshaft is supported by four crankshaft bearings. The numberfour bearing at the rear of the engine is the end thrust bearing. The bearings are retained by bearing caps that are machinedwith the block for proper alignment and clearances.

Camshaft The camshaft is supported by four full round, sleeve-type bearings. A sprocket on the crankshaft drives a camshaft timing chain which in turn drives the camshaft through a sprocket.

Pistons and Connecting Rods The pistons are madeof cast-aluminum alloy using two compression rings and one oil control ring assembly.Piston pins are offset 0.0354 in. (0,9 ram) toward the major thrust side (right side) reduce piston slap as the connecting rod travels from one side of the piston to the other side after a stroke. Thepins are a press fit in the connectingrod and a floating fit in the piston.

Balance Shaft The cast-iron balance shaft is mountedin the crankcase above and inline with the camshaft. A camshaft gear drives the gear attachedto the balanceshaft. The front end of the balanceshaft is supported by a ball-type bearing. The rear end of the balance shaft uses a sleeve-type bearing.

4-2

Engme/eng

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

Tools and Shop Equipment A clean, well-lit, work area should be available. Other necessary equipment includes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and an adequateset of hand tools. An approvedengine repair stand will help aid with the work and help prevent personal injury or component damage.

Special tools are Pisted and illustrated throughout this section with a completelisting at the end of the section. Thesetools (or their equivalents) are specially designed to quickly and safely accomplishthe operations for which they are intended. The use of these special tools will also minimize possible damageto engine components. Someprecision measuring tools are required for inspection of certain critical components.Torque wrenchesare necessaryfor the correct assemblyof various parts.

Eng,ne/eng

4-3

Accessories The various procedures in this manual assumethat the engine accessories have been removed.These accessories include all of the following: ¯ Power Steering Pump ¯ Alternator ¯ Distributor o Water Supply Pump o Accessory Brackets and Electrical e Starter Motor

Wiring

Cleaning Removethe engine accessories before cleaning to provide better access to the engine’s exterior surfaces. After removing the distributor, accessorybrackets, etc=, cover the openingswith tape to prevent the entry of contaminants.

Methods used to clean the engine will depend on the means which are available° Steamcleaning, pressure washing, or solvent cleaning are some of the acceptable methods. Allow the engine to dry thoroughly before beginning any work° It is important that the engine be as clean as possible to prevent dirt, water, or any other contaminantsfrom entering critical areas during disassembly.

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

4-4

Engmeieng

DRC6583

Engine Lubrication [=1--] Full pressurelubrication, througha full-flow oil filter is suppliedby a gear-typeoil pump.Oil is drawn up through the oil pump screen and passesthrough the pumpto the oil filter. Theoil filter is a full-flow paper element unit with an anti-drain back valve. An oil filter bypassvalve is used to ensure adequateoil supply, in the event the filter becomesplugged or develops excessive pressure drop.

E qgme/eng

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

4-5

Exhaust Manifold Removal 1. Drain water from exhaustmanifolds.

2. Disconnectwater hose from manifold.

3. Loosenupper exhaust hose clamps, then removehigh rise elbow.

4. Remove manifold attaching nuts and washers.Discard nuts.

Inspection 1. Inspectfor cracks.

E~] 2. To pressure checkmanifold, fabricate a prate such as pictured ~) and a newelbow gasket (~ to seal water passagein manifold. Be sure to apply sealer to gasket. Instalt rubberdrain capsto manifoldand securewith clamps. Attach a GearcasePressure Tester © (such as Stevens Company S-34) to the water inlet hose. A bushingcan be madeto secure pressure tester to hose. With the pressuretester attached to the manifold, submerge manifold in water. Pressurizethe manifold to 10-15 PSI (22-25 kPa) and checkfor leaks. Manifoldshouldnot leak aroundclampsandplate, if so, retighten clampsor reseal plate. Nodrop in pressureshouldbe realized.

DR2642

Installation 1 Clean mating surfaces on manifold and head. install newexhaust gasket, then install manifold and secure with newIocknuts and washers.

Tightennuts (~) to 20-28ft. Ibs. (27-35N.m).

2. install a newgasketand high rise elbowto manifold. Tighten bolts to 12-18ft. Ibs. (16-24N m).

3. Install exhausthose and secure with damps.

28287

4. Connectwater hose. Install and tighten drain petcocks. /~5. Start engine and check for fuel leaks.

4-6

Eng[ne/eng

Intake Manifold Removal I-3~ ~ 1. Drain coolant block.

from manifolds and both sides of

2. Disconnect: L~ a. Battery cables from battery. b. Coolant hoses at thermostat housing.

34091

c. Throttle cable from carburetor and anchor block. d. Crankcaseventilation sides).

hose from rocker arm covers (both

e.Wire at temperature gauge sender unit wiring harness from alternator.

and engine

f. Distributor high tension and ignition primary headsfrom coin= 34102

3. Remove: a. Distributor cap and mark the position of the rotor on the housing. Scribe a line on distributor housing and intake manifold for reassembly in the sameposition. Remove the distributor. b. Alternator and alternator mountingbracket from engine. c. Carburetor fuel line from carburetor and fuel pumpor fuel lines from throttle body and fuel pump/vaporseparator.

25140

d. Oil pressure sending unit. e. Manifomdattaching bolts and solenoid bracket. Lift manifold from engine. Discard front and rear seals and gaskets.

If manifold is to be replaced, transfer: carburetor or throttle body and ECMbracket, thermostat and housing (use newgasket), throttle cable anchor bEockassembly, distributor clamp and temperature sending unit. Transfer additional hardwareas required.

Engme/eng

~ Safety Related

4-7

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

Installation [~ Important:

Do NOTreuse intake manifold gaskets.

DRC6590

~] Install

or Connect:

12.7 mm

[~ 1. Sealant to the intake manifold gasket, cylinder head side.

Care must be used to apply the correct amountof sealant onto the gaskets= Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly.

2. Gasketsonto the cylinder head. a. Use gasket locator pins to properly seat gasket on cylinder head.

DRC6591

[~ b. Apply a 0.499 in. (13 mm)bead of GMSealant,P/N 12346141,or equivalent to the front and rear block sealant areas.

c. Extend the sealer bead 0.157 in. (4 ram) onto each gasket.

3. GMThread locking Sealant, P/N 12345382,or equivalent to the threads of the eight lower intake mountingbolts.

((}.499IN.)

4. Lower intake manifold onto engine block.

DRC6592

5. Lowerintake manifold bolts. ~-~ Tighten: Bolts in three steps, using the following sequence: a. Snugall bolts to 27 in. lb. (3 N.m)to minimizeshifting intake. b. Bolts to 106in. lb. (12 N.m). c0 Bolts to 11 ft. lb. (15 N.m).

DRC5593

4-8

Engme/eng

d. Distributor with rotor and aligned exactly as markedduring removal. =-NO~If engine wascrankedwhile distributor wasout, completeignition timing proceduremustbe followed. Seethe appropriate Ignition Circuit in Electrical/Ignition SystemsService Manual. e. Alternator with mountingbracket.

Distributor cap and high tension leads. Seethe General Informationsection in Electrical/Ignition ServiceManualfor correct firing order and sparkplug wire routing. g°

Oil pressuresendingunit.

3. Connect: ~=,~

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

Rocker Arm Cover Removal

E~] ~ Remove or Disconnect: 1. Valverocker armcover bolts.

2. Valve rocker armcover.

3, Gasket.

Ergme/eng

4-9

DRC6584

Clean: ® Parts in solvent. Removea}l sludge and varnish. ® Old gaskets from the gasket surfaces. /

[~ inspect: ® Gasket flanges for bending or damage. ¯ Rubber grommetsand parts for deterioration. installation [~ ~] Install

DRC6584

or Connect:

J

1. Newgasket.

2. Valve rocker armcover.

t

3. Valve rocker armcover bolts. [~ Tighten: Valve rocker armcover botts to 106 in. lb. (12 N.m).

DRC6585

Valve Train Removal

[~ important: Store all reusable components in an exact order, so they can be reassembled in the samewear pattern location from which they were removed.Mark the front end of the retainer.

E~ Remove or Disconnect: DRC6588

E~ 1. valve rocker arm nuts, balls, and valve rocker arms.

2. Valve push rods.

J 9290-1

3. Bolts and valve lifter

retainer.

/

[~ 4. Valve lifters.

Removethe lifters one at a time using J 9290-0t/J 3049 or equivalent and place them in an organizer rack.

E~ Lmportant: Store all reusable components in an exact order, so they may be reassembled in the same wear pattern bocation from which they were removed.

4-10

DRC6586

Eng,ne/eng

Clean: e All parts in clean solvent and dry them with compressed air. ¯ Makesure oil passagesin valve push rods are clear. [~ inspect: ¯ Valve rocker arms and balls at their mating surfaces.

These surfaces should be free from wear or any damage.

Valve rocker arm areas that contact the valve stems and the socket areas that contact the ends of the valve push rods. These areas should be free of damageor wear. ¯ Valve rocker arm nuts. ¯ Valve push rod ends for scoring, roughness, or bends. [~ Roll the valve push rod on a flat surface to determine its straightness. If the rod is bent, the rod will not roll freely. Replace if necessary° ValveLifters This engineuses hydraulic valve lifters. Valve lifters are serviced only as an assembly. No internal parts are available. Service is limited to a disassemblyand cleaning. Discard valve lifters that are excessively worn or damaged. [~ important: Whenever the camshaft needs to be replaced, a newset of valve lifters mustaasobe installed. mnstallation IT~ important: Replace all valve roller

lifters,

change the

engine oil and filter, and add GMEngine Oil Supplement,P/N 1052367, or equivalent to the engine oil whenever a new camshaftis installed.

Lubricate the valve lifter bodies and roller Engine Oil Supplement, P/N 1052367, or equivalent.

with GM

f~ lnstailorConnect: [3~ 1. Valve lifters

to the block.

[3~ 2. Valve lifter

guide.

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

Englne/eng

4-11

Tighten: BoBtsto 12 ft. lb. (16 N.m).

3. Valve push rods. a. Seat the valve pushrods into the socket of the valve lifters. b. Coat the mating surfaces of the valve rocker arms and balls with GMEngine Oil Supplement, P/N 1052365, or equivalent.

4. Valve rocker arms with balls on to the proper stud°

DRC6588

[~ 5. Valve rocker arm nuts onto the studs. o Align the valve push rod into the valve rocker arm while tightening valve rocker arm nut.

E~ important: No lash adjustment is needed. These models use screw-in rocker arm studs with positive stop shoulders. [~

Tighten: VaUverocker arm nuts to 20 ft. lb. (27 N.m).

DRC6589 J 8062

Cylinder Head Cylinder Head Removal E~ Remove or Disconnect: 1. Spark plugs.

2. Cylinder head bolts.

3. Cylinder heads.

4. Headgaskets.

DRC6594

CyminderHead Disassembly Tool Required: J 8062 Valve Spring Compressor [~

[~

~ Remove or Disconnect:

1. Compressthe springs with J 8062.

2. Keys Q. 3. Tool J 8062.

DRC6595

4. Valve spring cap (~.

5. Spring (~.

6. Seal ~.

7. Valves ~ and ~).

Place the valves in an organizer rack so they can be replaced in their original position at reassembly.

4-1

2

Eng,neleng

Cleaning, inspection,

and Measurement

Refer to General Engine Mechanical section in this manual.

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

E~ InsteB

or Connect:

Screwvalve rocker arm stud into cylinder head. ~ Tighten: Valve rocker arm stud to 36 ft. lb. (47 N-m).

Cylinder Head Assembly Tools Required" J 8062 Valve Spring Compressor nnstaii or Connect: 13 1. Valves (~) and (~. a. Lubricate the valve stemswith clean engine oil. b. insert the valves into the proper vaBveguides until the face of the valve contacts the valve seat.

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

it bottoms out

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

E,g,,e’e,g

4-13

EE] d. Release the compressor tool J 8062, making sure the valve keys O stay in place. e. Repeat the preceding steps on the remaining valves.

Measure: Refer to General Engine Mechanical section in this manualfor valve spring installed height. [~

Clean: Gasket surfaces on the block and cylinder head.

Cylinder HeadInstallation Tool Required’ J 36660 Torque/Angle Meter r~ install

or Connect:

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

2. Cylinder head. Carefully guide the cylinder headinto place over the dowel pfns and gasket.

3. Cylinder head bolts. Coat threads of the cylinder head bolts with GMSealing Compound,P/N 12346004, or equivalent and install liar-tight.

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

4. ~k plugs.

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

4-14

Englne/eng

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

I~

~ Remove or Disconnect:

1. Crankshaft balancer bolt and washer.

2. Crankshaft balancer using J 39046.

J 3£046

3= Crankshaftkey, (if necessary). [~ Inspect: Crankshaft balancer weight for signs of shifting on the hub.

Replace as needed. The area of the crankshaft hub shaft that contacts the front crankshaft seal for roughnessor nicks. Replace the balancer if this condition exists. If balancer is replaced, new balance weights of the samesize must be installed on the new balancer in the samelocation as the old balancer.

DRC6641

Installation J 39046

=Tool Ree~uired: J 39046CrankshaftBalancerInstaller [4"~[-~4-ILLj Install or Connect: 1. Apply GMRTVSealant, P/N 12345739,or equivalent to crankshaft keyway.

2. Crankshaft key (if removed). [~ The inertiah weight section of the crankshaft balancer is assembled to the hub with rubber type material. The correct installation procedures(’with the proper tool) mustbe foalowed rnovementof the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. :3. Stud (part of J 39046)to the crankshaft. Threadstud fully into the tapped hole in the crankshaft.

4. Crankshaft balancer over the end of the stud. Align the keyway in the crankshaft balancer shaft with the crankshaft key.

E ng,ne/eng

4-15

\

5. Bearing, washer, and nut. a. Turn the nut to pull the crankshaft balancer into place. b. Remove the tool.

6. Crankshaft balancer bolt and washer. [~ Tighten: Bontto 74 ft. lb. (100 N-m).

Oil Pan Removal B Remove or Disconnect: 1. Oil pannuts.

2. Oil panbolts.

3. Oil pan.

DRC6642

4. Gasket. [~

Clean: ® Parts in solvent. Remove all sludge and varnish. ¯ Old gaskets and RTVsealant from the gasket surfaces. inspect: ¯ Gasket flanges for bending or damage. ® Oil pan for damageor cracks. ¯ Oil pandeflector for lack of fit. ¯ Drain plug threads for stripping.

installation Tool Required: J 34673 Straight Edgeor Equivalent ~3 important: The alignment between the rear of the oil pan and rear of the block flange is critical. Thetwo surfaces must be flush to provide a rigid engine-to-transom bracket alignment.

10ram (0.393 |N.)

20mm

4-16

"~F~

DRC6639 Englne/eng

[~ Instal|

or Connect:

12~ ~] Apply GMRTVSealant,P/N 12346141, or equivalent to the engine front cover to block joint and to the rear crankshaft housing to block joint. Apply the sealant about 1.00 in. (25,4 mm) in both directions from eachof the four corners.

1. Oil pan gasket onto pan.

13 2. Oil pan against cylinder block.

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

DRC6640

4. l~an bolts and nuts but do not tighten.

I ]~J,:I

Measure:

[~ Use a feeler gauge to check the clearance between the three oil pan-to=transmission bell housing contact points as shown.If clearance exceeds0.010 in. (0,254 mm)at any of the three points repeat steps 2 and 3 until the clearance is within specification.

DRC6642

If the clearance is more than 0.010 in. (0,254 mm), powertrain durability maybe affected. [~ I-~

Tighten:

¯ Bolts to 18 ft. lb. (25 N.m)in the sequenceshown. ¯ Nuts to 17 ft. lb. (23 N.m). [~

Measure:

¯ Clearance between the three oil pan-to-transom bracket contact points to verify proper alignment.

5. Lubricate newoil filter

seal with clean engineoil.

DRC6646

®

®

6. Newoil filter.

Oim Pump

#

® I- i m

Removal IpBBm=~

@ @

~ Remove or Disconnect:

DRC6645

1. Bolt from oil pumpto crankshaft bearing cap.

2. Oil pump assembly.

3. Driveshaft and retainer

Engme/eng

4-17

DRC6643

[~

~ Disassemble:

3. Driveshaft(~) andretainer (~).

Do not removethe oil pumpscreen unless replacement is required. The oil pumpscreen has a press fit in to the pump cover. Do not remove the screen from the pipe ~. The oil pumpscreen is serviced as a complete assembly only.

2. Oil pumpscreen pickup ~.

3. Bolts @.

4. Pumpcover ~.

Mark where the idler gear and drive gear and shaft 0 meshtogether, so they can be reinstalled with the samegear teeth indexed.

5. Idler gear and drive gear and shaft (~.

6. Retaining pin Q. 7. Pressureregulator spring (~.

DRC6624

8. Pressureregulator valve (~. [~

Clean:

[~l~rts

in clean solvent and dry them with compressed air.

Inspect:

[~ Important: The pump gears, cover, and body are not serviced separately. If any of the parts are damagedor worn, the entire oil pumpassembly must be replaced. ¯ Pumpbody ~ for cracks, wear, or other damage. e Inside of the cover (~) for cracks and wear that would permit oiB to leak past the endsof the gears. ® Idler and drive gear 0 for wear. e Drive gear and shaft for lack of fit

in the pumpbody.

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

of

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

4-18

Engme/eng

Assemble J 21882

13 E~ Install

or Connect:

1. Pressureregulator valve (~ into the pumpcover (~). [~ Important: Replace the pressure relief when reusing the oil pumpassembly.

valve spring (~)

2. Pressure regulator spring Q into the pumpcover ~.

3. Retaining pin Q into the pumpcover (~.

DRC6625

4. Drive gear and shaft (~ into the pumpbody ~.

5. IdBer gear (~ into the pumpbody ~.

Match together the index marks on the two gears nqade during disassembly.

6. Pumpcover (~.

Bolts (~ to 106in. lb. (12 N.m).

With the driveshaft ~) installed on the pump,turn the driveshaft by hand to check for smooth operation. [~ Be careful of twisting, shearing, or collapsing the pipe wheninstalling it to the pump.A damagedpipe can cause lack of lubrication and engine failure.

Oil P~j~ Screeninstallation L~ install

or Connect:

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

2. Oil pumpdriveshaft (~) and retainer (~.

Eng ...... g

4-19

~

P~ Installation Install or Connect:

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

DRC6643

2. r~umpand bolt onto crankshaft bearing cap.

Tighten: Bolt to 66 ft. lb. (g0 N.m).

Engine Front Cover Removal E~ Important: Once the composite engine front cover is removedDONOTreinstall it. Alwaysinstall a newengine front cover.

Removeor Disconnect: 1. Enginefront cover bolts.

2. Enginefront cover.

Instanlation E~ important: Once the composite engine front cover is removedDONOTreinstall it. Alwaysinstall a newengine front cover.

Do not reuse the original O-ring seal wheninstalling onto crankshaft sensor body. Lubricate new O-ring seal with engine oil.

Wheninstalling crankshaft position sensor be sure the sensor is fully seated and held stationary in the engine front cover bore.

Torquehold downbolt to the specification shownbelow. A sensor that is not seated will cock in the engine front cover bore and may result in erratic engine operation.

4-20

Engme/eng

I~ install

or Connect:

1. Enginefront cover to engine.

2. E~nefront cover bolts.

1:3)1 Tighten: Bolts to 106in. lb. (12 N.m).

4

’Timing Chain and Sprockets DRC6633

Tool Required: J 5825-A Crankshaft Sprocket Puller Measure: Check camshaft timing chain free play. If the camshaft timing chain can be movedback and forth in excessof 0.625 in. (16 mm), makea note that the camshaft timing chain should be replaced during assembly.

IRemoval 12~ [~ Remove or Disconnect:

DRC6615

1. Camshaftsprocket bolts O. 2. Camshaftsprocket @and camshaft timing chain (~ together.

The sprocket has a light interference fit on the camshaft. Tapthe sprocket on its lower edgeto loosen it.

3. Balanceshaft drive gear. i2~ ~] 4. Crankshaft sprocket (~ using J 5825-A. 5. Key~) (if damaged).

’Englne/eng

4-21

[~ inspect: 1. Sprockets for chipped teeth and wear.

Excessively worn sprockets will

rapidly wear a new

chain.

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

DRC6694

InstaBnation Tool Required" J 5590 Crankshaft Sprocket Installer Install or Connect: 1. Crankshaft key (if removed).

EEl 2. Crankshaft sprocket using J 5590.

3. Balanceshaft drive gear.

View A DRC6634

4. Camshaft sprocket and camshaft timing chain, [~ [~ important: Line up the sprocket aBignment marks ~) on the camshaft sprocket and crankshaft sprocket.

/

The number4 cylinder is at top dead center of the compression stroke with the timing marksin this position.

I~ 5. Camshaft sprocket bolts Q. Tighten: Bolts 21 ft. lb. (28 N.m).

DRC6633

Camshaft Removal Removeor Disconnect: 1. Camshaftretainer bolts and camshaft retainer.

2. Camshaft.

DRC6635

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

4-22

Engme/eng

Measure: Camshaft Journals. Refer to General Engine Mechanical section in this manual.

Bearings Refer to General Engine Mechanical section in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly. nnstallation [~] instalm or Connect: Coat the camshaft lobes and journals with a high quality GMEngine Oil Supplement, P/N 1052367, or equivalent. Apply GMEngine Oil Supplement, P/N 1052367, or equivalent to all the teeth on the distributor drive gear.

1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft threaded holes. Use these bolts to handle the camshaft.

2. Camshaftinto the engine. Handle the camshaft carefully to prevent damageto the camshaft bearings.

3. Camshaftretainer and retainer bolts. ¯ Coat camshaft retainer plate with GMEngine Oil Supplement, P/N 1052367, or equivalent.

Tighten: Bolts to 124in. lb. (14 N.m).

Balance Shaft

DRC6631

Removan Tools Required: J 38834 Balance Shaft Bearing Service Kit J 26941 Rear Balance Shaft Bearing Remover p=.=,==q ~[~ Removeor Disconnect: 1. Bolt Q. 2. Drivengear (~).

DRC6617

3. Retainerbolts (s~. ~J36996 J

4. Retainer ®.

388~

[~ [~ 5. Balance shaft ~) using a soft faced hammer. [~ 6. Balance shaft rear bearing using J 38834 and J 26941.

DRC6618 Eng,ne/eng

4-23

[~ Inspect: ®

Balanceshaft front roller bearing and rear sleeve bearing for damageor excessive wear. The bearings are serviced as an assembly.Use the proper tools for properly servicing the bearings.

o BaDanceshaft drive and driven gears for nicks or burrs.

Replace gears that are damaged.

0

0

Front and rear bearing journal diameters. Replace the balance shaft if the diameter exceedsthe specifications, Refer to Specifications in this section.

DRC6629

Rear sleeve bearing journal clearance. Replace the balance shaft if the clearance exceedsthe specification.

Refer to Specifications in this section.

Instaination Tools Required: J 38834 Balance Shaft Bearing Service Kit J 36996Balance Shaft Installer J 8092 Driver Handle J 36660 Torque/Angle Meter ~]

Install

DRC6618

or Connect:

1. Dip bearing in clean engine oil before installation. [~] [~ 2. Balance shaft rear bearing using J 38834. ~] 3. Balance shaft into bBock using J 36996 and J 8092.

J 8092 J }6998

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

DRC6630

on case.

[~ 4. Install

4

balance shaft bearing retainer ~) and bolts ~)=

1

j

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

°I

Tighten: DRC6631

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

4-24

Engme/eng

e Turn the camshaft with the balance shaft drive gear temporarily installed. The timing mark on the drive gear must be straight up. ¯ With the balance shaft drive gear removed, turn the balance ,,;haft so the timing mark on the driven gear points straight down.

6. Balanceshaft drive gear onto camshaft. [~ Important: Make sure the timing marks on the balance shaft drive gear and driven gear line up.

Pistons and Connecting Rods Removal Tool Required" J 5239 Guide Set Fro...3 I’~=,~.J Remove or Disconnect: I~ Before attempting to remove piston, refer to General Engine Mechanicalsection in this manualfor cylinder bore ridge reamer procedures.

1. Mark the cylinder numberson the tops of each piston. Mark them from the front to the rear, with the engine in an upright position and viewed from the front. ¯ The right bank is numbered1-3-5 ¯ The left bank is numbered2-4-6 2. Checkthe connecting rod and cap for identification marks. If reusing the connecting rods, mark the parts in the sameway as istons.

~f

Important: Store the connecting rod and cap together as mating parts, so they may be reassembled in the same wear pattern and balance in which they were removed.

3. Connecting rod nuts, cap and bearings. [~ Umportant: ff reusing bearings, keep bearings with their originan connecting rod and cap.

IEngmeleng

4-25

DRC6632

4. Connecting rod and piston. [~ a. Attach J 5239 to the connecting rod bonts.

E~ b. Use the long guide rod J 5239 to push the connecting rod and piston out of the bore.

Disassembly Refer to General Engine Mechanical section in this manual for piston and connecting rod disassembly.

Assembly Refer to General Engine Mechanical section in this manual for piston and connecting rod assembly.

Be~ Selection important: Connectingrod bearings are of the precision insert type and do not use shims for adjustment. DONOTFiLE RODSOR ROD CAPS. If clearances are excessive, install a newbearing. Service bearings are available in standardsize 0.001 in. (0,0254 ram) and 0.002 in. (0,0508 mm)undersize for use with new and used standard size crankshafts. For reconditioned crankshafts 0=010in. (0,254 mm)and 0.020 in. (0,508 mm)undersize bearings are available.

DRC6619

\

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

@ DRC6507

E~] 2. Piston diameter. Measurethe skirt at a right angle to the piston pin hole, 1.0 in. (25 mm)below the oH ring groove.

DRC6514

4-26

Engme/eng

Measurepiston diameter at 70 degrees F (20 degrees C).

3. Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance.

4. Locate the piston-to-bore clearance, refer to EngineSpecifications. Determine if the piston-to-bore cUearanceis within the acceptable range.

Piston Ring EndGapand Fit Refer to General Engine Mechanical section in this manual. [!]

Important:

The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore. If a connecting rod is ever transposedfrom one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be renumbered to correspond with the new cylinder number. installation Tools Required: J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Torque/Angle Meter r~ install

or Connect:

1. Lubricate the cylinder walls lightny with engine oil.

2. Makesure the piston is installed in the matchingcylinder.

3. Connecting rod bearings. a. Makesure the crankshaft bearings are the proper size. b. Install the crankshaft bearings in the connecting rod and connecting rod cap. c. Lubricate the bearings with engine oil.

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

J 5239

b. Locate the piston ring end gaps. Lubricate the piston and rings with engine oil. c. Without disturbing the ring end gap location, install J 8037 over the piston and compression rings. d. The piston must be installed so that the notch in the piston faces the front of the engine. [~ e. Place the piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft. Using light blows with a hammerhandFe, tap the piston downinto its bore. At the sametime, from beneath the engine, guide the connecting rod on to the crankpin with J 5239. Hold the ring compressoragainst the block until aH rings have entered the cylinder bore. [~ f. RemoveJ 5239 from the connecting rod bolts. [~ important: Each connecting rod and bearing cap should be marked,beginningat the front of the engine. Cylinders 1, 3, and 5 are the right bank and 2, 4, and 6 are the left bank (whenviewed from the front). The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore.

If a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be numberedto correspond with the new cylinder number.

5. Connectingrod cap ,with crankshaft bearing.

DRC6619

ENGINELEFT ENGINEFRONT ENGINERI(~H,T

C~

~A,D

B-A OIL RINGSPACER GAP (TANGIN HOLEORSLOTWITHINARC) 8 OIL RINGRAIL GAPS C 2NOCOMPRESSION R~NGGAP O TOPCOMPRESSION RINGGAP

6. Connecting rod bolt nuts. [~

DRC6627

Tighten: ¯ Connectingrod bolt nuts to 20 ft. lb. (27 N.m). ® Connecting rod bolt nuts an additionaG 70 degrees using J 36680.

[~

J 8037

X

Measure:

Refer to General EngineMechanicalsection in this manual for connecting rod side clearance procedure.

4-28

DRC6628

Eng,ne/eng

CrankshaftRear Oil Seal Removal Take care whenremovingthe rear crankshaft oil seal so as not to damagethe crankshaft sealing surface. ~ Remove or Disconnect: F4~ Insert a screwdriver into the notches provided in the seal retainer and pry the seal out.

DRC6658

Installation qbol Required: J 35621 Crankshaft Rear OilSeal installer [5~N44-RLL.Lj Install or Connect: 1. Lubricate the inner and outer diameter of the oil seal with clean engine oil.

2. Install the oil seal on J 35621.

3. Position J 35621 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.

J 35621 0RC6626

4. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft.

5. Turn the handleuntil it bottoms.

6. RemoveJ 35621.

Crankshaft Rear Oil Seal Housing DRC6657

Removal [6~ E~ Remove or Disconnect: 1. Bolts and nuts.

2. Oil seal housing.

3. Gasket. [~

Clean: Gasketsurfaces on the block and seal retainer.

Engme/eng

4-29

Unstallation ~ mnstail or Connect: 1. Newgasket to the block.

It is not necessary to use sealant to hold the gasket in place.

2. Oil seal retainer.

3. Screws and nuts.

DRC6657

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

Crankshaft And Bearings Removal The crankshaft need not be removedfor replacement of the rear oil seal or crankshaft bearings. Thoseprocedures are covered in oth~_~arts of this section.

UT| Important: Checkthe crankshaft bearing caps for location markings. Mark the caps if necessary. The caps must be returned to their original locations during assembly.

Removeor Disconnect: 1. Crankshaft bearing cap bolts.

2. Crankshaft bearing caps and lower crankshaft bearings.

3. Crankshaft from the cylinder block with extreme care, taking care to avoid damageto crankshaft journals and thrust flange surfaces.

4. Upper crankshaft bearings.

Refer to General Engine Nlechanical section in this manual for cleaning, inspection, and measurements.

Installation 3 Install

or Connect:

er crankshaft bearing to the block.

.

~]

Bmportant: If any undersized bearings are used, they must be fitted to the proper journals.

2. Crankshaft.

3. Lower crankshaft bearings to the crankshaft bearing caps°

4-30

Engme/eng

[~

Measure: Refer to GeneranEngine Mechanical section in this manual for crankshaft bearing clearance procedures.

4. Apply engine oil to the crankshaft bearings. Install crankshaft bear~ caps (except rear cap) and bolts to the block.

Tighten: Crankshaftbearing cap bolts to 77 ft. lb. (105 N.m).

5. Rear crankshaft bearing cap. Apply engine oil to the crankshaft bearings.

(L Rear crankshaft bearing cap boRts. r~ Tighten: Rearcrankshaft bearing cap bolts to 124 in. lb. (14 N.m).

Measure: Refer to General Engine Mechanical section in this manual for crankshaft end play procedure. [~ Tighten: Finally tighten rear crankshaftbearing capbolts to 77 ft. lb.

(105 N-m)

CylinderBlock r)isassembly [~ Remove or Disconnect:

DRC6623

1. Coolantdrain fittings.

2. Camshaftand balance shaft cup plugs. i~-2~ 3. Front oil gallery cup plugs. [’3~ 4. Port side oil gallery plugs.

E4~5. Rearoil gallery plugs. [~

Clean:

DRC6621

1. Sealing material from mating surfaces.

2. Boil cylinder block in caustic solution. ® Flush with clean water or steam.

4-31

DRC6622

3. Cylinder bores.

4. Threaded holes.

5. Oil galleries and passages.

6. Scale deposits from coolant passages.

7. Spray or wipe cylinder ne oil

~

bores and machined surfaces with

inspect:

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

2. Camshaftlifter

bores for deep scratches and deposits.

3. Cracksin the block ® Cylinder walls. o Water jackets. ® Engine mount bosses. o Crankshaft bearing webs. ¯ Crankshaft bearing bores and caps. ¯ All crankshaft bearing bores should be rounded and uniform in inside diameter (I.D.) at all of the bearing supports. ® The area where the crankshaft bearings contact the crankshaft bearing bore should be smooth. ® If a crankshaft bearing cap is found to be damaged, repDacethe cap and line bore the block. [~ 4. Cylinder block head mountingsurface for flatness, using a precision straight edge and feeler gauge. a. Set the straight edge on the sealing surface to be inspected. b. Takethe feeler gaugeand at various locations, checkthe gap betweenthe straight edge and the sealing surface. c. if the gap is found to be greater than 0.004 in. (0,1016 mm) within 5.984 in. (152 mm)at any sea0ing location, the b0ock must be replaced.

4-32

DRC6620

Engine/eng

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

Minor irregularities maybe cleaned up with a flat file. nder Bere

[~

inspect:

Cylinder bores for scoring or other damage.Refer to General Engine Mechanical section in this manual. [~

Measure: Cylinder bore taper and out-of-round. Refer to General Engine Mechanical section in this manual.

~y_~

nder 8ore Reconditioning

[~==~-J Measure: Refer to General Engine Mechanical section in this manual.

Cylinder Block Assembly Fq ,nstaliorConnect: 1. Front oil gallery plugs. Coat plug outside diameter with GM Sealant, P/N 12346004,or equivalent.

[2~ [~ [~ 2. Rear oil gat)ery plugs. r~ Tighten: DRC6623

® Left rear plug to 15 ft. lb. (20 N.m). ® Right rear plug to 18 ft. lb. (25 N.m). ® Left side plug to 15 ft. lb. (20 N.m).

3. Camshaft and balance shaft cup plugs to proper depth. Coat bore inside diameter with GMSealant, P/N 12346004,or equivalent.

E~ nmportant: Do not allow residue on camshaft bearing or seizure mayresult.

DRC6621

DRC6822 Eqg...... g

4-33

Circulating PumpDescription The Volvo Penta cimulating pumpis manufacturedspecially for marine use. it is serviced only as an assembly.Donot replace with an automotive circulating pump. inspection 1. Remove alternator and powersteering belts.

2. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag.

3. Look for water leaking from indicator hole beneathpumpshaft behind pulley. Replacepumpif play, drag, or leakageare evident.

Removaland Installation 1. Drain water from block and disconnectwater hosefrom circulating pump.

2. Remove pulley. Remove circulating pumpbolts, pumpand gaskets.

3. Usenewpumpto block gaskets and sealer. Install new pumpassembly on cylinder block and tighten bolts as specified.

4. Install pulley. Install alternator andpowersteering belts, then adjust tension.

5. Install hoseto circulating pump.

6. Lakeor tank test unit and checkfor leaks.

4-34

Englne/eng

Front Engine Mounts Removal [1~ 1. Removetwo lag screws (~ and washers from mounts. l.~ 2. Lift enginewith a hoist capableof lifting at least 1500lb. {680 kg) to allow removalof front mount and bracket.

[2~ 3. Removethree mount screws and lock washers ®. Note screw lengths and location.

25929

[_3~ [~ Prior to disassembly of front mount assembly, measure distance and record measurement between large washer and flat on upper mount bracket.

Disassembly E4~ 1. Removethree nuts © and engine mount bracket @from mount bolt while holding bolt secure with socket ®.

[5~ 2. Removetwo flat washers, one large ® and one smaller @.

Removelock washer ®, and engine mount bolt (~ from mount.

25917

11980

11979

’®’® 1197:

Reassembly E~ 1. Place small washer(~) on mountbolt and insert bolt up through mount.Instalr large washerand securewith nut (~. Tightento 60-75ft. Ibs. (81-102 N,m).

E~ 2. Install upper inner nut and place engine mountbracket on engine mountbolt. ~ Measure distance between large washer and flat bracket. Adjust distance to recorded measurement.

on upper mount

3. Install lock washerandtop nut. Tightennut to 100-120ft. Ibs. (136-163 Nom). installation [~ 1. Spray the engine mountscrew threads with Loctite ® Primer N and allow to air dry. Apply Volvo PentaTreadSealing AgentP/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screwsand washers@.Tighten to 32-40 ft. Jbs. (43-54 N m). [~ 2. Instatl washersand lag screws(~ and tighten securely.

11979

Height Adjustment [~ 1. To changeengine height, tighten or loosen nuts ® and @as required. ~2. Lift enginewith a hoist capableof lifting at aeast 1500lb. (680 kg). Position engineat desired height.

3. After setting mountposition, turn nut ~) up against undersideof engine bracket and hold nut with a wrench.Tightennut (~ to 100-t20ft. Ibs. (I36-163 N,m). ~Any large adjustments to engine height should be followed by a checkof enginealignment.Failure to checkalignmentcould result in rapid engine coupler failure. SeeDrive Removal and Installation section of the SterndrivefTransom Bracket Service Manualfor alignment procedures.

25917

21929

4-36

2953 Eng,ne/eng

High-Rise Exhaust Elbow Replacement Removal [3 1. Loosentwo clampssecuring upper hose to elbow. Lubricate inside of hosewith a soapywater solution.

[7~ 2. Starboard EJbow:Remove circuit breaker bracket 3 and set aside.

Remove four screws, flat washers,and lock washersmountinghigh-rise elbow.

[8--"] ~] 3. Usea soft hammer to free elbow from manifold. Usea twisting motion to pull elbowfrom hose. Remove and discard the elbow gasket.

34719

installation 1. Thoroughlyclean manifold gasket surface. Apply Volvo Penta Gasket .Sealing Compound P/N 1161231-4to both sides of a newmanifold gasket and place it on the exhaustmanifold. i=9=-] [~ 2. Lubricate the inside of the exhausthose with a soapywater ,solution. Insert the high-rise elbowinto the hosewith a twisting motion,and pushit into hoseas far as it will go.

34721

3471

34716

Engme/eng

4-37

~717

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

them in the

Exhaust Hoseand intermediate Pipe Replacement 34720

Removal [~] 1. Looseneight clamps that secure the upper © and lower @ exhaust hoses. ~] 2. Lubricate inside of lower hose with a soapy water solution, and slide lower hose downonto exhaust Y-pipe. [] 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose if necessary to ease removal.

4. Slide upper hose off high-rise elbow. Slide lower hose off exhaust Y-pipe.

32371

32374

32375

//~ Safety Related

4-38

32363 Engme/eng

Installation [6~] 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe.

I-7---I ~ The inside diameter of both the upper and lower hoses has a step ® 1.5 in. (3,81 cm) from one end. The stepped ,end of the hose must face the intermediate pipe wheninstalled. ;2. Slide hoseonto high-rise elbowuntil it seats.

L-_N°-~ If hose is not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment.

32370

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

Exhaust (Flapper) Valve Replacement 32366

Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hoseand intermediate Pipe Replacement. [=-8~ 2. Slide the lower hose downfar enoughto exposethe valve pivot pin. Hold the valve while pulling out the pin, then lift out the va lye.

Eg~ 3. Inspect the two rubber bushings inside the pipe. Replace them as necessary.

32367

32368

Enr~me/eng

~/~ Safety Related

4-39

Installation [~] 1. If installing newrubber bushings, apply 3M® Scotch Grip Rubber Adhesive1300to outside of tips, and insert into inside of exhaustpipe. [~ 2. Position valve with longest lip pointing down,and insert into pipe.

Pushpivot pin throughbushingsand valve until pin endis flush with outside of pipe. Checkexhaust valve for freedomof movement. ~lf valve is not positioned properly (long lip down), it will restrict exhaustflow and fail to prevent water backingup into engine. Boat performancewould be adversely affected, and engine maysuffer water damage.

32368

3. Install intermediate pipe following procedureunder ExhaustHoseand Pipe Replacement,

Engine Coupler Replacement Removal 1. Remove engine from boat.

If coupler is being replaceddue to coupler failure (rubber hub of splined hub), checkenginealignmentafter installing newcoupler. SeeDrive Removaland Installation section of the Sterndrive/Transom Bracket Service Manual.

32369

2. Disconnectall wires, lines and connectorsfrom bellhousing. [~ ~ 3. Removescrews securing belihousing cover, and slide cover out.

20034

19085

4-40

Engme/eng

E 5]~[3 4. Pull drain hoseout of be,housing.

