Workshop Manual Engine Components

Workshop Manual
Engine Components
Models
30GSMEFS, 30GSPEFS
43GLPEFS, 43GiPEFS
50GLPEFS, 50GiPEFS
57GSPEFS, 57GSiPEFS
74GiPEFS, 74GSiPEFS
82GSiPEFS
DPX385XEFS, DPX415XEFS
Contents
General Information ......................................................... 1
General Engine Mechanical - V6 and V8 Models ............. 2
3.0 GS Engines................................................................. 3
4.3 GL, GS and Gi Engines ............................................... 4
5.0 GL, Gi, 5.7 GS and GSi Engines ................................. 5
7.4 Gi Engines ................................................................... 6
7.4 GSi and 8.2 GSi Engines ............................................ 7
Steering System................................................................ 8
Throttle and Shift Control Systems ................................. 9
Cooling Systems............................................................... 10
Engine Removal and Installation ..................................... 11
Safety ................................................................................ S
Engine/eng i
ii Engine/eng
Model Identification
M All stern drive system components must be matched for either single or
dual engine installations. Failure to properly match engine, transom bracket
and vertical drive will result in poor boat performance, and risk damage to
engine and drive because of incorrect drive gear ratio.
Model identification is located on the engine valve cover, and MUST corre-
spond with the transom bracket and vertical drive numbers as listed in this
document.
1
DR1145
• Engine Model Number 1 2 3
• Transom Bracket Model Number 4
• Vertical Drive Model Number 5
2
DR4282
3
DR6815
4
DR2058
5
DR4957
Engine/eng iii
iv Engine/eng
Section 1
General Information
Table of Contents
Battery Cable Requirements ........................................................... 1-40 1

Belt Adjustments
Alternator ....................................................................................... 1-25
Power Steering .............................................................................. 1-26
Belt Tension ...................................................................................... 1-24
Compresion Pressure Limit Chart .................................................... 1-7
Conversion Charts
Drill ................................................................................................. 1-42
Metric ............................................................................................. 1-41
Crankcase Oil ................................................................................... 1-11
Engine Break-in ................................................................................ 1-21
Engine Compression Testing ............................................................ 1-5
Engine Troubleshooting Guides ..................................................... 1-29
Gasolines Containing Alcohol ........................................................ 1-10
Gasoline Requirements ................................................................... 1-10
Intake Manifold Vacuum Testing ....................................................... 1-8
Introduction ........................................................................................ 1-2
20-Hour Check .................................................................................. 1-23
Off-Season Storage Preparations ................................................... 1-13
Oil Filter ............................................................................................. 1-12
Periodic Maintenance Chart ............................................................ 1-44
Positive Closed-Type Ventilation System ...................................... 1-27
Power Steering Fluid Level ............................................................. 1-13
Power Trim/Tilt Fluid Level .............................................................. 1-13
Preparation for Boating After Storage ............................................ 1-20
Steering System Lubrication ........................................................... 1-13
Submerged Engine ........................................................................... 1-23
Symbols ............................................................................................ 1-43
Torque Specifications, General ....................................................... 1-40
Troubleshooting - System Isolation ................................................ 1-28
Tune-up Specifications .................................................................... 1-36
Tuning the Engine .............................................................................. 1-5
Safety Warnings
Before working on any part of a Volvo Penta stern drive, read the
Safety section at the end of this manual.
Engine/eng 1-1
Introduction
This service manual is divided into sections concerning various sys-
tems and assemblies. Refer to the Contents to locate the section cov-
ering the system or assembly requiring service. Each section title page
has an additional listing that will describe the section’s contents in more
detail. Be sure to read the Safety Section at the end of this manual,
and pay special attention to all safety warnings as they appear through-
out the text. Since models are subject to change at any time, some
photos may not depict actual product.
Good Service Practice
Service required for stern drives is generally one of three kinds:
• Normal care and maintenance - which includes putting

a new stern drive into operation, storing engines, lubrica-
tion, and care under special operating conditions such
as salt water and cold weather.
• Operating malfunctions - due to improper engine or
drive mounting, propeller condition or size, boat condi-
tion, or the malfunction of some part of the engine. This
includes engine servicing procedures to keep the engine
in prime operating condition.
• Complete disassembly and overhaul - such as major
service or rebuilding a unit.
It is important to determine before disassembly just what the trouble is
and how to correct it quickly, with minimum expense to the owner.
When repairing an assembly, the most reliable way to ensure a good
job is to do a complete overhaul on that assembly, rather than just to
replace the bad part. Wear not readily apparent on other parts could
cause malfunction soon after the repair job. Repair kits and seal kits
contain all the parts needed to ensure a complete repair, to eliminate
guesswork, and to save time.
Repair time can also be minimized by the use of special tools. Volvo
Penta special tools are designed to perform service procedures unique
to the product that cannot be completed using tools from other sources.
They also speed repair work to help achieve service flat rate times. In
some cases, the use of substitute tools can damage the part.
Do not operate engine out of water even momentarily. If
operated in test tank, use proper test wheel. Failure to do so can dam-
age supply pump, overheat engine, or allow excessive engine RPM.
1-2 Engine/eng
Preparation for Service
Proper preparation is extremely helpful for efficient service work. A clean

work area at the start of each job will minimize tools and parts becom-
ing misplaced. Clean an engine that is excessively dirty before work
starts. Cleaning will occasionally uncover trouble sources. Obtain tools,
instruments and parts needed for the job before work is started. Inter-
rupting a job to locate special tools or repair kits is a needless delay.
Use proper lifting and handling equipment. Working on stern
drives without proper equipment can cause damage and personal
injury.
Always use clean fresh fuel when testing engines. Troubles can often
be traced to the use of old or dirty fuel.
Service Policy
It is a Volvo Penta policy to provide dealers with service knowledge so

they can give professional service demanded by today’s consumer. The
Volvo Penta Training Centers, frequent mailing of Service Bulletins, Let-
ters and Promotions, Special Tools and this Service Manual represent
the latest effort to assist dealers in giving consumers the best and most
prompt service possible. If a service question does not appear to be
answered in this manual, you are invited to write to the Volvo Penta
Service Department for additional help. Always be sure to give com-
plete information, including engine model number and serial number.
When a brand-name product or specific tool is called for, another item
may be used. However, the substitute must have equivalent character-
istics, including type, strength, and material. You must determine if in-
correct substitution could result in product malfunction and personal
injury to anyone. To avoid hazards, equivalent products which are used
must meet all current U.S. Coast Guard Safety Regulations and ABYC
standards.
Engine/eng Safety Related 1-3