E 8]~[] 5. Unscrewbolts and nuts retaining bellhousing. Disconnectground wires. Remove powersteering cooler bracket.

6, Remove be~ihousingfrom engine block. i[7~ 7. Unscrewsix nuts securing coupler and removecoupler from studs. & Remove old gasket from be, housing cover. Clean gasket surface thorougNy. 19842

~nstalJation [8~ 1. Install coupler and securewith six Iocknuts. Usea suitable adaptor andtighten to 40-45fl:. Ibs. (54-61N,m).

F_6~2. install belihousingand attach powersteering cooler. Tightennuts and bolts to 32-40ft. Ibs. (43-54 N,m). Attach groundwires and tighten nuts ~:o 15-20ft. Ibs. (20-27N®m). :3. Pushdrain hoseinto belihousing.

4. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a newbelihousinggasket and position it on cover.

6710

Eg~5. Cleansevenself-tapping screwswith a wire brush. Install bellhousing cover and screws.Tighten to 60-84in. Ibs. (7-9 N,m).

6. Connectall wires, lines and connectorsto bellhousing, 7. Install enginein boat.

7--q 6712

6714

Engme/eng

4-41

19996

Torque Specifications Balance Shaft Driven Gear Bolt .........................

15 ft. Ibs. (20 N-m)(Plus 35 degrees}

Balance Shaft Retainer Bolts ........................................

124 in. Ibs0 (14 N.m)

Bell Housing Cover Screws .......................................

60-84in. Jbs. (7-9 N.m)

Bell

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

Housing Nuts and Bolts .....................................

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

15 ft. Ibs. (20 N.m)

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

15 ft. Ibs. (20 N-m)

Block Oil Gallery

18 ft. Ibs. (25 N.m)

Plug, Right Rear .....................................

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

Camshaft Retainer

15 ft. Ibs. (20 N.m)

Bolt

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

124 in. Ibs. (14 N.m)

Camshaft Sprocket Bolts

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

21 ft. Ibs. (28 N.m)

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

20 ft. nbs. (27 N-m)(Plus 70 degrees}

Crankshaft

Balancer Bolt

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

74 ft. Jbs. (100 N-m)

Crankshaft

Bearing Cap Bolt ........................................

77 ft. Ibs. (105 N-m)

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

11 ft. Ibs. (15 N.m)

Cylinder HeadBolt First

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

22 ft. ibs. (30 N.m)

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

Medium Length Bolt .................................................

Long Length Bolt ...................................................

55 degrees 65 degrees 75 degrees

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

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

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

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

Exhaust Manifold

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

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

Front

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

106 in. Ibs. (12 N.m)

Cover Bolt

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

Upper ................................................

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

4-42

Eng,ne/eng

TorqueSpecifications High Rise Elbow Nuts ..........................................

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

Intake ManifoJd Bolts First Pass .......................................................

Second Pass ..................................................

Final Pass .....................................................

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

Oil Pan Nuts .........................................................

Bolts .........................................................

Studs in Engine Block ............................................

Oil

Pump Bolt

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

Oil Pump Cover Bolt

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

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

Spark Plugs Cylinder Head (New) .............................................

Cylinder Head (All Subsequent Installation) ...........................

22 ft. Ibs. (30 N-m) 15 ft. Ibs. (20 N.m)

Valve Lifter

12 ft. Ibs. (16 N.m)

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

Valve Rocker Arm Cover Bolts .......................................

106 in. Ibs. (12 N.m)

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

20 ft. Ibs. (27 N.m)

Valve Rocker Arm Stud .............................................

35 ft. Ibs. (47 N.m)

Englne/eng

4-43

EngineSpecifications Type .............................................................

Displacement ......................................................

Bore .........................................................

Stroke .......................................................

Compression Ratio .........................................................

Firing Order ..........................................................

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

Oil Capacity Without Filter Change ............................................

With Filter Change Add ........................................

6.0 PSU(41,4 kPa) at 1,000 engine RPM 18.0 PSn(24,1 kPa) at 2,000 engine RPM 24.0 PSI (165,5 kPa) at 4,000 engine RPM

Oi| Pressure (Minimum Hot) ..........................

Off Filter

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

Oil Pump Type .........................................................

Diameter ....................................

Out-of-Round ...........................................

Taper ..................................................

Piston

4 Qts. (3,75 LiVes) 0.42 Qts. (0,398 LiVes)

Full Flow Gear Driven

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

Bore Clearance ...................................

0.0024 in. (0,06096 mm)MAX.

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

Gap ...................................................

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

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

Gap ........................................................

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

4-44

Engme/eng

Engine Specifications

EngineBlock Clearance Tolerance

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

0.010 in. (0,254 mm)MAX.

Diameter .......................................

0.927 - 0.926 in. (23,545 - 23,548 mm) Clearance in Piston .......................................

0.001 in. (0,0254 mm)MAX. Fit In Connecting Rod ................

0.0008 - 0.0016 in. (0,02032 - 0,04064 mm)Interference

Surface Flatness

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

0.010 in. (0,254 mm)MAX.

Surface Flatness

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

0.004 in. (0,1016 ram) MAX.

Crankshaft Journal Diameter #1 ...................................

Diameter #2, #3 ...............................

Diameter #4 ...................................

Taper ..................................................

Out-of-Round ..........................................

2.4488 - 2.4495 in. (62,199 - 62,217 ram) 2.4485 - 2.4494 in. (62,192 - 62,215 mm) 2.4480 - 2.4489 in. (82,180 - 62,202 ram) 0.001 in. (0,0254 ram) MAX. 0.0010 in. (0,0254 mm)MAX.

Crankshaft Bearing Clearance Bearing #1 ....................................

Bearings #2, #3 ................................

Bearing #4 ....................................

0.0010 - 0.0015 in. (0,0254 - 0,0381 mm) 0.0010 - 0.0025 in. (0,0254 - 0,0635 ram) 0.0025 - 0.0035 in. (0,0635 - 0,0889 mm)

Crankshaft End Play .................................

0.002 - 0.008 in. (0,0508 - 0,2032 ram)

Connecting Rod Journal Diameter .....................................

Taper ..................................................

Out-of-Round ...........................................

Rod Bearing Clearance ...........................

Rod Side Clearance ...............................

Eng,ne/eng

2.2487 - 2.2497 in. (57,117 - 57,142 mm) 0.001 in. (0,0254 mm)MAX. 0.001 in. (0,0254 ram) MAX. 0.0010 - 0.0030 in. (0,0254 - 0,0762 mm) 0.006 - 0.017 in. (0,1524 - 0,4318 mm)

4-45

Engine Specifications

Journal Diameter .................................

End Play ..........................................

1.8677 - 1.8697 in. (47,440 - 47,490 mm) 0.001 - 0.009 in. (0,0254 - 0,2286 mm)

Lobe Lift ................................................... mntake .....................................................

Exhaust ....................................................

--- 0.002in. (4- 0,051ram) 0.2763 in. (0,7180 mm) 0.2855 in. (0,7252 ram)

Front Bearing Journal Diameter ....................

Rear Bearing Journal Diameter .....................

Rear Bearing Journal Clearance ....................

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

Valve Lifter ......................................................

Valve Rocker Arm Ratio .....................................................

Valve Lash Net Lash ................................................

Face Angle ...........................................................

Seat Angle ...........................................................

Seat Runout ............................................

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

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

Exhaust ..........................................

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

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

Intake ...................................

Exhaust .................................

Valve Spring Free Length ...................................................... installed Height ....................................

2.03 in. (52 mm) 1.690 - 1.710 in. (42,92 - 43,43 ram)

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

Open ...................................

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

ValveLift intake .......................................................

Exhaust .....................................................

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

4-46

Eng,ne/eng

GMSpecial Tools

J 5590

J 5239

J 3049 DRC6596

2-7

4--] J 5825-A 5~

DRC6597

J 8037

J 8o01

DRC6599

DRC6598

DRC6600

DRC6601

J~ Pliers, Valve Lifter Remover 12~ Connecting Rod Bolt Guide Set [3~ CrankshaftSprocket Installer [4~ Crankshaft Sprocket Remover ]5-~ Dial indicator Set

J 8062

[6-~ Piston Ring Compressor

DRC6602

I~ Valve Spring Compressor IN Driver Handle

J 8092 DRC6603

Englne/eng

4-47

GMSpecial Tools

J 9290-1

J 21882

J 34673 DRC6605

DRC6606

I E

L

J 36996

J 35621 DRC6607

DRC6608

DRC6609

Hydraulic Valve Lifter Remover Oil SuctionPipe Installer ~]

Straight Edge

[~

Rear MainSeal Installer

J 38834

Torque/Angie Meter I~] BalanceShaft Instal|er

DRC6610

BalanceShaft Bearing Service Kit [~ HarmonicBalancer Remover~Installer

J 39046 DRC6611

4-48

Eng~ne/eng

Section 5 5.7 GL, GS and Gi Engines Table of Contents Camshaft ..........................

5-16 5-20 Camshaft Lobe Lift, Measuring .........

Circulating Pump....................

5-27 Connecting Rod Bearing Replacement ... 5-24 5-22 Crankshaft .........................

Cylinder Block ......................

5-26 5-10 Cylinder Head ......................

Engine Coupler Replacement ...........

5-32 Engine Specifications .................

5-34 5-30 Exhaust Hose Replacement ............

5-5 Exhaust Manifold ....................

Exhaust (Flapper) Valve Replacement....

5-31 Front Engine Mounts .................

5-28 General Specifications ................

5-34 High-Rise Exhaust Elbow Replacement. ¯ ¯ 5-29

Intake Manifold .....................

5-3 Intermediate Pipe Replacement .........

5-30 Lubrication System ..................

5-17 5=18 Oil Pan ............................

5-18 Oil Pump ..........................

Oil Seal, Rear Main Bearing Replacement 5=21 Piston, Ring and Connecting Rod .......

5=25 5-2 Sealants, Lubricants and Adhesives ......

Special Tools ........................

5-2 Timing Chain and Sprocket ............

5-14 Torque Specifications .................

5-36~ Valve Lash Adjustment ................

5-8~ 5-6 Valve Lifter, Hydraulic ................

Valve Spring and Seal Repair ...........

5-9

Safety Warnings Before working on any part of the engine, read the section caged Safety at the end of this manual.

Unless instructed otherwise, always disconnect the battery cables from the battery before working on electrical system to prevent possible sparks or arcing in the engine compartment.

Before starting engine after repair or maintenanceprocedures, always makesure engine compartmentis free of fuel vapors to prevent possible fire and explosion.

Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator, power steering pump, supply pump, and circulating pumpbelts, pulleys and other moving parts.

£flg me,’eng

5-1

General Motors Tools item

Part Number

Air Line Adaptor ...........................................

DamperPul}er and Installer ..................................

Dial Indicator Set ............................................

Rocker Arm Stud Hole Reamer(0.003 Oversize) ..................

Rocker Arm Stud Hole Reamer(0.013 Oversize) ..................

Ring Compressor ...........................................

Rocker Arm Stud Remover .................................

Seal Installer ..............................................

Seal Installer ..............................................

Stud Installer ...............................................

Stud Protector ..............................................

Vacuum Pump ..........................................

Valve Guide Cleaner ......................................... ’Valve Guide ReamerSet ...................................

Valve Seal Tester ...........................................

Valve Spring Compressor ...................................

Valve Spring Compressor .....................................

Valve Spring Tester ..........................................

J-23590 J-39046 J-8520 J-5715 J-6036 J-8037 J-5802-01 J-35468 J-35621 J-6880 J-5239 J-23738-A J-8101 J-5830-02 J-23994 J-5892-C J-8062 J-8056

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

Material Required Molykote Lubricant Volvo Penta Gasket Sealing CompoundP/N 1161231-4 ~ No. 2 Permatex GMSuper Engine OiJ Supplement GMSilicone RubbverSealer, P/N 1052289 Plastigage TM(Green) DuraPlusTM SAE30 HeavyDuty Synthetic Motor Oil Black NeopreneDip For additional service information not coveredin this manual,obtain the appropriate Chevrolet EngineService Manualfrom: HelmInc. RO.Box 07130 Detroit, MI 48207

5-2

Engme/eng

intake Manifold Removal ~ 1. Drain coolant block.

from manifolds

and both sides of

2. Disconnect: L~ a. Battery cables from battery. b. Coolant hoses at thermostat housing.

42852

c. Throttle (:able from carburetor and anchor block. d. Crankcaseventilation sides).

hose from rocker arm covers (both

e. Wire at temperature gauge sender unit wiring harness from alternator.

and engine

f. Distributor high tension and ignition primary leads from coil.

42881

3. Remove" I~

a,

Distributor cap and mark the position of the rotor on the housing. Scribe a line on distributor housing and intake manifold for reassembly in the sameposition. Remove the distributor. b, Alternator and alternator mountingbracket from engine. c. Carburetor fuel line from carburetor and fuel pump. d. Oil pressure sending unit.

e.

f,

Eng,ne/eng

25140

Manifold attaching bolts and solenoid bracket. Lift manifold from engine. Discard front and rear seals and gaskets.

If manifold is to be replaced, transfer: carburetor, thermostat and housing (use new gasket), throttle cable anchor block assembly, distributor clamp and temperature sending unit. Transfer additional hardware as required.

L~ Safety Related

5-3

Installation 1. Cleangasketandseal surfaceson manifold,block andcylinder heads.

2. tnstatl: a. Newmanifold seals on block and newgaskets on cylinder heads. Usesealer at water passagesand whereseals butt to gaskets. [~ ~ On those engines not having front and rear manifold seals, place a 3/16 in. beadof GMSilicone RubberSealeronthe front and rear ridges of the cylinder case. Extendthe bead1/2 in. up eachcylinder headto seal and retain the manifold side gaskets.

DR2252

~] Tighten ail bolts to 30 ft. Ibs. (41 Nom)following the sequenceshown. b. Distributor with rotor and aFignedexactly as markedduring removal. ~lf engine was cranked while distributor was out, complete ignition timing proceduremust be folJowed. Seethe appropriate Ignition Circuit in Emectrical/Ignition SystemsService Manual. c. Alternator with mountingbracket. d.

DR3303

Distributor cap and high tension leads. Seethe General Information section in Electrical/Ignition Service Manual for correct firing order andspark plug wire routing.

e. Oil pressuresendingunit.

3. Connect: a. All electrical connections.ApplyBlack NeopreneDip, on all exposedconnections. b. Carburetorfuel line. c. Throttle cable, d. All water hoses, and close air drain petcocks. e. Both crankcaseventilation hoses. f. Battery cables. g. Start engine. Adjust ignition timing, carburetor idle speed and mixture. Checkfor leaks.

5-4

Engine/eng

Exhaust Manifold Removal I. Drain water from exhaustmanifolds, 2. Disconnectwater hose from manifold.

3. Loosenupper exhaust hose clamps, then removehigh rise elbow.

4. Remove manifold attaching nuts and washers.Discard nuts.

Inspection

@

1. Inspectfor cracks.

E~ 2. To pressure checkmanifold, fabricate a plate as shown~), and newelbowgasket (~ to seal water passagein manifold. Be sure to apply sealer to gasket. Install rubberdrain capsto manifoldand securewith clamps. Attach a GearcasePressure Tester © (such as Stevens Company S-34) to the water inlet hose. A bushingcan be madeto securepressure tester to hose. With the pressuretester attachedto the manifold, submerge manifold in water. Pressurize the manifold to 10-15 PSI {22-25 kPa) and checkfor leaks. Manifoldshould not leak aroundclampsand plate. If so, retighten clampsor reseal plate. Nodrop in pressureshouldbe realized.

DR2~2

Installation [~1. Clean mating surfaces on manifold and head. Install newexhaust gasket, then install manifold and securewith newIocknuts and washers.

Tighten nuts @to 20-26ft. Ibs. (27-35 N®m).

2. Install a newgasketandhigh rise elbowto manifold. Tighten bolts to 12-18ft. Ibs. (16-24N,m).

3. Install exhausthose and securewith clamps.

42861A

4. Connectwater hose. Install and tighten drain petcocks.

5. Start engineandcheckfor fuel leaks.

Englne/eng

5=5

HydraulicValveLifter Checking Hydraulic Valve Lifter When checkinghydraulic valve lifters, remember that grit. sludge, varnish, or otherforeign matterwill seriously affect their operation,ff anyforeign substanceis foundin the lifters or enginewhereit maybe circulated by the lubrication system,a thoroughcleaning job mustbe doneto avoid a repetition of lifter trouble.

To help prevent[ifter troubie, the engineoil and oil filter mustbe changed as recommended in GeneralInformation section. The engine oil must be heavy-duty type (for Service SG)and must also conformto General Motors Specification 6094Mto avoid detrimental formation of sludge and varnish.

WerecommendDuraPlusTMSAE30 Heavy Duty Synthetic Motor Oil. The boat ownershould be specifically advised of these requirementswhenthe unit is delivered. Faulty valve lifter operationusually appearsunderone of the following conditions: 1. RappingNoise Only WhenEngine is Started: When the engineis stopped, any lifter on a camshaft}obe is under pressure of the valve spring; therefore, leak downor escapeof oil fromthe lower chambercan occur. Whenthe engine is started, a few secondsmaybe requiredto fill the lifter, particularly in colderweather.If noiseoccursonly occasionally, it maybe considerednormal, requiring no correction. If noise occursfrequently, however,checkfor either oil too heavyfor prevailing temperatures,or excessivevarnish in lifters.

2. intermittent RappingNoise: An intermittent rapping noise that appearsand disappearsevery few secondindicates leakageat checkball seat due to foreign particles, varnish, or defective surfaceof checkball or seat. Replacelifters as necessary.

3. Noise at Idle andLowSpeed: If one or morevalve lifters are noisy at idle speedandup to approximately 1200RPM,but quiet at high speeds,it indicates excessiveleak downrate or faulty checkball seat or plunger.With engineidling, mifters with excessive leak downrate maybe spotted by pressing downon each rocker arm above the pushrod with equal pressure. Reconditionor replace noisy lifters.

5-6

Engme/eng

4= GenerallyNoisyat Anl Speeds: Checkfor low or high oil level in crankcase.High oil levels will be churnedby crankshaft and will force air bubbles into the nifters.

Lowoil levels allow pumpto pumpair at high speed. With engine idling, strike each rocker arm abovethe push rod several sharp blows with a mallet; if noise disappears, it indicates that foreign material was keeping check ball from seating. Stop engine and place lifters on camshaftbasecircle. If there is lash clearancein any valve linkage, it indicates a stuck lifter plunger, wornlifter body lower end, or worn camshaft lobe.

5. Load Noise at NormalOperating TemperatureOnly: if a lifter develops a loud noise whenthe engine is at normah operating temperature, but is quiet whenengine is below normal temperature, it indicates an excessively fast leak downrate of scored lifter plunger. Reconditionor replace lifter.

Removal 1. With air hose and cloths, clean dirt from cylinder heads and adjacent parts to avoid getting dirt into engine, it is extremely important that no dirt gets into the valve lifters.

2. Removeintake manifold. Removeexhaust manifold.

3. Removerocker arm covers. Do not pry, if covers stick use rubber mallet and strike cover end to jar loose. Loosenrocker arm nuts or screws and pivot the rocker arms free of the push rods. [~ 4. Removepush rods (~ and remove valve lifters ® that require service. Place lifters in a ,woodenblock having numbered holes or use other suitable meansof identifying them according to original position in the engine.

5. if less than a completeset of lifters is being removed,immediately disassembleone or two for presence of dirt or varnish. Rf lifters contain dirt or varnish, it is advisableto removeall lifters for replacement.Otherwise, it will be satisfactory to service only those lifters that are not operating properly.

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

Installation lifter

Before installing any newlifters, with Molykoteor its equivalent.

coat the bottom of the

1. Install valve lifters in cylinder block, if any newlifters or a new camshaft has been installed, an additive containing EPlubricant such as G.M. Engine Oil Supplement must be added to the crankcaseoil break-in.

Eng,ne/eng

5-7

ROTATING - NORMAL, OK NOT ROTATING

GAL LED o SHOULDBE REPLACED- SOFT, WORN

860000

2. Install pushrods onto lifters.

Install intake manifold.

3. Pivot rocker arms in place. Turn the adjusting nuts the amountnecessary to eliminate lash.

4. Install rocker arm covers, using G.M. Silicone RubberSealer, P/N 1052289,and tighten nuts to 90 in. Ibs. (10 N.m).

5. Install exhaustmanifold. Start engineand checkfor oil leaks at rocker arm covers.

Valve

Lash

DR2104.

Adjustment

1. Crank engine until mark on harmonic banancer lines up with center or "O" markon the timing tab fastened to the timing chain cover, with the engine in the number1 firing position. This may be determined by placing fingers on the number1 cylinder valves as the mark on the balancer comesnear the "O" mark on the front end cover. If the valves are not moving, the engine is in the numberI firing position. If the valves moveas the mark comesup to the timing tab, the engine is in number6 firing position and should be turned over one more time to reach to number 1 position. [~] 2. Valve adjustment is madeby backing offthe adjusting nut (rocker armstud nut) until there is play in the valve pushrod and then tightened to just removeall push rod to rocker arm clearance. This maybe determined by rotating push rod with fingers as the nut is tightened. Whenrod does not readily move in relation to the rocker arm, the clearance has beeneliminated. The adjusting nut should then be tightened an additional one turn to place the hydraulic lifter plunger in the center of its travel. No further adjustment is required.

Donot attempt to turn the adjusting nut one full turn while the engine is operating. Adjustmentin this mannerwill not allow the lifters to bleed down.This wouldresult in valve train damage, probably bent push rods. For those whoprefer to adjust the valve lash while the engine is running, the preferred methodwouid be to find the "zero lash" point as described aboveand then slowly turn the adjusting nut 1/4 turn. VVait for the lifter to bleed down (several engine revolutions) and again turn adjusting nut 1/4 turn.

Continuethis adjust and wait cycle until nut is one completeturn down from "zero lash" point. Repeat sequence on remaining valves.

Exhaust- 1, 3, 4, 8 Intake- 1, 2, 5, 7 3. Crankthe engine one revolution until the pointer "0" mark and harmonic balancer mark are again in alignment. This is number6 firing position. With the engine in this position, the following valves maybe adjusted.

Exhaust- 2, 5, 6, 7 Intake- 3, 4, 6, 8

5-8

Englne/eng

4. Install rocker arm covers, using G.M. Silicone RubberSealer, P/N 1052289.Tighten nuts to 90 in. Ibs. (10 N.m).

5. Install exhaustmanifold° Start engineand checkfor oil leaks at rocker arm covers.

Valve Spring and Seal Repair Removal ~1. Removerocker

arm cover.

2. Remove spark plug, rocker arm, and push rod on the cyhinder(s) ’to be serviced. [~ 3. Install Air Line Adapter tool J-235g0to spark plug port and apply compressedair to hold the valves in place. [~ 4. Using tool J-5892-C to compressthe valve spring, remove the valve mocks, valve cap and valve spring and damper.

5. Remove the valve stem oil seal.

DR2102

installation 1. Install seal over valve stern and seat against head.

2. Set the valve spring and damper,valve shield and valve cap in place. Compress the spring with tool J-5892-Cand instalr oil seal in the lower groove of the stem, makingsure the seal is flat and not twisted.

I~ A light coat of oil on the seal will help prevent twisting.

3. Install the valve locks and release the compressortool making sure the locks seat properly in the upper groove of the vanvestem. [~ Grease may be used to hold the locks in pnace while releasing the compressortool 4. Using VacuumPumpJ-23738-A, apply vacuumto the valve cap to makesure no air leaks past the seal.

5. Install spark plug and tighten to 20 ft. Ibs. (27 N.m).

6. Install

E’ngine/eng

and adjust valve mechanism as previously outlined.

5-9

Cylinder Head Removal 1. Drain water from block and exhaust manifolds. Removeintake and exhaust manifold.

2. Removevalve covers and spark plugs.

3. Loosen rocker arm nuts and turn rocker arms aside. Remove pushrods. If bifters are to be serviced, removethemat this point.

Otherwise protect the lifters and the camshaft from the entrance of dirt by covering the area with clean cloths.

4. Removecylinder head bolts, cylinder headsand gasket. Place cylinder heads on bench, supporting them at each end on blocks of woodto prevent damageto gasket faces of heads.

Disassembly 1. Removenut from rocker arms, bah seats and rocker arms. [~ 2= Using tool J-8062, compressthe valve springs and remove the valve keys. Release the compressortool, and removerotators or spring caps, oil shedders, springs and spring dampers, then removeoil seals and spring shims. [~ Some cylinder heads use exhaust valve springs shorter free length than the intake valve springs.

DR3125

with a

3. Removevalve from bottom of cylinder heads and place them and their respective valve springs in a rack in their proper sequenceso they can be assembledin their original positions.

Cleaning, inspection and Measurement Refer to GeneralEngineMechanical section of this manual.

DR2105

Repair 1. Rocker Arm Studs Rocker arm studs that have damagedthreads may be replaced with standard studs, if the studs are loose in the head, oversize studs, availabne in 0.003 in. or 0.013 in. (0,076, or 0,330 ram) oversize, maybe installed after reaming the holes as follows: a. Removeold stud by placing tool J-5802-01 @over the stud, installing nut and flat washerand removingstud by turning nut.

m

DR2107

b. Reamhole for oversize stud using ReamerJ-5715 for 0.003 in. (0,076 ram) oversize and ReamerJ-6036 for 0.013 in. (0,330 ram) oversize.

5-10

Engme/eng

c. Coat press-fit area of stud with hypoid axle Iqbricant. install newstud using tool J-6880 @. Tool should bottom on head. [a~o_o_~jDonot attempt to install an oversize stud without reaming stud hole.

2. Valve Seats: Reconditioning the valve seats is very important, because the seating of the valve mustbe perfect for the engine to deliver the powerand performancebuilt into it.

DR2106

Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve headwill be properly carried away.

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

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

Place roughing stone or forming stone over pilot and just cUeanup the valve seat. Usea 46° stone for both the inlet and exhaust valve seats.

Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smoothfinish.

d. Narrow downthe valve seats to the proper width for the intake and exhaust. See Engine Specifications. [~ °This operation is done by grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations.

15_~ ~ Valve seats should be concentric to within 0.002 in. t0,051 ram) total indicator reading.

I:ngmeleng

5-11

10425

3. Valves: Valves that are pitted can be refaced to the proper angle, ensuring correct relation between the head and stem on a valve refacing machine. Valve stems which show excessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be groundon part or all of the valve head due to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or preignition due to heat localizing on this knife edge.If the edgeof the valve headis less than 1/32 in. (0,792 ram) thick after grinding, replace the valve. ff necessary, dress the valve refacing machinegrinding ° wheel to makesure it is smoothand true. Set chuckat 45 mark for grinding valves. b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheel by movingthe never to the left. do

e.

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

Continue grinding until the valve face is true and smooth all aroundvalve° If this makesthe valve thin, the valve must be repnaced as the valve wina overheat and burn.

f. Removevalve from chuck and place stem in "V" block.

Feedvalve squarely against grinding wheel to grind any pit from rocker arm end of stem.

Only the extreme end of the valve stem is hardened to resist wearu Do not grind end of stem excessively. g°After cleaning valve face and cylinder head vaBveseat of grinding particles, makepencil marksabout 1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve. h=

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

i. Grind and check remaining valves in the samemanner° Assembly [~ Whenreplacing valve springs, catalog for ordering information.

refer to the latest

5-12

parts

Eng,ne/eng

E~ Starting with number1 cylinder, place the valves in the designated ports and assembleall but the seal and locks. Then, using tool J-8082, compress the spring L.~ and install the seal (~) and locks ©. Seethat the seal is flat andnot twisted in the valve stemgroove,andthat the locks seat properly in the valve stem groove. Notice that only the exhaustvalves have rotators ©.

ENo--~Place valve spring in position with the closed coil end towardthe cylinder head. hlstallation C03107

1. Wipeoff engineblock gasket surface and be certain no foreign material hasfallen into the cylinderbores,bolt holes, or the valvelifter area.It is .goodpractice to cleanout bolt holeswith an air hose.

F~ This engine has special marine head gaskets. Do not substitute .automotive headgaskets.

2. Install newheadgasketon cylinder block. DoweJs in the block will hold the gasketin position. Alwayshandlegasketscarefully to avoid kinking or damage to the surface treatment of the gaskets. DONOTuse any type of sealing material on headgaskets. Thegaskets are coated with a special lacquer to provide a goodseal, once the parts have warmedup.

3. Cleangasketsurface of cylinder headand carefully set in place on the engineblock dowelpins.

TM

4o Cleanand lightly lubricate the thread area of the bolts with DuraPlus £AE30 HeavyDuty Synthetic Motor Oil. Install bolts.

[2~ 5. Tighten the headbolts with a torque wrench,in three progressive steps, following the sequenceshown.

Step1 - 25 ft. Ibs. (34 N.m) Step2 - 45 ft. Ibs. (61 N m) Step3 - 65 ft. Ibs. (88 N.m)

E qgine/eng

5-13

@, ® i

@ @@® DR2254

Damage to the cylinder block threads can result if bolts are not lubricated with Volvo Penta Gasket Sealing Compound P/N 1161231-4 prior to installation or if the bolts are tightenedexcessively.Usean accurate torque wrenchwheninstalling headbolts and do not overtighten. Uneven tightening of the cylinder headbolts candistort the cylinder bores, causing compressionloss and excessive oil consumption.

Timing Chain and Sprocket Balancer and Cover Removal 1. Remove alternator and powersteering bracket bolts.

47287

2. Remove circulating pumppulley.

3. Remove harmonicbalancer pulley bolts and pulley. [~ 4. Install tool J-39046(~) to harmonicbalancer, and turn puller screw to removebalancer from crankshaft.

___ J

5. Drain cooling systemand disconnecthose at circulating pump.

6. Remove circulating pumpscrewsand swing alternator and powersteering brackets aside. Remove circulating pumpand discard gaskets.

47347

7. Remove timing chain cover screws and cover.

Oil Seal Replacement 1. Pry oil seal out of front of coverusinga large screwdriver. ~ Cover need not be removedto pry out or install

seal.

2. Install newseal with lip towardinside of cover. Usetool J-35468(hi) to drive seal into position.

Timing Chain Replacement 1. Remove harmonicbalancer and timing chain cover. [~]2. Crank engine until "O" markson camshaft and crankshaft sprockets are in alignment.In this position, engineis timedto fire no. 6 cylinder.

3. Remove camshaft sprocket bolts. Remove sprocket and timing chain together. Sprocketis a slight press-fit for approximately ]/8 inch. if sprocket doesnot comeoff easily, a light blow with a plastic-faced hammer on the lower edgeof the camshaftsprocket should dislodge it.

f

01~11~

0 ,~

\

E~] 4. Instalt timing chain on camshaftsprocket. Hold the sprocket vertical with the chain hangingbelow. Amignthe camand crank sprocket timing marks,then attach the chain to the crank sprocket.

47307

5-14

Englne/eng

5. ADigndowel in camshaftwith dowelhole in sprocket and install sprocket on camshaft. [~ Do not hammer sprocket onto camshaft. This may loosen rear camshaft welsh plug.

6. Draw sprocket onto camshaft using the mounting bolts.

7. Lubricate the timing chain with engine oil.

TimingChain CoverInstallation 1. Coat the cover gasket with sealer and place in position over dowel pins in cylinder block.

2. Lubricate timing cover seal lip with engine oil and place cover in position over dowet pins. :3. Install screwsandtighten to 80 in. Ibs. (9 N.m).

HarmonicBaRancerInstallation 1. Coat timing chain cover sean area on balancer hub with engine oil.

2. Align keywayand start balancer on to crankshaft.

[4~ 3. Using appropriate end of tool J-39046 threaded into crankshaft, or a large washer and a 7/18-20 x 4 in, bolt and nut threaded into center hole in crankshaft, tighten nut to seat harmonic balancer on crankshaft.

4. Remove bolt and washer. Install to specifications.

belt pulley and tighten screws

5. Thread7A6-20× 2 in. bolt and thick washerinto crankshaft and tighten to specified torque.

6. mnstall circulating pumpand pulley. Attach water hose to pump.

7. Instal~ alternator and powersteering pumpbrackets.

8. Install alternator and powersteering belts and adjust tension to specifications.

E,~glne/eng

5-1

5

34715

Camshaft Removal 1. Remove distributor per instructions in the appropriate section in Electricam/Ignition Systems Service Manual.Give special attention to markingposition of rotor in relation to distributor baseand intake manifold.

2. Removeintake manifold and circulating

pump.

3. Remove rocker arm covers, valve lifters,

and push rods.

4. Removepulley, harmonic balancer, timing chain cover, timing chain, camshaft sprocket, and camshaft thrust plate. Remove camshaft sprocket.

5. Removefuel pumpand push rod. [~ 6. install two s/16-18 × 4 in. bolts in camshaft sprocket bolt holes and carefully pull out camshaft. Use care not to damage camshaft bearings.

Measure: CamshaftJournals. Refer to General Engine IViechanicaH section in this manuahDo not attempt to repair the camshaft. Replacethe camshaft if damaged. Whenever the camshaft needs to be replaced, a newset of valve lifters mustamsobe installed.

Bearings Refer to General Engine MechanicaRsection in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly.

47317

Installation 1. Lubricate camshaft journals with engine oil.

Whenevera new camshaft is installed, lubricate the camshaft lobes with Molykote or its equivalent. Also add one can of G.M. Engine Oil Supplementto crankcase oil.

2. Install two ~8-18 x 4 in. bolts in camshaftbolt holes. Install camshaft, being careful not to damagebearing. Removethe two 4 in. Uongbolts. Install thrust plate andtighten screwsto 105in. Ibs. (11,9 N.m).

3. Install sprocket and timing chain.

4. Install timing chain cover, harmonic balancer, pulley and circulating pump.

5. Connectcoolant hose.

6. Install valve lifters,

pushrods, intake manifold and distributor.

7. Install rocker armcovers.

5-16

Englne/eng

Lubrication System Description and Operation E2~ The oil pumpconsists of two gears @and a pressure relief valve ® enclosed in a two-piece housing @, and driven from the distributor driveshaft whichin turn is driven by a helix gear on the camshaft.

It is flange mountedto the cylinder block with two bolts and piloted on the outside of the lower distributor bronze bearing.

Oil passes through an opening in the mounting flange to the cylinder block, then into the full flow oil filter. ]he pumpcover is equipped with the pressure regulator valve that regulates oil pressure at approximately 40-60 PSI (276-414 kPa) at 2000 RPM. =E2~ The pump intake @is of the fixed screen type. A mesh screen filters out small particles of dirt and sludge which maybe present.

©

®

®

’[’~ A baffle incorporated on the intake screen has been designed to eliminate pressure loss due to suddensurging stops. in the event that a screen becomesplugged, a steel grommet opens and bypasses oi~ to the pump.

[3 A full flow oil filter is externally mountedto the cylinder block on the left side of the engine. Normally,all engineoil passes through the filter element; however, if the element becomes restricted, a spring loaded bypass valve ~ opens as mentioned above. ]’he mainoil galleries run the full length of the crankcaseand cut into the valve lifter guideholes to supplyoil at full pressureto the lifters.

47357

©

DR2906

Engme/eng

5-17

The rocker arms and valves are lubricated by an oil channel in each push rod. Excess oil drains off and returns to the oil pan through passagesin the cylinder head and block.

Connecting passagesdrilled in the crankcase permit delivery of oil at full pressure to all crankshaft and camshaft bearings, distributor gear and shaft, the fuel pumppushrod, and the timing chain.

Holes drilled in the crankshaft carry oil from the crankshaft bearings to the connecting rod bearings. Pistons and cylinder walls are lubricated by oil forced through a smaal notch in the bearing parting surface on the connecting rod, which registers with the hole in the crankpin once every revolution. Piston pins are lubricated by splash.

Oil Pan Removal 1. Removeoil dipstick and withdraw oil using a suction pump.

2. Remove oil dipstick tube. Removescrews, oil pan and gasket.

Installation 1. Thoroughlyclean all gasket sealing surfaces. Apply RTVsealer to the front and rear of the block.

2. Install gasket on block. Install oil pan. Tighten1/4x20screwsto 80 in. Ibs. (9 N.m)and 5/16x18screvvs to 165in. Ibs. (18,6 N.m).

Ei-] 3. Install dipstick tube fitting to pan; heavescrew loose.

Orient fitting and attach dipstick tube. Thentighten fitting screw and flare nut. SeeTorqueSpecifications at the end of this section for the torque figure.

4. Fill crankcasewith engineoil.

Oil Pump Removal and Disassembly 1. Removeoil pan.

31576

5-18

Engme;eng

L-2~ 2. Removepumpto rear main bearing cap bolt, pump,extension shaft and collar.

and remove

l~.~ Raffle bolts have to be loosened.

3. Disconnect pumpshaft from extension.

4.. Remove four cover attaching screws, cover, gasket, idler gear and drive gear and shaft.

5. Remove pressure regulator vaive and valve parts. ~6. ff the pickup screen and pipe assemblyneed replacing, mount the pumpin a soft-jawed vise and extract pipe from pump. Do not ,disturb the pickup screen on the pipe. This is serviced as an assembly.

7. Washall parts in cleaning solvent and dry using compressed air.

47377

Inspection Should any of the following conditions be found during inspec1:ion operations, the pumpassembly should be replaced. r~ . Inspect pumpbody for cracks and excessive wear. Inspect oil pumpgears for excessive wear or damage.

2. Checkshaft for aoosenessin the housing. Checkinside of cover for wear that wouadpermit oil to leak past the ends of gears. :3. Checkthe oil pickup screen for damageto screen or relief grommet.Checkfor o[t in the air chamber.

4. Checkpressure regulator vaRveplunger for fit in cover.

Assembmy and installation 1. Place drive gear and shaft in pumpbody.

2, Install idler gear so that smoothside of gear will be towardthe (,’over. :3. Install a new pumpto cover gasket to ensure correct end clearance of the gears.

4. Install suction pipe and screen assemblyto cover and install (:over and attaching screws. Tighten screws to 6-9 ft. Ibs. (8-12 N.m), and check to see that shaft turns freely. [’~ [~ If the pickup screen and pipe assembly was removed, it should be replaced with a newpart. Loss of press fit condition could result in an air leak and loss of oil pressure. Mount the pumpin a soft-jawed vise, apply sealer to end of pipe, and using Tool J-8369 tap the pipe in place with a plastic hammer.

DR2099 Engme/eng

5-1

9

5. InstaIB regulator valve plunger, spring and retainer and pin.

6. Assemblecollar end of extension shaft assembly over pump driveshaft, aligning tang of extension shaft with slot in end of pumpdrive shaft.

7. Assemblepumpand extension shaft to rear main bearing cap, aligning slot on top end of extension shaft drive tang on lower end of distributor driveshaft.

8. Tightenbaffle bolts.

Oil pumpshould slide easily into place= ff not, removeand relocate slot or locate other problem.

9. Install tube.

oil pan using newgaskets and seals. Connectoil drain

MeasuringCamshaftLobe Lift 1. Removethe valve mechanismas previously outlined. [~] 2. Position indicator,with bah socket adapter (Tool J-8520) push rod. Makesure pushrod is in the lifter socket.

3. Rotatethe crankshaftslowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position.

4. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the pushrod is fully raised position.

Z~ 5. Wheneverthe engine is cranked: [~ Gi ModeUs:Removegray and bBack connectors from ignition coiD to preventaccidentalstarting of engine.

GL Models: The distributor from the distributor coil.

primary lead should be disconnected

6. Comparethe total lift specifications.

recorded from the dial indicator with

7= If camshaftlobe readings are not within specification, replace the camshaft. If camshaft readings for all lobes are within specifications, removedial indicator assembly and install and adjust valve mechanismas outlined.

SafetyRelated

5-20

DR2100

DRS655

Eng~ne/eng

Rear Main Bearing Oil Seal Replacement l~°~ Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft sealing surface. [_=3-7 1. Insert a screwdriver into the notchesprovided in the seal retainer and pry the seal out. Take care not to damagethe crankshaft sealing surface.

2. Inspect chamferon crankshaft for grit, Correct as necessary.

loose rust, and burrs.

DR’1878

3. Clean seal running surface on the crankshaft with a nonabrasive cleaner.

4. Lubricate the inner and outer diameter of newseal with engine oil.

[-4~ 5. Install the seal on Seal Instatler J-35621.Position installer against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.

6. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft.

DR1879

7° Turn the handle until it bottoms. Remove installer.

(3il Seal Retainer Replacement [=-5~] 1. Removeflywheel and oil pan. Removescrews, nuts and seal retainer ®.

2. Removegasket. ~},r Remove rear crankshaft oil seal as previously stated.

4. Clean gasket surfaces on block and seal retainer.

[Not~ Whenever the seal retainer is removed, a new retainer gasket and rear crankshaft oil seal mustbe installed. [’~5-~ 5. Attach gasket ® to the block. It is not necessaryto use sealant to hold the gasket in place.

6. Install seal retainer, screws and nuts. Tighten screwsand nuts to 135 in. Ibs. (15,3 N.m).

7. Install oil pan. install previously.

rear crankshaft oil seal as outlined

8. Install flywheel.

Englne/eng

5-21

DR188’t

Crankshaft Description Main bearings are of the precision insert type and do not utilize shims for adjustment. If clearances are found to be excessive, a new bearing, both upper and lower halves, will be required.

Bearings are available in standard size and 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (0,025, 0,051, 0,254, 0,508 mm)undersize.

Selective fitting of both rod and main bearings is necessary in production in order to obtain close tolerances. For this reasonyou mayfind one-haft of a standardinsert with one-half of a 0.001 in.

(0,025 mm)undersize insert which will decrease the clearance 0.0005 in. (0,0127 mm)from using a fu[a standard bearing.

Whena production crankshaft cannot be precision fitted by this method,it is then ground 0.009 in. (0,229 mm)undersize on only those main journals that cannot be properly fitted. All journals will not necessarily be ground undersize. A 0.009 in. (0,229 mm) undersize bearing and 0.010 in. (0,254 mm)undersize bearing maybe used for precision fitting in the samemanneras previously described.

If, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirement will be determined by bearing clearance.

Inspection Refer to GeneralEngineMechanicalsection in this manual for cleaning, inspection, and measurements.

In general, (except No. 1 bearing) the lower half of the bearing showsa greater wear and the most distress from fatigue. If upon inspection the lower half is suitable for use, it can be assumed that the upper half is also satisfactory, ff the lower half shows evidence of wear or damage,both upper and lower halves should be replaced. Never replace one half without replacing the other half.

To Check Crankshaft: Removemain bearing caps and connecting rod caps and lift crankshaft out of cylinder block. Pushpistons to top of bores. b. Inspect the crankshaft. Number1 main bearing is ground to 2.4484 - 2.4493 in. (62,1894 - 62,2122mm),number 3, 4 bearings to 2.4481 - 2.4490 in. (62,1817 - 62,2046 mm),number5 bearing to 2.4479 - 2.4488 in. (62,1767 62,1995 mm),and crankpin journals are ground to 2.0988 - 2.0998 in. (53,310 - 53,335 mm).

5-22

Eng,ne/eng

These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in.

(0,025 ram) out-of-round or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings.

The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the rear intermediate and front intermediate journals, using a dial indicator. Therunout limit of each of these journals is 0.002 in.

(0,051 mm). If the runout exceeds 0.002 in. (0,051 mm), crankshaft must be repaired or replaced.

Main Bearing Replacement 1. Install a mainbearing removingandinstalling tool in oil hole in crankshaft journal. [l~et~’~ If sucha tool is not available, a cotter pin maybe bent as required to do the job.

2, Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper bearing out of block.

3. Oil new selected size upper bearing and insert plain (unnotched) end betweencrankshaft and indented or notched side of block. Rotate the bearing into place, and removetool from oil hole in crankshaft journal.

4. Oil newlower bearing and install 5. Install engine.

in bearing cap.

main bearing cap with arrows pointing toward front of

6. Tighten main bearing cap bolts to specifications.

Measure: Refer to General Engine Mechanical section in this manual for crankshaft bearing clearance procedures.

Connecting Rod Bearing Replacement Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. DO NOTFiLE RODSOR ROD CAPS.If clearances are found to be excessive a newbearing will be required. Bearings are available in standard size and 0.001 in.

(0,025 mm)undersize for use with standard size crankshafts.

1. With oil pan and oil pumpremoved,removethe connecting rod cap and bearing.

2. inspect the bearing for evidence of wear or damage.(Bearings showing the above should not be installed.} 3. Wipethe bearings and crankpin clean of oil.

4. Measurethe crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition the crankshaft. If within specifications and a newbearingis to be installed, measure the maximumdiameter of the crankpin to determine new bearing size required.

5. If within specifications, measurenew or used bearing clearanceswith the Plastigage material or its equivalent. [~ If

a bearing

is

being fitted

to an out-of-round

crankpin,

be

sure to fit it to the maximum diameter of the crankpin. If the bearing is fitted to the minimumdiameter and the crankpin is out-of-round 0.001 in. (0,025 ram), interference between the bearing and crankpin will result in rapid bearing failure= a.

Place a piece of gauging plastic the full width of the crankpin parallel to the crankshaft. (Note: Surfaces must be free from oil.)

b. Install the bearing in the connecting rod and cap. c. Install the bearing cap and evenly tighten nuts to specifications.

Do not turn the crankshaft with the gauging plastic installed. d. Removethe bearing cap and using the scale on the gauging plastic envelope, measurethe gauging plastic width at the widest point.

6. If the clearanceexceedsspecifications select a new, correct size bearing and remeasure the clearance.

7. Coatthe bearingsurface with oil, install the rod capand tighten nut to specifications.

8. Whenall connecting rod bearings have been installed tap each rod lightly (parallel to the crankpin) to makesure they have clearance.

9. Measureall connecting rod side clearances (see Specifications at end of this section), betweenconnecting rod caps.

5-24

Piston, Ring and Connecting Rod Piston and Rod Removal 1. With oil pan, oil pumpand cylinder head removed,use a ridge reamer to removeany ridge and/or deposits from the upper end .of the cylinder bore.

I]~ Before ridge and/or deposits are removed, turn crankshaft until piston is at the bottom of stroke and place a cloth on top of piston to collect the cuttings. After ridge and/or deposits are removed, turn crankshaft until piston is at top of stroke and removecloth and cuttings. Refer to General EngineMechanical section in this manualfor cylinder bore ridge reamerprocedures.

2. inspect connecting rods and connecting rod caps for cylinder identification. If necessarymark them.

L-2~ 3. Removeconnecting rod cap and install tool J-5239 on studs. Push connecting rod and piston assembly out of top of cylinder block. [~ It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder.

Disassembly Refer to General EngineMechanicalsection in this manual for piston and connecting rod disassembly.

Assembly Refer to General EngineMechanicalsection in this manual for piston and connecting rod assembly.

Piston Ring EndGapand Fit Refer to GeneralEngineMechanicalsection in this manual. important Tlhe numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore. if a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be renumbered to correspond with the new cylinder number.

Piston and RodInstallation 1. Lightly coat pistons, rings and cylinder walls with light engine oil.

2. With connecting rod caps removed, install connecting rod studs.

tool J-5239 on

DR3792

[~] 3. Locate the piston ring end gapsas shownin figure 3, steps 1, 2, and 3. Without disturbing the ring gap locations, install toon J-8037 @on piston and compressthe piston rings.

4. Install eachpiston in its matchingbore, using tool J-5239 on each assembny.The notch side of the piston should face the front of the engine. The connecting rod bearing tang slots must be on the side opposite camshaft. Guide the connecting rod into place on the crankshaft journals with the Rongdetail of tool J-5239.

5. Install bearing caps and check the bearing clearance as described previously.

47437

Cylinder Block Cylinder Bore inspect: Cylinder bores for scoring or other damage.Refer to General Engine Mechanical section in this manual.

Measure: Cylinder bore taper and out-of-round. Refer to General Engine Mechanicalsection in this manual.

Cylinder Bore Reconditioning Measure: Refer to General Engine Mechanical section in this manual.

Piston Selection 1. CheckUSED piston to cylinder bore cJearanceas follows: a. Measurethe "Cylinder Bore Diameter" with a telescope gauge21/2 in. (64 ram) from top of cylinder bore. b. Measurethe "Piston Diameter" (at skirt across centerline of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance." d. Calculate piston to bore clearance and determine if piston to bore clearance is in the acceptable range.

2. If used piston is not acceptable, checkif a newpiston can be selected to fit cylinder bore within the acceptable range.

3. If cylinder bore must be reconditioned, measurenew piston diameter (across centerline of piston pin), then honecylinder bore to correct clearance (preferable range).

4. Markthe piston to identify the cylinder for which it wasfitted.

5-26

EngJne/eng

I=No--~Handlethe pistons with care, and do not attempt to force theminto the cylinder until the cylinder has beenboredto correct size as this type 13iston can be distorted throughcareless handling.

5. Thoroughlyclean the cylinder bores with hot water and soap. Scrubwell with a stiff bristle brushandrinse thoroughlywith hot water. It is extremely essential that a goodclean operation be performed.If any of the abrasive material is allowedto remainin the cylinder bores,it will rapidly wearthe .qewrings and cylinder boresin addition to the bearingslubricated by the contaminatedoil. Thebores should be swabbed several times with light engineoil and a clean cloth then wipedwith a deandry cloth. Cylinders should not be cleaned with keroseneor gasoline. Clean the remainderof the cylinder block to removethe excessmaterial spread during the honing operation.

Circulating Pump Description The’Volvo Pentacirculating pumpis manufactured specially for marineuse. it is serviced only as an assembly.Donot replace with an automotive ,circulating pump. inspection 1. Remove alternator and powersteering belts. ;2. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag. .3. Lookfor water leaking from indicator hole beneathpumpshaft behind pulley. Replacepumpif play, drag, or leakageare evident.

Flemoval and |nstailatien 1. Drain water from block and disconnectwater hose from circulating pump. :2. Remove pulley. Remove circulating pumpbolts, pumpand gaskets.

3. Usenewpumpto block gaskets and sealer, install on cylinder block and tighten bolts as specified.

newpumpassembly

4. Install pultey. Install alternator andpowersteering belts, then adjust tension.

5. Install hoseto circulating pump.

6. Lakeor tank test unit andcheckfor leaks.

t-=r’gme/eng

5-27

25929

11980

25917

Front Engine Mounts Removal E~ 1. Removetwo lag screws ~ and washers from mounts.

2. Lift enginewith a hoist capableof lifting at least 1500lb. {680 kg) to allow removalof front mountand bracket.

J~ 3= Removethree mount screws and lock washers ®. Note screw lengths and location.

1197

[~ ~ Prior to disassembly of front mount assembly, measure distance and record measurement between large washer and flat on upper mount bracket.

DisassembUy J~ 1. Removethree nuts © and engine mount bracket @ from mount bolt while holding bolt ~ secure with socket. [~ 2. Removetwo flat washers, one large (~ and one smaller @.

Removelock washer ®, and engine mount bolt (~ from mount.

N "®’@

1197

Reassembly J~] 1. Place small washer @on mount bolt and insert bok up through mount, mnstall large washer and secure with nut ©.

Tighten to 60-75 ft. Ibs. (81-102 N.m}. [~ 2. Install upper inner nut and p{ace engine mount bracket @ on engine mount bolt.

Measuredistance between large washer and flat on upper mount bracket. Adjust distance to recorded measurement.

11983

3. Install lock washerand top nut. Tighten nut to 100-120ft. Ibs. (136-163 N.m).

Z~ Safety ReJated

5-28

Engme/eng

Installation i~2~ 1 Spray the engine mountscrew threads with Loctite ~ Primer N and allow to air dry. Apply Volvo PentaTreadSealing AgentP/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screws and washers.Tighten to 32-40ft. Ibs. (43-54N=m).

[1.~ 2. install washersand lag screwsand tighten securely.

Height Adjustment [7.~ 1 To change engineheight, tighten or loosennuts (~) and0 required.

2953

~2. Lift enginewith a hoist capableof lifting at least 1500 lb. (680 kg). Position engineat desired height.

3. After setting mountposition, turn nut (~) up against undersideof engine bracket and hold nut with a wrench.Tighten nut O to 100-120ft. Ibs. (I36-163 N,m). [~ Any large adjustments to engine height should be followed by a checkof enginealignment. Failure to checkalignmentcould result in rapid engine coupler failure. SeeDrive Removaland Instamlation section of the Sterndrive/Transom Bracket Service Manualfor alignment procedures.

34719

High-Rise Exhaust Elbow Replacement Removal [~ 1. Loosentwo clamps securing upper hose to elbow. Lubricate inside of hosewith a soapywater solution. [~ 2. Starboard Elbow: Removecircuit breaker bracket ® and set aside.

Remove four screws, fiat washers,and lock washersmountinghigh-rise elbow. [t~] ~ 3. Usea soft hammerto free elbow from manifold. Usea twisting motion to pull elbowfrom hose. Remove and discard the elbowgasket.

34720

34718

34716 [ ngme/eng

5-29

34716

34717

34720

|nstallation 1. Thoroughlyclean manifold gasket surface. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a new manifold gasket and place it on the exhaustmanifold. [~ [~ 2. Lubricate the inside of the exhaust hose with a soapy water solution. Insert the high-rise elbowinto the hosewith a twisting motion,and pushit into hoseas far as it witl go.

E~3. Position elbow on manifold. Secure elbows and brackets with four screws,flat washers,and lock washers.Tighten screwsto 12-18ft. Ibs. (16-24 N®m).StarboardElbow:Instatl circuit breaker bracket @.

32371

E~] ~ 4. Slide clamps ® up onto hose and position them in the two surface channels. Tighten cla~ps securely.

Exhaust Hose and intermediate Pipe Replacement Rernovai [~ 1. Loosen eight clamps that secure the upper © and lower @ exhaust hoses.

32374

2. Lubricate inside of lower hosewith a soapywater solution, and slide lower hose downonto exhaust Y-pipe. [~ 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose if necessaryto ease removal.

4. Slide upper hoseoff high-rise elbow. Shdetower hoseoff exhaustY-pipe.

32375

5-30

32363 Engme, eng

installation Es~ 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe.

[9~ ~ The inside diameter of both the upper and lower hoses has a step ~ 1.5 in. (3,81 cm) from one end. The stepped end of the hose must face the intermediate pipe wheninstalled.

2. Slide hoseonto high-rise elbowuntil it seats. [~ If hose is not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment.

32370

Es~] [~ Z~ 3. Place four No. 68 clamps on upper hose. With a twisting motion, insert intermediate pipe all the way into the upper hose. Place four No. 64 clamps on lower hose. Align lower end of pipe with exhaustY-pipe, then slide lower hoseup until it’s halfway onto the intermediate pipe. Position clampsin channeas and tighten clampssecurely.

Exhaust (Flapper) Valve Replacement

32366

Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hoseand Intermediate Pipe Replacement.

[3 2. Slide the lower hose downfar enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the va lye.

[1-’~ 3. Inspect the two rubber bushings inside the pipe. Replace them as necessary.

32367

32368

Engme/eng

~ Safety Reaated

5-31

Installation E~ 1. if installing newrubber bushings, apply 3M~Scotch Grip Rubber Adhesive1300to outside of tips, and insert into inside of exhaustpipe. [~ 2. Position valve with longest lip pointing down,and insert into pipe.

Pushpivot pin throughbushingsandvalve until pin end is flush with outside of pipe. Checkexhaust valve for freedomof movement. ~[f valve is not positioned properly (long lip down), it will restrict exhaustflow and fail to preventwater backingup into engine.Boat performancewould be adversely affected, and engine maysuffer water damage.

32368

3. Install intermediate pipe following procedureunder ExhaustHoseand Pipe Replacement.

Engine CoupJer Replacement Removal 1. Remove engine from boat. [~lf coupler is being replaced due to coupler failure (rubber hub of spfined hub), checkengine alignmentafter installing newcoupler. SeeDrive Remeva| and installation section of the Sterrtdrive/TransemBracket Service Manual

32369

2. Disconnectall wires, lines and connectorsfrom bellhousing. [~ 3. Remove screws securing bellhousing cover, and slide cover out.

20034

19085

5-32

Englne/eng

[5"~ 4. Pull drain hoseout of bellhousing. l~ 5. Unscrewbolts and nuts retaining bellhousing. Disconnect ground wires. Remove powersteering cooler bracket.

6. Remove bellhousing from engine block.

17.~] 7. Unscrewsix nuts securing coupler and removecoupler from studs.

8. Remove old gasketfrombellhousingcover. Cleangasketsurfacethoroughly.

19842

|nstallatJon 18~1. Install coupler and securewith six Iocknuts. Usea suitable adaptor and tighten to 40-45ft. Ibs. (54-61N m).

16~2. Install bellhousing and attach powersteering cooler. Tighten nuts and bolts to 32-40ft. Ibs. (43-54N.m). Attach groundwires andtighten nuts to 15-20ft, Ibs. (20-27N.m).

3. Pushdrain hoseinto bellhousing.

4. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both ,,;ides of a newbellhousinggasketand position it on cover.

6710

[9~5. Cleansevenself-tapping screwswith a wire brush¯ Install beHhousing cover and screws.Tighten to 60-84in. Ibs. (7-9 N m).

6. Connectall wires, lines andconnectorsto bellhousing.

7. Install enginein boat.

6712

6714

E nglneleng

5-33

19996

GeneralSpecifications - 5.7 GL, GSand Gi Type - No of Cylinder .......................................................

Bore and stroke .....................................................

Piston Displacement .........................................

Cylinder Numbers- Front to Rear Starboard Bank ...........................................................

Port Bank ...............................................................

Firing Order .........................................................

Compression Ratio ...........................................................

Water Temperature Control ................................................

Thermostat Opens at ........................................................

Alternator Belt Adjustment ...............................

Full Throttle Operating Range .........................................

90° - V-8 4.000 x 3.480 in.

350 Cubic Inches (5.7 Litre) 2-4-6-8 1-3-5-7 1-8-4-3-6-5-7-2 9.3:1 Thermostat 150° F= 1/4-1/2 in. give with finger pressure 4200 - 4600 RPM

EngineSpecifications Pistons: Production Clearance .............................................

Service ..........................................................

Piston Rings, Compression: Production Groove Clearance Top ..................................................

2nd ..................................................

Service .....................................................

Gap Top ....................................................

2nd ....................................................

Service .....................................................

Oil Rings: Production Groove Clearance .....................................

Service ..............................................................

Production Gap .....................................................

Service ..............................................................

Piston Pins: Diameter .......................................................

Production Clearance ............................................

Service ...........................................................

Fit in Rod ..............................................

Connecting Rods: Bearing Clearance, Production ......................................

Service ..........................................................

Side Clearance ....................................................

5-34

0.0007 - 0.0017 in.

0.0027 in. Max.

0.0012 - 0.0032 in.

0.0012 - 0.0032 in. + 0.001 in.

0.010 - 0.020in.

0.010 - 0.025in. + 0.010 in.

0.002 - 0.007 in. Max. + 0.001 in.

0.015 - 0.055in. + 0.010 in.

0.9270 - 0.9273 in, 0.00025- 0.00035in.

0.001 in. Max. 0.008 - 0.0016 in. Interference 0.0013 - 0.0035 in.

0.0030 in. Max. 0.008 - 0.014 in.

Engme/eng

Engine Specifications

- Continued

,Crankshaft: End Play .........................................................

Main Journal Diameter No. 1 .................................................

No. 2, 3, 4 .............................................

No. 5 .................................................

Taper, Production ...................................................

Service ...........................................................

Out-of-Round, Production ............................................

Service ...........................................................

Main Bearing Clearance, Production No. 1 .................................................

No. 2, 3, 4 .............................................

No. 5 .................................................

Service No. 1 ..................................................

No. 2, 3, 4 ..............................................

No. 5 .................................................

Crankpin Diameter ...............................................

Taper Production ............................................

Service ..............................................

Out-of-Round, Production ............................................

Service ...........................................................

Camshaft: Camshaft End Play .................................................

Camshaft Bearing Journal Diameter ..................................

Camshaft Runout ...................................................

Lobe Lift (± 0.002 in.) ............................................

0,002 - 0.006 in.

2.4484 - 2.4493 in.

2.4481 - 2.4490 in.

2.4479 - 2.4488 in.

0.0002 in. Max. 0.001 in. Max. 0.0002 in. Max. 0.001 in. Max. 0.0008 - 0.0020in= 0.0011 - 0.0023 in.

0.0017 - 0.0032 in.

0.001 - 0.0015in.

0.001 - 0.0025in.

0.0025- 0.0035 in.

2.2487 - 2.2457 in.

0.005 in. Max. 0.001 in. Max. 0.0005 in. Max. 0.001 in. Max. 0.004 - 0.012 in.

1.8682 - 1.8692in.

0.0015 in. Max. V-8 nntake0°269in.

V-8 Exhaust0.276 in.

Valve Systems: Lifter Type ............................................................

Hydraulic Rocker Arm Ratio .........................................................

1.5 to 1 Valve Lash Adjustment One Turn Down From "Zero Lash" Point Intake and Exhaust (hot) ................. °45 VaDve Face Angle ............................................................. °46 Valve Seat Angle .............................................................

Stem to Guide Clearance Intake and Exhaust ......................................

0.0010 - 0.0027in.

Exhaust, Service .............................................. + 0.002 in.

Intake, Service ............................................... + 0.001 in.

RecommendedValve Seat Width Intake ....................................................

1/32in. to 1/16in.

Exhaust ..................................................

1A6in. to 3/32in.

Outer Valve Spring Free Length ..............................................

2.03 in.

Outer Valve Spring Pressure Lb. @ In. Closed ...........................................

76-84 @1.70 in.

Lb. @ In. Open .........................................

194-206 @1.25 in.

EngineSpecifications- Continued EngineLubrication: Type Oil Pump...............................................

Gear Crankcase Capacity ....................

Approx.5 qts., 5.5 qts. with Filter Normal Pressure, warm engine ...................

15-30 PSi @800 RPM 40-80 PSI @2000 RPM Oil Grade Recommended:ServiceSG - Meeting GMSpec 6094M 32° E (0 ° C) and Above ...................................

SAE 30 0° E to 32° F (-17 ° C -- 0° C) ...........................

SAE 20W-20 Below 0° F (-17 ° C) ......................................

SAE 10W Werecommend DuraPlusTMSAE30 HeavyDuty Synthetic Motor Oil, which is specially formulated for heavy duty marineuse, and ideal for VolvoPentaSterndrive engines.It providesbetter antiwearqualities, especially during long high speedoperation. In addition, Jt neutralizes acids causedin all internal combustion engines,offers superior corrosion protection, andis formulatedto offer better resistance to oxidation andhigh temperaturesludge formation.

Fuel Recommendation..................

SeeGeneral Information Section

5-36

Engine/eng

TorqueSpecifications- (Cont.)

(FT. LBS.t [nN. LBS.]

Camshaft Sprocket Connecting Rod Cap Crankshaft Oil Seal Retainer Exhaust Manifold Flame Arrestor Flare - Dipstick Tube Flywheel and Coupler Flywheel Bellhousing Front Mount Top Oil Pan(5/16 x 18) Oil Withdrawal Tube to Elbow Power Steering Bracket Rocker Arm Cover

21 45 135 20-26 30-40 15-18 40-45 32-40 100-120 15-18 13-15 -

Cylinder Head Step 1 Step 2 Step 3 HarmonicBalancer (7/16 x 20) High-Rise Elbow Front Mount Intake Manifold Main Bearing Cap Outer Bolts on #2, #3, and #4 Caps All Other Bolts Oil Pump RemoteOil Filter Adaptor (to block)

Eng[ne/eng

165 90

28 60 15,3 27-35 3,4-4,5 20-24 54-61 43-54 136-163 18,6 20-24 18-20 10

25 45 65 55-62 12-18 60-75 30

34 61 88 75-84 16-24 81-102 41

70 80 65 20-25

-

95 110 90 27-34

Flame Arrestor Flywheel and Coupler Power Steering PumpBracket

10-15 13-15

65-80 -

7-9 14-20 18-20

Spark Plugs Oil Filter Oil Pan Drain Retainer Oil Pressure Sender Oil Pressure Sender Adaptor Water Temperature Sender

20 27 OneTurn After Contact 15-18 20-24 14-19 10-14 10-14 14-19 18-22 24-30

5-37

Notes .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... ..........................................................................................

Section 6 5.7 GSi Engines Table of Contents Accessories .........................

Bamancer, Crankshaft .................

Camshaft ..........................

Circulating Pump.....................

Cleaning ...........................

Crankshaft and Bearings .............

Cylinder Block .......................

Cylinder Head ......................

Engine Coupler Replacement ...............

Draining ..........................

Lubrication ........................

Exhaust High-Rise Elbow Replacement ........

Hose Replacement ................. {Flapper) Valve Replacement .........

Manifold ..........................

Front Cover, Engine ..................

Front Mounts, Engine ................

6-6 6=17 6-25 6-39 6-4 6-312 6-35 6-14 6-43 6-6 6-4 6-40 6-41 6-42 6-7 6-23 6-3g

General Description ...................

GMSpecial Tools ....................

Intake Manifold ......................

Intermediate Pipe Replacernent .........

Oil Filter ...........................

Oil Pan ............................

Oil Pump ..........................

PCV System ........................

Pistons and Connecting Rods ..........

Rear Oil Seal, Crankshaft ..............

Rear Oil Seal Housing, Crankshaft .......

Rocker Arm Cover ...................

Rocker Arm Stud Replacement .........

Specifications Engine ..........................

Torque ..........................

Timing Chain and Sprockets ...........

Tools and Shop Equipment .............

Valve Train .........................

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual.

Always use the correct fastener in the proper location. Whenyou replace a fastener, use ONLYthe exact part number for that application. The text will call out those fasteners that require replacementafter removal. The text will also call out the fasteners that require thread lockers or thread sealant.

UNLESSOTHERWISE SPECIFIED, do not use supplement coatings (paints, greases, or other corrosion inhibitors) on tlhreaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clampingforce, and may damagethe fastener.

Whenyou instaB fasteners, use the correct tightening sequence and tightening specifications. Following these instructions can help you avoid damageto parts and systems.

E ng,ne/eng

6-1

6-2 6-50 6-8 6-41 6-20 6-18 6-20 6-45 6-27 6-30 6-31 6-10 6-15 6-48 6-46 6-24 6-6 6-11

General Description Cylinder Block The engine block is madeof cast iron and has eight cylinders arranged in a "V" shape with four cylinders in each bank. It’s a one piece casting with the cylinders encircled by coolant jackets.

Cylinder Head The cylinder heads are cast iron and have powderedmetal valve guides and valve seats pressedinto the intake and exhaust ports.

The spark plugs are located between the intake and exhaust ports.

Camshaft A steel camshaft is supported by five bearings pressed into the engine block. The camshaft sprocket, mountedto the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain. Motion from the camshaft is transmitted to the valves by hydraulic roller valve nifters, valve push rods, and ball-pivot type rocker arms.

Crankshaft Thecrankshaft is madeof cast nodular iron. It is supportedby five crankshaft bearings that are retained by crankshaft bearing caps which are machined with the block for proper alignment and clearances. Light duty 5.7L engines have two bolts per cap. Heavy duty 5.7L engines have four bolts per cap on caps two, three, and four. Thenumberfive crankshaft bearing at the rear of the engine is the end thrust bearing. Four connecting rod journals (two rods per journal) are spaced90 degrees apart.

6-2

Engme/eng

Pistons and Connecting Rods The pistons are cast aluminumthat use two compression rings and one oil control ring assembly. The piston is a low-friction, lightweight design with a fiat top and barrel-shaped skirt. The piston pins are chromiumsteel. They have a floating f:.t in the piston and are retained by a press fit in the connecting rod assembly. The connecting rods are made out of either forged powderedmetal or forged steel. They are machinedwith the rod cap installed for proper clearances and alignment.

Lubrication The gear-type oil pumpis driven through an extension ddveshaft.

The extension driveshaft is driven by the distributor which is gear driven by the camshaft. The oil is drawnfrom the oil pan through a pickup screen and tube. Pressurized oil is delivered through internal passagesto lubricate camshaft and crankshaft bearings and to provide valve lash control in the hydraulic valve lifters. Oil is metered from the valve lifters through the valve push rods to lubricate the valve rocker armsand ball pivots. 0il returning to the oil pan from the cylinder heads and the front camshaft bearing, lubricates the camshaft timing chain and crankshaft and camshaft sprockets.

Valve Train Thevalve train is a ball pivot type. Motionis transmitted from the ,camshaft through hydraulic roller valve lifters and tubular valve push rods to the valve rocker arms. The valve rocker arm pivots on a ball to openthe valve. Thehydraulic roller valve lifters keep all parts of the valve train in constant contact. ’The valve rocker armball is retained on the valve rocker armstud with a locking nut. Thevalve rocker armstuds are pressedinto the ,cylinder head. intake Manifold Theintake manifold is a single piece design. It supports either a throttle bodyor multiple injectors to meter and distribute fuel to each engine cylinder.

[ng,ne/eng

6-3

Cleaning Before cleaning the engine, remove the engine accessories to provide better access to the engine’s exterior surfaces. After removingthe throttle body, distributor, etc., cover the openings with tape to prevent the entry of coolant, solvent, or dirt.

Methodsused to clean the engine will dependon what equipment is available. Steamcleaning, pressure washing, or solvent cleaning are someacceptable methods. Allow the engine to dry before beginning the work.

It is important that the engine be as clean as possible to prevent dirt from entering critical areas during disassembly.

EngineLubrication -)~ Full pressure Uubrication, through a futU-flow oil filter is supplied by a gear-type oil pump. Oil is drawn up through the oia pumpscreen and passesthrough the pumpto the oil filter. The oil filter is a full-flow paper elementunit with an anti-drain back valve. An oil filter bypass valve is used to ensure adequateoil supply, in the event the filter becomesplugged or develops excessive pressure drop.

Filtered oil flows into the maingallery and then to the camshaft, rear bearing, and crankshaft bearings. The valve Uifter oil gallery supplies oil to the valve lifters. Oil flows from the valve lifters through the hollow valve push rods to the valve rocker arms. Oil drains back to the crankcase through oil drain holes in the cylinder head. The camshaft timing chain is drip fed from the front camshaftbearing. Thepistons and piston pins are lubricated by oil splash.

6=4

Engme/eng

’~= ,===:~,_j C DRC6612

Front View

t ,

Stbd View Engme/eng

DRC6613

6-5

Rear Vilew

C DRC6614

Tools and Shop Equipment A clean, weln lit work area should be available. Other necessary equipment includes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and an adequateset of hand tools.

An approvedengine repair stand will help prevent personal injury or damageto engine components.

Special tools are illustrated throughout this section and listed at its end. ThesetooJs (or their equivaBents)are specially designed quickly and safely accomplish the operations for which they are intended. The use of these tools will also minimize possible damageto engine components.

Someprecision measuring tools are required for inspection of certain critical components.Torquewrencheswill be necessaryto correctly tighten various fasteners. Thosefasteners will be called out within this section.

Accessories This manual assumes that the engine accessories have been removed. These accessories may include one or more of the following: ® Power Steering Pump ® Alternator ¯ Distributor ¯ Water Supply Pump ¯ AccessoryBrackets and Electrical ¯ Starter Motor

Wiring

It is beyondthe scopeof this section to detail the manydifferent accessory installations.

Refer to the proper Service Manualfor this information. Diagrams of vacuumhose routing, wiring harness routing, accessory drive belt layout, etc., should be made before removing these components.

Draining The Engine Follow the procedures in Section 1, GeneraaInformation of this manualto drain crankcase engine oil and the cooring system.

Exhaust Manifold Removal 1. Drain water from exhaustmanifolds.

2. Disconnectwater hose from manifold.

3. Loosenupper exhaust hose clamps, then removehigh rise elbow.

4. Remove manifold attaching nuts and washers.Discard nuts. inspection 1. Inspectfor cracks.

[1~] 2. To pressure checkmanifold, fabricate a plate @as shown,and a newelbowgasket (~) to seal water passagein manifold. Be sure to apply sealer to gasket. Install rubberdrain capsto manifoldand securewith clamps. Attach a GearcasePressure Tester © (such as Stevens Company S-34) to the water inlet hose. A bushingcan be madeto securepressure tester to hose. With the pressuretester attached to the manifold, submerge manifold in water. Pressurizethe manifold to 10-15 PSI {22-25 kPa) and checkfor leaks. Manifoldshould not leak aroundclampsand plate. If so, retighten clampsor reseal plate. Nodrop in pressureshould be realized.

DR2642

Installation 12~1. Clean mating surfaces on manifold and head. Install newexhaust gasket, then install manifold and securewith newIocknuts and washers.

Tighten nuts @to 20-26ft. Ibs. (27-35 N.m).

2. Install a newgasketand high rise elbowto manifold. Tightenbolts to 12-18ft. Ibs. (16-24N,m).

3. Instal~ exhausthoseand securewith clamps.

42861A

4. Connectwater hose. Install and tighten drain petcocks.

Z~5. Start engine and check for fuel leaks.

I--=ngme/eng

6-7

Intake Manifold Removal I~ 1. Drain coolant from manifolds and both sides of block.

2. Disconnect: Z~ a. Battery cables from battery. b. Coolant hoses at thermostat housing.

42861

c. Throttle cable from throttle d. Crankcaseventilation sides).

body and anchor block.

hose from rocker arm covers (both

e.Wire at temperature gauge sender unit wiring harness from alternator.

and engine

f. Distributor high tension and ignition primary leads from coil.

3. Remove:

25140

a. Distributor cap and mark the position of the rotor on the housing. Scribe a line on distributor housing and intake manifold for reassembly in the sameposition. Remove the distributor. b. Alternator and alternator mountingbracket from engine. c. Fuel lines from throttle rator assembly.

body and fuel pump/vaporsepa-

d. Oil pressuresending unit. e. Manifold attaching bolts. Lift manifold from engine.

Discard front and rear seals and gaskets.

If manifold is to be replaced, transfer: throttle bodyand ECMbracket, thermostat and housing (use new gasket), throttle cable anchor block assembly, distributor clamp and temperature sending unit. Transfer additional hardware as required.

Safety Related

6-8

Englne;e{lg

[~ Clean:

12.7 mm (0.499 IN.),/\

0/~,

® Old pieces of gasket or RTVfrom the gasket surfaces. ¯ Excessive carbon build-up in the intake passagesof the intake manifold. ® Scale and deposits from the coolant passages of the intake manifold.

Ilnstallation [’~ Important: Do NOTreuse intake manifold gaskets.

DRC6591

I~ ,nstallorConnect: 1. Sealant to the intake manifold gasket, cylinder headside. [~ Care must be used to apply the correct amount of sealant onto the gasket. Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly.

2. Gasketsonto the cylinder head. a, Use gasket ~ocator pins to properly seat gasket on the cylinder head.

DRC6592

[~] I~ b. Apply a 0.499 in. (13 mm)bead of GMSealant, P/N 12346141,or equivalent to the front and rear block sealant areas.

EEl c. Extend the sealer bead 0.157 in. (4 mm)onto each gasket.

4.0 mm

3. GMThread Locking Sealant, P/N 12345382,or equivalent to the threads of the eight lower intake mounting bolts.

4. Lowerintake manifold onto engine block.

DRC6590

5. Lowerintake manifold bolts. [~ Tighten:

4

!E~ Bolts in three steps, using the following sequence. a. The first pass to 27 in. lb. (3 N.m). Snugall bolts minimizeshifting of the intake. b. The secondpass to 106 in. lb. (12 N.m).

DRC6593

c. Final passto 11 ft. lb. (15 N.m).

Eng,ne/eng

6-9

d. Distributor with rotor and aligned exactly as markedduring removal. ~lf engine was cranked while distributor was out, complete ignition timing proceduremust be followed. Seethe appropriate Ignition Circuit in Electrical/Ignition SystemsService Manual. e. Alternator with mounti ng bracket.

Distributor cap and high tension leads. Seethe General Informationsection in Electrical/Ignition ServiceManualfor correct firing order and spark plug wire routing. g. Oil pressuresendingunit.

6. Connect:

&

a. All electrical connections. Apply Black NeopreneDip, on all exposedconnections. b. Fuel lines to throttle body and fuel pump/vapor separator. c. Throttmecable. d. All water hoses, and close all drain petcocks. e. Both crankcaseventilation hoses. f. Battery cables.

9. Start engine. Checkignition timing. Check for leaks.

Rocker Arm Cover Removal ~~ Remove or Disconnect: 1. Valverocker armcover bolts.

2. Valverocker armcover.

3. Gasket.

6-10

DRC6647 Engme/eng

l~

Clean: ¯ Parts in solvent. Remove all sludge and varnish. ¯ Old gaskets from the gasket surfaces.

I~]

inspect: o Gasket flanges for bending or damage. e Rubber grommetsand parts for deterioration.

installation [3 F’~ Install

or Connect:

1. Newgasket.

2. Valve rocker arm cover. :3.Valve rocker arm cover bolts. [~ Tighten:

bolts to"

106 in. lb. (12 N.m)

Valve Train Bemoval [~ important: Store all reusable components in an exact order, so they (;an be reassembledin the samewear pattern location from which they were removed.Mark the front end of the retainer.

["-="1

[~_.~ Removeor Disconnect: Tools Required: J 3049-AValve Lifter Removal(Plier Type) J 9290-01 Valve Lifter Removal (Slide Hammer Type)

/

[Every effort should be madeto ensure that the mating parts are installed in their original locations during assembly. A simple valve train componentorganizer rack can be madefrom a piece of wood. l~ 1. Valve rocker arm nuts, balls, and valve rocker arms.

[3 2. Valve push rods.

DRC6648

E nglne/eng

6-11

DRC6650

3. Valve lifter [~ 4. Valve lifter

guide retainer and bolts. guides.

5. Valvelifters.

Remove the valve lifters one at a time using a magnet.Place the valve lifters in the organizer rack, or tag themin a wayto ensure they can be returned to the valve Uifter bore from which they were removed.

EEl EEl Somevalve lifters maybe stuck in their bores due to gum or varnish deposits. These valve lifters can be removed using either J 3049-Aor J 9290-01.

DRC6649

Clean: ¯ Parts in solvent. Blow dry with compressedair. ® Makesure the oil passages in the valve push rods are clear. [~ inspect: ¯ Valve rocker arms and balls at their mating surfaces.

These surfaces should be smooth and free from scoring or other damage. ¯ Valve rocker arm areas that contact the valve stems and the sockets that contact the valve pushrods. Theseareas should be smooth and free of damageand wear. e Valve rocker arm nuts or bolts. [~

important:

All enginesuse prevailing torque nuts. At least 55 in. lb. (6,2 N.m) of torque should be required to thread the nuts onto the valve rocker armstuds. If not, it is possibUethat the nut(s) couRdbackoff during engine operation causing a loss of lash and create valve train noise.

6-12

DRC6651

J 9290-1

/

S

DRC6586

Engine/eng

I, nstallation !~ Important: Replace all valve roller lifters, change the engine oil and filter, and add GMEngine Oil Supplement,P/N 1052367, or equivalent to the engine oil whenever a new camshaftis installed. [~ Lubricate the valve lifter bodies and roller Engine Oil Supplement,P/N 1052367, or equivalent.

F=~’I Install

with GM

or Connect:

1. Valve lifters

in samelocation from which they were removed.

[1-~ 2. Valve lifter guides, valve lifter lifter guideretainer bolts.

guide retainer and valve

[~ Valve lifter guide retainer must contact all valve lifter guides, if valve lifter guide retainer is bent it mustbe replaced.

Tighten: bolts to 18 ft. lb. (25 N.m). :3. Coat valve rocker arm and rocker armball bearing surfaces with prelube, GMEngine Oil Supplement, P/N 1052367, or equivalent, wheninstalling.

Keepthese componentsand valve push rods in samesequenceto ensure their return to the original position from which they were removed.