Replacement Parts
When replacement parts are required, always use genuine Volvo

Penta parts, or parts with equivalent characteristics, including type,
strength, and material. Failure to do so may result in product malfunc-
tion and possible injury to the operator and/or passengers.
Parts Catalogs
Parts Catalogs contain exploded views showing the correct assembly

of all parts, as well as a complete listing of the parts for replacement.
These catalogs are helpful as a reference during disassembly and re-
assembly, and are available from Volvo Penta Parts.
Special Service Tools
Volvo Penta has specially designed tools to simplify some of the dis-
assembly and assembly operations. These tools are illustrated in this
Service Manual, in many cases in actual use. All special tools can be
order from Volvo Penta Parts. Individual purchasers of Service Manu-
als must order Special Tools through an authorized dealer.
Product References, Illustrations & Specifications
Volvo Penta reserves the right to make changes at anytime, without

notice, in specifications and models and also to discontinue models.
The right is also reserved to change any specifications or parts at any
time without incurring any obligation to equip same on models manu-
factured prior to date of such change. All information, illustrations and
specifications contained in this manual are based on the latest prod-
uct information available at the time of printing. The right is reserved
to make changes at anytime without notice.
All photographs and illustrations used in this manual may not depict
actual models or equipment, but are intended as representative views
for reference only. The continuing accuracy of this manual cannot be
guaranteed.
Safety Related 1-4 Engine/eng

Tuning The Engine
The purpose of an engine tune-up is to restore power and performance
that has been lost through wear, corrosion or deterioration of one or
more parts or components. In the normal operation of an engine, these
changes can take place gradually at a number of points, so that it is
seldom advisable to attempt an improvement in performance by correc-
tion of one or two items only. Time will be saved and more lasting re-
sults will be obtained by following a definite and thorough procedure of
analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete
tune-up is performed once every year, preferably in the spring. Compo-
nents that affect power and performance can be divided into three
groups:
• Components affecting compression

• Components affecting ignition
• Components affecting fuel system
Tune-up procedures should cover these groups in the order given. While
the items affecting compression and ignition may be handled according
to personal preference, correction of items in the fuel system group
should not be attempted until all items affecting compression and igni-
tion have been satisfactorily corrected. Most of the procedures for per-
forming a complete engine tune-up will be covered in greater detail in
this manual. This section will deal mainly with the order of procedures
involved in tuning the engine.
Engine Compression Testing

During all work done around the engine, while the engine is
running or being cranked, use extreme care to avoid getting fin-
gers or clothing caught in any belts, pulleys, or other moving parts.
1. Visually inspect stern drive unit for leaks, missing parts or other
obvious defects. Replace deteriorated parts.
2. Compression check: Proper compression is essential for good en-
gine performance. An engine with low or uneven compression cannot
be properly tuned.
a. Operate engine to normal operating temperature.
Engine must not be started and run without water for cooling.

b. Remove any foreign matter from around spark plugs by blow-
ing out with compressed air.
c. Remove and inspect all spark plugs. Install thread-type com-
pression gauge in spark plug hole.
d. To Prevent Sparking:
• All Models Except 5.0 GL and 5.7 GS: Remove (grey)

2-wire connector, with purple and grey wires, at ignition
coil.
• 5.0 GL and 5.7 GS Models Only: Remove both distribu-
tor primary wires from the ignition coil. Tape wire termi-
nals to prevent accidental grounding.
e. With choke and/or throttle plates wide open, crank engine
through at least four compression strokes.
Test Conclusion
The indicated compression pressures are considered normal if the low-

est reading cylinder is within 75% of the highest.
Example:
If the highest pressure reading was 140 PSI, 75% of 140 is 105. There-
fore, 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 specifi-
cations, and compression is 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
compression pressure check on the cylinders.
1. If compression improves considerably, the piston rings are at fault.
2. If compression does not improve, valves are sticking or seating
poorly, or valve guides are worn.
3. If two adjacent cylinders indicate low compression pressures and
squirting oil on the pistons does not increase the compression, the
cause may be a cylinder head gasket leak between the cylinders. This
problem could allow engine oil and/or coolant to enter the cylinders.

It is recommended the following quick reference chart be used when checking cylinder compression pressures. The
chart has been calculated so that the lowest reading number is 75% of the highest reading.
Compression Pressure Limit Chart
Max. PSI Min. PSI Max. PSI Min. PSI Max. PSI Min. PSI Max. PSI Min. PSI
134 101 154 115 174 131 194 145

136 102 156 117 176 132 196 147
138 104 158 118 178 133 198 148
140 105 160 120 180 135 200 150
142 107 162 121 182 136 202 151
144 108 164 123 184 138 204 153
146 110 166 124 186 140 206 154
148 111 168 126 188 141 208 156
150 113 170 127 190 142 210 157
152 114 172 129 192 144 212 158
After checking cylinder compression, repairs should be made as necessary.

Subsequent adjustments to an engine that does not have proper compres-
sion will not measurably improve performance or correct operational prob-
lems. After verifying compression, check ignition and fuel system compo-
nents.
Ignition System Fuel System
• Spark Plugs • Fuel Tank Pickup and

• Spark Plug Leads Screen
• Distributor Cap • Fuel Tank Vent
• Rotor • Anti-Siphon Valve (if
• Ignition Coil equipped)
• High Tension Lead • Fuel Octane and Quality
• Ignition Switch • Boat Fuel Lines and Valves
• Circuit Wiring and Connectors • External Engine Fuel Filter
• IC Module • Fuel Pump(s) and Line
• Carburetor Fuel Filter or
Screen
• Carburetor Adjustments
• Engine PCV Valve
• Flame Arrestor
• Pressure Regulator and
injectors
All of the above listed components are not necessarily part of an engine
tune-up, but must be considered when attempting to correct engine/boat
performance problems. Repair or replace components only as required.
Do not substitute automotive parts. Volvo Penta marine compo-
nents meet U.S. Coast Guard regulations for external ignition proof op-
eration and marine use. Volvo Penta marine components are specially
designed not to cause ignition of fuel vapors in the bilge or engine
compartment. The use of automotive parts can result in fire and explo-
sion.

Intake Manifold Vacuum Testing
Test Procedures
1. Install a vacuum gauge to a good intake manifold source, following

the gauge manufacturer’s instructions. Start and warm up the engine.
2. Observe the vacuum gauge while operating the engine over a range
of engine speeds.
Test Results
1. A steady vacuum reading between 18 and 22 in. Hg. (60,7-74,3