[3 4. Valve push rods. Makesure valve push rods seat in valve lifter sockets.

[5~ 5. Valve rocker arms, balls, and nuts.

Valve Adjustment r~=l~ ! 6~1 Adjust: Valve rocker arm nuts until all lash is eliminated.

1. Turn crankshaft until cast arrow on crankshaft balancer hub is in 12 o’clock position and number1 cylinder is in firing position (top deadcenter). ¯ Watch number1 cylinder valves as crankshaft balancer hub arrow approaches 12 o’clock position. If a valve movesas arrow movesto position, engine assemblyis in number6 cylinder firing position. Crankshaft must then be turned one more time to reach number 1 cylinder firing position.

E ngme./eng

6-13

.

DRC6650

/

%

2. With engine assembly in number 3 cylinder firing following valves can be adjusted"

position,

o Exhaust1, 3, 4, 8 o Intake 1, 2, 5, 7 [~ 3. Backoff valve rocker armnut until lash is felt in valve push rod. Thentighten valve rocker arm nut until all lash is removed.

Zero lash can be felt by moving valve push rod up and down between thumb and forefinger until there is no more movement.

4. Whenall free play has been removed,tighten valve rocker arm nut one additional turn (360 degrees).

DRC6673

5. Turn crankshaft one revolution until hub arrow is again at 12 o’clock position. This is number6 cylinder firing position. Following valves can now be adjusted"

<5>

¯ Exhaust2, 5, 6, 7 ¯ Intake 3, 4, 6, 8

<5>

Cylinder Head

~

nder Head Removal Removeor Disconnect:

1. Spark plugs.

2= Cylinder head bolts.

3. Cylinder heads.

4. Headgaskets. [~ important: Use care when handling the cylinder prevent damageto the gasket sealing surfaces.

~

heads, to

nder Head Disassembly

DRC6585

J 8062

Removeor Disconnect:

Tool Required: J 8062 Valve Spring Compressor ~ 1. Valve keys. Compressthe valve springs with J 8062.

Removethe valve keys and tool J 8082.

DRC6663

6-14

Er~g,ne/eng

[2~ 2. Capsand springs.

3. Vaive stem oil seals, valves, and components.Place them in a rack so they can be returned to their original position at assembly. \

Cleaning, inspection, and Measurement Refer to General Engine Mechanical section in this manual.

Rocker Arm Stud Replacement "Fools Required: J 5802-01 Valve Rocker Arm Stud Removal J 5715 Reamer0.003 in. (0,0762 mm)oversize) J 6036 Reamer0.013 in. (0,3302 mm)oversize) J 6880 Valve Rocker ArmStud installation

(~\

.<

......

4__[I

I DRC6664

Valve rocker arm studs that have damaged threads or are loose in cylinder heads should be replaced. Newstuds are available in 0.003 in. (0,0762 mm)and 0.013 in. (0,3302 mm)oversize.

[4~ 1. Place J 5802-01over the stud to be removed.Install and flat washer. Remove the stud by turning the nut.

\

"

--’

J 6036

a nut

[3 2. Reamthe hone to the proper size for the replacement oversize stud. UseJ 5715 for 0.003 in. (0,0762 mm)oversize studs, J 6036 for 0.013 in. (0,3302 mm)oversize studs.

DRC6665

[3 3. Coat lower end (press-fit area) of stud ,with hypoid axle lubricant. Drive the stud into place with a hammerand J 6880.

Stud is installed to proper depth whenthe tool bottoms on the cylinder head.

Cylinder Head Assembly Tools Required" J 8062 Valve Spring Compressor J 6880

1~ ,nsta,,orConnect: 1. Valves. o Lubricate the valve stems with clean engine oil. e Insert the valves into their proper location.

2. Oil seals. Unstall the oil seals over the vaavestemsand seat them against the cylinder head.

3. Valve springs.

DRC6686

Eng[ne/eng

6-15

4. Caps.

[-~ a. Compressthe valve spring, using J 8062. Compressthe spring enoughso the lower valve stem grooves can be clearly seen.

J 8062

b. Apply a small amount of grease to the area of the upper valve stem groove. Assemble the two valve keys using the grease to hold the keys in place. Makesure the keys seat properly in the valve stem grooves. c. Release the compressortool. Makesure the valve keys stay in place.

DRC6663

d. Repeat the preceding steps on the remaining valves. [~] ~ ~ Measure: Valve spring valve spring as follows:

installed

height

of each

1. Use a narrow, thin scale. A cut awayscale @maybe helpful.

2. Measurefrom the cylinder head spring seat to the top of the cap.

DRC6667

Cylinder HeadInsta|lation Tool Required: J 36660 Torque/Angle Meter r~ Clean: ¯ Gasket surfaces on block and cylinder head.

E~ Install

or Connect:

1. Headgasket onto engine block.

2. Place the gasket in position over the cylinder head dowel pins aligning the gasket locating mark facing up.

DRC6668

3. Cylinder headonto block. Carefully guide the cylinder headinto place over the dowel pins and head gasket.

6-16

Engine/eng

4. Coat threads ot cylinder head bolts with GMSealing Compound, P/N 12346004,or equivalent.

5. ~j.~der head bolts. l;3}!

Tighten: [~] 1. in sequencefirst

pass to 22 ft. lb. (30 N.m).

[~ 2. in sequencefinal pass using J 36660 to: Short bolts - (3,4,7,8,11,12,15,16) 55 degrees.

Mediumbolts - (14,17) 65 degrees.

Longbolts - (1,2,5,6,g,10,13) 75 degrees.

Crankshaft Baiancer IRemoval

16 12

8 4

3

7

11 15

]bol Required: J 39046 Crankshaft Balancer Remover I~ The inertial weight section of the crankshaft balancer is assembledto the hub with a rubber sleeve. The removal procedures must be followed (with the proper tools) or movement tlqe inertiaR weight section of the hubwill destroy the tuning of the crankshaft balancer and the engine timing reference.

EF3

Removeor Disconnect:

DRC6672

J 39046

\

1. Crankshaft balancer bolt and washer.

E5~ 2. Crankshaft baJancer using J 39046. :3. Crankshaftkey, (if necessary).

DRC6871

Et~ Unspect: Crankshaft balancer weight for signs of shifting on the hub.

Replace as needed. The area of the crankshaft hub shaft that contacts the front crankshaft seal for roughnessor nicks. Replace the balancer if this condition exists. If balancer is replaced, new baBanceweights of the samesize must be installed on the new balancer in the samelocation as the old balancer.

E ngme/eng

6-17

Installation Tool Required" J 39046 Crankshaft Balancer Installer El Install

or Connect: J 39046

[~ The inertial weight section of the crankshaft banancer is assembledto the hub with a rubber type material. The correct installation procedures(with the proper tool) must be followed movementof the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

1. Use a small amountof RTVsealant to seal the balancer keyway to crankshaftjoint.

\ DRC8671

[~ 2. Crankshaft balancer hub, until completeny seated against the crankshaft position sensor reluctor ring using J 39046.

3. Removetool J 39046.

4. Bolt and washerinto front of crankshaft.

Tighten: bolt to specifications: 74 ft. Ib= (100 N.m).

Oil Pan Removal Removeor Disconnect:

1. Oil pan bolts, nuts, and studs.

DRC6637

2. Oil pan reinforcements.

3. Oil pan.

4. Oil pan gasket.

Clean: ¯ Parts in solvent. Remove all sludge and varnish. ¯ Old gaskets and R-IV sealant from the gasket surfaces.

6-18

Engme/eng

I~]

inspect: ¯ Gasket flanges for bending or damage.

10ram (0.q93 iN.)

¯ Oil pan for damageor cracks. ¯ Drain plug threads for stripping. mnstallation

r==...~

[~-=.~J install or Connect: [3~ E~ 1. Apply a small amount of GMSea/er, P/N 12346141, or equivalent, to engine front cover and engine block junction, and to crankshaft rear oil seal housing and engine block junction.

Apply sealer 1.0 in. (25 mm)in either direction of radius cavity junctions.

NF %

DRC6639

2. Oil pan gasket, oil pan and reinforcements.

3. Oil pan nuts, bolts and studs. [~

[~

Tighten:

Cornerbolts or stud, and nuts to 15 ft. lb. (20 N.m).

Remainderof bolts and studs to 108 in. lb. (12 N.m).

4. OrO~andrain plug and gasket.

IJ]l

Tighten:

Oil pan drain plug to 18 ft. lb. (25 N.m).

Eng,ne/eng

6-19

25 4 rnrn (1.00IN DRC6640

Oil Filter RemovaU [~]

L~ Remove or Disconnect:

1. Oinfilter, 2. Oil filter

adapter bolts and washers.

3. Oil filter

adapterand oil filter

adaptergasket.

[~ Inspect: o Oil filter adapter bypassvalve and spring for operation. ¯ For cracked or broken bypass valve.

Installation [~= Oil filter unit.

adapter and bypass valve must be rep0aced as a

[~ ~J insta01

or Connect:

1. Oil filter

adapterand oil filter

2. Oil filter

adapter bolts and washers.

DRC6638

adaptergasket.

Tighten: Oil filter

°°°l

adapterbolts to 20 ft. lb. (26 N.m).

3. Oil filter.

Tighten: Oil filter to 12 ft. lb. (16 N-m).

OiR Pump Removal pam==wm !

[~ ~L~ Remove or Disconnect: 1. Crankshaftoil deflector nuts.

2. Crankshaftoil deflector.

DRC6654

6-20

Englne/eng

:3. Bolt attaching oil pumpto rear crankshaft bearing cap.

4. Oil pump,retainer, and driveshaft from rear crankshaft bearing ca ,

I~ Disassemb,e:

1. Driveshaft (~) andretainer (~.

I~ Do not remove the oil pump screen unless replacement is required. Theoil pumpscreen has a press fit in to the pump cover. Do not remove the screen from the pipe ~. The oil pumpscreen is serviced as a complete assembly only.

2. Oil pumpscreen pickup ~.

3. Bolts ~ and pumpcover (~).

Mark where the idler gear and drive gear and shaft (~ meshtogether, so they can be reinstalled with the samegear teeth indexed.

DRC6624

4. {dler gear and drive gear and shaft 0.

5. Retaining pin 6.

6. Pressure regulator spring @and valve Q. [~

Clean: AIL~p,~rts in clean solvent and dry them with compressedair.

07’~| F~ important:

The pump gears, cover,

and body are not

serviced separately. Thepressurerelief valve spring is the only serviceable component. If any of the parts are damagedor worn, the entire oil pumpassembly must be replaced. ¯ Pumpbody {~ for cracks, wear, or other damage. ¯ inside of the cover (~) for cracks and wear that would permit oil to leak past the endsof the gears. e idler and drive gear Q for wear. ¯ Drive gear and shaft for lack of fit

in the pumpbody.

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

of

e Pressure regulator valve (~ for fit. The regulator valve shouldslide freely in its bore without sticking or binding.

Engmeieng

6-21

Assemble: [~ ~ Install

or Connect:

1. Pressure regulator valve ® into the pumpcover (~). important: Replacethe pressure relief when reusing the oil pumpassembly.

valve spring (~)

2. Pressure regulator spring Q into the pumpcover (~.

3. Retaining pin Q into the pumpcover (~.

4. Drive gear and shaft O into the pumpbody ~.

5. Idler gear O into the pumpbody ~.

Match together the index marks on the two gears made during disassembUy. 6. Pumpcover (~.

7. Bolts ®. [~ Tighten: to 106 in. lb. (12 N.m).

DRC6624 J 21882

With the driveshaft (~ installed on the pump,turn the driveshaft by hand to check for smooth operation. [~ Be careful of twisting, shearing, or collapsing the pipe wheninstalling it to the pump. A damagedpipe can cause lack of lubrication and engine failure.

Oil PumpScreenInstallation

!

,

install or Connect: DRC6625

[~ 1. Oil pump screen pickup. a. The oil pumpscreen assembly should be replaced with a newpart. Loss of press fit condition could result in an air leak and loss of oil pressure. b. Mountthe oil pumpin a soft jawed vise. c. Apply sealer to the end of the pipe. d. Tap the pickup screen and pipe into place, using J 21882and a hammer. e. The oil pumpscreen must be parallel with the bottom of the oil pan wheninstalled.

6-22

Eng,ne/eng

OiU Pump instal|at ion 1~ ,nstallorConnect: [1~ 1. Oil pumpdriveshaft @and retainer (~o [3 2. Oil pumpto the engine. a. Align the slot in the oil pumpshaft with the tang on the distributor shaft. b. The oil pumpshould slide easily into place. c. Nogasket is used.

[3~ 3. Oil pumpand bolt onto crankshaft bearing cap. ~=~ Tighten:

4

Bolt to 66 ft. lb. (90 N.m).

EngineFront Cover DRC665d

Removal

r’--’t

[~ [~ The composite engine front NOT REUSABLE.

cover and gasket are

[~==~.J Removeor Disconnect: 1. Enginefront cover bolts.

2. Enginefront cover.

3. Crankshaftfront oil seal. Pry the seal out with a screwdriver. [~ If cover is off engine, drive seal out with multiple hits on the inside of seal from inside of the cover. lnsta|iation ¯ Lubricate the sealing surface of the crankshaft front oil seal with clean engineoil. anstall or Connect: r ~L--3=cz~j

L.~°~I A newcompositeengine front cover and gasket must be installed on 5.7L engines. DONOTreuse the compositeengine front cover.

[1~] 1. Engine front cover and gasket.

2. Bolts. [~ Tighten: to 106 in. lb. (12 N-m).

DRC6655

Timing Chain and Sprockets Tool Required: J 5825-A Crankshaft Sprocket Puller Removal [~ To prevent damageto pistons or valves, do not turn the crankshaft after the camshaft timing chain has been removed. p.,..==.~

E~ ~ Remove or Disconnect:

DRC6656

1. Camshaftsprocket bolts.

2. Camshaftsprocket and camshaft timing chain together.

J 5825-A

The sprocket has a light interference fit on the camshaft. Tapthe sprocket on its lower edgeto loosen it.

3. Crankshaft sprocket using J 5825-A. 4o Key (if damaged).

DRC66~5

inspect: 1. Sprockets for chipped teeth and wear. [~ Excessively chain.

worn sprockets will

rapidly

wear a new

2. Camshafttiming chain for damage.

An excessively worn chain will rapidly wear a new set of sprockets.

3. Crankshaft sprocket for wear in the keywayarea.

4. Crankshaft sprocket key for wear.

6-24

Englneleng

llnstallation Tool Required: J 5590 Crankshaft Sprocket Installer I~

Install or Connect:

1. Crankshaft key (if removed).

[3 2. Crankshaft sprocket using J 5590.

DRC6669

I ~,-E"~ Important: Makesure the sprocket alignment mark faces away from the engine block. Makesure the sprocket is fully seated against the crank shoulder.

[3 3. Camshaft timing chain to the camshaft sprocket.

[3 4. Camshaftsprocket and camshaft timing chain to the front of camshaft. [~ important: [3 ¯ Makesure that camshaft and crankshaft timing marks (~ align. [~ The number6 cylinder is at top dead center of the compression stroke with the timing marksin this position.

DRC6633

¯ Makesure the camshaft dowel pin and camshaft sprocket hole are properly aligned ¯ Gears and chain mesh.

5. Camshaftsprocket bolts. Use the bolts to draw the camshaft ,sprocket onto the camshaft. DO NOTATTEMPT TO HAMMER THE CAMSHAFTSPROCKETONTO THE CAMSHAFT. TO DO SO MAY DISLODGE THE REAR CAMSHAFTPLUG AND/OR DAMAGETHE CAMSHAFT. [~

Tighten: bolts to 21 ft. lb. (28 N-m).

Camshaft Removal [~RemoveorDisconnect: [~ All camshaft journals are the samediameter so care must be used in removing the camshaft to avoid damage to the bearings.

Engme/eng

6-25

DRC6670

1. Camshaftretainer bolts and camshaft retainer.

2. Camshaft.

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

[~

Measure:

CamshaftJournals. Refer to General EngineMechanical section in this manual.Do not attempt to repair the camshaft. Replacethe camshaft if damaged. Whenever the camshaft needs to be replaced, a newset of valve lifters mustalso be installed.

Bearings Refer to General Engine Mechanical section in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly.

Installation E~] install

or Connect:

[~ Coat the camshaft lobes and journals with a high quality GMEngine Oil Supplement, P/N 1052367, or equivalent. Apply GMEngine Oil Supplement, P/N 1052367, or equivalent to all the teeth on the distributor drive gear.

EEl 1. Twoor three 5/16 - 18 (4.0 in.) bolts long into the camshaft threaded holes. Use these bolts to handle the camshaft.

EEl 2. Camshaftinto the engine. Handle the camshaft carefully to prevent damageto the camshaft bearings.

3. Camshaftretainer and retainer bolts. ¯ Coat camshaft retainer plate with GMEngine Oil Supplement,P/N 1052367,or equivalent.

Tighten: 106ft. lb. (12 N-m).

6-26

Engme/eng

Pistons and ConnectingRods Removal Tool Required: J 5239 Guide Set [~ Remove or Disconnect: 1. Before attempting to remove piston, ridge as necessary.

remove cylinder

bore

[~ Refer to General EngineMechanicam section in this manual for cylinder bore ridge reamer procedures.

2. Mark the cylinder numberson the tops of each piston. Mark them from the front to the rear, with the engine in an upright position and viewed from the front. ¯ The right bank is numbered1-3-5-7 o The left bank is numbered2-4-6-8 ,’.3. Checkthe connectingrod and cap for identification marks. If none, place match marks or numbers on connecting rods and caps. Markthe parts from the front to the rear, with the engine in an upright position and viewed from the front. Connecting rod (;a s must be assembledto their original connecting rods. [:a.~-’Ei important: Store the connecting rod and cap together a s mating parts, so they may be reassembled in the same wear pattern and balance in which they were removed.

4. Connecting rod nuts, cap and bearings.

Important: if reusing bearings, keep bearings with their original connecting rod and cap. ¯ Wipe oil from bearings and crank pins.

5. Connecting rods and pistons. [~ a. Attach J; 5239 to the connecting rod bolts.

I~ b. Use the long guide rod J 5239 to push the connecting rods and pistons out of the top of the engine block.

Disassembny Refer to General EngineMechanicalsection in this manual for piston and connecting rod disassembly.

Assembly Refer to General EngineMechanicalsection in this manual for piston and connecting rod assembly.

Engrr~e,’eng

6-27

DRC6619

Piston Selection Measuringthe Piston Checkthe used piston to cylinder bore clearance, as fol6ows: [~ 1. Cylinder bore diameter. Use a telescoping bore gauge, located 2.5 in. (65 mm)below the top of the cyninder bore. [~ 2. Piston diameter. Measurethe skirt at a right angle to the piston pin hole, 1.0 in. (25 ram) belowthe oil ring groove. [~ Measure piston diameter at 70 degrees F (20 degrees C).

DRC8507

3. Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance.

4. Locate the piston-to-bore clearance, refer to EngineSpecifications. Determine if the piston-to-bore clearance is within the acceptable range.

Piston Ring End Gapand Fit Refer to General Engine Mechanical section in this manual.

DRC65’m4

~] important: The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore. If a connecting rod is ever transposedfrom one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be renumbered to correspond with the new cylinder number.

Installation Tools Required" J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Torque/Angle Meter Instala or Connect: 1. Lubricate the cylinder walls lightly with engineoil.

2. Makesure the piston is installed in the matchingcylinder.

3. Connecting rod bearings. a. Makesure the crankshaft bearings are the proper size° b. Install cap.

the crankshaft bearings in the connecting rod and

c. Lubricate the bearings with engine oil.

6=28

Engme,’eng

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

J 5239

~] b. Locate the piston ring end gaps. Lubricate the piston and rings with engine oil. c. Without disturbing the ring end gap location, install J 8037 over the piston and compressthe rings= d. Place the piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft.

Using light blows with a hammerhandle, tap the piston down into its bore. At the sametime, from beneaththe engine, guide the connecting rod onto the crankpin with J 5239. Hold the ring compressoragainst the block until all rings have entered the cylinder bore. e. RemoveJ 5239 from the connecting rod bolts. [ ~=~] Important: Eachconnecting rod and bearing cap should be marked,beginningat the front of the engine. Cylinders 1, 3, and 5 are the right bank and 2, 4, and 6 are the left bank (whenviewed from the front). The numberson the connecting rod and bearing cap must be on the sameside wheninstalled in the cylinder bore.

If a connecting rod is ever transposed from one block or cylinder to another, newconnecting rod bearings should be fitted and the connecting rod should be numberedto correspond with the new cylinder number.

A OIL RING SPACERGAP (FANGIN HOLEOR SLOTWiTHiNARC) 8 CIL RINGRAILGAPS C 2ND COMPRESSION RING GAP O T3P COMPRESSION RING CAP

DRC6627

J 8037

5. Connecting rod cap with crankshaft bearing.

6. Connecting rod bolt nuts. [~

Tighten: DRC6628

20 ft. lb. (27 N.m)plus an additional 55 degreesusingJ 36660. [~

Measure:

Refer to General EngineMechanicalsection in this manual for connecting rod side clearance procedure.

Engme/eng

6-29

CrankshaftRear Oil Seal Removal Take care whenremovingthe rear crankshaft oil seal so as not to damagethe crankshaft sealing surface.

E~ Remove or Disconnect: EEl Unsert a screwdriver into the notches provided in the oil sean housing and removethe oil seal.

DRC6658

Installation Tool ReCruited: J 35621Crankshaft Rear Oil Seal Installer [~ I-~<-I~ install or Connect: 1. Lubricate the inner and outer diameterof the oil seal with clean engineoil.

2. Instanl the oil seal on J 35621.

3. Position J 35621against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.

J 35621 DRC5626

4. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft.

5. Turn the handle until it bottoms.

6. RemoveJ 35621.

6-30

Engme/eng

CrankshaftRearOil Seal Housing Removal [~ ~ Remove or Disconnect: 1. Bolts and nuts.

2. Oil seal housing.

3. Gasket. [~

DRC6657

Clean: Gasketsurfaces on the block and seal retainer.

Installation ~] ~ Install

or Connect:

o Always use newcrankshaft rear oil seal and newhousing gasket during installation of rear oil seal housing.

1. Newgasket to the block.

It is not necessary to use sealant to hold the gasket in place.

2. OiUseal retainer.

3. Screwsand nuts. [~ Tighten: to 11 ft.

lb. (15 N.m).

CrankshaftAndBearings Removal The crankshaft need not be removedfor replacement of the rear oil seal or crankshaft bearings. Thoseproceduresare covered in othr~..parts of this section.

I¥i Important: Checkthe crankshaft bearing caps for location markings. Mark the caps if necessary. The caps must be returned to their original locations during assembly.

F.~,ne/e.~

6-31

[~ Remove or Disconnect: 1. Crankshaft bearing cap bolts and studs.

2. Crankshaft bearing caps and lower crankshaft bearings.

3. Crankshaft from the cylinder block with extreme care, taking care to avoid damageto crankshaft journals and thrust flange surfaces.

4. Upper crankshaft bearings.

Cleaning, inspection, and Repair Refer to General Engine Mechanical section in this manual for cleaning, inspection, and measurements.

The following is the recommended gasket cleaning procedure for General Motors engine components: Carefully removeall gasket material from the part using a plastic or woodscraper. Use Loctite brand "Chisel Gasket Remover"(P/N 4MA)or equivalent. Do not use any other methodor technique to removegasket material from a part. Do not use abrasive pads, sand paper or power tools to clean gasket surfaces. These methods of cleaning can damagethe part. Abrasive pads also producea fine grit that the oil filter cannot removefrom the oil This grit is abrasive and has been knownto cause internal engine damage.

DRC6659

If the engine is damaged internanly and needsto be rebuilt, make sure all foreign material is completely flushed out of the cooling and Rubrication systems. Failure to rid the oil or cooling systems of debris can result in damageto the rebuilt engine.

Measure: Crankshaft bearing verticaB inside diameter (ID). Use an inside micrometer. This dimension should be the same as the other crankshaft bearing bore vertical diameters.

Clean: [~ Use care not to scratch crankshaft journals. e Crankshaft with solvent. ¯ Bnowall debris from the oil passageswith compressed air. e Crankshaft bearings. Wipefree of oil with a soft cloth. ¯ Oil seal surfaces with a non-abrasive cleaner.

6-32

Eng,ne/eng

Installation I~ important: Crankshaft bearings are the precision insert type and do not use shims for adjustment, if clearances are excessive, a newbearing will be required. Service bearings are available in standard size and 0.001 in. (0,0254 mm),0.002 in. (0,0508 mm),0.010 in. (0,2540 ,mm),and 0.020 in. (0,5080 mm)undersize. Also a 0.009 in. (0,2286 ram) is available for 5.7L enginesonly.

Selective fitting of both connectingrod and crankshaft bearings is necessary to obtain close tolerances. For this reason you may use, for example, one half of a 0.001 in. (0,0254 mm)undersize bearing which will decreasethe clearance 0.0005 in. (0,0127 ram) "from using a full standardbearing.

Undersize Crankshaft Journals Whena production crankshaft cannot be precision fit by the methoddescribed previously, it is then ground 0.009 in. (0,2286 mm) undersize.

GRIND ONLY THOSECRANKSHAFTJOURNALS THAT CANNOTBE PROPERLYFITTED. ALL JOURNALSWILL NOT NECESSARILYBE GROUND. A 0.009 in. (0,2286 mm)undersize bearing or 0.010 in. (0,254 ,undersize bearing will then be usedfor precision fitting in the samemanneras previously described.

Oversize Rear Crankshaft Bearing Thrust Faces :Someproduction engines mayhave rear crankshaft bearings that are 0.008 in. (0,2032 ram) wider than standard across the thrust faces. The crankshaft on these engines can be identified by ".008" :stampedon the rear counterweight. If the rear crankshaft bearings are replaced, they must have the proper distance between thrust faces to obtain correct crankshaft end play.

E~ Install 1.

or Connect:

er crankshaft bearing to the block.

~]

Important: If any undersized bearings are used, they mustbe fitted to the proper journals.

2. Crankshaft.

3. Lowercrankshaft bearings to the crankshaft bearing caps.

Measure: Refer to General Engine Mechanical section in this manual for crankshaft bearing cDearanceprocedures.

4. Apply engine oil to the crankshaft bearings. Install crankshaft bearing caps and bolts to the block. DONOTinstall the rear crankshaft bearing cap at this time. [~ In order to prevent the possibility of cylinder block and/or crankshaft bearing cap damage,the crankshaft bearing caps are to be lightly tappedinto their cylinder block cavity using a brass or leather mallet before attaching bolts are installed. DONOT USE ATTACHINGBOLTS TO PULL CAPSINTO THEIR SEAT. EEl Brnportant: The arrows on the crankshaft must be facing the front of the engine. [’~

bearing caps

Tighten:

Crankshaft main bearing cap bolts to specifications.

All inboard bolts 74 ft. lb. (100 N-m).

Outboardbolts (four bolt caps) 67 ft. lb. (90 N.m).

5. Rear crankshaft bearing cap and bolts to the block. [~ Tighten: bolts temporarily to 35 in. lb. (4 N-m).

Measure: Crankshaft end play, as follows:

°o

EEl 1. Firmly thrust the crankshaft first rearward then forward.

This will line up the rear crankshaft bearing and crankshaft thrust surfaces. [~

Tighten:

Rear crankshaft bearing cap bolts to specifications: 74 ft. lb. (100 N-m).

6-34

1-3

DRC6530

Englne/eng

2. With the crankshaft wedgedforward, measureat the front end of the rear crankshaft bearing with a feeler gauge. The proper clearance is 0.002 - 0.006 in. (0,0508 - 0,1524 mm).

3. If correct end play cannot be obtained, makesure the correct size rear crankshaft bearing has been installed. Production engines mayhaverear crankshaft bearings that are 0.008 in. (0,2032 ram) wider across the thrust faces than standard, as explained iously.

~

Inspect:

Crankshaft for binding. Try turning the crankshaft to check for binding, if the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on one cap at a time until the tight bearing is located. Burrs on the bearing cap, foreign matter betweenthe bearing and the block or the bearing cap, or a faulty bearing could causea lack of clearance at the bearing.

DRC6660

¯ A bent crankshaft could cause binding. Makesure the steps outlined in General Engine Mechanical section have been performed when checking for a bent crankshaft.

DRC6661

Cylinder Block Disassembly [~ Remove or Disconnect: 1. Coolantdrain fittings.

2. Cooling jacket plugs.

DRC6662

Obtain a suitable self-threading screw. Drill a hole into the plug and install the self-threading screw. Remove jacket plugs.

3, Oil gallery plugs. ~ Clean: 1. Sealing material from mating surfaces.

2. Boil cylinder block in caustic solution. ¯ Flush with clean water or steam.

3. Cylinder bores.

4. Threadedholes.

Engme/eng

6-35

5. Oil galleries and passages.

6. Scale deposits from coolant passages.

7. Spray or wipe cylinder ne oil.

~

bores and machined surfaces with

inspect:

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

2. Camshaftlifter

bores for deep scratches and deposits.

3. Cracksin the block a. Cylinder walls. b. Waterjackets. c. Engine mount bosses. d. Crankshaft bearing webs. e. Crankshaft bearing bores and caps. ® All crankshaft bearing bores should be rounded and uniform in inside diameter {I.D.} at aEI of the bearing supports. ¯ The area where the crankshaft bearings contact the crankshaft bearing bore should be smooth. ¯ if a crankshaft bearing cap is found to be damaged, replace the cap and line bore the block.

4. Cylinder block head mountingsurface for flatness, using a precision straight edge and feeler gauge. a. Set the straight edge on the sealing surface to be inspected.

DRC6521

b. Takethe feeler gaugeand at various locations, checkthe gap betweenthe straight edge and the sealing surface. c. If the gap is found to be greater than 0.004 in. (0,1016 ram) within 5.984 in. (152 mm)at any sealing location, the block must be replaced. d. If the gap is found to be aess than 0.004 in. (0,1016 ram) within 5.984 in. (152 mm)at any sealing Rocation and a cause for leakage is suspected, then the minor irreguRarities maybe carefully machinedfrom the block. ¯ Oil pan and intake manifold mountingsurfaces for nicks.

Minor irregularities maybe cleanedup with a flat file.

6-36

Engrne/eng

,Cylinder Bore Inspect: Cylinder bores for scoring or other damage.Refer to General Engine Mechanical section in this manual. [~

Measure: Cylinder bore taper and out-of-round. Refer to General Engine Mechanical section in this manual.

DRC6660

Cylinder Bore Reconditioning J~ Measure: Refer to General Engine Mechanical section in this manual.

~

nder Block Assembly Install

or Connect:

1. Oil gallery plugs. Coat plug outside Sealant, P/N 12346004,or equivalent.

diameter

with

GM DRC6661

2. Camshaftcup plugs to proper depth. Coat bore inside diameter with GMSealant, P/N 12346004,or equivalent. [~ Important: Do not allow residue on camshaft bearing or seizure mayresult.

J~ "0 ~ Y(,.’7~.",

3. Coolantdrain fittings.

DRC6662

Engme/eng

6-37

Circulating Pump Description TheVolvo Penta circulating pumpis manufactured specially for marine use.

It is serviced only as an assembly,Donot replace with an automotive circulating pump. inspection 1. Remove alternator and powersteering belts.

2. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag.

3. Lookfor water leaking from indicator hole beneathpumpshaft behind pulley. Replacepumpif play, drag, or leakageare evident.

Removaland installation 1. Drain water from block and disconnectwater hose from circulating pump.

2. Remove pulley. Remove circulating pumpbolts, pumpand gaskets.

3. Usenew pumpto block gaskets and sealer. Install newpumpassembly on cylinder block and tighten bolts as specified.

4. install pulley. Install alternator andpowersteering belts, then adjust tension.

5. install hoseto circulating pump.

6. Lakeor tank test unit andcheckfor leaks.

6-38

Engme/eng

?

25917

25929

11880

Front Engine Mounts Removal LI~ 1. Removetwo lag screws (~) and washers from mounts.

Z~ 2. Lift enginewith a hoist capableof lifting at least 1500lb.

(880 kg) to allow removalof front mountand bracket.

13 3. Removethree mount screws and lock washers ®. Note screw lengths and location.

11979

[~ [~ Prior to disassembly of front mount assembly, measure distance and record measurement between large washer and fiat on upper mount bracket.

Disassembly [~ 1. Removethree nuts © and engine mount bracket @from mountbolt while holding bolt secure with socket (~).

I~ 2. Removetwo flat washers, one large O and one smaller @.

Removelock washer ®, and engine mount bolt O from mount,

"®’@®

11978

Reassembly ~ 1. Place small washer @ on mount bolt and insert bolt up through mount, install large washer and secure wfth nut @.

Tighten to 60-75 ft. Ibs. (81-102N.m). [~ 2. Install upper inner nut and place engine mount bracket @ on engine mount bolt. [~ Measure distance between large washer and flat on upper mount bracket. Adjust distance to recorded measurement.

3. Install lock washerand top nut, Tighten nut to 100-120ft. Ibs. (136-163 N.m)=

EoO,,,~/~g Z~ Safety Related

6-39

11983

25929

2853

Installation [~ 1 Spray the engine mountscrew threads with Loctite ~ Primer N and allow to air dry. Apply Volvo PentaTreadSealing AgentP/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screws and washers.Tightento 32-40ft. Ibs. (43-54Nora). [~ 2. Instatl washersand lag screwsand tighten securely.

Height Adjustment [~] 1 To changeengine height, tighten or loosen nuts (~) and @required.

34719

/~2. Lift enginewith a hoist capableof lifting at least 1500lb. (680 kg). Position engineat desired height.

3. After setting mountposition, turn nut @up against undersideof engine bracket and hold nut with a wrench.Tightennut (~ to 100-120ft. Ibs. (136-163 Nom). ~Any large adjustments to engine height should be followed by a checkof enginealignment. Failure to checkalignmentcould result in rapid engine coupler fai{ure. SeeDrive Removal andInstallation section of the Sterndrive/TransomBracket Service Manualfor alignment procedures.

34720

High-Rise Exhaust Elbow Replacement Removal ~1. Loosentwo clamps securing upper hose to elbow. Lubricate inside of hose with a soapywater solution.

E~] 2. StarboardElbow:Remove circuit breaker bracket @and set aside.

Remove four screws, flat washers,and lock washersmountinghigh-rise elbow.

34718

I~ ~ 3. Use a soft hammerto free elbow from manifold. Use a twisting motion to pull elbow from hose. Remove and discard the elbow gasket.

6-40

34716 Engme;eng

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

[7~ [~ 2. Lubricate the inside of the exhaust hose with a soapy water solution. Insert the high-rise elbowinto the hosewith a twisting motion,and pushit into hoseas far as it will go.

[5"~ 3. Position elbowon manifold. Secureelbowsand brackets with four screws,flat washers,and lock washers.Tighten screwsto 12-18ft. Ibs. (16-24 N,m). StarboardElbow:Install circuit breaker bracket (~.

34717

[3 ~ 4. Slide clamps (~ up onto hose and position them in the two surface channels. Tighten clampssecurely.

Exhaust Hoseand Intermediate Pipe Replacement Removal I~ 1. Looseneight clamps that secure the upper © and lower exhaust hoses (~.

32371

[1_~_12. Lubricateinside of lower hosewith a soapywater solution, andslide lower hose downonto exhaust Y-pipe.

C~3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose if necessaryto ease removal.

4. Slide upperhoseoff high-rise elbow.Slide lower hoseoff exhaustY-pipe.

32374

.\

32375

=

Eng,ne/eng

6-41

32363

32366

32370

32363

installation [~] 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe. ~ The inside diameter of both the upper and lower hoses has a step (~ 3.5 in. (3,83 cm) from one end. The stepped end of the hose must face the intermediate pipe -wheninstalled.

2. Slide hoseonto high-rise elbowuntil it seats.

32374

Jf hose is not properny positioned, it will not completely engagethe high-rise elbow or allow secure attachment. [~ ~ Z~ 3. Place four No. 68 clamps on upper hose. With a twisting motion, insert intermediate pipe all the way into the upper hose. Place four No. 64 clamps on lower hose. Align lower end of pipe with exhaust Y-pipe, then slide lower hoseup until it’s halfway onto the intermediate pipe. Position clamps in channels and tighten cmamps securely,

Exhaust (Flapper) Valve Replacement

32367

Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hoseand intermediate Pipe Replacement. [~ 2. Slide the Lower hose downfar enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the va lye.

3. Inspect the two rubber bushings inside the pipe. Replace them as necessary.

SafetyRelated

6-42

32368

Engme/eng

1Installation 6~ 1. If installing newrubber bushings, apply 3M® Scotch Grip Rubber J.,’ Adhesive1300to outside of tips, and insert into inside of exhaustpipe.

I[~ 2. Position valve with longest lip pointing down,andinsert into pipe.

Pushpivot pin throughbushingsand valve until pin end is flush with outside of pipe. Checkexhaust valve for freedomof movement. ~lf valve is not positioned properly (long tip down),it will restrict exhaustflow and fail to preventwater backingup into engine. Boat performancewould be adversely affected, and engine maysuffer water damage.

3,?:369

3. Install intermediatepipe following procedureunderExhaustHoseand Pipe Replacement.

’Engine CouplerReplacement Rernoval 1. Remove engine from boat. ~lf coupler is being replaced due to coupler failure (rubber hub of splined hub), checkengine alignmentafter installing newcoupler. SeeDrive Removaland Installation section of the Sterndrive/TransomBracket Service Manual.

20034

2. Disconnectall wires, lines and connectorsfrom bellhousing. ’[~ r~ 3. Removescrews securing bellhousing cover, and slide cover out.

19085

Eng ...... g

6-43

[~ 4. Pull drain hose out of bellhousing. [~ 5. Unscrewbolts and nuts retaining belthousing, Disconnect ground wires. Remove powersteering cooler bracket.

6. Remove bellhousing from engine block. [~ 7. Unscrewsix nuts securing coupler and removecoupler from studs.

8. Remove old gasket from bellhousing cover. Clean gasket surface thoroughly.

19842

Installation [~1. Install coupler and securewith six Iocknuts. Usea suitable adaptor and tighten to 40-45ft. Ibs. (54-61N®m). []2. Install bellhousing and attach powersteering cooler. Tighten nuts and bolts to 32-40 ft. Ibs. (43-54N®m).Attach groundwires and tighten nuts to 15-20ft. Ibs. (20-27N,m).

3. Pushdrain hoseinto bellhousing.

4. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a newbellhousing gasketand position it on cover.

6710

[~ 5. Cleansevenself-tapping screwswith a wire brush. Install bellhousing cover and screws.Tighten to 60-84in. Ibs. (7-9 N-m).

6, Connectall wires, lines and connectorsto bellhousing.

7. Install enginein boat.

6712

6714

6-44

19996 Engne/eng

Positive Closed-TypeVentilation System A malfunctioning closed crankcase ventilation system may be indicated by loping or rough engine idle. Do not attempt to compensatefor this idle condition by disconnecting the crankcase ventilation system and making carburetor adjustments. The removalof the crankcaseventilation systemfrom the enginewill adverselyaffect fuel economy and engineventilation with resultant shorteningof engine life. To determine whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the following tests.

1. RemovePCVvalve from its mounting, but leave vacuuminlet side connectedto hose. If the valve is functioning properly and not plugged, a hissing noise will be heard as air passesthrough valve. A strong vacuumwill be felt whena finger is placed over valve inlet. Check for vacuum leaks in hose line and at all connections.

2. Reinstall PCVvalve, then removecrankcase air inlet hose at flame arrestor connection. Loosely hold a small piece of stiff paper (such as a 3 x 5 memo card or parts tag card) over opening at end of inlet hose. After a minute or so, (to allow crankcase pressure to lower) the piece of paper should be sucked against hose opening with a noticeable force.

RemovePCVvalve from its mounting and shake it. A metallic clicking noise should be heard, indicating that valve parts are free, and not sticking.