kPa) at idle indicates an engine in good mechanical condition.
2. A vacuum reading below 18 in. Hg. (60,7 kPa) at idle, indicates an
engine that is not developing enough vacuum. Further testing for base
mechanical problems is needed.
3. Possible causes of low intake manifold vacuum are late ignition tim-
ing, low compression, poor engine sealing, leaks at vacuum lines and
connections or bad MAP sensor.
4. If the gauge fluctuates at idle, possible causes are sticking or leak-
ing valves, or an ignition miss.
5. If the gauge fluctuates at idle but smooths out as engine RPM in-
creases, check for bad valves or camshaft.
6. If the gauge fluctuates more with increases engine RPM, check for
weak or broken valve springs, bad valves, ignition miss, or a leaking
head gasket.
7. If the vacuum gauge fluctuates regularly with each engine cycle,
check for a bad valve.
8. If the vacuum reading drops steadily as engine RPM increases,
check the exhaust system between the engine and vertical drive for
restrictions.
9. See chart on the following page for more information.
1-8 Engine/eng
DRC6688
Engine/eng 1-9
Gasoline Requirements
The models covered in this manual are designed for maximum perfor-
mance with the use of lead-free gasoline with the following minimum
or higher octane specification:
Inside the U.S., (R+M)/2 (AKI) - 89
Outside the U.S., (RON) - 93
4.3 GL, GS, 5.0 GL, and 5.7 GS Models Only - The ignition timing will
have to be retarded if lower octane fuels, with minimum 86 AKI (90
RON) octane, are used. Refer to “Timing” in Tune-up Specifications.
When ignition timing is retarded, a slight decrease in power can be
expected.
Use of gasoline with lower than 89 AKI (93 RON) octane in 4.3
GL, GS, 5.0 GL, and 5.7 GS models, without retarding ignition timing
as specified, will result in serious damage to your engine and will void
the engine warranty.
All Other Models - Lower octane fuels, with minimum 86 AKI (90 RON)
octane, can be used. With the use of lower octane fuel, a slight de-
crease in power can be expected.
Engine damage resulting from the use of gasoline with
octane lower than 86 AKI (90 RON) is considered misuse of the
engine and will void the engine warranty.
Some marinas sell fuel with lead additives. Do not use such fuel as it
may plug the fuel injectors. Premium fuel contains injector cleaners
and other additives that protect the fuel system and provide optimum
performance. The use of premium grade fuels in all models is
strongly recommended. To prevent gum formation and corrosion in
the fuel system, use DuraPlus TM Marine Fuel Cleaner in the gasoline.
DuraPlus TM Marine Fuel Cleaner is available from your authorized
dealer.
Gasoline is extremely flammable and highly explosive under
certain conditions. Always stop engine and do not smoke or al-
low open flames or sparks near the boat when refueling gas tanks.
When filling the gas tank, ground the tank to the source of
gasoline by holding the hose nozzle firmly against the side of the
deck filler plate, or ground it in some other manner. This action
prevents static electricity build-up which could cause sparks and
ignite fuel vapors.
Gasolines Containing Alcohol

Many gasolines being sold today contain alcohol. Two commonly used
alcohol additives are Ethanol (ethyl alcohol) and Methanol (methyl al-
cohol).

See the boat’s Operators Manual to determine if the boat’s fuel system
is compatible with alcohol blended fuels. If it is, your engine may use
gasolines blended with no more than 10% Ethanol (ethyl alcohol) meet-
ing the minimum octane specification. Do not use any gasoline which
contains METHANOL (methyl alcohol).
Continued use of METHANOL (methyl alcohol) fuel will cause
serious damage to the fuel system.
If you use gasoline containing alcohol, be aware of the following:
• The engine will operate leaner. This may cause engine

problems such as vapor lock, low speed stalling, or hard
starting.
• Alcohol blended fuels attract and hold moisture. Moisture
can cause fuel tank corrosion. Inspect fuel tanks at least
annually. Replace corroded or leaking fuel tanks.
• Frequently inspect non-metallic parts of fuel system and
replace if excessively stiff, deteriorated or leaking.
Fuel leakage can contribute to a fire and/or explosion.
Crankcase Oil 1
DRC6834
1 2 Initial factory fill is a high quality motor oil for API Service SG/
CD. During the break-in period (20 hours), frequently check the oil level.
Somewhat higher oil consumption is normal until piston rings are seated.
The oil level should be maintained in the safe range between the Add
and Full marks on the dipstick. This range represents approximately 1
liter (1 quart). If it is necessary to add or change the motor oil, use a
quality oil with API service category SG/CD that meets General Motors
Standard GM-6094-M.
At the end of the break-in period (20 hours), change the crankcase oil 2
and replace the oil filter. Refer to Lubrication and Inspection Chart DR1563C
for recommended oil change intervals.

The use of multi-viscosity oils, such as 10W-30 or 10W-40,
is not recommended.
Draining and Filling the Engine Crankcase
Drain and refill crankcase every 100 hours of operation or once a year,
whichever occurs first.
To prevent fire and explosion, always make sure engine com-
partment is free of gasoline fumes before using any spark-produc-
ing tools such as the electric drill motor used with oil withdrawal
pump kit.

1 3 Check the motor oil level frequently with the dipstick.
When oil is to be changed, remove dipstick and withdraw oil from crank-
case through withdrawal/dipstick tube. The oil withdrawal tube is pro-
vided so oil does not have to be drained into the bilge. Withdraw oil
with a suction pump.
Fill the crankcase to the specified capacity with a quality motor oil la-
beled for service category SG/CD which meets General Motors Stan-
dard GM-6094-M. Oils conforming to this standard contain detergent
and anti-wear additives that will prolong engine life. 1
37904
When changing motor oil, select from the following chart the SAE vis-
cosity that matches the temperature range in which the boat will be
operated. If it is necessary to add motor oil, use motor oil of the same
viscosity.
THE FOLLOWING SAE

IF THE LOWEST ANTICIPATED
VISCOSITY OILS ARE
TEMPERATURE IS:
RECOMMENDED:
32° F (0° C) and above SAE 30

0° F (-18° C) to 32° F (0° C) SAE 20W-20
Below 0° F (-18° C) SAE 10W
2
34101
Disregard any reference to multi-viscosity oil printed on

engine. Such reference is intended for automotive use only and
not marine application. Do not fill above full mark. Overfilling results
in high operating temperatures, foaming (air in oil), loss of power, and
overall reduced engine life.
Crankcase Capacities
Model Less Filter With Filter 3

37210
3.0 GS 3.5 qts. (3,3 litres) 4.0 qts. (3,8 litres)
4.3 GL and Gi 4.0 qts. (3,8 litres) 4.5 qts. (4,3 litres)
5.0 GL and Gi 5.0 qts. (4,7 litres) 6.0 qts. (5,7 litres)
5.7 GS and GSi 5.0 qts. (4,7 litres) 6.0 qts. (5,7 litres)
7.4 Gi and GSi 8.0 qts. (7,5 litres) 9.0 qts. (8,5 litres)
8.2 GSi 8.0 qts. (7,5 litres) 9.0 qts. (8,5 litres)
Oil Filter
Replace the oil filter whenever the motor oil is changed. This filter is a
self-contained, screw-on type. To remove, unscrew filter canister coun-
terclockwise and discard. When attaching a new filter, be sure the gas-
ket is lightly lubricated with motor oil. Hand tighten only, run engine
and check for leaks. Do not run engine without supplying cooling wa-
ter. See parts catalog for model and filter requirements.
1-12 Engine/eng
Power Steering Fluid Level
4 5 Maintain the level with DuraPlusTM Power Trim/Tilt & Steering
Fluid. Approved power steering fluids such as GM power steering fluid
or Dexron II automatic transmission fluid can also be used. Do not overfill
the pump reservoir.
Steering System Lubrication