If ventilation systempassesthese two tests, it can be considered functionally OK,andno further service is required. If it fails either test, replace PCVvalve and repeat Engine Idling Test.

If systemstill doesnot pass test, clean ventilation systemhoses and all passagesto induction system in accordance with established procedures.

Servicing PCVValve Do not attemptto clean crankcaseventilation regulator valve, it shouldbe replaced. Clean crankcase ventilation system connection(s) on intake manifold by probing with a flexible wire or bottle brush. Clean hoses, tubes and associated hardware with a lowvolatility, petroleum-basesolvent and dry with compressedair.

TorqueSpecifications Bell Housing Cover Screws .......................................

60-84 in. Ibs. (7-9 N.m)

Bell housing Nuts and Bo0ts .....................................

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

Camshaft Retainer

Bolt

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

106 in. lb. (12 N.m)

Camshaft Sprocket

Bolt

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

21 ft. lb. (28 N.m)

Connecting

Rod Nut ........................

20 ft. lb. (27 N.ml plus an additional 55 degrees

Crankshaft

Balancer Bolt ............................................

74 ft. lb. (100 N.m)

Crankshaft Bearing Cap Inboard Bolt ...................................................

Outboard Bolt (Four Bolt Caps) ......................................

74 ft. lb. (100 N.m) 87 ft. lb. (90 Nora)

Crankshaft Oil Defmector Nut ..........................................

27 ft. lb. (36 N.m)

Crankshaft Rear Oi0 Sea| Housing Screws and Nuts ........................

11 ft. lb. (15 N.m)

Cylinder HeadBolt First Pass all Bolt in Sequence ......................................

Final Passall Bolts in Sequence: Short Bolt .........................................................

Medium Bolt .......................................................

Long Bolt .........................................................

Distributor

Clamp Belt

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

22 ft. Ibo (30 N.m) 55 degrees 65 degrees 75 degrees 18 ft. lb. (25 N.m)

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

Oil Gallery Plug ..................................................

15 ft. lb. (20 N.m) 15 ft. lb. (20 N.m)

Engine Coup|er Nuts ...........................................

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

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

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

Exhaust Manifold

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

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

Front

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

106 in. lb. (12 N-m)

Cover Bolt

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

Upper Nut ............................................

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

6-46

Engme/eng

"TorqueSpecifications Fuel PumpOpening Cover Upper Bolt Lower Bolt

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

30 ft. lb. (40 N.m) 106 in. lb. (12 N.m)

First Pass ........................................................

Second Pass ...................................................

Final Pass ......................................................

27 in. lb. (3 N.m) 106in. Ib, (12 Nora) 11 ft. Ib0 (15 N.m)

intake Manifold

Oim Fimter Bypass Valve Bolt ...........................................

20 ft. lb. (26 Nom)

Oil Level indicator

106 in. nb. (12 N.m)

Tube BoUt .........................................

Oil Pan Corner Nut or Stud ...............................................

Side Reinforcement Bolt or Stud ...................................

Drain Plug ......................................................

Oil Filter

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

15 ft. lb. (20 N.m) 108 in. lb. (12 N.m) 18 ft. lb. (25 N-m) 12 ft. lb. (16 N.m)

Oil Pump Bolt-to-Rear Crankshaft Bearing Cap ..................................

Cover Bolt .....................................................

66 ft. lb. (90 N.m) 106 in. lb. (12 N.m)

Spark Plugs Spark Plugs (cytinder head - new) ....................................

Spark Plugs (cylinder head - all subsequentinstallations) ..................

Valve Lifter

Guide Retainer BoUt .......................................

Valve Rocker Arm Cover Bolt ........................................

22 ft. lb. (30 N.m) 15 ft. Ib, (20 N.m) 18 ft. lb. (25 N.m) 106 in. lb. (12 N.m)

EngineSpecifications Type .....................................................................

Displacement ........................................................

Bore ...........................................................

Stroke .........................................................

Compression Ratio ...........................................................

Firing Order .........................................................

Oil Pressure (Minimum} .....................................

Diameter ......................................

90° V8 5.7L (350 CID) 4.00 in. (101,6 mm) 3.480 in. (88,39 mm) 9.4:1 1-8-4-3-6-5-7-2 6 PSI (41,4 kPa) at 1,000 RPM 18 PSI (124,1 kPa) at 2,000 RPM 24 PSI (165,5 kPa) at 4,000 RPM 4.0007 - 4.0017 in. (101,618 - 101,643ram)

Out-of-Round Production ................................................

Service Limit ..............................................

0.005 in. (0,12 ram) MAX. 0.002 in. (0,05 mm)MAX.

Taper Production Thrust Side ...........................................

Relief Side ...........................................

Service Limit ...........................................

0.0005 in. (0,012 mm)MAX. 0.001 in. (0,0254 ram) MAX. 0.001 in. (0,0254 mm)MAX.

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

Service Limit ...........................................

0.0007 - 0.0021 in. (0,018 - 0,053 mm) 0.0027 in. (0,068 mm)MAX.

Piston Compression Ring Groove Clearance Production Top ................................

Production 2nd ................................

Service Limit ..............................................

Gap Production Upper ..................................

Production 2nd ...............................

Service Limit ................................................

Piston Oil Ring

0.0012 - 0.0032 in. (0,030 - 0,081 mm) 0.0012 - 0.0032 in. (0,030 - 0,081 mm) 0.001 in. (0,0254 mm) 0.010 - 0.020 in. (0,25 - 0,51 mm) 0.018 - 0.026 in. (0,46 - 0,66 mm)MAX. 0.010 in. (0,25 mm)

Groove CDearance Production ......................................

Service Limit ..............................................

0.002 - 0.007 in. (0,051 - 0,17 mm) 0.001 in. (0,0254 mm)

Gap Production .......................................

Service Limit ..............................................

8-48

0.010 - 0.030 in. (0,25 - 0,76 mm) 0.001 in. (0,0254 mm)

Eng,ne/eng

EngineSpecifications Diameter ........................................

0.9270 = 0.927’1 in. (23,545 - 23,548 ram)

Clearancein Piston Production ....................................

Service Limit ...........................................

Fit In Connecting Rod ....................

0.0004 - 0.0008 in. (0,0102 - 0,0203 ram) 0.001 in. (0,0254 mm)MAX. 0.0008 - 0.0016 in. (0,0203 - 0,0406 mm)Interference

Surface Flatness

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

0.010 in. (0,254 mm)MAX.

Surface Flatness

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

0.004 in. (0,1016 mm)MAX.

Crankshaft Journal Diameter #1 ....................................

Diameter #2, #3, #4 ............................

Diameter #5 ...................................

Taper

2.4484 - 2.4493 in. (62,189 - 62,212 ram) 2.4481 - 2.4490 in. (62,182 - 62,205 mm) 2.4479 - 2.4488 in. (62,177 - 62,199 ram)

Production ...........................................

Service Limit .........................................

0.0002 in. (0,005 mm)MAX. 0.001 in. (0,0254 mm)MAX.

Out-of=Round Production ...........................................

Service Limit .........................................

Crankshaft Bearing Clearance

0.0002 in. (0,005 ram) MAX. 0.001 in. (0,0254 mm)MAX.

Production #1 ...................................

Production #2, #3, #4 .............................

Production #5 ..................................

Service Limit #1 ................................

Service Limit #2, #3, #4 ..........................

Service Limit #5 ..................................

0.0007 - 0.0021 in. (0,018 - 0,053 mm) 0.0009- 0.0,324 in. (0,022 - 0,061 ram) 0.0010 - 0.0027 in. (0,0254 - 0,069 mm) 0.0010 - 0.0020 in. (0,0254 - 0,051 ram) 0.0010 - 0.0025 in. (0,0254 - 0,064 ram) 0.0015- 0.003 in. (0,038 - 0,076 ram)

Crankshaft End Play .................................

0.002 - 0.008 in. (0,0508 - 0,2032 ram}

,Connecting Rod Journal Diameter ....................................

2.0978 - 2.0998 in. (53,2840 - 53,3340 mm)

’Japer Production ..............................................

Service Limit ...........................................

t ng,,~J,oQ

0.0003 in. (0,007 ram) MAX. 0.001 in. (0,0254 mm)MAX.

6-49

Engine Specifications

Out-of-Round Production .............................................

Service Limit ...........................................

Rod Bearing Clearance

0.0003 in. (0,007 ram) MAX. 0.001 in. (0,0254 mm)MAX.

Production ......................................

Service Limit .....................................

0.0013 - 0.0035 in. (0,033 - 0,088 mm) 0.001 - 0.003 in. (0,0254 - 0,076 mm)

Rod Side Clearance .....................................

0.006 - 0.014 in. (0,16 - 0,35 mm)

Journal Diameter ...................................

End Play ............................................. ........................................................

1.8677 - 1.8697 in. (47,44- 47,49 mm) 0.004 - 0.012 in. (0,11 - 0,30 mm) 0.002 in. (0,05 mm)

Intake ........................................................

Exhaust ......................................................

0.276 in. (7,02 mm) 0.285 in. (7,25 mm)

Lobe Lift

Valve Lifter .........................................................

Valve Rocker Arm Ratio .......................................................

Valve Lash ............................................

Face Angle .............................................................

Seat Angle .............................................................

Seat Runout ................................................

Hydraulic Roller 1.50:1 One Turn Down From Zero Lash 45 degrees 46 degrees 0.002 in. (0,05 mm)MAX.

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

Exhaust ............................................

0.040 - 0.065 in. (1,02 - 1,65 mm) 0.065 - 0.098 in. (1,65 - 2,49 mm)

Stem Clearance Production Intake .......................................

Exhaust .....................................

0.0010 - 0.0027 in. (0,0254 - 0,069 mm) 0.0010 - 0.0027 in. (0,0254 - 0,069 ram)

Service intake High Limit Production ................................

Exhaust High Limit Production ...............................

+ 0.001 in. (0,0254 mm) + 0.002 in. (0,0508 mm)

Valve Spring Free Length ....................................................

2.02 in. (51,3 mm)

Pressure Closed ................................

Open ...............................

Installed

338 - 76 - 84 lb. at 1.70 in. (374 N at 43,2 mm) 187 - 203 lb. at 1.27 in. (832 - 903 N at 32,3 mm)

Height ......................................

1.69 - 1.71 in. (42,92 - 43,43 mm)

6-50

Engnne/eng

GMSpecial Tools

J 5715

J 6036 DRC6674

J 6880

J 5802-01 DRC6675

J 24086-C DRC6677

J 35468

DRC6676

J 24270 DRC657

J 35621 DRC6878

DRC6582

J 36660 DRC6607

DRC6808

[-1-7 Rocker Arm Stud Bore Reamer0.003 in. (0,0762 mm)O.S. L-2~ Rocker Arm Stud Bore Reamer0.013 in. (0,3302 ram) O.S. [-3---] Rocker Arm Stud Remover [_-4--] RockerArmStud Installer) [-5~ Piston Pin Remover/ Installer E6-~ Cylinder Bore Ridge Reamer [-7--I Front CoverAligner / Oil Seal Installer

J 39046

[=-8~E] CrankshaftRearOil Seal Installer [-9----I TorqueAngleMeter

DRC6611

[~0"~ Crankshaft Balancer Remover/ Installer

Er~gme/eng

6-51

GIVl SpecialTools

J 3049

J 5239 DRC6596

J 5590 DRC6597

J 5825-A

J 8037 DRC6599

DRC6598

J 8062 DRC6601

DRC6602

J 38834

J 8358

J 9290-01 DRC6680

[~

J 21882 DRC6610

DRC6605

Valve Lifter Remover(plier type) Connecting Rod Guide Tool

[~

Crankshaft Sprocket Installer Crankshaft Sprocket Remover

I~

Piston Ring Compressor

[~ [-~

Valve Spring Compressor

[~

Valve Lifter

J 23738-A

Carbon Removal Brush Remover(slide hammertype)

DRC6681

Oil PumpScreen Installer Vacuum Pump

6-52

Eng,ne/eng

Section 7 7.4GL, Gi, GSi and 8.2GSi Table of Contents Camshaft ...................................................

Camshaft Lobe LEft, Measuring ...............................

Circulating Pump ...........................................

Crankshaft .................................................

Cylinder Block ..............................................

Cylinder Head ...............................................

Engine Specifications .......................................

Exhaust Hose and intermediate Pipe Replacement .............

Exhaust Manifold Replacement ...............................

Front Engine Mount Replacement ............................

General Motors Tools .........................................

High-Rise Exhaust Elbow Replacement ....................... intake Manifold ..............................................

Lubrication System .........................................

Oil Pan .....................................................

Oil Pump...................................................

Oil Seal Replacement, Rear Main Bearing .....................

Piston, Ring and Connecting Rod ............................

Remote Engine Oil Filter ....................................

Timing Chain, Cover and Seal ................................

Torque Specifications .......................................

Valve Lifter, Hydraulic ........................................

Valve Spring and Seal Repair .................................

7-16 7-21 7-32 7-23 7-30 7-9 7-37 7-36 7-5 7-33 7-2 7-34 7-3 7-18 7-19 7-20 7-22 7-26 7-19 7-14 7-40 7-6 7-8

Safety Warnings Beforeworkingon any part of the engine,read the section called Safely at the end of this manual.

Unlessinstructed otherwise, always disconnectthe battery cables from the battery before workingon electrical systemto prevent possible sparks or arcing in the engine compartment.

Beforestarting engineafter repair or maintenance procedures,alway,,; makesure enginecompartment is free of fuel vaporsto prevent possible fire and explosion.

Whenworking on an enginethat is running or being cranked, use extremecare to avoid getting hands,fingers or clothing caughtin the alternator, powersteering pump,raw-waterpumpand circulating pumpbelts, pulleys and other movingparts.

Engme/eng

7-1

Genera/Motors Tools atem

Part Number

Air Line Adaptor ...........................................

Crakshaft Seal/Sprocket Installer ..............................

Crakshaft Sprocket Puller .....................................

Dia~ Indicator Set ............................................

Hydraulic Lifter Remover..................................

Hydraulic Lifter Remover...................................

Main Bearing Replacer .......................................

Ring Compressor ...........................................

Seal Installer ..............................................

Seal Installer ..............................................

Stud Protector ..............................................

Valve Spring Compressor ...................................

Torsional DamperPuller ...................................

Valve Spring Compressor .....................................

J-23590 J-22102 J-1619 J-8520 J-9290-01 J-3049-A J-8080 J-8037 J-35468 J-38841 J-5239 J-5892-C J-23523-E J-8062

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

Material Required Varsol or Equivilent CleaningSolvent Molykote Lubricant Volvo Penta Gasket Sealing CompoundP/N 1161231-4 ~ No. 2 Permatex GMSuperEngine Oil Supplement GMSilicone RubbverSealer, P/N 1052366 Plastigage rM (Green) DuraPlusTMSAE30 HeavyDuty Synthetic Motor Oil Black NeopreneDip For additional service information not coveredin this manual,obtain the appropriate Chevrolet EngineService Manualfrom: Helmmnc.

P.O.Box 07130 Detroit, MI 48207

7=2

Engme/eng

intakeIVlanifoUd Removal Gi Models: see On-BoardService section for removal of compo= nents from intake manifold= I~ [~ Z~ 1. Disconnect battery cables at battery, and drain coolant from both sides of block and manifolds.

13~ 2. Removecover ® and flame arrestor= 19048

3. Remove alternator. If electrical leads are not disconnected,tie alternator to oil hoses to prevent alternator weight damaging leads.

[3~ 4. Removethermostat housing ®.

[3 5. Disconnect fuel line © at carburetor. Disconnect purple/ white stripe wire @at choke housing.

6. Disconnect throttle

cable at carburetor and anchor block.

7. Removemain electrical harness from clamps on port side of manifold and at front of manifold. Disconnect other wire connec= tions as necessary.

19046

I~ 8. Removedistributor cap (~ and mark the position of the rotor on the housing. Scribe a line on the distributor housing and intake manifold for reassemblyin the sameposition. Remove the distributor.

9= Unscrew attacl~ing bolts, and remove intake manifold and carburetor as an assembly. NOTE:If necessary to pry manifold away from cylinder heads, do not damagegasket sealing surfaces.

37346B

10. Removeand discard intake manifold gaskets and seals.

Cleaning Remove all gasket material and clean the sealing surfaces of the manifold, block and thermostat housing. Removeexcessive caribon deposits from exhaust passages, scale and deposits from cooling passages. Clean the manifold in a suitable solvent and dry it with compressed air.

Inspection 31841

llnspect the manifold for cracks, damagedgasket surfaces, or other defects that wouldmakeit unfit for further service. Replace all studs that are stripped or otherwise damaged.RemoveaH filings and foreign matter that mayhave enteredthe manifoldas a result of repairs.

Eng,ne/eng

~ Safety Related

7-3

installation 1. Install newmanifoldseals on block, and newgaskets on cylinder heads.

Useonly side gaskets having metal inserts covering the center exhaust passage.Usesealer at water passagesand whereseals butt to gaskets.

2. Install intake manifold. Tighten bolts in the sequence shown.See TorqueSpecifications at end of section for torque figure. ~ Checktorque of the intake manifold screws annually. The center screws can becomeloose under normal usage.

3. Install distributor with rotor and align exactly as marked during removal.

Install clampandtighten screwto 25 ft. Ibs. (34 Nora). ~lf engine was cranked while distributor timing proceduremust be followed.

was out, complete ignition

4. Install distributor capand high tensionleads.

5. Place main wire harness under clampson port side of manifold and at front of manifold. Makeother wire connectionsas necessary.

6. Attach throttle cable to carburetor andanchorblock.

DR6351

7. Connectpurple/whitestripe wire to chokehousing.Attach fuel line to carburetor. ~8. Apply Volvo Penta Gasket Sealing CompoundP/N 1161231-4 to both sides of a newthermostathousinggasket and place it on manifold.

Placelifting eye on long bolt, then install and tighten both bolts to 12-16 ft. robs.(16=22N®m).

9. Install alternator and properly tension belt. Tighten mountingscrews securely.

10. fnstall flamearrestor andtighten nut to 25-35ft. Ibs. (2,8-4,0 N®m).

Install flame arrestor cover andtighten nut 30-35ft. Ibs. (3,4-4,0 N,m).

Z~I 1. Attach battery cables at battery. Start engineandcheck for fuem and water leaks.

-4

Englneleng

Exhaust Manifold Replacement Removal ~ Drain water from respective exhaust manifold before beginning procedure.

1. Remove high-rise exhaust elbow following procedure under High=Rise Exhaust Elbow Replacement.

2. Carefully pull wires off sparkplugs.

3. Loosenhoseclampat front of manifold, andpull off water hose.

4. Remove manifold attaching screws, nuts and washers.Discard nuts.

Remove manifold and discard manifold gasket.

Cleaning Clean mating surfaces on manifold and cylinder head. Clean the threads on the exhaustmanifoldbolts. inspection [2~ Inspect for cracks. To pressurecheckmanifold, fabricate a plate @as shownand a newelbow gasket (~) to seal water passagein manifold. sure to apply sealer to gasket. Install rubberdrain capto manifoldand secure with clamp. Attach a gearcasepressure tester © (such as Stevens Company S-34) to the water inlet hose. A bushing can be madeto secure pressuretester to hose. With the pressuretester attachedto the manifold, submerge manifold in water. Pressurize the manifold to 10=15PSI (22°25 kPa) and checkfor leaks.

DR2875

Installation 1. Install a newexhaustmanifoldgasket.

18946

[3~ [~] 2. Instal~ manifold and secure with screws, washersand new Iocknuts. Tighten nuts to 20-26ft. Ibs. (27-35N®m).Tighten screwsto 24-28 ft. Ibs. (33-38N,,m).

3. Attach water hose1.o nipple at front of manifoldand tighten clamp 4.. Attachspark plug wires to plugs. Makesure firing order is correct.

5;. Install high-rise exhaustelbowfollowing procedureunderHigh-Rise Exhaust Elbow Replacement ~,6. Start engine and check for water and exhaust leaks.

189,$4

HydraulicValve Lifter CheckingHydraulic Valve Lifter When checkinghydraulic valve lifters, remember that grit, sludge, varnish, or other foreign matterwill seriously affect their operation.If anyforeign substanceis foundin the lifters or enginewhereit maybe circulated by the Jubrication system, a thoroughcleaning job must be doneto avoid a repetition of lifter trouble.

To help preventlifter trouble, the engineoil andoil filter mustbe changed as recommended in GeneralInformationsection. The engine oil must be heavy-dutytype (for Service SG)and must also conformto General Motors Specification 6094Mto avoid detrimental formation of sludge and varnish.

WerecommendDuraPlusTM SAE30 Heavy Duty Synthetic Motor Oil. The boat ownershould be specifically advised of these requirementswhenthe unit is delivered. Faulty valve lifter operationusually appearsunderoneof the following conditions: 1. RappingNoise Only WhenEngine is Started: When the engineis stopped, any lifter on a camshaftlobe is under pressure of the valve spring; therefore, leak downor escapeof oil from the lower chambercan occur. Whenthe engine is started, a few secondsmaybe requiredto firt the lifter, particularly in colderweather.If noiseoccursonly occasionatly, it maybe considerednormal, requiring no correction. If noise occursfrequently, however,checkfor either oil too heavyfor prevailing temperatures,or excessivevarnish in lifters.

2. Intermittent RappingNoise: An intermittent rapping noise that appearsand disappearsevery few secondindicates leakageat checkball seat due to foreign particles, varnish, or defective surfaceof checkball or seat. Replacelifters as necessary.

3. Noise at Idle and LowSpeed: if one or morevalve tilters are noisy at idle speedand up to approximately 1200RPM,but quiet at high speeds,it indicates excessiveleak downrate or faulty checkball seat or plunger. Withengineidling, lifters with excessive leak downrate maybe spotted by pressing downon each rocker arm above the pushrod with equal pressure. Reconditionor replacenoisy mifters.

7-6

Engine/eng

4. Generally Noisyat All Speeds: Checkfor low or high oil level in crankcase.High oil leveBswill be churnedby crankshaft and will force air bubbles into the lifters.

Lowoil levels allow pumpto pumpair at high speed. With engine idling, strike each rocker arm above the push rod several sharp blows with a malDet;if noise disappears, it indicates that foreign material was keeping check ball from seating. Stop engine and place lifters on camshaftbasecircle. If there is lash clearancein any valve linkage, it indicates a stuck lifter pnunger,wornlifter body lower end, or worn camshaft lobe.

5. LoudNoise at NormalOperating TemperatureOnly: If a lifter develops a loud noise whenthe engine is at normal operating temperature, but is quiet whenengine is below normal temperature, it indicates an excessively fast leak downrate of scoredlifter plunger. Reconditionor replace lifter. .,,.

1. With air hose and cloths, clean dirt from cylinder heads and adjacent parts to avoid getting dirt into engine, it is extremely important that no dirt gets into the valve lifters.

1 DR378¢3

2. Removeintake manifold. Removeexhaust manifolds. ,’3. Removerocker arm covers. Do not pry. if covers stick use rubber mallet and strike cover end to jar loose. Loosenrocker arm nuts and pivot the rocker arm free of the push rods.

[1~] [~ 4. Removepush rods. Removethe hydraulic lifters that require service one at a time and place them in an organizer rack.

The tifters must be installed in the samebore from which they were removed. NOTE:A stuck hydraulic lifter can be removed using Tool J-3049-A (plier type) or Tool J-9290-01 (slide hammer type).

DR3786

5. If less than a completeset of lifters is being removed,immediately disassembleone or two for presence of dirt or varnish. If lifters contain dirt or varnish, it is advisableto removeall lifters for replacement.Otherwise, it will be satisfactory to service only those lifters that are not operating properly.

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

~TA~NG ~ NORMAL,

installation [~ Before installing any new lifters, lifter with Molykoteor its equivalent.

E ngme/eng

coat the bottom of the

7-7

869000

1. Install valve lifters in cylinder block, ff any newlifters or a new camshafth,is been installed, an additive containing EPlubricant such as G.M. Engine Oil Supplement must be added to the crankcase oil for breakdm 2. Install pushrods onto lifters.

Install intake manifold.

3. Pivot rocker armsin place and install rocker armbolts. Tighten bolts to 40 ft. Ibs. (54 N.m).

4. Install rocker arm covers, using G.M. Sealer No. 1052289,and tighten nuts to 115 in. Ibs. (13 N.m).

5. Install exhaustmanifold. Start engineand checkfor oil leaks at rocker arm covers.

Valve Spring and Seal Repair Removal EEl1. Removerocker arm cover.

2. Remove spark plug, rocker arm, and push rod on the cylinder(s) to be serviced.

3. Install Air Line Adaptertool J-23590to spark plug port and apply compressedair to hold the valves in place.

I~] 4. Using tool J-5892-C, compress the valve spring and removethe valve locks. Release and removetool. Removevalve cap and shield, and valve spring and damper.

5. Remove the valve stem oil seal. installation

~3796

n,,.

1. Install seal over valve stem and seat against head.

J 5892-C

--~

2. Set the valve spring and damper,valve shield and valve cap in place. Compress the spring with tool J-5892-Cand install oil seal in the lower groove of the stem, makingsure the seal is flat and not twisted. NOTE: A light coat of oil on the seal will help prevent twisting.

3. Install the valve locks and release the compressortool making sure the locks seat properly in the upper grooveof the valve stem.

NOTE: Grease may be used to hold the locks in place while releasing the compressortool.

I

DR3794

4. Install spark plug and torque to 20 ft. lb. (27 N.m).

5. Install rocker armcover. Tightennuts to 115 in. [bs. (13,0 N.m).

7-8

Engme/eng

Cylinder Head Removal 1. Drain water from block and exhaust manifolds. Removeintake and exhaust manifolds.

2o Removevalve covers and spark plugs.

3. Loosen rocker arm bolts and turn rocker arms aside. Remove pushrods. if lifters are to be serviced, removethemat this point.

Otherwise protect the lifters and the camshaft from the entrance of dirt by covering the area with clean cloths.

4. Removecylinder head bolts, cylinder heads and gasket. Place cylinder heads on bench, supporting them at each end on blocks of woodto prevent damageto gasket faces of heads.

Disassembly 1. Removerocker arm bolts, ball seats and rocker arms.

[3~ 2. Using too[ J-8062, compressthe valve springs and remove the valve keys. Re6easethe compressortool, and removerotators, springs and spring dampers, then removeoil seals.

3. Removevalve from bottom of cylinder heads and place them and their respective valve springs in a rack in their proper sequenceso they can be assembledin their original positions.

Cleaning and Inspection Refer to General Engine Mechanical section in this manual for cylinder head cleaning and inspection.

Repair 1. Valve Seats: Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the powerand performancebuilt into it.

Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve headwill be properly carried away.

I-ngme/eng

7-9

DR3125

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

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

C.

Place roughing stone or forming stone over pilot and just clean up the valve seat. Usea 46° stone for both the inlet and exhaust valve seats.

Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smoothfinish.

d. Narrowdownthe valve seats to the proper width for the intake and exhaust. See Specifications at the end of this section. °This operation is doneby grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations.

EEl ~ Valve seats should be concentric to within 0.002 in. total indicator reading.

2. Valves: Valvesthat are pitted can be refaced to the proper angle, ensuring correct relation betweenthe head and stem on a valve refacing machine. Valve stems which show excessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be groundon part or all of the valve head due to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this knife edge. If the edgeof the valve headis less than 1/s2 in= thick after grinding, replace the valve.

7-10

1 O425

Eng~ne/eng

a. If necessary, dress the valve refacing machinegrinding °wheelto makesure it is smoothand true. Set chuckat 45 mark for grinding valves. b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheel by movingthe lever to the left. d.Turn the feed screw until the valve head just contacts wheel. Movevalve back and forth across the wheel and regulate the feed screwto provide light valve contact.

Continuegrinding until the valve face is true and smooth all around valve. If this makesthe valve thin, the valve must be replaced as the valve will overheat and burn. f. Removevalve from chuck and place stem in "V" block.

Feedvamvesquarely against grinding wheel to grind any pit from rocker arm end of stem. NOTE:Only the extreme end of the valve stem is hardenedto resist wear. Do not grind end of stem excessively. g. After cleaning valve face and cylinder head valve seat of grinding particles, makepencil marksabout 1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve. h. Remove valve and checkface carefully. If all pencil marks have not been removedat the point of contact with the valve seat, it will be necessary to repeat the refacing operation and against recheck for proper seating.

.©

i. Grind and check remaining valves in the samemanner.

Assembly Whenreplacing valve springs, refer to the latest parts catalog for ordering information.

Starting with number1 cylinder, place the valves in the designated ports and assembleall but the seal and locks. Then, using tool J-5892-C, compressthe spring (~ and install the seal and locks ©. Seethat the seal is flat and not twisted in the valve stem groove, and that the locks seat properly in the valve stem groove.

DR3795

Engine/eng

7-11

~ Place valve spring in position with the closed coil end toward the cylinder head.

Installation 1. Wipeoff engineblock gasket surface and be certain no foreign material hasfallen into the cylinder bores,bolt holes, or the valvelifter area.It is goodpractice to clean out bolt holes with an air hose.

N~-o-te~This engine has special marineheadgaskets. Donot substitute automotive head gaskets.

2. Install newheadgasketon cylinder block. Dowelsin the block will hold the gasketin position. Alwayshandlegasketscarefully to avoid kinking or damage to the surface treatment of the gaskets. DONOTuse any type of sealing material on headgaskets. Thegaskets are coated with a special lacquer to provide a goodseal, once the parts have warmedup.

3. Carefully set in place on the engineblock dowelpins.

4. Cleanand lubricate the headbolts with Volvo PentaGasketSealing Compound P/N 1161231-4.Install bolts.

J~ 5. Tighten the headbolts with a torque wrench,in three progressive steps, following the sequenceshown.

Step1 - 35 ft. Ibs. (47 N.m) Step2 - 65 ft. Ibs. (88 Nom) Step 3 - 85 ft. Ibs. (115 N,m) ~ Damageto the cylinder block threads can result if bolts are not lubricated with Volvo Penta Gasket Sealing Compound P/N 1161231-4 prior to installation or if the bolts are tightenedexcessively.Usean accurate torque wrenchwheninstalling headbolts and do not overtighten. Uneven tightening of the cylinder headbolts can distort the cylinder bores, causing compression[oss and excessive oil consumption.

DR2905

Timing Chain, Cover and Seal Harmonic Bahancer Removam 1. Remove alternator and powersteering belts, and crankshaft pulley.

J~2. Attach tool J-23523-Eto balancer, and turn puller screw to remove balancer from crankshaft.

DR3573

Oil Seal Replacement ~ Cover need not be removedto replace the craknkshaft seal.

1. Pry oil seal out of front of coverusinga large screwdriver.

7-12

Eng,ne/eng

~] 2. Coat seal lips with engine oil. Install new seal with lip toward inside of cover. Use tool J-35468 to drive seal into position.

Timing Chain Cover Removal 1. Removecirculating steering pump.

pumppulley, alternator brace, and power

2. Drain cooling system and remove hose at circulating pump.

Disconnect temperature sender wire, then remove circulating pumpand discard gaskets.

DR3787

3. Remove oil pan. See Oil Panin this section.

4. Removethe front cover-to-block front cover and gasket.

attaching screws. Remove

Timing Chain and Sprocket Replacement 1. Crank engine until "0" marks on camshaft and crankshaft sprocketsare in alignment,in this position, engineis timedto fire No. 6 cylinder.

DR3579

2. Removecamshaft sprocket boBts. Removesprocket and timing chain together. Sprocketis a slight press-fit for approximately1/8 inch. If sprocket does not comeoff easily, a Right blow with a plastic-faced hammeron the lower edge of the camshaft sprocket should dislodge it.

I[~ 3. If crank sprocket requires replacement, use a two or three jaw puller such as J-1619 that pilots on end of crankshaft to pull off sprocket. [~ 4. Install crank sprocket using tool J-22102to drive it into place over keyway.

DR3574

[~ 5. Install timing chain on camshaftsprocket. Hold the sprocket vertical with the chain hanging below. Align the camand crank sprocket timing marks, and attach the chain to the crank sprocket.

i,i:,:,,7

DR3577

///

Englne/eng

7-13

/ /f,C"~

DR3576

6. Align dowelin camshaftwith dowelhole in sprocket and install sprocket on camshaft. [~ Do not hammer sprocket onto camshaft. This may loosen rear camshaft welsh plug.

7. Draw sprocket onto camshaft using the mounting bolts. Lubricate the timing chain with engine oit.

TimingChain CoverBnstallation 1. Clean gasket surface on block and crankcase front cover.

2. Install section.

new oil pan gasket and oil pan. See Oil Pan in this

3. Coat the gasket with sealer and place in position on cover.

Apply a 1/8 inch bead of GMSilicone RubberSealer, P/N 1052388 (or equivalent), to the joint formed at the oil pan and cylinder block.

4. Position crankcase front cover over crankshaft. Press cover downwardagainst oil pan until cover is aligned and installed over dowel pins on block.

5. Install the front cover-to-block attaching screws.

8. Tighten front cover to block bolts. SeeTorqueSpecifications at the end of this section for the torque figure.

HarmonicBalancer Unstallation 1. Coat machinedouter surface of balancer hub with engine oil.

Align keywayand start balancer onto crankshaft.

E~ 2. Using appropriate end of tool J-23523-E threaded into crankshaft, or a large washer and a 7/16-20 x 4 in. bolt and nut threaded into center hole in crankshaft, tighten nut to seat harmonic balancer on crankshaft.

DR3576

E~ 3. Removeinstalling tool. Instal~ crankshaft pulley and tighten screws securely. Thread 7/16-20 x 2 in. bolt and thick washer into crankshaft and tighten. See Torque Specifications at the end of this section for the torque figure.

4. install circulating pumpand pulley, and tighten screws securely. Attach water hose to pump.

5. Install alternator and power steering pumpbrackets. Install alternator and powersteering belts and adjust tension to specifications.

7 - 14

24965

Engme/eng

Camshaft Removal [~ 1. Removedistributor lating pump.

(~. Removeintake manifold and circu-

2. Removerocker arm covers, loosen rocker arms, then remove push rods and valve lifters.

3. Removecrankshaft pulley, harmonic balancer, timing chain cover, timing chain, and camshaft sprocket.

28257

[~ 4. Install two or three s/16-18x 4 in. bolts in camshaftsprocket bolt holes and carefully pull out camshaft. Use care not to damagecamshaft bearings.

Measure: CamshaftJournals. Refer to General Engine Mechanical section in this manual.Do not attempt to repair the camshaft. Replacethe camshaft if damaged. Whenever the camshaft needs to be replaced, a newset of valve lifters mustalso be installed.

DR3790

Bearings Refer to General EngineMechanicalsection in this manual for camshaft bearing disassembly, cleaning, inspection, and assembly.

Installation 1. Lubricate camshaftjournals with engine oil. [~ Whenevera new camshaft is installed, lubricate the camshaft lobes with Molykote or its equivalent. Also add one can of G.M. Engine Oil Supplementto crankcase oil.

2. Install three 5A6-18x 4 in. bolts in camshaftbolt holes. Install camshaft, being careful not to damagebearings.

3. Install camsprocket (making sure timing marksface outward), timing chain, and timing chain cover.

4. Install harmonicbalancerand crankshaftpulley. Install circulating pumpand connect coolant hose.

5. Install valve lifters, push rods, rocker arms, and intake manifold. Install rocker armcovers.

6. Install distributor andset initial timing.

Engine/eng

7-1 5

Lubrication System Description and Operation The oil pumpconsists of two gears and a pressure relief valve enclosed in a two-piece housing, and is driven by the distributor driveshaft which in turn is driven by a helix gear on the camshaft.

The pumpis flange mountedto the cylinder block with two bolts.

The pumpcover is equipped with a pressure regulator valve that regulates oil pressure at approximately 40-60 PSI at 2000 RPM. The pumpintake is of the fixed screen type. A meshscreen filters out small particles of dirt and sludge which maybe present.

A baffle incorporated in the intake screen has been designed to eliminate pressure loss due to suddensurging stops. In the event that a screen becomesplugged, a steel grommetopens and bypasses oil to the pump. Oil passes through an opening in the mountingflange to the cylinder block, then into an oil filter adapter.

Themainoil galleries run the full length of the crankcaseand cut into the valve lifter guide holes to supplyoil at full pressureto the lifters.

The rocker arms and valves are Rubricated by an oil channel in eachpush rod. Excessoit drains off and returns to the oil pan through passagesin the cylinder head and block.

Connecting passagesdrilled in the crankcase permit delivery of oil at full pressure to all crankshaft and camshaft bearings, distributor drive gear, and shaft, and the timing chain.

Holes drilled in the crankshaft carry oil from the crankshaft bearings to the connecting rod bearings. Pistons and cylinder walls are Bubricated by oil forced through a small notch in the bearing parting surface on the connecting rod, which registers with the hole in the crankpin once every revolution. Piston pins are lubricated by splash.

28256

RemoteEngineOil Finter EEl [~] A full flow oil filter @is mountedto a bracket attached to the port exhaust elbow. Twohoses connect it to an oil cooler and an engine block adaptor ®. [~] Oil exits the block through the rear opening @of the adaptor, andtravels througha hoseto the rear oil cooler fitting, it leaves the front cooler fitting, and travels through a hose that connectsto the filter bracket inner (starboard) opening@. Return oil leaves the filter bracket at the outer (port) opening(~, travels through a hose and re-enters the engine at the forward opening ® of the adaptor. [~ If hoses are improperly attached at adaptor or filter bracket, oil flow will be reversed. Oil pressure will drop and engine damagemay result.

7-16

Englne/eng

[3~ Normally, all engine oir passes from the block through an OEMfilter adapter @. If the remote oil filter or lines become restricted, a spring loaded bypass valve ® opens in the adaptor and circulates oil back into the block.

©

[3~ Inspect bypass valve spring and valve disc ® for proper operation or damage.If replacement of bypass valve is necessary, removebolts and adaptor. Clean valve chamberin block and replace adaptor.

Oil Pan

DR2966

Removal 1. Removetiming chain cover. See Timing Chain, Cover and Seal in this section.

2. Removeoil dipstick and withdraw oil using a suction pump. :3. Remove oil dipstick tube. Remove screws, oil pan and gasket.

4. Remove oil dipstick tube fitting

from oil pan.

DR3788

1. Thoroughlyclean all gasket sealing surfaces.

[4~ 2. Apply RTVsealer to the front and rear corners of the block.

14~3. Attach gasket to block. Install rear portion of oil pan seal in groove in rear main bearing cap.

14~ 4. Install front portion of oil pan seal by pressing the corners into sealer applied to block.

31576

5. install oil pan and tighten screws. SeeTorqueSpecifications at the end of this section for the torque figure.

6.

Install

dipstick

tube

fitting

to

pan;

leave

screw

loose.

Orient fitting and attach dipstick tube. Thentighten fitting screw and flare nut. SeeTorqueSpecifications at the end of this section for the torque figure.

\

7. Fill crankcasewith specified engine oil. See CrankcaseOil in the General Information Section.

Oil Pump Removal and Disassembly 1, Remove oiD pan.

2. Removepumpto rear main bearing cap bolt, and remove pump, extension shaft, and collar. NOTE:Baffle nuts have to be loosened.

DR3580

3. Disconnect pump shaft from extension. Removefour cover attaching screws, cover, gasket, idler gear and drive gear, and shaft.

4. Removepressure regulator valve and valve parts.

5. If the pickup screen or pipe need replacing, replace the entire pump and pickup screen assembly.

6. Washall parts in cleaning solvent and dry using compressed air. inspection Should any of the following conditions be found during inspection operations, the pumpand pickup screen assembly should be replaced.

1. Inspect pumpbody for cracks or excessive wear. inspect oil pumpgears for excessive wear or damage.

2. Checkshaft for loosenessin the housing. Checkinside of cover for wear that would permit oil to leak past the ends of gears.

3. Check the oil pickup screen for damageto screen or relief grommet.Checkfor oil in the air chamber.

4. Checkpressure regulator valve pnungerfor fit

in cover.