6 7 Every 60 days, grease the steering ram A with Volvo Penta
grease.
4
24074
Power Trim/Tilt-Fluid Level

8 At the beginning of each boating season, check the fluid level in
the reservoir as follows:
• Level should be between the “MIN” and “MAX” marks on

the reservoir.
• If necessary, add DuraPlusTM Power Trim/Tilt & Steering
Fluid. Replace the cap B and tighten securely.
5
Off-Season Storage Preparations COA6781A
There are nine steps that must be completed for off-season

storage preparation.
Step 1. Condition Fuel System:
Add DuraPlus TM Marine Fuel Stabilizer to fuel system. Follow instruc-

tions for adding conditioner and running engine as stated on the con-
tainer. This will stabilize the fuel and prevent formation of varnish and
gum in entire fuel system. Do this before continuing with the following
procedures.
6
Models equipped with 4 BBL carburetors should be run under a 3253
load at a high enough throttle setting to circulate conditioner through

the secondary fuel system.
7
29819
8
47564

Step 2. Change Motor Oil and Oil Filter:
• Engine should first be operated under load until oil is thor-

oughly warmed up. If oil is allowed to warm up before
draining, a more complete draining will be accomplished.
In addition, accumulated impurities will be held in sus-
pension by the oil and be removed during draining op-
eration.
• Remove motor oil by siphoning it out of oil withdrawal
tube. Follow the procedure under Draining and Filling
the Engine Crankcase.
• Install a new oil filter and fill crankcase with recommended
oil.
Vertical drive must be submerged in water or an accessory
flushing adaptor must be used while operating engine.
When using a flushing adaptor, remove propeller before start-
ing engine to prevent accidental contact with rotating propeller.
• With vertical drive in full down position, run engine at a

fast idle for a few minutes to distribute clean oil through
engine.
• Shut off engine and check oil level. Check oil filter gasket
for leaks. Add oil if necessary to bring oil level up to, but
not over, the full mark.
Step 3. Change Vertical Drive Lubricant:
Drain and refill with fresh DuraPlusTM GL-5 Synthetic Gear Lubricant
or Mobilube 1 SHC Fully Synthetic SAE 75W-90 (meeting or exceed-
ing MIL-L-2105C or D, API GL-4 or 5) gear lubricant. Refer to Vertical
Drive Service Manual.
Step 4. Fog Engine:
Carbureted Models Only:
• Warm up engine to ensure fuel conditioner is throughout

fuel system. Use 1/2 pint (0.24 liter) of Volvo Penta Fog-
ging Oil 12 oz. (355 ml) spray can to fog engine.
• Remove flame arrestor from carburetor. Following instruc-
tions on container, bring engine up to a fast idle and slowly
pour or spray 2/3 of fogging oil into carburetor. Keep en-
gine running while pouring fogging oil into carburetor
throat.
• Rapidly add remaining 1/3 of fogging oil to carburetor,
then reduce throttle to idle and let engine die. Turn off
ignition and replace flame arrestor. Close fuel shutoff valve
(if so equipped).

Fuel Injected Models Only:
Prepare an engine “storage mixture” in an outboard V6 six gallon fuel

tank. It must consist of 5 gallons fuel; 4 pints (64 oz.) Volvo Penta Fog-
ging Oil; and 1/3 cup (2.5 oz.) DuraPlusTM Marine Fuel Stabilizer. Mix
these ingredients thoroughly.
• Disconnect boat fuel line at engine fuel pump. Run engine

on the “storage mixture” for approximately 5 minutes at
1500 RPM. This will ensure that all fuel system and inter-
nal engine components are thoroughly protected. Shut off
engine before the “storage mixture” is used up.
Do not run engine out of fuel. The electric fuel pumps will be
damaged.
Step 5. Drain Cooling System:
When draining engine, raise or lower bow of boat to position engine in a

horizontal plane. This will provide for complete drainage of block and
manifolds. If bow of boat is higher or lower than stern, some water may
be trapped in block or manifolds. Improper or incomplete draining
may result in freeze damage to the engine, manifolds, vertical drive
or other components. Freeze damage is not covered under the war-
ranty.
3.0 GS Models
1 Starboard
1 Disconnect and drain large hose at circulating pump.
2 Port
2 Remove exhaust manifold drain plug. Clear hole with a small wire to
ensure complete drainage. 1
23907
3 Remove cylinder block drain plug. Clear hole with a small wire to
ensure complete drainage.
2
46195
Engine/eng 1-15
1 2 3
49457 44195 49458
4.3 Gi Models Only
1 Front
1 Disconnect the small water by-pass hose at the top of the thermo-
stat housing.
2 Rear
2 Disconnect the water discharge hose. Lower to the rear of the block. 4
49459
Blow out water by applying air to the by-pass hose.
4.3 GL, GS and Gi Models
3 Front
4 Remove plug and drain intake manifold.
4 Port And Starboard

5 Remove brass drain plug. 5
34091A
5 Starboard
6 Port
6
34102A
1-16 Engine/eng
5.0 GL and Gi Models
7 Front
8 Starboard
4 Remove brass drain plug.
5 Remove cylinder block drain plug. Clear hole with a small wire to 7
49458
9 Port
5.0 Gi and 5.7 GSi Models Only
1 Front
8
49460
1 Disconnect the small water by-pass hose at the top of the thermostat
housing.
2 Rear
2 Disconnect the water discharge hose. Lower to the rear of the block.
Blow out water by applying air to the by-pass hose.
5.7 GS and GSi Models
7 Front
9
3 49461
Disconnect and drain large hose at circulating pump.
8 Starboard
9 Port
Engine/eng 1-17
7.4 Gi, GSi and 8.2 GSI Models Only
1 Front
Disconnect the water bypass hose at large diameter of check valve.
• Drain or blow out check valve and short hose to thermo-

stat housing.
• Drain or blow out long hose to fuel reservoir.
1
1 Front 42863
Disconnect and drain large hose at circulating pump.
2 Starboard
Loosen clamp and remove rubber hose from exhaust manifold.
7.4, 8.2GSi only: Remove cylinder block drain plug. Clear hole with a
small wire to ensure complete drainage.
7.4Gi only: Remove Knock sensor. Clear hole with a small wire to
ensure complete drainage. 2
28283
3 Port
Loosen clamp and remove rubber hose from exhaust manifold.
Remove Knock sensor. Clear hole with a small wire to ensure com-
plete drainage.
3
28284
1-18 Engine/eng
Models With Oil Coolers
4 On models so equipped, remove the lower water hose from the
power steering cooler. If cooler is mounted horizontally, remove one
water hose A from oil cooler, loosen mounting bolt B , and tip oil cooler
downward to drain.
5 Loosen and slide hose clamps back. Remove hoses from the sup-
ply pump and drain. Crank the engine no more than 2 seconds (DO
NOT START) to expel any water trapped in the supply pump. Replace
supply pump hoses. 4
21122
Step 6. Inspect Vertical Drive Water Pickup for Obstructions.
Step 7. Disconnect the Battery and Place in Storage. When
storage will be for a considerable length of time, periodically
recharge the battery following the manufacturer’s recom-
mendations.
Step 8. Spray Entire Engine and Vertical Drive With a Rust
Preventative. Use DuraPlus TM Corrosion Spray following the
directions on the container.
5
49462
Engine/eng 1-19
Preparation for Boating After Storage
1. Install all drain plugs. Install cooling hoses and clamps. Check con-
dition of hoses, manifold end caps and clamps. Connect hoses to en-
gine and tighten clamps securely. Install boat drain plug, if removed.
2. Remove the distributor cap and rotor. Wipe the inside of the dis-
tributor cap dry with a clean cloth and spray with DuraPlus TM Corro-
sion Spray. Replace the rotor and cap.
3. Clean the battery terminals. With the ignition switch in the “OFF”
position, install the battery and attach the battery cables. Spray termi-
nals with DuraPlus TM Corrosion Spray .
4. Open the fuel shut-off valve (if so equipped) and check all
fuel line connections for leaks.
5. Check the flame arrestor and clean if necessary. Reinstall,
make sure all parts are in place and tighten nut securely.
6. Make a thorough check of the boat and engine for loose or missing
nuts and screws. Pump the bilge dry and air out the engine compart-
ment.
Safety Warning
• To prevent a possible explosion, operate the blower
as recommended by the boat manufacturer before
starting engine. If the boat is not equipped with a bilge
blower, open engine cover or hatch prior to starting
and leave open until after engine is running.
• If operating boat in water, tie boat securely to dock to
prevent forward or backward movement.
• When using a flushing adaptor, remove the propeller
before starting engine to prevent accidental contact
with rotating propeller.
7. Test run engine: Launch boat or use a flushing adaptor installed on
vertical drive.
Do not start engine out of water unless using a flushing adap-
tor. Always turn water on before starting engine. Control water pres-
sure as full water pressure may cause damage to supply pump and
engine.
8. With engine compartment open, start the engine. Monitor the
voltmeter, oil pressure and water temperature gauges frequently to be
sure all systems are operating properly. Check for fuel, oil, and wa-
ter leaks.

Engine Break-in
All engines have been run for a short period of time as a final test at the
factory. You must follow the Engine Break-In procedure during the first
20 hours of operation to ensure maximum performance and longest
engine life.
To ensure proper lubrication during the break-in period, do not
remove factory break-in oil until after the 20-hour break-in is completed.
First Two Hours

For the first five to ten minutes of operation, operate engine at a fast
idle (above 1500 RPM). After engine has reached operating tempera-
ture, momentarily reduce engine speed, then increase engine speed,
to assist break-in of rings and bearings.
During the remaining first two hours of operation, accelerate to bring
boat onto plane quickly and bring throttle back to maintain a planing
attitude. During this period, vary the engine speed frequently by accel-
erating to approximately three-fourths throttle for two to three minutes,
then back to minimum planing speed. Maintain planing attitude to avoid
excessive engine load.
DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED
PERIODS OF TIME DURING THE BREAK-IN PERIOD.
Next Eight Hours

During next eight hours, continue to operate at approximately three-
fourths throttle or less (minimum planing 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 CONSTANT RPM FOR PROLONGED PE-
RIODS OF TIME DURING THE BREAK-IN PERIOD.
Final Ten Hours

During the final ten hours of break-in, after warming engine to operat-
ing temperature, it is permissible to operate at full throttle for five to ten
minutes at a time. Momentarily reduce then increase engine speed to
assist break-in of rings and bearings. Occasionally reduce engine speed
to idle to provide cooling periods.
Engine/eng 1-21
DO NOT RUN ENGINE AT A CONSTANT RPM FOR PROLONGED
PERIODS OF TIME DURING THE BREAK-IN PERIOD.
During break-in period, be particularly observant during initial running
of engine, as follows:
1. Check crankcase oil 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 dip-
stick, rotate dipstick 180 ° in tube.
2. Watch oil pressure gauge. If indicator fluctuates whenever boat at-
titude (i.e. turning, climbing on plane, etc.) is changed, it may be the
oil pickup screen is not covered with oil. Check crankcase dipstick,
and add oil to crankcase if required. DO NOT OVERFILL. If oil level is
correct and condition still exists, check for possible gauge or oil pump
malfunction.
Oil pressure will rise as RPM increases, and fall as RPM de-
creases. In addition, cold oil will generally show higher oil pressure for
any specific RPM than hot oil. Both of these conditions reflect normal
engine operation.
3. Watch engine temperature indicator to be sure there is proper water
circulation.
Failure to follow the break-in procedure will void the engine
warranty.
At end of break-in period (20 hours), remove motor oil and replace oil
filter. Fill crankcase with recommended 4-cycle motor oil.
Operation After Break-in
After break-in, the engine can be operated at any RPM from idle to full
throttle. However, cruising at 3600 RPM or less saves fuel, reduces
noise, and prolongs engine life.
When starting a cold engine, always allow engine to warm up gradu-
ally. Never run engine at full throttle until engine is thoroughly warmed
up. Be sure to check oil level frequently during the first 50 hours of
operation, since oil consumption will be high until piston rings are prop-
erly seated.
1-22 Engine/eng
Submerged Engine
Remove engine from water as quickly as possible.
It is imperative that your dealer remove all water from the engine and
immediately relubricate all internal parts. All electrical devices must also
be dried and inspected for water damage. Delay in completing these
actions may allow extensive engine damage.
Frequently check engine compartment for gasoline fumes and exces-
sive water accumulation; water depth in bilge should be kept well below
flywheel housing.
20-Hour Check
1. Change engine oil and oil filter.
2. Check power trim/tilt reservoir for proper fluid level.
3. 3.0 GS Models Only: Clean and inspect the ceramic filter located
under the fuel pump.
4. All Models Except 3.0 GS: Change fuel filter/water separator.
5. Check flame arrestor for proper mounting.
6. Start engine and check complete fuel system for leaks.
7. Lubricate steering cable ram with Volvo Penta grease. Check
power steering pump reservoir for correct fluid level on models
equipped with power steering. Failure to properly lubricate the
steering system could lead to loss of steering control.
8. Check shift system for proper adjustment and operation.
9. Inspect exhaust system. Tighten all hose clamps, and check
for leaks.
10. Check tension on all drive belts.
11. Check all engine mount screws for tightness.