Assemblyand Installation 1. Place drive gear and shaft in pumpbody. Install idler gear so that smoothside of gear will be toward the cover.

2. Install a new pump to cover gasket to ensure correct end cRearanceof the gears.

3. Install cover and attaching screws. Tighten screwsto 80 in. Ibs. (9 N.m), and checkto see that shaft turns freely.

4. Install regulator valve plunger, spring, retainer, and pin.

5. Assemblecollar end of extension shaft assembly over pump driveshaft, aligning tang of extension shaft with slot in end of pumpdriveshaft.

6. Assemblepumpand extension shaft to rear main bearing cap, aligning slot on top end of extension shaft with drive tang on lower end of distributor shaft. NOTE:Oil pumpshould slide easily into place. If not, remove and relocate slot or locate other problem. Install mounting screws and tighten. See TorqueSpecifications at the end of this section for the torque figure.

7. Tighten baffle nuts.

8. mnstall oil pan using newgasket. Connectoil drain tube.

7-18

Engme/eng

MeasuringCamshaftLobe Lift [1~ 1. Removerocker arm covers. Loosen rocker arms and pivot awayfrom push rods. Position indicator with ball socket adapter (Tool J-8520) on push rod. Makesure push rod is in the lifter socket.

2. Rotatethe crankshaftslowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position.

3. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the pushrod is fully raised position. ,/~ Wheneverthe engine is cranked: [2-2] Gi Models: removegray and black connectors from ignition coil to preventaccidentalstarting of engine.

DR3791

r

[3 GL Models: remove the 14-pin connector from the ignition moduleto prevent accidental starting of engine.

4. Comparethe total lift recorded from the dial indicator with specifications. If camshaftreadingsfor all lobes are within specifications, removedial indicator assembRy.

DR5655

!5. Install valve mechanism as outlined. Install rocker armcovers.

Rear Main Bearing Oil Seal Replacement Removal Pry out rear crankcaseoil seal. NOTE:Care should be taken when removing the rear crankcase oil seal so as not to nick the crankcaseseal surface.

28267A

Cleaning and inspection Clean sealing surface on crankshaft with a non-abrasive cleaner.

Inspect chamfer on crankshaft for grit, loose rust, and burrs.

Correct as necessary.

Ilnstallation 1. Lubricate the inner and outer diameter of the seal with engine oil.

DRlg79

14-~] 2. Position the seal onto tool J-38841(~) so seal lip will face 1:heblock.

IT! 3. Position tool J-38841 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft and tighten securely. This will ensure that the seal ® is installed =squarelyover the crankshaft. Turn the handleuntil it bottomsthen =’emovethe tool.

FngmeJeng

~ Safety Related

7-19

DR3789

Crankshaft Description Mainbearings are of the precision insert type and do not utilize shims for adjustment. If clearances are found to be excessive, a new bearing, both upper and lower halves, will be required.

Bearings are available in standard size and 0.001 in., 0.002 in., 0n010in. and 0.020 in. undersize.

Selective fitting of both rod and mainbearing inserts is necessary in production in order to obtain close tonerances. For this reason you mayfind one-half of a standardinsert ,with one-half of a 0.001 in. undersize insert which will decreasethe clearance 0.0005 in. from using a full standard bearing.

Whena production crankshaft cannot be precision fitted by this method,it is then ground 0.009 in. undersize on only those main journals that cannot be properly fitted. All journals will not necessarily be ground undersize. A 0.009 in. undersize bearing and 0.010 in. undersize bearing maybe used for precision fitting in the samemanneras previously described. [~ If, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirement will be determined by bearing clearance.

Cleaning, Inspection and Repair Refer to GeneralEngineMechanicalsection in this manual for cleaning, inspection, and measurements.

In general, (except No. 1 bearing) the lower half of the bearing showsa greater wear and the most distress from fatigue, ff upon inspection the lower half is suitable for use, it can be assumed that the upper half is also satisfactory. If the lower half shows evidence of wear or damage,both upper and lower halves should be replaced. Never replace one half without replacing the other haiti These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in. out-of-round, or taper, the crankshaft shouRdbe repaaced or reconditioned to an undersizefigure that will enable the installation of undersize precision type bearings.

The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the rear intermediate and front intermediate journals, using a dial indicator. Therunout limit of eachof these journals is 0.002 in. If the runout exceeds0.002 in., the crankshaft must be repaired or replaced.

Main Bearing Replacement [~ 1. Install a main bearing removingand installing tool J-8080 @in oil hole in crankshaft journal. NOTE:If such a tool is not available, a cotter pin maybe bent as required to do the job.

7-20

DR2916 Engme/eng

2. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper bearing out of block.

3. Oil new selected size upper bearing and insert plain (unnotched) end betweencrankshaft and indented or notched side of block. Rotate the bearing into place, and removetool from oil hole in crankshaft journal.

4. Oil newlower bearing and install in bearing cap. Install main bearing cap with arrows pointing toward front of engine. Torque main bearing cap bolts to specifications, Measure: Refer to General EngineMechanicalsection in this manual for crankshaft bearing clearance procedures.

Connecting Rod Bearing Replacement Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. DO NOTFILE RODSOR ROD CAPS.If clearances are found to be excessive a new bearing will be required. Bearings are available in standard size and 0.001 in. undersize for use with standard size crankshafts.

1. With oil pan and oil pumpremoved,removethe connecting rod cap and bearing.

2. Wipethe bearings and crankpin clean of oil. Inspect the bearing for evidence of wear or damage.

3. Measurethe crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition the crankshaft. If within specifications and a newbearingis to be installed, measure the maximumdiameter of the crankpin to determine newbearing size required.

4. if within specifications, measurenew or used bearing clearances with Plastigage or its equivalent. [~ If a bearing is being fitted to an out-of-round crankpin, be sure to fit to the maximum diameter of the crankpin. If the bearing is fitted to the minimumdiameter and the crankpin is out-ofround 0.001 in., interference betweenthe bearing and crankpin will result in rapid bearingfailure.

Place a piece of gauging plastic the full width of the crankpin parallel to the crankshaft. (Note: Surfaces must be free from oil.) b. lnstall the bearing in the connecting rod and cap. c. Install the bearing capand evenly tighten nuts to specifications.

L[V°~el De not turn the crankshaft with the gauging plastic installed.

Eqg,ne/eng

7-21

d. Removethe bearing cap and using the scale on the gauging plastic envelope, measurethe gauging plastic width at the widest point.

5. If the clearanceexceedsspecifications select a new,correct size bearing and remeasure the clearance.

6. Coatthe bearing surface with oil, instalU the rod cap andtighten nuts to specifications.

7. Whenall connecting rod bearings have been installed tap each rod lightly (parallel to the crankpin) to makesure they have clearance. [~ 8. Measureall connecting rod side clearances (see Specifications at end of this section), betweenconnecting rod caps.

Piston, Ring and ConnectingRod Piston and Rod Removan 1. Removeoil pan, oil pump, and cylinder head. Turn crankshaft until piston is at bottomof stroke. Placea cloth on top of piston to colnect cuttings.

2. Before attempting to remove piston, ridge as necessary.

remove cylinder

47427

bore

Refer to General Engine Mechanicalsection in this manual for cylinder bore ridge reamer procedures.

3. Inspect connecting rods and connecting rod caps for cylinder identification. If necessarymark them. [~ 4. Removeconnecting rod cap and install tool J-5239 on studs. Push connecting rod and piston assembly out of top of cylinder block.

DR3792

[~ It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder.

Disassembly Refer to GeneraREngine Mechanical section in this manual for piston and connecting rod disassembly.

Assembby Refer to General Engine Mechanical section in this manual for piston and connecting rod assembly.

Piston and RodInstallation 1. Lightly coat pistons, rings and cylinder walls with light engine oil.

7-22

Erlgme/eng

2. With bearing caps removed,install bolts.

tool J-5239 on bearing cap

~] Check position of ring end gaps. They must be aligned with each other as described previously. See General Engine Mechanical 3. Install eachpiston in its respective bore, using tool J-5239 on each assembly. For valve cnearance, the teardrop in the piston faces up and the oil hole on the connecting rod should be to the center of the cylinder block. Guide the connecting rod into place on the crankshaft journals with the long detail of tool J-5239. [~] 4. Use tool J-8037 (~ to compressthe piston rings.

5. Install bearing caps and check the bearing clearance. Refer to GeneralEngineMechanicalsection in this manualfor connecting rod side clearance procedure.

Cylinder Block Cylinder Bore Inspect: Cylinder bores for scoring or other damage.Refer to General EngineMechanicalsection in this manual.

Measure: Cylinder bore taper and out-of-round. Refer to GeneralEngine Mechanicalsection in this manual.

Cylinder Bore Reconditioning Measure: Refer to GeneralEngineMechanicalsection in this manual.

Piston Selection 1. CheckUSEDpiston to cylinder bore clearance as follows: a. Measurethe "Cylinder Bore Diameter" with a telescope gauge2 1/2 in. (64 ram) from top of cylinder bore. b. Measurethe "Piston Diameter" (at skirt across centerline of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance." d. CaRculate piston to bore clearance and determine if piston to bore clearance is in the acceptable range.

2. If used piston is not acceptable, checkif a newpiston can be selected to fit cylinder bore within the acceptable range.

®

47437

3. If cylinder bore must be reconditioned, measurenewpiston diameter (acrosscenterline of piston pin), then honecylinder bore to correct clearancePreferablerange). Markthe piston to identify the cylinder for whichit wasfitted.

Handlethe pistons with care, and do not attempt to force themthrough the cylinder until the cylinder hasbeenboredto correct size as this type piston can be distorted through careless handling.

Circulating Pump [~ The Volvo Penta circulating pumpis manufacturedspecially for marineuse. It is serviced only as an assembly.Donot replace with an automotivecirculating pump.

11982

inspection Remove alternator and powersteering belts. Graspcirculating pumppulley and checkend and side play. Turn pulley to checkfor drag. Look for water leaking from indicator hole beneathpumpshaft behind pulley. Replace pumpif play, drag, or leakageare evident.

Removaland Installation 11981

1. Drain water from block and disconnectwater hose from circulating pump.

Remove pulley. Remove circulating pumpbolts, pumpand gaskets.

2. Use newpumpto block gaskets and sealer. Install newpumpassembly on cylinder block andtighten bolts as specified. Install pulley. Install alternator and powersteering belts, then adjust tension. Connecthoseto circulating pump.Lakeor tank test unit and checkfor leaks.

Front Engine Mount Replacement Removal

/ 11980

1. Removetwo lag screws @and washers from mounts. [~ ~ 2. Lift engine with 1500 lb. (680 kg) minimumcapacity hoist to allow removal of front mountand bracket. Removethree mount screwsand lock washers(~). ~] ~ Prior to disassembly of front mount assembly, measure distance betweenlarge washerand flat on upper mountbracket.

Disassembly [~ 1. Removethree nuts ©, one Iockwasher, and engine mountbracket @from mountbott (~b while holding bolt securewith socket.

7-24

11979

Eng,nezeng

[~ 2. Removeone large washer (~) one small washer @and engine mountbolt (~) from mount.

Reassembly ,1~ 1. Place small washer(~) on mountbolt and insert bolt up through mount.Install large washer(~ and securewith nut ©. Tighten to 60-75ft.

Ibs. (81-102 Nom). ~2. Install upper inner nut and place engine mountbracket on engine mountbolt. i~ Measure distance between large washer and flat on upper mount bracket. Distancemust be the sameas that prior to disassembly.

11978

3. Install lock washerandlower nut. Tightennut to 50-70ft. Ibs. (68-95N m).

Ilnstallation 1. Spray the engine mountscrewsthreads with Loctite ~ Primer N and allow lo air dry. Apply Volvo Penta TreadSealing AgentP/N 1161053-6to the screws. Attach engine mountassemblyto engine with three screwsand washers.Tighten to 32-40ft. Ibs. (43-54 N,m).

11983

;2. Install lag screwsandtighten securely.

Height Adjustment 17~1 To changeengine height, tighten or loosen nuts (~ and (~) required. /~2. Lift engine with 1500 Ib.(680 kg) minimumcapacity hoist.

Position engineat desired height.

I7"~ 3. After setting mountposition, turn nut g-~ up against undersideof engine bracket and hold nut with a wrench.Tightenupper nut ~) to 100-120 ft. Ibs. (136-163N=m).

2953

High-Rise Exhaust Elbow Replacement Removal [~ Drain water from respective exhaust manifold.

1. Loosentwo clampssecuring upper hose to elbow. [.8~ 2. Port Elbow- Remove four thru-bolts, lock washers,and washers.

Moveremoteoil filter aside.

28262

*

Gi Models:Movecrankcaseoil filler

and ESAbracket aside.

E~ ., GL Models:Loosenthe smalRscrew (~) attaching the ignition modulebracket, then Jilt moduleoff elbow. [~ 3. Starboard Elbow - Remove two thru-bolts (~), lock washers, and washersattaching circuit breaker bracket. Set bracket assemblyaside. [~4. Lubricate inside of exhausthose with a soapy water solution, then removeremainingelbowbolt. Tapelbowwith a soft hammer to free it, then twist it out of the hose. Remove and discard the manifoldgasket.

5. Port Elbow, GL ModelsOnly - Removeand retain small screw on inside of elbow.

28267

InstaRlation 1. Port Elbow, GLModelsOnly - Install small screwfrom original elbowon inside of newelbow. [~ 2 Apply Volvo Penta Gasket Sealing CompoundP/N 1161231-4 to both sides of a newgasket ©, and place it on the manifold. Lubricate inside of exhausthosewith a soapywater solution to easeelbowinstallation.

3. Twist elbowinto hoseandposition it on the gasket.Install the outer rear thru-bolt, washer,andlock washer,and turn it in finger tight.

E~4. Port Elbow- Position remoteoil filter

37349

at front of elbow.

o GL Models:- Set ignition modulebracket on small screw (~ on side of elbow. o Gi Models:- Mountoil fiEler and ESAbracketon elbow.

Install four thru-bolts, washers,andlock washersfinger tight. Tightensmall screwsecurely. ~5. Starboard Elbow- Position circuit breaker assemblyat front of elbowInstall two thru-bolts (~), washers,and lock washersfinger tight.

6. Tightenall elbowthru-bolts to 12-18ft. tbs. (16-24N®m). ~7. Properly position the two exhaust hose dampsand tighten them securely.

28265

E×haustHoseand intermediate Pipe Replacement Removal 1. Looseneight clamps that attach the upper and lower exhaust hoses, and slide clamps down onto exhaust Y-pipe.

[6~ 2. Lubricate inside of lower hose with a soapy water solution, and push lower hose down onto exhaust Y-pipe. ~7~ 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose with a soapy water solution for ease of removal 4~. Slide upper hose off high-rise elbow. Slide lower hose off exhaust Y-pipe.

Installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a soapywater solution. Slide it all the wayonto the exhaust Y-pipe.

28264

ES~2. Onthe inside of the 4 in. (10,16 cm) I.D. upper hose, there is a circular rib 1.5 in. (3,81 cm) from one end. Theribbed end the hose must face the intermediate pipe (rearward) whenit’s installed. Slide hoseonto high-rise elbowuntil it seats. NOTE:If hoseis not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment.

E7~ 3. With a twisting motion, insert intermediate pipe all the wayinto the upper hose. Slide the lower hoseup until it’s halfway onto the intermediate pipe.

4. Slide four No. 68 clampsup onto the upper hose. Slide four No. 64 clamps up onto lower hose. Position clamps in their proper channelsand tighten them secureOy.

16041

E:.xhaust (Flapper) Valve Replacement Removal 1. Removethe intermediate exhaust pipe folnowing the procedure under Exhaust Hose and intermediate Pipe RepOacement.

L=~ 2. Slide the lower hose downfar enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the valve.

19445

I’~ 3. Inspect the two rubber bushings inside the pipe, and =~eplacethem as necessary.

19444

Installation 1. If installing newrubber bushings,apply 3fvP ScotchGrip RrubberAdhesive 1300to outside of tips, and insert into inside of exhaustpipe. [~ 2. Position valve with longest lip pointing downand insert into pipe.

Pushpivot pin throughbushingsand vamveuntil pin end is flush with outside of pipe. ~lf valve is not positioned properly (long lip down),it will restrict exhaustflow and fail to prevent water backingup into engine. Vaive must also movefreely and not bind. Boat performancewould be adversely affected, and engine maysuffer water damage.

1944,3

3. Install intermediate pipe following procedureunder ExhaustHoseand intermediate Pipe Replacement.

EngineCoupleror TimingRing Replacement Removal 1. Remove engine from boat.

2. Disconnectall wires, lines and connectorsfrom beflhousing.

20034

[~ [~ 3. Removeseven screws securing bellhousing cover and s{1de coveroff. ~] 4. GL Models Only - Removenuts from sensor cover and remove cove r,

5. GL ModelsOnly - Remove nuts and washersand lift bellhousing.

sensor off

19996

19994

7-28

19993

Engme,eng

[6--7 6. Pull drain hoseout of bellhousing.

7. Removebolts and nuts retaining bellhousing. Disconnect ground wires and oil cooler bracket. Note oil cooler orientation.

I3. Remove bell housing.

[3 9. Use an offset box end wrench to remove the six nuts securing the coupler, and slide coupler off studs.

[8~ 10. GL Models Only - Removetiming ring from studs.

11. Removeold gasket from bellhousing surface thoroughly.

cover. Clean gasket

19842

Installation [9~ 1. GLModels Only - Place timing ring on crankshaft studs.

Mount so small hole (~ in ring lines up with locating pin ® in flywheel. NOTE:Timing ring must be correctly installed in order for ignition systemto function properly. If ring hole is not aligned with flywheel pin, engine wila exhibit one of several symptoms suchas ignition misfire, loss of RPMor power,or failure to start. f’l~ 2. install coupler and attach six Iocknuts. Use a suitable adaptor and tighten nuts to 40-45 ft. Ibs. (54-61 N.m).

19990

20037

20039

3. ~nsta~lbell housing.Attachoil cooler with sameorientation as notedin a previousstep. Tightennuts andbolts to 32-40ft. Jbs. (43-54N.m). Attach groundwires and tighten nuts to 15-20ft. Ibs. (20-27 N.m).

4. Pushdrain hoseinto betihousing.

EEl 5. GL Models Onay- Place sensor on mounting studs and press spring tab to allow properpositioning of sensorover timing ring. While holding spring tab depressed,install a washerand nut on each stud, and tighten both nuts to 48-60in. Ibs. (5-7 N.m). Recheck sensorposition after installation by depressing tab to seeif it contactstiming ring. If tab contacts ring, loosen nuts and reposition sensor. NOTE: If sensoris not properly installed, timing ring will contact sensorwhenengineis cranked.Sensorwill be damaged and will have to be replaced.

6. GLModelsOnKy- Placecover over sensor. Install two self-locking nuts andtighten to 48-60in. Ibs. (5-7 Nom).

7. Apply Volvo Penta Gasket Sealing Compound P/N 1161231-4to both sides of a newbellhousinggasket and position it on cover.

I~ 8. Cleansevenself-tapping screwswith a wire brush. Install bellhousing cover and screwsand tighten to 60-84in. Ibs. (7-9 N®m).

9. Connectall wires, lines andconnectorsto belihousing. Install enginein boat.

7-30

Engme/eng

EngineSpecifications 7.4 GL, Gi, GSi and8.2 GSi Type - No. of Cylinder ..................................

Valve Arrangement ..............................

Bore and Stroke: 7.4 models ..................

8.2 models ..................

90° - V-8 Overhead Valves

4.250 x 4.000 in. (107,95 x 101,6 ram) 4.468 x 4.000 in. (113,48 x 101,6 mm)

Piston Displacement 7.4 models ..........................

8.2 models ..........................

454 Cubic Inches (7.4 Liters) 502 Cubic inches (8.2 Liters)

Cylinder Numbers- Front to Rear Starboard ..............................................

Port ...................................................

Firing Order .....................................

Compression Ratio 7.4 GL ..................................................

7.4 Gi, GSi ...............................................

8.2 GL ..................................................

Water Temperature Control ...........................

Thermostat Opens @ ...............................

Full Throttle Operating Range 7.4 GL, Gi ....................................

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

8.2 GI ........................................

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

8.0:1 8.6:1 8.8:1 Thermostat 160°F (71 °C) 4200 - 4600 RPM 4800 - 5200 RPM 4400 - 4800 RPM

Pistons: Production Clearance 7.4 Models ................

0.003 - 0.004 in. (0,0762 - 0,1016 mm) 8.2 Models .................

0.004 - 0.005 in. (0,1016 - O,1270ram) Service Limit ...............................

0.005 in. (0,127 mm) Piston Rings: Top Groove Clearance .....

0.0012 - 0.0029 in. (0,0304 - 0,0736 ram) Second Groove Clearance . 0.0012 - 0.0029 in. (0,0304 - 0,0736 mm) Third Ring Groove Clearance . 0.005-0.0065in.(0,127-0,1651 mm) Service Limit ............................ +0.001 in. (+0.0254 mm) Top Ring Gap .................

0.010 - 0.018 in. (0,254 - 0,457 mm) Second Ring Gap ..............

0.016 - 0.024 in. (0,406 - 0,609 mm) Third Ring Gap ................

0.010 - 0.030 in. (0,254 - 0,762 mm) Service Limit .............................. +0.010 in. (0,254 ram)

7-31

Engmeteng

EngineSpecifications Piston Pins: Diameter ................

0.9895 - 0.9897 in. (2,5133 - 2,5138 mm) Clearance ...............

0.0002 - 0.0007 in. (0,0050 - 0,0177 mm) Service Limit ...............................

0.001 in (0,0254 ram) RodFit, interference fit .... 0.0031 - 0.0021 in. (0,0787 - 0,0533 ram) Connecting Rod: Bearing Clearance, New.. 0.0011 - 0.0029 in. (0.0279 - 0.07366 ram) Bearing Clearance, Service Limit ............

0.003 in. (0,0762 ram) Side Clearance ............

0.0013 - 0.023 in. (0,0330 - 0,5842 mm) Crankshaft: Thrust ......................

0.006 - 0.010 in.(

0,1524 - 0,254 mm)

Main Journal Q Main Bearing Clearance, No.l, 2, 3, 4 ..............

No. 5 ....................

New 0.00t7 - 0.0030 in. (0,0432 - 0,0762 mm) 0.0025 - 0.0040 in. (0,0635 - 0,0965 mm)

Main Bearing C~earance No. 1,2, 3, 4 .............

No. 5 ....................

0.0010 - 0.0030 in. (0,0254 - 0,0762 mm) 0.0025 - 0.0040 in. (0,0635 - 0,1016 mm)

Crankpin Diameter 7.4 GL ...................

2.199 - 2.1996 in. (55,854 -55,8698 mm) 8.2 GL .....................................

2.20 in. (55.88 mm) Taper and Out-of-Round, New ..............

0.0005 in. (0,0127 mm) Taper and Out-of-Round, Service Limit .......

0.001 in. (0,0254 mm) Camshaft: Camshaft Bearing Journal Q 1.9482 - 1.9492 in. (49,484 - 49,509 mm) 7.4 Models Lift, Intake ................

0.2343 __+ 0.002 in. (5,9512 _ 0,0508 mm) Lift, Exhaust ..............

0.2530 + 0.002 in. (6,4262 + 0,0508 ram) 8.2 Models Lift, Intake and Exhaust ...... 0.510 + 0.002 in. (12,954 _+ 0,0508 mm}

Englne/eng

7-32

EngineSpecifications Valve Systems: Lifter

Type ...........................................

Hydraulic

Rocker Arm Ratio 7.4 GL, Gi ...............................................

1.7:1 8.2 GL, 7.4 GSi ...........................................

1.7:1 Valve Adjustment ............................ zero lash + one turn ° Valve Angle ................................................

45 ° Seat Angle .................................................

46 Valve Seat Run-out ............... +0.002 in (0.0508 mm) Maximum Valve Stem Clearance Intake, New ..............

0.0010 - 0.0027 in. (0.0254 - 0,0270 ram) Exhaust, New ............

0.0012 - 0.0029 in. (0,0304 - 0,0736 ram) tntake, Service Limit ...................... +0.001 in. (0,0254 ram) Exhaust, Service Limit ..................... +0.002 in. (0,0508 ram) Valve Seat Width, Intake ........

1/32 to 1/16 in. (0,794 to 1,587 ram) Valve Seat Width, Exhaust ......

1/16 to 3/32 in. (1,587 to 2,381 mm) Valve Spring Length ..........................

2.15 in. (54,41 mm) Valve Spring Installed Height, Installed ......

1 51/64 in. (45,641 ram) Valve Spring Pressure Ibs. @ in. (kg @ mm)compressed.....

74-86@1.80 in. (33,5-39@45.72) Ibs. @in. (kg @mm) compressed . 195-215@1.40 in.(88.4-97.5@35.56) Installed Height ............................... + 1/32 in. (0,794 ram) Valve Spring Fit In Damper..........

0.042 - 0.094 in. (1,06 - 2,38 ram) Erlgine Lubrication: Type Oil Pump ..............................................

Gear Normal Oil Pressure, WarmEngine ......

10 psi (70,3 kPa) @500 RPM 40-60 psi (281-422 kPa) @2000 RPM Crankcase Capacity 8 qts (7,57 liters); 9 qts (8,51 liters) w/filter Oil Grade Recommended 32° F (0 ° C) and above ..................................

0° F (-17 ° C) to 32° F (0 ° C) .........................

0° F (-17 ° C) and below ................................

SAE 30 SAE 20W-20 SAE 10W

Werecommend Volvo Penta DuraPlusTMSynthetic Motor Oil, which is specially fo~’mulatedfor heavyduty marineuse, and ideal for Volvo PentaEngines.It provides better anti-wear qualities, especially during long high speedoperation. In addition, it neutralizes acids common to all internal combustionengines, offers superior corrosionprotection, andis formulatedto offer better resistanceto oxidation and high temperaturesludge formation.

Fuel Recommendation .............

See General information Section

7-33

Engme/eng

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

Camshaft Sprocket Circulating Pump Distributor Clamp Dipstick TubeFitting Flywheel Bellhousing Flywheel Cover Front Mount Bracket to Block Oil Filter BypassValve Oil Pan to Block Oil Pan to Front Cover Oil PumpCover Power Steering PumpBracket Rocker Arm Cover Starter Motor Thermostat Housing Timing Chain Cover

2O 3O 25 15-18 32-40 60-84 32-40 2O

26-30

160 70 80 60-90

30-36 12-16 96

7-34

27 4O 34 20-24 43-54 7-9 43-54 27 18,1 7,9 9 35-41 7-10 41-49 16-22 10,8

Englne/eng

’TorqueSpecifiications(cont,)

Connecting Rod Cap Exhaust Manifold Flame Arrestor Flame Arrestor Cover (GL Models) Flare-Dipstick Tube Flywheel Bellhousing Flywheel and Coupler Front Mount (Rower) Front Mount (upper) Power Steering PumpBracket

48 20-26 25-35 30-35 15-18 32-40 40-45 50-70 100-120 13-15

-

65 27-35 2,8-4,0 3,4-4,0 20-24 43-54 54-61 88-95 138-163 18-20

m Cylinder Head Step 1 Step 2 Step 3 Exhaust Manifold Front Mount Harmonic Balancer High-Rise Elbow nntake Manifold Main Bearing Cap (All) Oil Pump RemoteOil Filter Adaptor (to block) Rocker Arm Sensor and Cover

35 65 85 24-28 65-75 85 12-18 30 100 65 20-25 40 -

48-60

47 88 115 33-38 81-102 115 16-24 40 135 90 27-34 54 5-7

m Rywheel and CoupBer

10-15

Oil Filter Spark P~ugs

22

Eog,oo/eng

7-35

14-20

one turn after contact 30

Notes .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... ..........................................................................................

Section 8 Steering System

Table of Contents Mechanical (Non=power) Steering System .................................

Cable Installation .........................

Cable Removal ...........................

Lubrication ..............................

Sealants, Lubricants and Adhesives .........

Steering Tube Replacement ................

Trim Tab Adjustment .....................

Power Steering System ......................

Belt Adjustment .........................

Cable Installation ........................

Cable Installation Problems ...............

Checking Fluid Level ......................

Cylinder Installation .....................

Cylinder Removal .......................

Cylinder Servicing .......................

Description ..............................

Diagnosis Chart .........................

PowerSteering System.. (cont.)

External Leakage .........................

Feedback To Helm .......................

Hoses .................................

Hydraulic Fluid ...........................

Lubrication .............................

Pumpinstallation .........................

Pump Leakage ..........................

PumpOperation ..........................

PumpPressure Test .....................

Pump Removal ...........................

Purging Air From Steering System ..........

Sealants, Lubricants, and Adhesives ........

Special Tools ............................

Specifications-Torque ...................

Steering Without Power Assist ..............

System Diagnosis .......................

System Operation ........................

8-2 8=2 8-2 8=3 8-1 8=3 8-15 8-4 8-10 8=13 8=20 8-9 8-12 8-11 8-12 8=4 8-18

Special Tools Required:

Materials Required:

CrowfootWrench(steering cable anchor nut) P/N 9995443-08.2 GL PumpPulley Remover P/N 9995444-88.2 GLPumpPulley Installer P/N 3854367-4Volvo Penta Hydraulic CyTinder Rod Holder

Volvo Penta Grease VolvoPentapowertrim/tilt & steering fluid or GMPowerSteering Fluid Dexron,or DexronII

Safety Warnings Before workingon any part of the engine, read the section called Safety at the end of this manual.

Unlessinstructed otherwise, always disconnectthe battery cables from the battery before workingon electrical systemto prevent possible sparks or arcing in the engine compartment.

Before starting engine after repair or maintenance procedures,always makesure enginecompartment is free of fuel vapors to prevent possible fire and explosion.

Whenworking on an engine that is running or being cranked, use extremecare to avoid getting hands,fingers or clothing caughtin the alternator, powersteering pump,supply pump,and circulating pJmp belts, pulleys and other movingparts.

Eng,ne,eng

8-1

8-18 8-21 8-14 8-8 8=13 8-8 8-19 8-7 8-19 8=8 8=9 8=1 8-1 8-21 8-6 8-14 8-5

® 1864O

C02740

MechanicaU (Non-power)Steering System Description The mechanicalsteering systemconsists of a helm assembly(~, the steering cabJe(~), and attaching hardware© that connectthe steering systemto the inner transombracket and steering arm.

Steering Cable Removam Thesteering cable is serviced as an assembly°

6825

[~] l~ 1 To removethe steering cable, removethe cotter pin ~ and steering arm pin (~ securing the cable ram to the steering arm ®. Remove both steering arm bushings(~).

2. Turnthe helmto the port full lock position.

EEl 3= Loosenthe cable anchor nut (~, and removethe cable.

Steering Cable nnstagation I~ Steering tube position in the anchor block is preset at the factory for proper centering of the steering system.Donot loosen the jam nut or changethe position of the steering tube.

31837

~1. Turn the steering wheelto fully extend the steering cable ram to its maximum extension. Lubricate the full length of the steering cable ram with Volvo Penta GreaseP/N 828250-1.

2. Instal[ the steering cable ramthroughthe steering tube.

3. Whileholding the steering cable in the steering tube, thread the steering cable anchornut onto the steering tube until the steering cable anchornut bottomson the end of the steering tube.

2921

[~ ~ 4. Attach a crowfoot wrench (~ at a 90° angle to the torque wrench.Tighten the steering cable anchornut to 120 in. lbs. (14 N®m).

18653

8-2

Engme/eng

L_2~_E~5.Insert bushings~) into steering arm. Install the steering arm pin (~) throughthe top hole in the steering armand throughthe hole of the steering cable ram.

13 ~ 6. Install the cotter pin @through the steering arm pin and secureby spreadingthe endsof the cotter pin.

I~ 7. Turn the steering wheelto fully extendand retract the steering cable ram @.The steering arm shouJdmovefrom stop to stop as the steering rammovesfrom fully retracted to fully extended.Steering armmustnot contact inside of transomcutout in either direction. Checkfor equal clearance of steering arm.. Center the steering wheeland checkcentering of ,~teering arm. Readjustas necessary.

Steering SystemLubrication

3253

®

[8~/~ Lubricate the steering ram with Volvo Penta Grease PIN 828250=1every 50 hoursor 60 days, whichever comesfirst. [~ Dueto local conditions, it maybe necessary to lubricate your steering ramat morefrequent intervals.

Steering Tube Replacement 0R172

1. Loosenthe jam nut and screwthe steering tube out of the anchorblock.

Remove the jam nut from the steering tube.

I3 2. Screwthe jam nut (~ all the wayonto a newsteering tube.

®

[___9~___ 3. Measure 3¼in. (8,26 cm)(&) in fromthe endof the steering tube.

Cleanthe following 1 ¼in. (3,18 cm) of thread ~) with Loctite ~ Primer N and allow to air dry. Apply Volvo PentaTreadSealing AgentP/N t 181053-6to the 1¼in. (3,18 cm) lhread area ~).

IN 4. screwthe anchorblock onto the steering tube until the block is ,.35/32 in. (8,02 cm) ~ from the end. This dimensionpositions the steering tube for accurate centering of the steering system.

DR1727

5. Screwthe jam nut up against the anchorblock andtighten to 35-40ft. Ibs. (47-54N-m). Donot disturb the anchorblock position while tightening the nut. [~ ~ ~ 6. If the anchor block was removedfrom the transom plate, apply a small mountof Volvo Penta GreaseP/N 828250qto both bushings.

Install the b~ockwith the original screws.Tightenbothto 40=45ft. Ibs. (54=61 N~m).Securescrewswith two cotter pins. [~ Filling the bushing pockets with grease can cause the screws to hydraulically lock and break the transomplate whentightened.

Engme/eng

8=3

8012

8011

© ®

® @ DR2959

Power Steering

System

Description

® The oil cooler (~ is a heat exchangerthat uses engine cooling water to keep the hydraulic fluid cooL.

The power steering system consists of a mechanical cable from the helm to the inner transom plate, an engine mounted pump, and a power cylinder to movethe vertical drive steering arm.

o A high pressure hydraulic hose @carries fluid from the pump to the control valve, and low pressure hoses ~ and (~ carry the fUuid from the valve to the oil cooner, and back to the reservoir.

hydraulic pump (~ is mounted on the ~ The front of the engine and is belt driven by the

e The steering cable casing @attaches to the steering cylinder vanve.

crankshaft pulley. The reservoir fill dipstick attached.

cap has a

¯ The cable ram passes thru the valve and attaches to the clevis ®. The drive steering arm O is also attached to the clevis°

¯ Thecontrol valve and cylinder ® is a single unit mountedto the inner transom bracket.

8-4

CobrEng/eng

®

® _

_ ....

E

®

DR3007

DR3008

Pump Operation [3 During normal operation, fluid is drawn into dual pump intake ports @from the reservoir ®. The reservoir is supplied by a low pressure return line ~ from the power steering oil cooler.

The pumpoutput is thru ports (~. The vanes ® are held out against the pumpbore by pressure behind the vanes. The pump has sufficient output @to allow quick boat maneuverseven at engine idle RPM.The pumpoutput at high RPMis Rimited to about 2.3 gallons per minute by a flow restriction orifice ®.

The pumpoutput pressure is determinedby the resistance to flow of the system. Whenno steering changes are being made, the pressure will be about 50-100 PSt. Whenthere is steering input, the pressure will be higher and wilt dependon the steering forces required due to the boat attitude, drive trim position, throttle position and quickness of the maneuver.

[3~1 The pump is protected from very high pressures by a pressure relief valve @that is located in the pumpbody. ff the steering load becomesextremely high, the relief valve will open and limit the output pressure ® to about 1,000-1,100 PSI. [~ InternaB damageto the pump will occur if the system is operated at relief valve pressure for morethan a few seconds.

[4~ The pumphas a metric output fitting. metric fitting.

Use only a hose with a

2635

E ngme/eng

8-5

PORT

STARBOARD

DR3508

System Operation

PORT

DR3506

Steering To Pert - Steering WheelTurning To Left

No Steering input - Steering WheelNot Turning

Whenthe helm is turned to port (either turning boat to left or straightening from a right turn) the steering armis pulled to starboard. The steering cable casing pushes the valve spool ® to port. Fluid from the pumpenters the valve at ©, is routed to the rod-end outlet (~, and to the low voDumeside end of the cylinder ®. The pump pressure moves the piston and steering arm to starboard. Fnuid in the high volume side of the cylinder @is forced out thru the valve from @to return port ® and back to the reservoir. As long as the helmis turning to port this motion continues, swinging the outdrive to port.

Whenthere is no steering input from the helm, the spring (~ in the control valve keeps the spool (~ centered. Fruid from the pumpenters the control valve thru the pressure port ©, flows past both cylinder ports @and (~ with little restriction, then thru the return port (~ and back to the reservoir. There is a small equal force at both ends @ and ® of the cylinder and the cylinder does not move.

With no steering input, the outdrive is held in one position and the boat movesin a constant turn or in a straight line.

Whenthe helm input stops (steering wheel not turning), the steering cable stops pulling the steering arm to starboard, and the steering casing stops pushing the valve spool to port. When the spring (~ movesthe valve spool to a "centered" position, hydraulic fluid is again routed past both cylinder outlets. The steering cylinder has an equal force at both ends and stops moving. The steering system is then back to the No Steering input condition described previously.

8-6

Engme/eng

STARBOARD

PORT

PORT

DR3509

DR3507

Steering To Starboard- Steering Wheel ’TurningTo Right

Steering Without PowerAssist

~] Whenthe helm is turned to starboard (either turning boat to right or straightening from a left turn), the steering arm is pushedto port. The steering cable casing pulls the valve spool ® to starboard. Fluid from the pumpenters the valve at @and is routed to the piston-end outlet @and to the high volume side of the cylinder @. The pump pressure moves the piston and steering arm to port. Fluid at the low volumeside of the cylinder (E)is forced out and thru the valve from (~ to return port CF~and back to the reservoir. As long as the helm is turning to starboard this motion continues, swinging the outdrive to starboard.

Whenthe helm input stops (steering wheel not turning), the steering cabUestops pushing the steering arm to port, and the steering casing stops pulling the valve spool to starboard. When the spring @movesthe valve spool to a "centered" position, hydraulic fluid is again routed past both cylinder outlets. The steering cylinder has an equal force at both ends and stops moving. The steering system is then back at the No Steering input condition described previously.

STARBOARDSTARBOARD ’PORT PORT

I:ng,ne/eng

8-7

If the steering systemis not providing power assist, the operator maystill steer the boat.

Turning the steering wheel to port causes the steering cabDeto pull the steering arm to starboard. This causes the cable casing to push the valve spool ® to port against the stop about 0.125 in. (3,18 mm). The steering cable then transmits the full manualeffort to pull the steer= ing arm.

The fluid @aheadof the piston is forced out of the cylinder thru outlet @into the valve, and thru return port ® back to the reservoir. Additional fluid is drawnout of the reservoir thru the pressure inlet @and (~) to the opposite side of the piston ®.

Moresteering effort is required since all of the power required to steer the boat must be sup= plied by the operator, and additional force is required to movethe fluid through the system whenthe pumpis not operating.

Pump Removal E! 1. Place an oil drain pan under pump.Disconnect high pressure hose ~) and return hose (~) at pump.Donot lose O-ring on pressurehosefitting.

Securehoseendsin a raised position to prevent fluid draining from hoses.

Capor tape ends of hoses to keep out dirt° Drain pumpcompletelybefore removing. [~ ~ ~ 2. Loosen pump bracket drive belt.

mounting screws and remove

20497

¯ 3.0 Models

[~

o 4.3 and 5.7 Models e 7.4, 8.2 Models E~ 3. Take out mounting screws and removepumpfrom engine. [~ 4. Removepumppulley using a pulley remover, then remove mountingbracket.

23916A

PumpInstallation [~ 1. Attach mountingbracket to pump.Attach pulley using a pulley installer.

2. Mountpumpbracket loosely on the engine.

E~ 3. Makesure O-ring is in place and in goodcondition, then connect high pressurehosefitting (~). Tightenfitting to 15-26ft. Ibs. (20-35N®m).

4. Connectreturn hose ® to reservoir. Tighten hose clampto 12-17 in.

Ibs. (1,4-2,0 N®m).

20496A

5. Fill pumpreservoir with VolvoPentapowertrim~tilt & steering fluid. Bleed pump,hoses, and valve by turning pulley clockwise(as viewedfrom front of engine)until reservoir no longer showsair bubbles.Keepreservoir filled while purging air from system.

6. Install drive belt andadjust belt tension as describedunderBelt Adjustmentin this section. Donot pry against pumpreservoir while tightening belt.

7. Bleed entire system as outlined under Purging Air FromSteering System.

8-8

20510

Englne/eng

HydraulicFluid TM PowerTrim/Tint & Usean approvedpowersteering fluid such as DuraPlus SteedngFluid or GM’PowerSteeringFluid. If thesefluids are not available, any automatic transmission fluid labeled Dexronor DexronII maybe used.

CheckingFluid Level 1’7~] 1. Runengineand rotate steering wheellock-to-lock for a reasonably tong period of time to warmup steering fluid, then shut engineoff. Remove ,eservoir filler capandcheckif fluid level is at "HOT"markon dipstick.

20847

I~ 2. If fluid level is low, addrecommended hydraulic fluid to bring fluid up to "HOT"markon dipstick. Replacefiller cap.

Eel Donot over-fill a cold reservoir. Fluid could overflow whensystem reaches operating temperature.

Purging Air FromSteering System Whensystem componentshave been serviced, pumpmust be refilled with fluid before engineis started. Performthe following steps to purgeair from the steering system.

I~ Do not run pumpeven momentarily without fluid. ruined or severely damaged.

Pumpwill

20846

be

1. With engine"OFF,"turn helmall the wayto port. Addpowersteering fluid to bring fluid level to "COLD" markon dipstick.

2. Start engine, run momentarilyandshut off engine. Recheck fluid level and fill to "COLD"mark°Repeatthis step as necessaryuntil systemno longerrequiresaddit!onal fluid.

3. Completepurging of air from systemby starting engineand turning wheel slowly lock-to-lock. Maintainfluid level abovepumpbodyin reservoir.

20509

4. Returningfluid with air in it will often be in the formof foamandwill have a light tan or red appearance.

Maintainfluid level high enoughso foamis not drawninto pumpinlet. All air mustbe eliminated from fluid before normal steering action can be obtained. If excessivefoamaccumulatesin reservoir it mustbe removed,or let unit stand for an hour and repeat steps above.

5. After all air has beenpurged,return wheelto centeredposition. Continue to run enginefor several minutesand then shut engineoff.

31839

.~ngme/eng

8-9

6. Withengine"OFF"andwith fluid at normaloperatiingtemperature, recheck to make surefluid level is at "HOT" markon the dipstick.

7. Watertest the boatto make surethe steeringfunctionsnormallyandis free fromnoise.

PowerSteering PumpBelt Adjustment [~ "==~EEl With enginestopped,the belt shouldbe tight enough.so that it will deflect ¼"to ½"(6-13mm)whenpressed with the finger at the pointindicated(~. If the belt is too tight, excessive belt wearcanoccur.If it is too loose,slippagecanoccur,resulting in belt wearandpoorpower steeringoperation.Belt tensionshouldbe checked after 10 hoursof serviceandevery50 hoursthereafter.

23910

PowerSteering PumpPulley Circulating Pump Pulley ¼"- Y2" (6-13mm)Deflection Checkpowersteering pumpbelt tension O midwaybetweenthe circulating pumppulley (~ andthe powersteering pump pulley O. Retightennewbelt, or checkold belt after 10 hoursof serviceandevery50 hoursthereafter. ~Whenadjusting a power steering pumpbelt, never pry against the pump reservoiror pull againstthe filler neck.

DR4933

3.0 Models

m

m

Toincrease belt tension:- Loosen nut on lowerpivot bolt, andloosenscrewon bracebehindpulley. Place½" breakerbar into the squarehole in the pumpmountingbracket, andpivot pumpawayfrom engineas shown.Whilemaintainingpressureon pump,retighten all mountingscrews.Recheck belt tension.

24278

4.3 and 5.7 Models [~ E~ E~]To increase belt tension: - Loosenpumpmountingbracket screws,insert a ½" breakerbar into the squarehole in the pump mounting bracket, andpivot pump awayfrom engineas shown.Whilemaintaining pressureon pump,retighten all mountingscrews.Recheck belt tension.

7.4 and 8.2 Models [~ ~ [~ To increase belt tension: - Loosenmounting screws.

Rotatebottomof pumpoutwardby prying betweenthe harmonicbalancer andthe bottomtab of the powersteering pumpsupportbracket.

8-10

DR4935

20510 Engme/eng

© 16067

DR2859

20572

Steering Cylinder [7~] The steering cylinder assembly is a combination power cylinder and control valve. A piston rod clevis @provides the attachment to the steering arm and steering cable ram. The steering cable casing attaches to the threaded valve (~).

Cylinder RemovaJ [8~ 1. Turn helmto port full lock position. Remove the cotter pin @and the steering cable pin @.

20606

[3 2. Hold steering tube with wrench. Loosen steering cable anchor nut (~ and pull steering cable out of valve.

[1~] 3. Removecotter pin, then pull pin 0 out of clevis and steering arm.

I1~ 4. Removeboth hose fittings @from the valve. Raise hoses and cover the ends to keep out dirt. ~.~ Do not movecylinder rod in or out untB cyRinder has been drained completely. A dangerousspray of fluid can discharge from the cylinder ports if the rod is movedin or out.

20504

20583

Eng,ne/e.g

L~ Safety Related

8-11

®

5. Remove cotter pins (~) and loosen both anchor screws3 until steering cylinder assemblycan be removed.

Cylinder Servicing [~ 1 Pry out steering pivot bushings@if they are to be replaced. If necessarythey maybe carefutly drilled in two placeswith a 1/16 in. (1,5 mm)drill bit and then removed.

2. Newbushingsshould be lubricated and pushedinto place. [~ 3. The cylinder rod should be wrappedwith heavy paper or pasteboard and held in a vise with Holder, P/N 3854367-4 (~). To removethe clevis (~), unscrew the 19 mmIocknut ®, [~ ~ 4. To reinstall Ibs. (31=38N-m).

20576

clevis, tighten piston rod Iocknut (~ to 23-28 ft.

CylinderInstallation [~ 1. Install anchorscrews(~) flush with inside of inner transombracket. [~]2. Apply Volvo Penta GreaseP/N 828250-1to both bushings.

31842

~ Filling the bushing pockets with grease can cause the screws to hydrau}ically lock and break the transomplate whentightened. [~ ~ 3. Posit{on steering cylinder assemblyon inner transom bracket.

Align bushingsof steering cylinder with screws. Handstart both anchor screws to ensure alignment and engagement into bushings. Tighten anchor screwsto 40-45ft. Ibs. (54-61 N m). [~ Z~ 4. Install cotter pins (~) through holes in transombracket from transomside. Spreadendsof cotter pins to secure, @Do not movecylinder rod if cylinder contains any fluid° A danger= ous spray of fluid maydischargefrom the ports.

Eng,neJertg

8-12

20574

z~z3

®

20504

31837

28570

J~5. Connecthosesto cylinder. Start eachfitting by hand, Tighten pressurefitting (~) to 10-12ft. Ibs. (-4-16 N.m).Tightenreturn fitting (~ 15-17ft. Ibs. (2--23 N®m). [~ ~ 6. Pull steering arm (~ into hydraulic cylinder clevis @. Align holes and install large pin ® from top of arm. Securelarge pin by installing and spreadingends of cotter pin.

Cableinstallation E~ ~ 1. Turn the steering wheel to fully extend the steering cable ram to its maximum extension. Lubricatethe full length of the steering cable ram with Volvo Penta Grease.

20506

[~ 2. Retract steering cable ram (~ and insert ram through valve (~. [~ 3. Hold steering cable anchor nut back on cable casing to makecertain the steering cable is completelyseatedin end of valve. [’~4. While hoFdingsteering cable tight against valve, thread steering cable anchornut (~) onto valve until snug. ~ ~ 5. Hold cable tube with a 22 mmwrench on the flat @.

Attach a crowfoot wrenchat 90° to a torque wrench® and tighten the steering cable anchornut to a torqueof 120 in. Ibs. (14 N.m).

20606

6. Anigncable ram@with steering cylinder clevis (~) andinstall small pin from top of clevis. Securesmall pin by installing and spreading endsof cotter pin.

7. Fill systemwith fluid andremove all air. SeePurgingAir FromSteering System.

20605

20S07 Eng...... g

8-13

Lubrication ~ Every 60 days, grease the steering ram with Volvo Penta Grease P/N 828250-1 ~Dueto local conditions, it maybe necessary to lubricate your engineat morefrequent intervals.

Hoses ~Do not start

engine with any power steering hose disconnected.

31837

The pumpoutput fitting has metric threads. Do net attach a hose with SAEthreads to the pumpfitting.

After connecting powersteering hoses, makesure that there’s ample clearance betweenthe hoses and drive belts and other components.Hoses installed out of position mayrub during operation and be damaged.

If fluid return hoseis removedat pump,be sure to use a "wormdrive" clamp whenreinstalling it.

System Diagnosis Complaintsof faulty steering are frequently the result of problemsother than the steering cylinder assemblyor pump.Conditions such as hard or loose steering, or vibrations, are often related to suchfactors as the drive belt; pump andcylinder mounting;fluid level; or incorrect installation of the steering cable. Thesefactors should be checkedand corrected before disassemblingor replacing parts of the steering system.

System Checks Manyfactors affect poweroperation of the steering system. Someof the most commonproblem areas are: ¯ Fluid level.

Looseor worndrive belt, or oily belt. ® Steering cable jammedagainst somethingin boat at stern.

Steering cable too short or steering cable too long.

Loosely mounted components.

Loose pumppulley.

8-14

Engme/eng

After the problem has been found, determine the cause. For example,if the fluid level in the reservoir is foundto be low, refill and bleed the system and check the entire hydraulic system for leaks. Just refilling the reservoir will makethe unit operate, but will not correct the condition that causedthe problem.

Trim Tab Adjustment Models With Fower Steering 1 1~ Most power steering models are not equipped with trim tabs. If equipped,trim tab adjustmentis not required. Thetrim tab should be preset to dimension @3I/4 in. (83 mm), ° ® fo r left-hand rotation) and dimension@21/4 in. (57 mm),° @ for right-hand rotation). They should remain at this setting for all applications.

If the trim tab is NOTset correctly, movetrim tab to the correct position. Tighten the trim tab screwto a torque of 14-16 ft. Ibs. (19-22 N-m).

Models Without Power Steering "]’he boat maybe slightly easier to steer in one direction or the other due to steering forces or other reasons.To adjust, preset the trim to the dimensions above for models with power steering. ’Then checkby running the boat in a straight line with a balanced load in an area wherecurrent and wind will not be a factor. To obtain equal steering effort, adjust the trim tab as follows: Z~ Safety Warning: Improper trim tab adjustment can cause difficult steering.

1. Turn the steering wheel in both directions to determine the direction that requires the least amountof steering effort.

2. Loosenthe trim tab bolt and if less steering effort is required to port, movethe trim tab slightRy to port. If less steering effort is required to starboard, movethe trim tab slightly to starboard.

Twin engine installations require both trim tabs be movedan equal amountin the samedirection.

3. For twin engineinstallations wheretrim tabs are used, set both trim tabs to the s~meposition.

4. Retighten trim tab bolt and recheck steering effort in both directions. Repeatprocedureuntil steering effort is equal in both directions.

5. After final adjustment,retighten the trim tab screwto 14-16ft.

Ibs. (19-22 N.m).

Eog ......g Z~ Safety Related

8-15

Power Steering System Diagnosis Chart Condition

Possible Cause

Correction

SYSTEMNO~SE: Pumpnoise "chirp."

Loosebelt.

Adjust belt tension to specification.

Belt squeal.

Loosebelt.

Adjust belt tension to specification.

"Hissing" sound.

Somenoise exists in all power steering systems. "Hiss"may be expected whenturning the steering whee!, particularly at low speed.

None; a slight "hiss" is normal and in no wayaffects steering.

Rattle

Pressure hose touching other parts of powerhead.

Adjust hose position.

Rattle or chuckle.

Steering system looseness.

Checkcable nut and cylinder pivot points for wear or looseness.

Replace bushings if necessary.

Groan

Lowfluid level.

Find and repair leak. Fill reservoir and bleed system.

Fill reservoir, find and repair leak.

Check connections, bleed system.

Air in fluid.

Growl

Excessive back pressure caused by hoserestriction,

Locate restriction and correct. Replace part if necessary.

Pumpgrowl,

incorrect steering cable adjustment.

Cable to boat interference,

Adjust cable per procedure. Eliminate interference.

Whine in pump.

Pumpshaft bearing scored.

Flush system, replace pump.

SYSTEMOPERATION: Excessive wheel kickback Steering cable attachment loose. or loose steering (not boat wander).

Air in system.

Replace pin, Tighten steering cable anchor nut.

Steering wheel surges or jerks whenturning with engine running, especially during snow speed operation.

Loose pumpbelt.

Adjust tension to specification.

Air in fluid.

Fill reservoir, find and repair leak.

Bleed system.

Replace pumpif defective.

Momentaryincrease in effort whenturning wheel fast to right or left.

Insufficient

pumppressure.

Pumpbelt slipping.

Add fluid to pumpreservoir and bleed system. Checkall connections.

Lowfluid level.

Tightenor replacebelt. If oily, fix leak.

Fill reservoir and bleed system.

High internal leakage.

Replace pumpif defective.

8-16

CobrEng/en

Condition Hard steering or Jack of assist.

Possible Cause

Correction

High internal leakage. (Power cylinder or pump.)

Repmace pumpif defective.

Replacecylinder if defective.

Cable jacket movementrestricted (bulkhead, fuel tank, jammed against inside of hull).

Do not clamp cable tight near output end. Eliminate interference.

Loose pumpbelt.

Adjust belt tension to specification.

Lowfluid level in reservoir.

Fill to properJevel. If excessivelylow, checkall lines and joints for evidence of external leakage, torque to specs.

Lackof lubricant in lube points.

Lubricate, relubricate at proper intervals.

Excessivefriction in steering linkage.

Find reason for excessivefriction; relubricate or repair.

Cable has too tight a radius at output end.

Eliminate ,small radius.

Cable movementrestricted by tie straps, anchors, attached wires, etc.

Remove all cable anchors, tie straps, etc. on cabmebetweenlast bend and valve attachment point.

insufficient fluid pressure.

Replace pumpif defective.

Hard steering to starboard. Cable too long or movement restricted by bulkhead, etc.

Replacecable, or eliminate restriction.

Hard steering to port.

Cable too short or movement restricted by bulkhead, etc.

Replacecabbie, or eliminate restriction.

Lowfluid pressure due to restriction in hoses.

Checkfor kinks in hoses.

Removekink.

Foreign object stuck in hose.

Remove restricting hose.

object or repmace

Lowfluid pressure due to steering cylinder,

Pressure loss in cylinder due to worn Replace cylinder assembly. piston ring or scored housing bore.

Lowfluid pressure due to steering pump.

Loosebelt.

Adjust tension to specification.

Lowfluid level

Defective hoses.

Find and repair leak. Fill reservoir and bleed system.

Fill reservoir, tighten fittings and hose (:lamps. Bleed system.

Correct as necessary.

Pump worn or damaged

Flush system, replace pump.

Air in fluid and loss of fluid due to internan pumpleakage causing foaming and overflow.

Checkfor leak and correct. Bleed system. Keep fluid Bevel up whenvery cold. If fluid level is correct and pump stiln foams, replace pump.

Air in fluid.

Foaming milky power steering fluid, Bowlevel and possible low pressure.

CobrEng/eng

8" 17

External Leakage General Procedure 1. Wipe suspected area dry.

2. Checkfor over-filled reservoir.

3. Checkfor fluid aeration and overflow.

4. Checkhose connections - tighten if necessary.

5. Determineexact point of leakage.

6. Whenservice is required, replace component.

Leakage Checks Although someleaks are easily found, seepagetype leaks maybe difficult to pinpoint. Locate seepageleaks as follows: 1. With the engine off, wipe the complete power steering system dry (pump, hoses, and connections).

2. Checkthe fluid level in the pumpreservoir and adjust as directed.

3. Start the engine and turn the steering wheel from stop-tostop several times.

4. Find the exact area of leakage.

Easily Fixed Leaks 1. Loose clamp on pumpreturn hose.

2. Loosepumpor cylinder hosefitting, if fittings are not cross-threaded, tighten to correct torque. See Torque Specifications.

3. DamagedO-ring on pumppressure fitting.

Replace O-ring.

4. External leakage of power cylinder. Replace power cylinder.

5. Leakageof fluid in cooling water. Replaceoil cooler.

8. Damageor cracked hose. Replace hose.

If the return hose is removed,the dampmust be replaced with a wormdrive clamp. Replace leaky hoses.

8-18

CobrEng/eng

DR1443

DR3009

Pump Leakage [~ 1. An over-filled pumpreservoir can cause a leak. Thefluid in the steering systemexpandsas it heats up during normal usageand fluid level rises in reservoir. Excessfluid is forced through the breather cap hoUe where it may be sprayed over the engine by the drive belt. [’~ 2. Install newO-ring. Tighten hosefitting ~) to 15-26ft. Ibs. (20-32 N.m). If leakagepersists, replace pumpor hose as required. ~ 3. Check torque on fitting ®. Tighten to 37-75ft. Ibs. (50-102N.m}.If fitting is not loose, replace pump.

F~ 4. Check fluki level ©. if leakage persists with fluid at correct level and cap tight, replace cap or pump. [~ 5. Somenon-repairable pumpleakage areas are markedwith the oil-drop symbol. If leakage occurs in these areas, replace pump.

PumpPressure Test ~’~ 1. With engine off, disconnect high pressure (output) hose at pump. Use a spare pressure hose @to install Kent-Moore Tool J-5176 (~ between pump and steering cylinder pressure hose (~. Gauge must be positioned between shut-off valve and pump. Connectsteering cylinder pressure hoseto shut-off vaRve.Openshut-off valve.

Eng,ne/eng

~ Safety Related

8-19

2. Removefiller cap from pumpreservoir and checkfluid level. Fill pumpreservoir to full mark an dipstick.

Start engine, momentarily hold steering wheel against stop, and check connections at Tool J-5176 for leakage.

3. Bleed system as o,Jtlined From Steering System.

under Purging Air

4. Insert thermometer Kent-Moore Tool J-5421 into reservoir filler opening°Start the engineand movesteering wheel from stop-to-stop several times until thermometerindicates that hydraulic fluid has reached its normal operating temperature of approximatelyr150° to 190° F (65° to 88° C).

5. Checkfluid level; add fluid if required. When engine is at normal operating temperature, the pressure reading on the gauge (valve open) should be in the 50-100 PSI (345-690 kPa) range. if pressure exceeds specifications, check the hosesfor restrictions.

6. Pumprelief valve pressure can be checked by momentarily closing the shutoff valve. Do not leave vanveclosed longer than it takes to read gauge; high hydraulic pressures are developed.

Relief valve pressure is approximately 1000-1100 PSi (6895-7584kPa).

Replace pumpif fluid pressures or temperature do not meet specifications.

DR1450

DR1451

DR1452

Cable Installation Problems The hydraulic valve reacts to steering cable casing movement.

Total valve movementis about 1/4 inch° This small motion is sufficient to operate the valve and direct hydraulic pressureto the appropriate side of the steering cylinder. Any restriction of movement of the steering cable casing at the stern of the boat wilt limit or restrict the movement of the valve and will result in hard steering in one or both directions.

Whenreplacing the steering cable, the following points must be followed for proper power steering system operation:

DR1453

I~ 1. Do not install a cable that is too short, inadequatelength will put tension on the cable casing, and cause binding of the steering cable. This will restrict valve movement,cause hard steering to port and a tendency to self steer to starboard.

I~ 2. Donot install a cable that is too long. Excessivelength will push on the cable casing, and causebinding of the steering cable.

This will restrict valve movement,cause hard steering to starboard and a tendency to self steer to port.

3. Do not position steering cable in a sharp bendof less than 6 in. radius. Tight bends will cause binding and limit control valve movement.This will contribute to hard or uneven steering, or rough steering wheel movement.

DR5643

4. Do not jam anything against cable at the engine end. Do not bind cable against inside of boat or against fuel tanks, battery boxesor flotation blocks. Jamming the steering cable will restrict steering cable movementand cause hard steering.

I~ 5. Do not interfere with or restrict steering cable movement through the last 90° of bendto the engine. Cableretainers, clips, clamps or tie straps should not be used in a mannerthat will restrict the cable movement near the engine. Do not attach wiring harnessor control cables to this end of the steering cable.

DR5~A

/~ Do not restrict steering cable casing movement.

Any restriction of the cable also restricts the valve movement.

This ,will limit or stop hydraulic assist, or mayho|d the valve in one steering mode.

Safety Related

8-20

Englne/eng

FeedbackTo The Helm The steering system requires at least a little friction in the helm (and cable) to prevent hydrodynamic forces on the gearcase from feeding back and turning the steering wheel without the operator activating the powerassist system. This mayhappenon single engine installations (or on twin engines having both drives rotating in the samedirection).

Runthe boat in a straight line in opposite directions at normal cruising speed with the drive trimmed in both a "bow up" position and in a "bow down" position. In each trim position, momentarilyrelease the steering wheel to see if the wheel is turned by the gearcase, and in which direction.

If the steering wheel turns to both starboard and port, then helm friction must be increased slightly. This will allow the powersteering system to hold the desired steering position. ~ If the helm always turns in one direction (when it turns), it may be caused by steering cable that is too short, too long, or has restricted movement. See Cable Installation Problems. Twin engine problems may be corrected by adjusting the tie bar for "toe-in" (~ or for "toe-out" ® of the vertical drives.

Specifications PowerSteering PumpRelief Valve Pressure ....................

1000-1100psi (6895-7584kPa).

TorqueSpecifications Component

Torque

Anchor Screw - Cylinder assy. to TransomPlate

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

Bolts - Power Steering PumpMounting Bracket

25 ft. Ibs. (34 N.m)

Bolts - Power Steering PumpMounting

25 ft. Ibs. (34 N.m)

Fitting

- Power Steering Pump

37-75 ft. Ibs. (50-102N.m)

Fitting

- Power Steering PumpHose

15-26 ft. Ibs. (20-35 N-m)

Fitting - Inlet Control Valve Hose

10-12 ft. Ibs. (14-16 N.m)

Fitting - Outlet Control Valve Hose

15-17 ft. Ibs. (20-23 N.ml

Hose Clamps - Oil Cooler and Power Steering Pump

12-17in. Ibs. (1,4-2,0 N.m)

JamNut - Anchor Block

35-40 ft. Ibs. (47-54 N-m)

Locknut - Piston RodTo Clevis

23-28 ft. Ibs. (31-38 N.m)

Nut - Steering Cable Anchor

120 in. Ibs. (14 N.m)

Screw - Trim Tab

14-16ft. Ibs. (19-22 N.m)

Engme/eng

8-21

Notes .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... ..........................................................................................

Section 9 Throttle andShift ControlSystems

Table of Contents

ilnstailation of SAECables Engine and Shift Cable Routing .................................

Shift Cable to Drive ...........................................

Throttle Cable to Engine .......................................

Replacement of RemoteControl Cables ..........................

9-2 9-3 9-5 9-6

Materials Required

Volvo Penta Grease MolybdenumGrease

Z~ Safety Warnings Before working on any part of the engineorrelated systems,read the section called Safety at the endof this manual.

Unlessinstructed otherwise, alwaysdisconnectthe battery cables from the battery before working on electrical systemto prevent possible sparks or arcing in the engine compartment.

Before starting engine after repair or maintenanceprocedures,always make sure enginecompartment is free of fuel vaporsto prevent possible fire and explosion.

Whenworking on an engine that is running or being cranked, use extremecare to avoid getting hands,fingers or clothing caughtin the alternator, powersteering pump,supply pump,and circulating pumpbelts, pulleys and other moving F~rts.

Shift and Throttle Cable Routing 1. If the remotecontrol shift andthrottle cablesare installed in the remote controls, proceed to CheckRemoteControl Shift Cable Stroke= 2. If the remotecontrol shift andthrottle cableshavenot beeninstalled, the following procedurewill permit you to order the correct length remote control shift andthrottle cables.

3. Measurethe proposedroute of the remotecontrot shift and throttle cables. All bendsmust havea radius greater than 6 inches (15,2 cm). ¯

Remotecontrol shift cable: Add(~+(~ plus 20 in. (50,8 cm), roundup to next cable length.

/ L T

® Remotecontrol throttle cable: Add(~)+(~)+© plus 4 (10,1 crn), (© is to center of throttle armpin). Roundup next cable length. ~Whenremoving shift and throttle cables from the packing box, DO NOTbendthe cables tighter than a 6 inch radius.

®

___Y_

9-2

Englne/eng

Lll

34045

34044

34041

Installation of SAECablesto Engine/Drive Shift Cableto Drive Unit installation

i-aote__l Remotecontrol shift and throttle cables must be SAEtype cables Notei 1. If the throttle cable is attachedto the throttle armandanchor block, removeit from both. The throttle cab}e must be disconnectedfrom the throttle armprior to shift cable installation andadjustmentto prevent "loading" the control boxand adverselyaffecting shift adjustments. [’~ 2. Notethe position of small seal (~) andlarge seal (~) on the shift cable. Remove and retain jam nut, small seal, and large seal from the shift cable.

34039

[~ 3. Apply a light coating of Volvo PentaGreaseto the end of the remote control shift cablecasing. S{ide shift cablethroughshift cabletube until it appearson the outside of the transom.

L"~4. For easeof installation of shift cable, turn drive unit to port. Reim stall the retained large seal ~) and small seal (~ onto the shift cable in the sameposition as noted in step 2.

5. Loosencable clamp screw @and pull clamp out.

34037

L.~ 6. Slide shift cable throughpivot housingand frive unit.

7. Slide clampin fully, engagingthe shift cable anchorgroove. ,~(~CAUTION:Tighten clamp screw securely.

34038

34427

34421

34425

[~ [~ 8. Rotate shift lever to extend bellcrank @. Remove cotter pin, flat washer,and anchorpin (~).

9. Threadanchorpin halfway onto remotecontrol cable end. [~10. Rotate shift lever back to neutral detent position, then moveremote control handleto its neutral detent position. Turnanchorpin IN or OUT until it aligns with center of bellcrankslot ®. [~] Z~ 11. Install flat washerand cotter pin. Secure by spreading end of cotter pin InstaJl jam nut ~) and tighten securely against cotter pin.

SX Models Only [~12. For left handrotation propelners: the bellcrank link must be installed into the starboardhole (~) of the shift lever. [~ 13. For right hand rotation propellers: the bellcrank link must be installed into the port hole (~ of the shift lever.

34426

344,20

9-4 34423

3403(}

34423A

34419

I.--~ [~ 14. To reposition bell crank link, removecotter pins ~) and pin (~) lrom clevis, then rotate linkage © out of bell crank.

13~ [~ 15. Install linkage © into oppositeside of bell crank. Install washerand cotter pin ~). Position clevis on starboardside of shift lever andinstall pin (~) andcotter pin (~).

[5~ 16. Reinstall rea.r cover and securewith three original screws@.

Throttle Cableto EngineInstallation 34031

[NO----0~ Moveremotecontrol handle to NEUTRAL detent position. Turn propeller shaft and shift into the FORWARD gear detent position, then pull HALFWAY BACKtowards NEUTRAL. This positions the control for proper throttle cable adjustment.Failure to follow this procedurecan bind the shift linkage in the control, andproduce"hard shifting." [~6=~1. Align internal ~ooss(~ of trunnion with throttle cable groove(~.

Presstrunnion on throttle cable until seated. [~ [~ Carbureted Models Only: Engine anchor bracket may have two sets of anchorblock holes. The top set (marked)is for the 4V carburetor models,and the bottomset is for the 2V carburetedmodels.

34112

[~ ~ 2. Install open end @of trunnion in anchor block. Install screw in anchorblock andposition throttle cable assemblyin selected set of holes.

Nut (~) mustbe against the anchorbracket, tighten securely.

®

34751

Eng,ne/eng

9-5 DR4977

®

DR4978

DR4979

DR4980

~’~ /~ 3. Install throttle armconnectoronto the throttle cable. Pull connector froward~) to remove all endplay fromthrottle cable, thenturn the connector in until holesalign with the throttle arm@.Throttlearm connector (~) musthavea minimum of 9 full turns of 1/~ in. of throttle cable thread engagement.

[Note~If throttle armconnectorhole cannotbe adjustedto align with the throttle arm,checkfor propercableinstallation in the remotecontrolbox.

Carbureted Models: Install connectorontothrottle arm.Install washerandcotter pin ®, andsecureby spreading endof cotter pin.

Tightenjamnut (~ againstconnector.

34426

Replacementof RemoteControl Cables Shouldit become necessaryto remove or replacethe remotecontrol cables,the attachment at the engineis veryimportant.Followthesesteps for removalandinstallation of remotecontrol cables.Beforebeginning,shift remotecontrol handleinto NEUTRAL detent position; propeller should rotatefreely.

Throttle Cable RemovalFromEngine [~ 1. Remove cotter pin andflat washer(~ or lock nut (~ fromthrottle arm.

3,$424

[~ 2. Loosenanchorretainer nut ® and rotate retainer @awayfrom cabletrunnion.Remove throttle cablefromthrottle armandanchorbracket.

Shift CableRemoval FromDrive 1. Remove sterndrive rear cover. Remove flat washerand cotter pin from anchor pin. Removejam nut ® from shift cable core w[reo 2. Removeanchor pin @from bell crank slot. Unscrewanchor pin from shift cable core wire°

34038

[] 3. Loosenscrew and slide retainer out of shift cable anchor groove. Removethe shift cable from drive and transomshield.

Eng=ne/eng

Installation Of Shift andThrottle Cables 1. If the remotecontrol shift andthrottle cablesare installed in the remote controls, proceed to Check RemoteControl Shift Cable Stroke.

2. If the remote control shift and throttne cables have not been instaIMed, the following procedure ,will permit you to order the correct length remotecontrol shift and throttle cables.

[6~ 3. Measurethe proposed route of the remote control shift and throttle cables. All bends must have a radius greater than 6 inches (15,2 cm). e Remotecontrol shift cable: Add ®+(~) plus 20 in. (50,8 cm}, round up to next cable length. e Remotecontrol throttle cable: Add ®+Q+~)plus 4 in. (10,1 cm), (@ is to center throttle arm pin). Roundup to next cable length. [~ Whenremoving shift and throttle cables from the packing box, DONOTbend the cables tighter than a 6 inch radius.

]U !

A

B

(K) I I

_L DR4939

En,gino/eng

9-7

Check RemoteControl Shift Cable Stroke [~ Control cable should "PULL" for forward gear.

1. Moveremote control handle into the forward gear, wide open throttle position. Pull out cable core wire to removeend play° Mark cable core wire at end of casing. [~ 2. Return remote control shift handle to the neutral detent position. Measureand record the distance betweenmark (~) and end of casing. This dimensionis the shift cable stroke for forward gear.

36560

[~ 3. Mark cable core wire at end of casing with control in the neutral detent position.

E~ 4. Movethe remote control handle into the reverse gear, wide open throttle position. Pushin on cable core wire to remove end play. Measureand record the distance between mark ® and end of casing. This dimensionis the shift cable stroke for reverse gear. ¯ The distance between forward and neutral must be no less than 11/4 in. (31,8 ram} andno greater than 13/8 in.

(35,0 ram). ¯ The distance between neutra~ and reverse must be no less than 11/4 in. (31,8 ram)and no greater than 13/8 in.

(35,(} ram).

3656~

Checkyour remotecontrol installation instructions, if your measurements are not within these specifications. Makesure the cables are attached correctly inside the control box before continuing. All control boxes must meet these minimumand maximum specifications in order for the shift systemto function properly.

Should it become necessary to remove or replace the remote control cables, the attachment at the engine and vertical drive is very important. Follow these steps for removal and installation of remotecontrol cables.

Removal of SAE Remote Control Cables

36562

7

Before beginning, shift remote control handle into Neutra| detent position; the propeller should rotate freely.

365S3

SafetyRelated

9-8

Englneseng

Section 10 Cooling System Table of Contents Components Circulating Pump- Engine ..................................

Hoses, Clampsand Drain Plugs .............................

Manifold and Elbows ......................................

Thermostat ..............................................

Sherwood Raw Water Pump................................

Johnson Raw Water Pump..................................

Description ...............................................

Draining Engine Block or Exhaust Manifold ...........................

Pivot Housing ............................................

PowerSteering Oil Coolers .................................

Sherwood Raw Water Pump................................

Johnson Raw Water Pump..................................

Thermostat Replacement ...................................

Troubleshooting isolating Problem ..........................................

Possibilities to Consider ....................................

Problem Checkpoints .......................................

Quiz the Customer .........................................

Water flow Diagrams Drive Unit and TransomShield ...............................

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

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

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

5.7GL and GS ............................................

5.7Gi ....................................................

7.4GL ...................................................

7.4Gi, GSi ................................................

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

10-17 10-16 10-17 10=16 10=18 10-21 10-2 10-23 10-24 10-24 10-18 10-21 10-25 1 0=4 10=4 10-6 10-3 10=8 1 0=9 10-10 10-11 10=12 10-13 10-14 10=15 10=15

Safety Warnings Before workingon any part of the engine, read the section called Safety at the end of this manual.

Unlessinstructed otherwise, always disconnectthe battery cables from the battery before workingon electrical systemto prevent possible sparks or arcing iq the engine compartment.

Before starting engine after repair or maintenanceprocedures,always make sure enginecompartment is free of fuel vaporsto prevent possible fire and explosion.

Whenworking on an engine that is running or being cranked, use extremecare to avoidgetting hands,fingers or clothing caughtin the alternator, powersteering pump,supply pump,and circulating pumpbelts, pulleys and other moving parts.

EngineJeng

10-1

Description Water is supplied to the engine by meansof an impeller type pump (supply pump). The water supply pump is mounted on the engine. Water supplied to the engine is circulated in the engine by meansof a centrifugal type pump(circulating pump).

The supply pumpused on all models is a self priming impeller type pump, mounted on the engine and belt driven. During low speed operation the impeller functions as a positive displacement pump. At higher speeds it functions as a combination centrifugal and positive displacement pump.

The shape of the housing and liner cause an eccentric action of the impeller blades during engine operation. During periods of high speed operation, the resistance of the water on its way through the pumpis sufficient to prevent the ends of the impenler blades from making contact and following the inside perimeter of the pump housing. The blades merely flex in toward the center of the impeller to perform as a combination centrifugal and positive displacementpump.

10-2

All Models: The circulating pumpis mountedon the front of the cylinder block. It has a pulley bolted to the pumpshaft hub at its forward end.

This in turn is driven by meansof a belt from the crankshaft pulley. The pumpshaft and bearing assembly is pressed in the water pumphousing.

The bearing is permanently lubricated during manufactureand sealed to prevent Rossof lubricant and entry of dirt. The pumpis sealed against coolant leakage by a non-adjustable seal assembly pressed into the pumpcover.

Cooling water for the engine is picked up at the water intakes on both sides of the lower gearcase. Water is pulled upward thru the lower gearcaseuntil it enters a water tube that transfers it to the upper gear housing.

Water is pulled through the upper gear housing water passage where it meets a nipple and hose attached to the pivot housing. Water is routed through the transom mount assembly to a tube that’s mountedon the inside of the gimbal housing. Fromthis tube the water is drawnthrough a supply hose that’s connectedto the inside nipple of the supply pump. Water exits the outside nippge of the supply pump under pressure and carried through a hose to the inlet nipple of the thermostat housing.

Englne/eng

All Models: The water is now carried downward through the thermostat housing where it enters the flexible hosewhich attaches to the inlet pipe of the circulating pump.This inlet pipe is a part of the pumpcover and feeds the coolant into a low pressurearea located at the axis of the impeller.

Vaneson the rotating impeller cause the coolant to be thrown outwardand into the cylinder block.

In the event the engine cooling water is cold, as in first starting up, the thermostatwill be closed and will not allow any of the water to pass through for eventual discharge overboard. Instead, the water will be carried via the flexible hose back to the circulating pumpfor recirculation within the block. While the water within the block is recirculating, the supply pumpis pumping water to the block.

The cooling water flows rearward through the water jacket which surrounds each cylinder and extends below the lower limit of piston ring travel. After flowing the full length of the cylinder block, the water is forced upward through two passagesand into the cylinder head(s). The water nowflows forward in the cylinder head(s) cool the combustion chamberareas.

Since this water is not able to enter the cylinder block, it is necessary to provide a method of discharge. This is provided by the bypass passage within the thermostat housing, ff this were not provided, the resulting water pressure would be enoughto force the thermostat off its seat, resulting in a greatly increased warm-upperiod.

At the forward end of the cylinder head(s), the water enters the thermostat housing. If the water within the block is sufficiently warmedup, the thermostat will be open and a portion of the water will be pumpedupward past the thermostat. The remainder will be returned via the flexible hose to the water pumpfor recirculation within the powerhead. The water which was pumpedupward past the thermostat will enter the hose(s) connected to the thermostat housing outlet(s) and travel to the manifold(s).

Cooling SystemTroubleshooting 1. Quiz Customerfor the Following Information: a. How old is unit, how many hours of operation? (Wear and corrosion.) b. Hovv long has problem existed? (Gradual or sudden..)

At this point the water flows rearward through the manifold passages and into the high-rise elbow. All of the water that enters the high-rise elbow is mixed with the exhaust gases prior to entering the exhaust pipe(s) and hose(s). mixture of exhaust gases and water then enters the exhaust passages of the gimbal housing, pivot housing and vertical drive whereit is discharged under water.

Engme/eng

Co

d.

Whatwere the operating conditions prior to problem?(Fresh or salt water, silty or sandy water.)

Whatprevious repairs and service have been madeon unit? (Tune-ups, impeller replacement, etc.)

e. At what RPMdoes problem occur? (Low, high.)

10-3

2. Possibilities To Consider: a. Temperature GaugeMalfunction. ® Improper or defective sender unit ¯ Malfunctioning gauge - Checkground wire - substitute good gauge. b. Engine Water Circulation PumpMalfunction. ¯ Loose alternator belt e Impeller vanes worn - replace pump. e Impeller shaft seal failure - replace pump. c. Water Intake ScreensBlocked. d. Ventilation - Marinegrowthon keel, hull deformities, etc. e. Ignition Timing o Running with retarded timing - Checktiming.

3. Isolating CoolingProblem:

a. Procedure - Replace water hose between thermostat housing and the supply pumpwith clear plastic hose.

Operateunit in test tank or boat in water at RPMat which overheat occurs.

If operating unit in test tank, run motor in neutral. Some test tanks maynot have sufficient water volumeto allow running engine in gear without creating turbulence. This can be picked up by the water intake and misconstrued as evidence of a cooling problem. b. Results and Conclusions - No bubbles in hose, air/ exhaust is not entering cooling water. Bubbles in hose, air~exhaust is entering cooling water. c. Checkfor - Defective lower gearcase water tube guide and seals; damagedwater tube grommet; leaking water passagecover gasket or adaptor-to-gear housing gasket.

10-4

Engme/eng

ao

b~

C.

-

Procedure- Disconnect water supply hose from transom bracket at thermostat housing. Operate engine at specified idre RPM.Hold end of hoselevel with the top of the flame arrestor.

Resultsand Conclusions - A 1 inch (2,5 cm) head of water discharge, water supply is good. If less than 1/2 inch (1.2 cm), look for source of water loss.