12. Carbureted Models Only: Check and adjust carburetor for cor-
rect idle mixture and RPM.
13. Check for any deficiencies, malfunctions, signs of abuse, etc. Cor-
rection of any problems at this time will prevent the worsening of a
minor problem and help ensure a trouble-free boating season.
14. Check oil level in vertical drive and add as necessary with
DuraPlus TM GL-5 Synthetic Gear Lubricant or Mobilube 1 SHC Fully
Synthetic SAE 75W-90 (meeting or exceeding MIL-L-2105C or D, API
GL-4 or 5) gear lubricant. 1
DRC7451
14. Make sure engine can achieve maximum rated RPM. See engine
specifications.
Belt Tension
• All Carbureted Models Except 3.0 Liter 1
1 Power Steering Pump Belt

2 Alternator Belt
2
47507
With engine stopped, check belt tension half way between the crank-
shaft and the appropriate accessory pulley using one of the following
methods:
1 Use belt tension gauge to set tension to 75 ± 10 lb.
(33.6 ± 44.5 N).
2 Use light thumb pressure and check for 1/4 in. (6.4
mm) belt deflection.
If belts are too tight, excessive belt and bearing wear can occur. If they
are too loose, slippage can occur, resulting in belt wear; and poor cir-
culating pump, alternator, supply pump or power steering operation. 3
Tension of a new belt should be checked after 10 hours of service and
every 50 hours thereafter.
Alt.
• All Other Models 4 Circ.
Pump
5 Serpentine belts do not require tensioning. Replace when the
tnesion indicator lines up wth the single line on the housing.
P/S
C/S or Idler
4
47508
5
GR991021
1-24 Engine/eng
Alternator Belt Adjustment
• All Carbureted Models Except 3.0 liter 6

1 Crankshaft Pulley
2 Circulating Pump Pulley
3 Alternator Pulley
4 Belt Tension Check Point
5 Supply Pump Pulley
6
DRC7451A
6 Check alternator belt tension 4 midway between the circulating
pump pulley 2 and the alternator pulley 3 .
1. Loosen alternator mounting screws and nuts, and pivot alternator
away from engine to increase belt tension.
2. While maintaining pressure on alternator, retighten top screw, bot-
tom screw and nut. Recheck belt tension.
The belts used for the alternator, circulating pump, and power
steering pump are heavy-duty. DO NOT replace with automotive belts.
Engine/eng 1-25
Power Steering Pump Belt Adjustment
• All Carbureted Models Except 3.0 liter 1
1 Power Steering Pump Pulley

3 Belt Tension Check point
Improper power steering belt adjustment will cause a loss of 1
power steering assist, resulting in hard steering. DRC7451
2 Check power steering belt tension midway between the circulat-

ing pump pulley and the power steering pump pulley.
4.3GL, 5.0GL, and 5.7GS Models
3 To increase belt tension: Loosen pump mounting bracket screws,

insert a 1/2 in. breaker bar into the square hole in the pump mounting
bracket, and pivot pump away from engine as shown. While maintain-
ing pressure on pump, retighten all mounting screws. Recheck belt
tension. Never pry against the pump reservoir or pull filler neck. 2
16067
3
24278
1-26 Engine/eng
Positive Closed-Type Ventilation System
A malfunctioning closed crankcase ventilation system may be indicated
by loping or rough engine idle. Do not attempt to compensate for this
idle condition by disconnecting the crank-case ventilation system and
making carburetor adjustments. The removal of the crankcase venti-
lation system from the engine will adversely affect fuel economy
and engine ventilation with resultant shortening of engine life. To
determine whether loping or rough idle condition is caused by a mal-
functioning crankcase ventilation system, perform the following tests.
With Engine Idling

1. Remove PCV valve from its mounting, but leave vacuum inlet side
connected to hose. If the valve is functioning properly and not plugged,
a hissing noise will be heard as air passes through valve. A strong
vacuum will be felt when a finger is placed over valve inlet. Check for
vacuum leaks in hose line and at all connections.
2. Reinstall PCV valve, then remove crankcase 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.
With Engine Stopped

Remove PCV valve from its mounting and shake it. A metallic clicking
noise should be heard, indicating that valve parts are free, and not stick-
ing.
If ventilation system passes these two tests, it can be considered func-
tionally OK, and no further service is required. If it fails either test, re-
place PCV valve and repeat Engine Idling Test.
If system still does not pass test, clean ventilation system hoses and all
passages to induction system in accordance with established proce-
dures.
Servicing PCV Valve
Do not attempt to clean crankcase ventilation regulator valve, it

should be 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 low-volatility, petroleum-
base solvent and dry with compressed air.
Engine/eng 1-27
Troubleshooting - System Isolation
The following is to help you isolate a malfunction of one or possibly several systems. After determining which sys-
tems are related to the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.
Engine should crank at specified RPM. If not, check for:
Cranking 1. Discharged or dead battery

System 2. Loose or corroded connections
3. Cranking System Troubleshooting Chart in the Electrical/
Ignition/Fuel Service Manual
Must have good spark at spark plugs. If not, check the:
1. Distributor cap and rotor

Engine 2. Coil and spark plug leads
Ignition
Does Not 3. Ignition timing
System
Run 4. Automatic spark advance
5. Appropriate Ignition Troubleshooting Chart in the
Electrical/Ignition/Fuel Service Manual
6. EFI Models: refer to GM Diagnostic Manual
EFI Models: refer to GM Diagnostic Manual
Non-EFI Models: Carburetor accelerator pump should squirt fuel into

venturi when throttle is advanced. If not, check the:
Fuel
System 1. Fuel tank, valves, and lines
2. Fuel pumps and filter
3. Carburetor and filter
4. Boat Fuel System Troubleshooting Chart
5. Carburetor Troubleshooting Chart
6. Engine Fuel System Troubleshooting Chart
Check the following:
1. Compression
2. Ignition system
Engine Runs 3. Fuel and carburetor/injector system
Improperly 4. Lubrication system
5. Cooling system
6. Vertical drive and propeller
7. Vertical drive gear ratio and installation
8. PCV Valve
9. Engine Troubleshooting Guides
1-28 Engine/eng
Engine Troubleshooting Guides
EFI Engines Only: Refer to EFI Diagnostic Service Manual.
These guides were written to help you trace the symptoms of the trouble
to the source, without having to read through and prove every possibil-
ity. Much of the information here will be familiar to well informed me-
chanics.
Also, many factors will seem insignificant but when you think of it, usu-
ally the toughest problem to troubleshoot is caused by the smallest er-
ror. The greatest aid to solving a service problem is information. Start
gathering information from the boat operator and write it on his job card
or work ticket. Find out pertinent facts, such as:
• When did this trouble start?
• How was the boat loaded?
• Did the trouble occur suddenly, or start gradually?
Analyze this information and try to match it to similar situations you
have experienced in the past. Keep in mind the fundamental rules:
1. COMPRESSION - Mixture inducted into cylinder and compressed.
2. SPARK - Proper intensity at the proper time.
3. FUEL - Proper mixture of air and fuel.
These are very old rules, but necessary for the engine to run. Use these
charts and the service information they refer to. Do not try to remember
tolerances, settings, measurements, etc., as they are written in the ser-
vice manual. Leave your mind free to analyze the problem.
Following is a list of the troubleshooting guides which may be found on
the pages indicated.
Title ................................................................................................... Page
1. Engine Will Not Crank ................................................................. 1-30
2. Engine Cranks, But Will Not Start .............................................. 1-30
3. Hard Starting - Cold Engine ........................................................ 1-31
4. Hard Starting - Hot Engine .......................................................... 1-31
5. Engine Runs Rough .................................................................... 1-32
6. Engine Noises and Vibrations .................................................... 1-32
7. Engine Overheats ........................................................................ 1-33
8. Engine Dies Out .......................................................................... 1-34
9. Engine Won’t Reach Operating RPM ......................................... 1-34
10. Defective Engine Lubricating System ........................................ 1-35
11. Low Battery Voltage After Short Storage ................................... 1-35
Engine/eng 1-29
Engine Will Not Crank
Starter Circuit - Check:
• Battery condition: weak, dead, sulfated, bad cells
• Battery cables for loose or corroded connections
• Shorted or open ignition switch
• Starter motor and solenoid for shorts, grounds or open
circuits
• Starter assist solenoid/starter relay
• Circuit breakers
• Wiring from battery to ignition switch
• See Electrical/Ignition/Fuel Service Manual
Engine Cranks, But Will Not Start