Checkfor - Blocked intake screens; damagedimpeller housing O-ring or impeller plate gasket; broken or worn impeller; defective pivot housing water passageO-ring or water drain screw seal; loose pivot housing-to-gimbal housing water hose clamps. ,

o ¯

, - overheating or slow warm-up"

a. Procedure- Operate engine until indicated temperature exceeds 160° . Touch hoses between thermostat and exhaust manifolds. b. Results and Conclusions- Hoses cold, thermostat is stuck closed. Hoseswarmor hot, thermostat is good. c. Checkfor - Thermostat stuck open or closed, defective thermostat O-ring, correct thermostat style for engine type, clear thermostat housing bypass passage.

~

- overheating or hard starting

a.

b.

C.

Procedure- Allow engine to cool. Replace water hose(s) between thermostat housing and exhaust manifold(s) with clear plastic hose. Operate unit at RPMat which overheat occurs.

Results and Conclusions - No bubbles evident, head gaskets not leaking. Bubblesevident, head gaskets leaking.

Check for - Cylinder compression using appropriate tester, water in engineoil, water in cylinders, spark plugs wet with water.

E~g,n~.’e~

10-5

ProblemCheckpoints: Numbersrefer to Cooling System Flow Diagrams.

O intake Screen - Blocked with debris. (~ Water Tube Guide and Seal - Improperly sealed. (~) Water Tube- Pluggedwith debris. (~ Grommet- Deteriorated, improperly seated. ~) Upper Gear Housing - Debris blocking damaged.

passage, freeze

(~)Pivot Housing Seal - Damaged,out of position, sealed. (~ Nipple O-ring - Out of position, aged.

improperly

improperly sealed, dam-

(~) Nipple - Blockedby debris, freeze cracked. (~)Water Hose and Clamps- Clamps loose, hose collapsed or leaking. (~ Transom Mount Water Tube - Blocked by debris.

Supply Pump(Engine Mounted} - Failed seal, corroded or bad bearings, eroded impeller, leaking mounting gaskets or backing plate. [~) Thermostat Housing- Corroded, restricted, ket.

or leaking gas-

Thermostat - Defective thermostat, or wrong type for engine; improperly seated or damagedO-ring.

Belts- Loose, or "worn and slipping.

Circulating Pump(Engine}- Failed seaB, corroded or bad bearings, eroded impeller, leaking mounting gaskets or backing plate.

10-6

Eng,ne/eng

[~] Cylinder Block WaterPassages- Corrosion, slag, blocked passages,or leaking core plugs. {~ Cylinder Head- Corrosion, slag, blocked passagesor leaking gaskets.

ExhaustManifold, Elbows, Gaskets, and Hoses- Gasketsimproperly installed; corrosion, sand, or slag in manifoldand elbows;hosescollapsed, burnedthrough, or leaking. {~ ExhaustPipe and Seal - Improperlysealedor installed, lea.king. {~ Bellows, Clamp,and Retainer - Looseclamp, detachedor torn bellows. {~ PowerSteering Cooler - Restricted, or crackedand leaking. {~ Intake Manifold- Crackedcasting, or leaking gasket(s). {~ EngineOil Cooler- Restricted, or crackedand leaking. {~ 7.4Gi, GSi, and 8.2GSi Models: CheckValve - WaterBy-pa:ss Hose- Pluggedwith debris.

In addition, check: ® Ignition Timing *

BoatHull - Conditionof hull, marinegrowth, or underhull equipment.

Fittings protruding through hull maycauseair bubblestreamswhich can be picked up by the lower gearcaseand mixed with incomingcooling waLerto cause an overheat condition.

Eng,ne/eng

10-7

® Water In ®To Thermostat Housing © Return From Exhaust Pipe (~Exhaust and Water Out

Vertical Drive and TransomBracket All Models DR6252 1 0-8

Engme/eng

@ FromTransomBracket @ Water Flow With WarmEngine (c~BypassPassage @ WaterFlowWith ColdEngine

%

®

3.0 GS Models ~;oQ,~e,eog

1 0-9

® DRC671

(~) From TransomBracket (~)Water Flow With WarmEngine © Bypass Passage @Water Flow With Cold Engine

~

~¢’ __ ~ .~..I

4.3 GL and GS Models DR6374

® From Transom Bracket ® Water Flow With WarmEngine © Bypass Passage @ Water Flow With Cold Engine

4.3 Gi Models Englne/eng

10-11

DRC6717

® ® © ®

From Transom Bracket Water Flow With WarmEngine Bypass Passage Water Flow With Cold Engine

®

®

5.7 GL and GS Models 10-12

® DRC6716 Engme/eng

® ® © ®

From Transom Bracket Water Flow With, WarmEngine Bypass Passage Water RowWith, Cold Engine

5.7 Gi and GSi Models 10-13 Eng,ne/eng

DRC6718

® From Transom Bracket (~)Water Flow With WarmEngine @ Bypass Passage @WaterFlow With Cold Engine

\

@

/

/

7.4 GL Models DR6379

® ® © ®

From Transom Shield Water Ftow, WarmEngine Bypass Ps~ssage Water Flow, Cold Engine

/

/

®

7.4,

8.2

Gi,

GSi

IVlodels

......

Cooling SystemComponents For all modeis.Nospecialtools required. inspection Procedure:Examineall external cooling system components for leaks, wear, deterioration, and damage.Checkall connectionsfor tightness. Inspect hosesfor cracks, checkingor deterioration.

RepairProcedure-Repair or replace as required.

N~--0-te--] Watersupply hosesusedfor replacementmustconformto S.A.E. 20R3, crass D-2.

¯

°All ModelsExcept 7.4 GLand Gi: A 160 thermostatis standard.

® °7.4GL Gi, GSi and 8.2GSi Models: A 140 thermostatis standard. inspectionProcedure:Checkfor proper rating and style, corrosion, restricted movement, or brokenspring.

DR3232

r~ ~ Test Procedure - Al| Models Except 7.4GL Gi, GSi and 8.2GSi: Immersethe thermostat and a thermometerin a container of water. Heat water. Thermostatshould start to openbetween157-163° F. and should opento 5/32 in. (3,96 mm)minimum (~ at ° F. E~ Test Procedure:7.4GL Gi, GSi and 8.2GSi: immersethe thermostat and a thermometerin a container of water. Heat water. Thermostatshould ° F. and should opento 5/32 in. (3,96 mm) start to openbetween138-142 minimum(~ at 162° F. DR3051

¯ 3.0 GS Models r~ °

All v-6 andV-8 Models[2--7

Repair Procedure: None, replace unit.

For atl models.Nospecial tools required.

Inspection Procedure: Pressure check componentsfor leaks. Disassembleand inspect for corrosion or accumulationof foreign materia I. Repair Procedure:Rodout any accumulationof foreign matter built up in water passages.If evidence of porosity betweenwater passagesand exhaustchambersor exterior is found, replace component.Install new gaskets on reassemb~y.

For all models.Nospecial tools required. inspection Procedure:Makesure belt tension is correct. With the engine running,observethe rotation of the circulating pump pulley. If the pulley does not run true it can causeexcessivedrive belt wear and damage to the circulating pump itself.

If the leakageof water occurs at the circulating pumpwhile the engineis in operation, the pumpmaybe loosely mountedto the engine, the shaft seal in front of the pumpmaybe bad, the backing plate gasket maybe defective, or the circulating pumpmountinggaskets are leaking.

If the aboveinspections do not detect any defect, the pumpmustbe removedand inspected for internal corrosion, blockage, or damage.Inspect impeller for erosion.

Repair Procedure: None, replace the pump. [~ Volvo Penta marine engines have a special circulating water pump with stainless steel components and a special marineshaft seal assembly.

Donot replace with an automotive water pump.

10-17

En,...... g

Removal 1. Drain engine, refer to Draining Engine Block or ExhaustManifold. [~] 2. Loosen hose clamps and removehoses from supply pump. ~The inside hose (~) is the inlet

hose.

3. Loosenpumpto bracket mountingscrews ~) and removedrive belt.

Removemounting screws and remove pumpassembly.

45330

Impeller Removal [~ 1. Removethe three screws @securing the end cover. ~2. Removeand discard gasket. [~ 3. Graspimpeller securely and pull from housing.

Cleaning and inspection 1. Cleanall parts with solvent andblow dry thoroughly.

42864

2. Remove any old gasket from end cover and housing. Clean sealing surfaces.

3. Inspect impeller housingand camfor wear, and housingfor cracks and distortion causedby freezing. Replaceif necessary.Donot removecamif not required.

4. Hnspectend cover; checkimpeller contact surface for wear, scoring, or distortion causedby freezing. Replaceif necessary.

5. Inspect impeller; if bladesare set in a bent position, cracked,or broken, or showflat instead of roundededgeson the housingcontact surfaces, replacethe impeller.

39149

6. Checkbearings for smoothoperation.

39150

39154

39152

39155

Impeller installation - V-6 andV=8Models E~ 1. Apply a light coat of Volvo Penta GreaseP/N 828250-1to impeller surfaces.Install impelleruntil flush with surface.

2. Install newgasket without sealant. [[~ 3. Install end cover and securewith screws. Tighten screwssecurely.

Instal|ation 1. Orient pumpassemblyto the pumpbracket with the camscrew(~) up. Install mountingscrewsand belt. Refer to Supply PumpBelt Adjustment in the General Unformation Section.

42865

2. Attachthe inlet hoseto the inside nipple and the outlet hoseto the outside nipple, Tighten hoseclampssecurety.

Draining EngineBlock or ExhaustManifold Someservice work performed on the engine block and exhaust manifold mayrequire the complete drainage of those components.

45331

3.0

Models

[~ 1. Removethe Long supply hose at thermostat housing (~. Lower it alongsidethe cylinder block and drain it completely.

2. Disconnectand drain large hose (~ at water pump.

3. Remove the drain plugs from cylinder block port side @and exhaust manifold (~ Clear holes with a small wire to ensure complete drainage.

23907

23913

E..~,oo/o.9

10-19

4.3 Gi Models [~] 1. Disconnect the small water by-pass hose ~) at the top of thermostat housing.

2. Disconnect the water discharge hose ® at the port side exhaust elbownipple. Lowerto the rear of the block. Blowout the water trapped in the vapor separator and lines by applying air to the by-pass hose.

All 4.3 Models [~ 1. Removethe long water supply hose at the thermostat housing ©. Lower it alongside block and drain it completely. [~ 2. Disconnect and drain the large hose at the water pump@. [~ 3. Removehose (~) from the port and starboard exhaust manifolds. Removedrain plugs ® on the port and starboard side of the cylinder block. Clean holes with a small wire to ensure complete drainage.

5.7 Gi Modeis [~ 1. Disconnect the small water by-pass hose @at the top of thermostat housing.

44195

[~ 2. Disconnect the water discharge hose ® at the port side exhaust elbownipple. Lowerto the rear of the block. Blowout the water trapped in the vapor separator and lines by applying air to the by-pass hose.

All 5.7 Models [~ 1. Removethe long water supp[y hose at the thermostat housing O. Lower it alongside block and drain it completely. [~] 2. Disconnect and drain the large hose at the water pump0.

4285

42861

42862

42863

All 5.7 Models(continued) [~ [~ 3. Removehose ® at front of each port and starboard exhaustmanifold, and removedrain plugs (D on both sides of the cylinder block. Clear holes with a small wire to ensurecomplete drainage.

All 7.4 and 8.2 Models E~ 1. Removethe long water supply hose at the thermostat housing (~. Lowerit alongsideblock and drain it completely.

28283

2. Disconnectand drain the large hose at the water pump(~.

E~ [~ 3. Removehose @at front of each port and starboard exhaust manifold, and removedrain plugs ® on both sides of the cylinder block. Clear holes with a small wire to ensurecomplete drainage.

7.4 Gi, GSi and 8.2GSi Models [~ Drain the small water by-pass hose @betweenfuel reservoir and the top of thermostat housing. Disconnecthoseat the reservoir side of the checkvalve. Blowout water in both directions. Inspect checkvalve for debris, then reassemble.

28284

DrainingPowerSteering Coolers [~ Remove the lowest water hose from the powersteering oil cooler.

If cooler is mountedhorizontally, removeone water hose ® from the cooler, loosen cooler mountingbolt ~), and tip cooler downward to drain.

Draining SupplyPump

15819

[~ 1. Loosenand slide hose clamps back. Removehoses (~) from the rear of pumpand drain.

2. Crank the engine no more than 2 seconds (DONOTSTART) expel any water trapped in water pump.Reattach hoses.

10-21

45330

34687

45332

45333

Draining Pivot Housing [~ 1. Tilt vertical drive to the full tilt up position and removethe water drain plug @from the port side of the pivot housing.

2. Tilt the vertical drive to the full tilt downposition. Allow unit to drain. After unit has completely drained, replace pivot housing plug.

Failure to ensure complete drainage of the cooling system mayresult in serious damageto the engine and/or drive unit if temperature should drop below freezing.

45334

Thermostat Replacement 3.0 GS Models E~ 1. Removeall

hoses ® from the thermostat housing.

2. Removethe engine coolant temperature sender nut, lead and -washers @from the sender. [~] 3. Loosen the alternator adjusting screw. Removescrew securing alternator bracket @to the thermostat housing. Pivot time bracket out of the way.

E~ 4. Removetwo screws ® securing thermostat housing to the cylinder head. Removethe housing from the head. Clean aln gasket surfaces. [~ 5. Removethermostat O-ring ® and thermostat @from the housing°

45335

® ® 45354

10-22

E,~ .......

45355

45356

45357

E~ ~ 6. install thermostat @ into the thermostat housing with the pointed end ® facing into the housing. Place the O-ring ® into position in the O-ring groove to retain the thermostat. [] 7. Place a newgasket (Z)into position at the front of the head.

Nosealer is required with this gasket. [~ 8. install the thermostat housing into position and secure with two screws ~. Tighten the screws to 12-16 ft. Ibs. (16-22 N.m).

45358

E~ 9. Install the alternator bracket on the engine. Set alternator belt tension following the procedures in the General information section. Tighten both screws @to 26-30 ft. Ibs. (35-41 N-m). [~ 10. Attach the engine coolant temperature sender washers, lead and nut © to the sender. Tighten the nut securely.

I[~ 11. Install all hoses ® and secure with clamps. Tighten the clamps securely.

45345

45344

Engme/eng

10-23

V=6 and V-8 Models [~ [~ 1 Removeall water hoses from the thermostat housing. ¯

Carburetor Models: four hoses ~) [~

- EFI Models: five hoses (~) [~ E~ 2. Note position of lifting eye @. Removetwo screws @then remove Jifting eye and thermostathousing. [~ 3. The thermostat (~ is held in place by an O-ring. Pry the O-ring out of its groove,then lift the thermostatout of the housing.

28546

4. Discard the housinggasket and O-ring. Thoroughlyclean the housing and manifold gasket surfaces.

E~ 5. Place the thermostat in the housing. The temperature sensing element(3 must face you wheninstalled. Install a newOoringto seal thermostatin housing. Makesure O-ring is completelyseatedin its groove.

J’~ 6. Coat both sides of a new gasket with Volvo Penta Gasket Sealing Compound P/N 1161231-4and place it on the manifold. Position thermostat housingand lifting eye on engineadapteras notedin Step 2. Install two lock washersand screws@.Tighten the screwsto 20-25 ft. Ibs. (27-34 N,m).

38259

[~ 7. Connectthe water supply hose to hippie (~ and tighten hose clamp securely. Connectthe three remainingwater hoses and tighten hose clampssecurely. Makesure lifting eye @is positioned as shown. ~lf the water supply hose is attached to the wrong nipple, the engine will overheat.

28548

14849

1 0-24

28547 Eng,ne/eng

Section11 EngineRemoval andinstallation

Table of Contents

Engine Alignment ................................................ mnstallation ...............................................

Removal .................................................

Determining MinimumEngine Height ........................

Engine Mounts, Rear .......................................

Exhaust Pipe Replacement ...................................

11-7 1 1-6 11 =2 11-12 11-11 11-6

VolvoPenta Special Tools P/N

Description

3851083-0 3850609-3

Volvo Penta Alignment Tool Volvo Penta Drive Handle

Sealants, Lubricants and Adhesives Volvo Penta Grease 3Madhesive or equivalent Gasket Sealing Compound

Z~ Safety warnings Before beginning work in this section, read Safety chapter at end of this manual.

Proper installation is important for the safe, retiable operation of all mechanical products. The procedures we recommendand describe in these instructions are effective methodsto be followed wheninstalling Volvo Penta sterndrive products. Someof these methodsrequire the use of tools specially designed for the purpose. The special tools should be used when and as recommended.

Engine Removal Before removing engine, check engine height. See Determining Minimum Engine Height.

Check engine clearance between front of engine and engine compartmentbulkheadprior to starting "work. If clearance is less than 6 in. (15,2 cm), the verticai drive must be removed disengage U-joint shaft from engine coupler. See Vertical Drive and TransomBracket Service Manual Whenengine clearance is more than 6 in. (15,2 cm), the engine can be pulled forward to disengage the U-joint shaft from the flywheel coupler, and be removedfrom the engine compartment.

22703

The vertical drive can remain installed only if engine removaldoes not require re-alignment of the engine. If the engine mounts, boat stringers, or engine coupler are being repaired or replaced, removethe vertical drive for engine alignment.

To preventpossible fire and explosioncausedby ignition of fuel vapors which maybe present in the engine compartment, removethe positive and negative cables from the battery.

22704

DisconnectBattery AHswitches mustbe in the "’OFF" position prior to disconnecting the red (positive) and black (negative) cables from the battery. This will safeguard against permanentdamage to electrical components.

Disconnect PowerSteering Lines [~ 1. Disconnect both power steering lines cylinder.

at the steering

[~ ~] 2= If original steering line connector, P/N 914728, is available, useit to link both steering lines together. If Connectoris not used, cover both steering cylinder openings and line fittings to prevent fluid loss and entry of contaminants. Tie lines onto engine higher than power steering pumpto prevent damageand loss of oil during engine removal.

22706

DisconnectFuel Suppmy [~ Z~ Disconnectboat fuel line at the fuel filter of fuel Uine and inlet opening.

inlet. Seal end 2913

DisconnectElectrical Cables E~ 1. Disconnect the plastic two-wire trim/tilt

motor connector

@.

11-2

38277

E,,......g

[__6~_2. Remove wire retainer (~) and unplugrubbertwo-wiretrim/tilt connector.Cut tie strap © securingsendercable, if required.

sender

[~ 3. Unscrewclamp @and disconnect large rubber instrument cable connector(~). Unprugrubber three-wire trim/tilt cable connector Throttle Cable Disconnection [~ Prior to disconnecting the remote control throttle you have a "Push-To-Open"or "Pull-To-Open" throttle [~ [~ 1. Remove cotter pin and flat

cable, note wheter arm attachment.

washer@from throttle

arm.

24208

[8~] [~ 2. Loosenanchor retainer nut ~) and rotate retainer (~ away from cable trunnion. Remove throttle cable from throttle arm and anchor bracket. ® All Models(except 7.4Gi, GSi and 8.2GSi)

.

7.4Gi, GSi and 8.2GSi Models [~ 33727

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1 1-3

Disconnect ExhaustHose- 3.0 Models ~] 1. Loosen four hose clamps. ~] 2. For ease of moving hose, lubricate exhaust pipe.

3. To free exhaust hosefrom elbow, pry or twist hose. SRide hose down onto exhaust pipe.

DisconnectExhaustHose- All V-6 and V-8 Models [~ 1. Loosen four clamps (~ on lower exhaust hose. For ease of moving lower hose, lubricate exhaust pipe.

6361

~-~ 2. To free lower hose from intermediate pipe, pry or twist hose. Slide hose downonto exhaust pipe ®.

6362

6363

17370

11-4

17371

Englne/eng

Disconnect Water Hose 16~ Loosen clamp and pull bracket water tube;.

water supply

hose off transom

Separate Engine Mounts [3 Z~ 1. Attach a hoist to lifting brackets of engine. Hoist must havea lifting capacity of at least 1500Ibs. (680 kg).

[8~] 2. Remove and retain both lock nuts © and both flat washers @from rear engine mounts.

[9~ [~ 3. Removeand retain mounts.

lag screws from front

22698

engine

¯ 3.0 Modens ¯ AiR V-8 and V-8 Models[~] 4. If vertical drive wasremoved,lift engineout of enginecompartment. If vertical drive was not removed,Pift engine slightly and pull it forward to disengageU-joint shaft and flywheel coupler.

With U-joint shaft clear of flywheel coupler, lift engine out of compartment.

i

-,

31444

12211

2888

Engme/eng

1 1-5

2933

Exhaust Pipe Replacement Removal 1. Remove engine following previous procedure. [~ 2. Removeand retain four exhaust pipe screws. Removeexhaust pipe and discard seal (~). Cleanall material from transomshield and exhaust pipe seal surfaces.

[_N~eExhaust pipe mounting holes have bcking Hefi-CoiP inserts. Do not clean screwholes with a thread tapping tool, otherwiselocking feature will be destroyedandHell-Coil will haveto be replaced.

22780

Installation 1 Coat a newseal with 3Madhesiveor equivalent and place in transomshield groove(~). [~ 2. Apply Volvo Penta Gasket Sealing CompoundP/N 1181231-4to the four exhaust pipe mountingscrews ©.

3. Secureexhaustpipe (~) to transomshield with four screws.Tighten to 20-25 ft. Ibs. (27-34 N.m). Slide exhausthosesand clamps~ onto exhaustpipes if they were removed.

15048

4. Install engine.

EngineInstallation Engine Mount Attachment 1. Lowerengine into engine compartment: If drive unit wasnot removed,and engine crankshaft wasnot rotated, engageU-joint shaft with engine coupler and slide engine backonto rear mounts.If coupler and Ujoint shaft will not align, either the engineor U-joint shaft will haveto be rotated to allow engagement.If engine mountheight was disturbed, engine must be realigned as describedlater. r’-zl L~_J

o

15047

If drive unit has beenremoved,lower engine onto rear mounts.

[~ 2. Install flat washers(~D into recessesof engine bracket and secure engineto mountwith lock nuts (~). Tightenlock nuts to 28-30ft. fbs. (38-40 Nom).

11-6

12212

12211 Engme/eng

[6.~ E~ 3. Install forward engine mountlag screws and tighten them securely. ® 3.0 Models [~] *

All V-,6 andV-8 Models

Jf the sterndrive wasnot removed,go to ExhaustHoseAttachment.If the sterndrive wasremoved,continue with Engine Alignment section.

EngineAlignment

2888

I~ Correct engine alignment is essential to long engine drivetrain life.

The front engine mounts mayneed adjustment UPor DOWN to produce correct engine alignment. UseVolvo Penta Alignment Tool P/N 3851083-0 with Volvo Penta Drive HandleP/N 3850609-3to check engine aJignment.

[8~E] 1. Slide alignment tool O throughdriveshaft gimbal bearing (~. The alignmenttool mustslide through the gimbal bearing and into engine couplerwith ease. If the alignmenttool binds going into enginecoupler, makesure the gimbal bearing is properly aligned. If gimbalbearing alignmentis correct, the front engine mountsmust be adjusted either UPor DOWN, as required, until alignmenttoot slides easily in and out of engine coupler.

2933

[9~E] [~ 2. To changeengine height, tighten or loosen nuts @and ® as required. See respective engine section, Front MountHeight Adjustment. ¯ 3.0 Models [~ ® All V-6 and V-8 Models [~ 3. After correct alignment has beenmade,the front mount(s) must tightened to maintainalignment.

34080

3.0 Models- While holding one nut with an open-endwrench, tighten the second adjustingnut to a torqueof 115-140ft. Jbs. (158-190 N=m).

V-6 and V-8 Models- While holding one nut with an open-endwrench,tighten the secondadjusting nut to 100-120ft. Ibs. (136-163 N®m).

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2972

zgs3 11-7

Connect Exhaust Hose E~] 3.0 Mode|s- Slide exhaust hose (~) up onto high-rise exhaust elbow

®. [~ V-8 and V-8 Mode~s- Push lower hoses @up onto intermediate exhaust pipes ®. [~ Position and tighten all hose clamps securely betweenribs of exhaust hose(s) as shown. ~] ~ DONOTinstaN hose clamps =n expandedarea (~) of hose(s).

2945

Coolingwill be restricted and enginedamagewill occur.

ConnectThrottle Cable ~ Determine whether you have a "pull-to-open" or "push-to-open" remotecontrol throttle cable. Position remotecontrol handlein neutral, propeller shouldrotate freely. Turnpropeller shaft andshift into the forward gear detent position, then pull handle HALFWAY BACKtowards NEUTRAL. This positions the control for properthrottle adjustment.Failure to follow this procedurecanresult in "hard shifting" out of neutral. [~ 1. Align internal bosses(~ of trunnion with throttle cable groove~).

Presstrunnion on throttle cable until seated.

17372A

[~] ~ 4.3 GL and GS Models Only" Engine anchor bracket may havetwo sets of anchorblock holes. Thetop set (~) is for GSmodelsonly.

The bottom set (D is for GLmodelsonly. ~ 2. Install openend @of trunnion in anchorblock. Install screw in anchorblock and position throttle cable assemblyin selected set of holes.

Nut mustbe against the anchorbracket, tighten it securely. [~ ~ 3. Throttle arm connector ® must have a minimumof g fuUl turnsor 1/~ in. of throttle cablethreadengagement.

Install throttle arm connectoronto the throttle cable. Pull connectorforward ® to removeall end play from throttle cable, then turn the connectorin until hole aligns with the "pull-to open"(~ throttle armstud.

17370A

~lf throttle arm connector hole cannot be adjusted to align with the throttle arm, checkfor propercableinstallation in the remotecontrol box.

34751

@

11-8

DR4977 Englne’eng

DR4978

DR497~

22698

AR,

[__7_~___ W~.4. Install connectoronto throttle arm. Install washer andcotter pin (~), and spreadcotter pin prongs.Tightenjam nut @against connector. ~NO---~For throttle and shift cable adjustmentprocedures,see Throttle andShift Control Systemssection. ’Water Hoseinstallation E_8_~_ 1. Slide hoseclamp® onto water inlet hose, Lightly lubricate inside of water inlet hoseand push hoseonto water inlet tube (~).

15864

E~ 2. If inlet hoseis not installed properly, undersideof hosemaycollapse. Checkundersideof hose for proper installation and adjust hoseas required. Tighten hose clampsecurely.

J-~ Failure to instarl water inlet hose correctly can result in engine damage from blockageof water circulation.

PowerSteering Line Installation 1, Remove tape or protective cover from small hydraulic hose fitting (or unscrewsteering line connector)and small steering cylinder opening.

22702

l’;~ 2, Install smallhosefitting into steeringcylinder andtighten to 10-12ft.

Ibs. (14-16N.m).

3, Remove tape or protective cover from large hydraulic hosefitting large steering cylinder opening.

and

[~1~]4. Install large hosefitting into steeringcylinder andtighten to 15-17ft.

It)s. (20-23N.m).

22701

Eqgme/eng

1 1-9

Electrical Cable Connections [~ 1. Connectplastic two-wire plug of engine harness to two-wire receptacte (~) of trim/tilt motor.Connectors shouldlock together.

2. Connectrubber two-wire trim/tilt senderplug to two-wire receptacle (~) of instrument harness. Secureconnectorswith wire retainer and cable with a tie strap @.

3. Routethe instrument cable plug to join enginecable receptacle on engine. ~ Ensure cable is routed to prevent cutting or chafing on any sharp or hot object. This could result in an electrical short, andcontributeto fire and explosion in the engine compartment.

E~]4. Carburetor Models:Route trim/tilt install plug @into electrical bracket.

31461

cable behind shift bracket and

[~5. Apply a light coat of Volvo Penta GreaseP/N 828250-1around large engine plug (~.

E~ 6. Align the marksof the trim/tilt together.

plug and receptacle ® and press 24208

[~7. Slide hose clamp over large engine receptacle. Align the two large terminals on plug and receptacle (~ and press together. Slide hose clamp over receptacle and tighten securely.

Z~8. Models with Starter Solenoids: Position the red cable protector over solenoidterminal. ~9. All switches must be in the "OFF" position prior to connecting the battery cablesto the battery. Besure polarity is observed;positive (+) cable to the positive terminal, andnegative(--) cable to the negative terminal.

31730

33727

11-10

Engme’eng

ConnectFuel Supply Attachboat’s fuel supplyhoseto fuel filter canister. Tighten connectionsecurely. Checkfor fuea leaks whentesting engine, and repair any leaks that mightoccur.

Rear Engine Mounts Removal 1. Remove engine as previously described in this section.

[5~ 2. Unscrewtwo screws and washers, then lift bly off transomplate.

6678

mount assem-

Disassembly [ 6~[] Hold square nut and remove screw. Mount assembly will break downinto componentsshown. Pay particular attention to the two mount washers; their thickness, their shape (concave or fiat), and their position in the assembly (above or below the rubber mount).

Assembly

16348

[~ 1. Slide Iowe,r washer ® onto mount bolt; make sure you choose the correct washer (as determined during the mount disassembly)for this position. Insert bolt into bottom(flat) side rubber mount assembly, and install remaining washer and square nut. Do not tighten nut at this time. [~ If top and bottom washersare not installed in their original positions, mount maytransmit excessive engine vibrations into boat and cause undesirable operating conditions.

1:7--1 2-Pdrn mount assembly upside down and clamp square nut in vise. Rotate rubber mountuntil mounting holes are positioned at 90° to any side of square nut. Hold mountin this position and tighten center bolt to 44-52 ft. Ibs. (60-71 N-m).

6680

I~ If 90° relationship between nut and mounting holes is not maintained, slot of engine mount pad cannot engagerear mount .during installation.

Installation L=8-7 1. Place mount assembly on transom plate. Install two screws and washers, and tighten them to 20-25 ft. Ibs. (27-34 M.m}.

I==9~ 2. Install engine as previously described in this section.

Makesure mount pad slot engagessquare nut. Install both flat washersand lock nuts, then tighten lock nuts to 28-30 ft. Ibs. (38-41 N.m).

6677

® ©

DR4960

Determining

Minimum Engine

Height

EEl 1. To determine minimum engine height, use a level (~ placed on top of the transom, measurefrom bottom of level to top of elbow @and record distance.

I~ 2. Measurefrom bottom of level to static record distance.

water line © and

EEl 3. Subtract dimension ® from dimension © and record result. See engine height requirements below: e 3.0 Models - Measurement© minus (~) shouldnot be lessthan9 in.(22,8cm). ¯ V-6 Models - Measurement © minus ® should not be less than 13 in. (33 cm). ¯ V-8 Models - Measurement © minus (~ should not be less than 14 in. (35,6 cm).

4. Whenengine installations do not meet these specifications, an exhaust elbow high-rise kit must be installed.

An installation that permits water to enter the engine through the exhaust manifolds(s) will not be covered by warranty, unless damage is due to defective part(s).

11-12

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Safety Section

Part A Marine Products and Safety of People Who Use Them . . . . . . . . . S-2 Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . S-4 Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5 Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . S-7

Part B Marine Products and Safety of People Who Fix Them . . . . . . . . S-11 Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11 Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12 Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13 Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14

Safety

S-1

Part A - Marine Products and safety of People Who Use Them

Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure...

Product User is informed. . .

Products are safe and reliable. . .

It's up to you, the People who. . .

Install accessories. . .

Service and Maintain the boat. . .

Service and maintain the sterndrive. . . . . . to keep the products safe and reliable.

This section talks about safe boating and how you can help keep it safe. Some things you may know . . . but others you may not.

First!

A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.

Do Not Substitute Fasteners

They look the same, but . . . are they?

The Same Size?

The Same Strength?

The Same Material?

The Same Type?

Standard or Metric Thread?

Don't substitute unless you know they are the same in all characteristics.

Second!

Special locking screws and nuts are often used to attach steering, and remote control components to the sterndrive.

When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with other parts When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and control cables, plus related parts.

Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.

S-2

Safety

Sterndrive Shift System

The Shift System starts here at the remote control lever. . .

. . . and ends here at the propeller.

What's Most Important?

When the control lever is in Forward, Neutral or Reverse position . .

. . . Shift mechanism must match control lever position.

What Could Happen?

If . . . Neutral

If . . . Forward

Forward or Reverse Reverse

. . . Propeller is still powered (turning) unknown to operator, or engine will start in gear, boat will move unexpectedly.

. . . boat will move opposite to direction intended by operator.

How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . .

Read, understand and follow manufacturers instructions.

Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . .

Test your work. Don't guess. Make sure propeller does what the operator wants and nothing else.

Safety

S-3

Sterndrive Throttle Control System

The throttle Control System starts here and the remote control lever . . . . . . and ends here on the engine.

What's Most Important?

When the control lever is moved from Forward (or Reverse) to Neutral . . .

. . . engine speed must slow to idle RPM and allow operator to shift into Neutral.

Operator must be able to stop propeller.

What Could Happen?

If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control of boat.

How Can Loss of Throttle Control be Minimized? In pre-delivery inspection and when servicing . . .

Read, understand, and follow manufacturers instructions.

Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . .

Test your work. Don't guess. Make sure engine throttle response is smooth.

Make sure full throttle operating RPM can be reached so operator won't overload engine

S-4

Safety

Sterndrive Steering System

The Steering System starts here at the helm . . .

What's Most Important?

The Steering System . . .

. . . and ends here at the propeller on the sterndrive

must be installed properly must be adjusted properly must be lubricated

What Could Happen? . . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator may be thrown into water and could be hit.

. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic. . . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of boat control.

Safety

S-5

How Can Loss of Steering Control be Minimized?

In predelivery inspection and when servicing

use steering components which meet marine industry (BIA/ABYC) standards . . .

Read, understand, and follow manufacturer's instructions.

Assemble parts and make adjustments carefully . . .

Closely follow the warnings marked with ...

Keep parts moving freely . . . lubricate parts as soon as shown in manuals Use bolts, nuts, and washers supplied with steering attachment kits

When power assisted or mechanical steering systems are used, check to uncover possible trouble!

Cable housing in this area must not be restricted

Steering components must not bind

Why? Unit may go to full turn without turning steering wheel (Power assist models)

Why? Possible jamming of steering system.

Engine stringer must not interfere with power steering pump and pulley

Maintain proper belt tension.

Power steering parts and push/pull cable must be free to move in order to actuate power steering valve when operator turns steering wheel

Check for damaged parts . . . impacts to the sterndrive like this

or this . . . or ? ? ? can put stress on steering components. Look for . . .

Cracked parts Bent parts Loose fasteners

Replace damaged parts. If weakened, parts could fail later . . . on the water . . . when least expected.

S-6

Safety

Sterndrive Fuel and Electrical Systems

The electrical System begins here at the battery . . . . . . and ends here at the carburetor or fuel injectors

The fuel system starts here at the fuel tank . . .

. . . and ends here on the engine.

What's Important?

Fuel leakage must be prevented.

Electric sparks must not happen.

What Could Happen?

Gasoline can explode and/ or burn easily: When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire connection, or a damaged or deteriorated electrical component.

How Can Fire and Explosion Be Minimized?

Read, understand and follow manufacturers instructions.

Closely follow the warnings marked with

...

Do not substitute fuel or electrical parts with other parts which may look the same. These parts are designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and explosion.

If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write to . . .

------------------------National Technical Information Service Springfield, Virginia 22161

. . . and ask for copies of: (1) Electrical System Compliance Guideline (AD/A-049-638) (2) Fuel System Compliance Guideline (AD/A-047-767) These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explosions.

Safety

S-7

Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard requirements. Most automotive parts do not, especially electrical components that must meet ignition protection requirements of the U.S. Coast Guard regulations.

When nonmetallic parts look to be in poor shape . . . replace them!

Wires Cracked!

Torn Boots!

Cracked Fuel Lines!

Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . .

It's time for replacement BEFORE sparks and/or fuel leaks occur.

Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires (to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with either of these CRITICAL safety related systems.

When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.

STOP

If you smell gasoline in the engine compartment . . . find its source and stop the leakage.

S-8

Safety

Follow "Starting Procedure" outlined in the operator's manual.

Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble.

Backfire flame arrestor must be in place and securely attached to the air intake.

Do not alter the backfire flame arrestor.

If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compartment. If fumes are present in compartment, fire and explosion could result.

Safety

S-9

Summing Up Now you know some things that can take the joy out of enjoyable boating.

No doubt about it . . . it takes time!

Reading and understanding instructions.

Reading and understanding warnings marked with

...

Putting parts together correctly . . .

Making correct adjustments . . .

Testing you work.

and making sure Worn or damaged parts are replaced, Replaced parts are like originals . . . in every way.

Customer is told of things which need attention . . .

But do you really want the alternative?

S-10

Safety

Part B - Marine Products and Safety of People* Who Fix Them

Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you?

Mechanics can be hurt while . . .

Servicing boats Servicing sterndrives Troubleshooting problems Testing their work Some items you'll know . . . others you may not.

When Lifting Engines If hoist is poor shape . . . or too small for the job Engine may drop suddenly

DR3471

DR3469

Make sure shop aids have extra capacity — and keep them in good repair!

When Running Engine with Engine Compartment Cover Removed The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember: Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands, arms, belts can be caught by moving belts or spinning pulleys Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into moving parts.

Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electrical part, near the propeller, etc.) *Mechanics, technicians, backyard do-it-yourselfers.

Safety

S-11

Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly!

When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated areas.

Eyes Need help

Grinding

Sprayed Cleaners, Paints

End of Cables

Acid

Chiseling (steel on steel) (Tip: Use plastic or brass type hammers.

They don't chip off as easily as steel hammers.)

Handling Lead Acid Batteries

If spilled or splashed on any part of body..

Wash with lots of water. . .

If solution gets into eyes. . .

Wash. . . and see a Doctor, fast!

Charging Lead Acid Batteries Attach and remove these cables with charger unplugged from 110 volt wall socket. (Prevents shocks if the charger is defective.)

Observe correct polarity when connecting these charger leads.

Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. . . Make sure vents are open.

If clogged, pressure inside may build. . . battery may explode.

S-12

Safety

Never yank cables off battery posts. . . it's a sure way to make lots of sparks. . .surrounded by battery gas

Battery gas is explosive!

While charging or discharging, remember. . .

No Smoking No Flames No Sparks

After Charging. . .

Don't check battery condition by placing metal objects across posts.

Shut off charger Remove charger plug from wall socket Then. . .

You're sure to make sparks and serious burns are possible.

Take charger cable off battery posts

Gasoline! Handle With Care When you smell any odor of gasoline, explosion is possible Gasoline fumes are heavier than air and will sink to the lowest point in the boat or room, and will stay there. . . waiting Gasoline explodes easily and violently when mixed with air

If the air around you is quiet . . . the pilot light in the heater may ignite the heavy fumes before your nose ever smells the fumes . .

5 Parts Gasoline 100 Parts Air

What Can you Do?

Store in sturdy, sealed gas can . . .and . . . keep outside Safety

Store properly . . .

Fill portable tanks outside boat to prevent spillage in boat Use fuel for fuel . . . not for a solvent If fumes are smelled (in shop, basement, garage), immediately: Put out open flames, cigarettes, sparking devices Wipe up spill or leak; get towels, rags outside fast Check lowest area for fumes; open doors or windows

S-13

Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled.

Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ?????????

How many of these are in your area?

Hazardous Products

Read the container label. It tells you . . .

"How, and where, to use," "How to give First Aid," and have "recommended" first aid materials on hand- should an emergency arise "How to dispose of can," Remember: Little children are very curious and will try to taste everything, so . . .

Keep containers away from children

. . . yummmmmmmmmmm

S-14

Safety

VOLVO PENTA MODEL iDENTIFiCATION Engine Modelidentification is located on the engine valve cover for four cylinder (in-line} models, on the inside of the port valve cover for V6 & V8 models, or on the Thick Film ignition (TFm) module bracket for Ford fuel injection models. The identification numbersmust correspond with the transom shield and drive unit numbers. See below.

Engine Model Number(GL, GS, and Gi Models) Engine Model Number

SX MODELS: [~

Transom Shield Model Number

[~

Drive Unit Model Number

DP & DPX MODELS:

Nunber plate for drive unit andtransomshield.

Onlyfields 2 and3 are filled for transom shield.

4 1. ProductDesignation 2. Model Number 3. Serial Number 4. Reduct~ion Ratio