Ignition Circuit - Check:
• Primary circuit wiring from ignition switch to ignition coil/
ignition module
• Secondary circuit wiring from coil to spark plug
• Spark plugs for proper gap, fouling, burned electrodes,
cracked or dirty insulator
• Low battery voltage
Fuel System - Check:
• Quantity and condition of fuel in boat tank
• Operation and flow capacity of boat anti-siphon valve
• Fuel tank vent is unrestricted
• Fuel tank pick-up screen is clean
• Correct diameter/unrestricted boat fuel lines
• Fuel shutoff and multiple tank valves are open and oper-
ating properly
• Fuel pump vent hose for signs of fuel or oil that would
indicate a fuel pump failure.
• Fuel pump/relay/circuit breaker operation
• External fuel filter canister and carburetor filter
• Carburetor accelerator pump
• See Electrical/Ignition/Fuel System Service Manual
Cylinder Compression - Check
• Conduct test following procedure in this section, and com-
pare readings to Compression Limit Chart
1-30 Engine/eng
Hard Starting - Cold Engine
Ask these questions first:
Has Engine Always Done This? Check:

• Carburetor choke operation and adjustment
• Fuel lines for obstructions
• For debris inside fuel tank
Was Engine Used For A Long Time? Check:
• For clean external canister and carburetor fuel filters
• Empty carburetor float bowl due to evaporation
• Water in fuel due to condensation
• Fuel quality deterioration
Is This A New Condition? Check:
• Carburetor accelerator pump
• Fuel system for leaks, dirt, or obstructions
• Engine timing and ignition system
Hard Starting - Hot Engine

Ask these questions first:
Has Engine Always Done This? Check:

Is This A New Condition? Check:
• Brand, type or octane of fuel
• Spark plugs
• Water in fuel
• Condition of battery and cables
• Starter motor for overheat damage
Did Engine Refuse To Start After Being Run? Check:
• Ignition system primary circuit
• Ignition coil/ignition module
• Engine timing
Engine/eng 1-31
Engine Runs Rough
If At Slow Speed - Check:
• Idle speed and idle mixture
• Engine timing and spark plugs
• Fuel pump pressure
• Water or contaminants in fuel
• Carburetor or manifold vacuum leak
• Internal carburetor fuel leak
If At High Speed - Check:
• Air leak on suction side of fuel system
• Too low octane fuel
• Ignition system secondary circuit
• Engine timing
• Wrong model or size carburetor, improper main jets or
power valve, defective secondary fuel circuit, secondary
vacuum diaphragm failure
• External canister and carburetor fuel filters
• Fuel pump pressure
• Engine compression
• Water or contaminants in fuel, water in cylinders
• See General Information section and Electrical/Igni-
tion/ Fuel System Service Manual
Engine Noises and Vibrations

Valves - Hydraulic Lifters
• Rapping only when starting (oil too heavy for prevailing
weather, varnish on lifter, oil needs to be changed)
• Intermittent rapping (leakage at lifter check ball)
• Idle noise (excessive leak down rate, faulty check ball
seat)
• Generally noisy (excessive oil in crankcase, stuck lifter
plunger)
• Loud noise at operating temperature (scored lifter plunger,
fast leak down rate, oil viscosity too light for prevailing
weather or operating temperatures)
• See appropriate Engine section
1-32 Engine/eng
Engine Noises and Vibrations, Cont.
Ignition System (Ping or Knock)
• Improper tuning
• Incorrect spark plug wire routing
• Use higher octane fuel
Cooling System
• Supply pump
• Loose belts, pulleys
• See Cooling System section
Mountings
• Loose, broken or worn engine mounts
• Loose lag screws holding mounts to stringer
Crankshaft Balancer or Flywheel
• Loose bolt(s)
Alternator
• Loose pulley, worn bearings
• Loose mounting bolts
Vertical Drive
• Failed U-joints or gimbal bearing
• Damaged internal drive components
• Worn, bent or broken propeller hub or blades
• Loose, worn or damaged engine coupler
Engine Overheats - Check:

• Actual engine temperature by verifying with an accurate
thermometer
• Gauge operation and wiring circuit
• Sending unit operation and wiring circuit
• Supply pump, circulating pump and belts
• Water intake screens for blockage
• Thermostat
• Water supply hoses
• Engine timing
• Water leaks on pressure side of supply pump
• Air leaks on suction side of supply pump
• Engine compression
Engine/eng 1-33
Engine Dies Out
Loss Of, Or Out Of, Fuel - Check:
• Fuel gauge operation and wiring
• Fuel level in tank
• Water or debris in fuel
• Fuel pickup tube and screen blockage
• Fuel tank vent blockage
• Plugged external canister or carburetor fuel filters
• Air leak on suction side of fuel system
• Fuel leak on pressure side of fuel system
• Inoperative, restricted or incorrectly sized anti-siphon valve
• Boat fuel lines too small in diameter
• Fuel pump pressure and suction
• Carburetor cleanliness and operation
Loss Of Ignition - Check:
• Primary and secondary ignition circuits
• Ignition switch
• Circuit breakers
• Wiring between engine and dash
• Main engine harness wiring
Engine Stops Or Dies Out Due To Seizure - Check:
• Vertical drive for internal damage
• Oil pressure gauge and crankcase oil level
• Temperature gauge and cooling system operation
• Internal engine components as required
Engine Won’t Reach Operating RPM - Check:

• Fuel type or octane
• Propeller pitch or diameter, damaged blades, slipping hub
• Crankcase oil volume
• Marine growth on hull and drive
• Wrong vertical drive gear ratio
• Operating at high altitude
• Restricted carburetor air intake
• Restricted exhaust outlets in engine, transom bracket 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
• Remote control cables and linkage for proper attachment
and travel
1-34 Engine/eng
Defective Engine Lubricating System
Engine Components - Check:
• Clogged or incorrect oil filter
• Worn oil pump gears, cover or shaft
• Worn or collapsed oil pump relief valve spring, or foreign
material caught on valve seat
• Oil pump relief valve plunger loose in cover
• Damaged filter bypass grommet
• Clogged oil pickup screen, broken tube or housing
• Plugged crankshaft or blocked oil galleys
• Dirty or defective hydraulic lifters, clogged push rod pas-
sages
• Poor quality, incorrect viscosity or quantity of oil
• Incorrect hose routing on remote filter systems
• Water in crankcase oil from condensation, defective head
gasket, oil cooler, or cracked manifold/block water pas-
sages
Oil Pressure Warning System - Check:
• Oil gauge/warning horn operation and wiring
• Engine temperature
• Oil pressure gauge and warning horn sender operation
and wiring
Low Battery Voltage After Short Storage

Engine/Boat Components - Check:
• All electrical accessories including ignition circuit off
• Disconnect main battery negative cable from battery
• Connect ammeter or 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 movement no matter how slight indicates draw
from battery
• Disconnect main engine harness 10-Pin Connector
1. Meter drops back to “0”, problem caused by boat sys-
tem, continue to isolate each boat electrical acces-
sory until problem is found
2. Meter does not drop back to “0”, problem caused by
engine electrical system, continue to isolate each en-
gine electrical accessory until problem is found
• Repair or replace components as necessary
Engine/eng 1-35
Tune-up Specifications
Engine Firing Order
3.0 GS ....................................................................................................... 1-3-4-2

4.3 GL and Gi ..................................................................................... 1-6-5-4-3-2
5.0 GL and Gi ............................................................................... 1-8-4-3-6-5-7-2
5.7 GS and GSi ............................................................................ 1-8-4-3-6-5-7-2
7.4 Gi and GSi ............................................................................. 1-8-4-3-6-5-7-2
8.2 GSi ......................................................................................... 1-8-4-3-6-5-7-2
Fuel Pump Pressure
Carbureted Models Only ........................................................................ 5 - 7 PSI

(34-48 kPa)
at idle RPM
Gi and GSi models: See GM EFI Diagnostic Service Manual
Crankcase Capacities
Model Less Filter With Filter

4.5 qts. (4,3
3.0 GS 3.5 qts. (3,3 litres) litres)
4.3 GL, Gi 4.0 qts. (3,8 litres) 6.0 qts. (5,7
5.0 GL, Gi 5.0 qts. (4,7 litres) litres)
5.7 GS, GSi 5.0 qts. (4,7 litres) 6.0 qts. (5,7
7.4 Gi, GSi 8.0 qts. (7,5 litres) litres)
8.2 GSi 8.0 qts. (7,5 litres) 9.0 qts. (8,5
litres)
1-36 Engine/eng
Idle* and Operating RPM
3.0 GS
Idle ......................................................................................... 650-750 RPM
W.O.T.# ............................................................................. 4200-4600 RPM
4.3 GL
Idle ......................................................................................... 550-650 RPM
W.O.T.# ............................................................................. 4200-4600 RPM
4.3 Gi
Idle ..................................................................... 600 RPM - Not Adjustable
W.O.T.# ............................................................................. 4400-4800 RPM
5.0 GL
Idle ......................................................................................... 550-650 RPM
W.O.T.# ............................................................................. 4400-4800 RPM
5.0 Gi
W.O.T.# ............................................................................. 4600-5000 RPM
5.7 GS
Idle ......................................................................................... 550-650 RPM
W.O.T.# ............................................................................. 4400-4800 RPM
5.7 GSi
W.O.T.# ............................................................................. 4600-5000 RPM
7.4 Gi
W.O.T.# ............................................................................. 4200-4600 RPM
7.4 GSi
W.O.T.# ............................................................................. 4800-5200 RPM
8.2 GSi
W.O.T.# ............................................................................. 4600-5000 RPM
* In Forward Gear # Wide Open Throttle
Engine/eng 1-37
Oil Pressure - All Models
800 RPM ...................................................................... 15-30 PSI (103-207 kPa)

2000 RPM .................................................................... 40-60 PSI (276-414 kPa)
Timing and Fuel Requirements
3.0 GS .................................................................. -2° ATDC - w/86 AKI or higher

Shunt (Volvo Penta 885163-6) required
4.3 GL ...................................................................... 6° BTDC w/89 AKI or higher
1° BTDC - w/86-88 AKI
Shunt (Volvo Penta 885163-6) required
4.3 Gi ....................................................................... 8° BTDC w/86 AKI or higher
set timing with diagnostic leads shorted*
5.0 GL ................................................................. 10° BTDC - w/89 AKI or higher
5° BTDC - w/86-88 AKI
5.0 Gi ....................................................................... 8° BTDC w/86 AKI or higher
5.7 GS ................................................................ 12° BTDC - w/89 AKI or higher
7° BTDC - w/86-88 AKI
5.7 GSi .................................................................... 8° BTDC w/86 AKI or higher
7.4 Gi ..................................................................... 10° BTDC w/86 AKI or higher
7.4 GSi .................................................................. 10° BTDC w/86 AKI or higher
8.2 GSi .................................................................. 10° BTDC w/86 AKI or higher
All Timing Set At Idle RPM

* At the diagnostic connector, use the Code Tool. If a Code Tool is not available,
use a short jumper lead to connect the white/black wire to the black wire inside
the connector. Refer to appropriate section of the GM EFI Diagnostic Service
Manual.
1-38 Engine/eng
Spark Plugs
3.0 GS
Spark Plug ......................................... AC-MR43LTS, Champion RS12YC

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
4.3 GL, Gi

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
5.0 GL

Gap .............................................................................. 0.035 in. (0.89 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
5.0 Gi
Spark Plug .................................................................. Champion RS12YC

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque .............................................................................. 20 ft. lb. (27N m)
•
5.7 GS

Gap .............................................................................. 0.035 in. (0.89 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
5.7 GSi

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
7.4 Gi

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
7.4 GSi
Spark Plug ........................................... AC-MR43T, Champion RV15YC4

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
8.2 GSi
Spark Plug ........................................... AC-MR43T, Champion RV15YC4

Gap ............................................................................ 0.045 in. (1.143 mm)
Torque ............................................................................. 20 ft. lb. (27 N m)
•
Engine/eng 1-39
General Torque Specifications
The following specifications are for nut and screw sizes not having specific torque recommendations.
U.S. Screw Sizes Ft. Lbs. N•m Metric Thread Sizes Ft. Lbs. N•m
No. 6 ... 1,1-1,6

No. 8 ... 2,2-2,8
M-6 6-9 8-12
No. 10 2-3.5 2,7-4,7
M-8 14-21 19-28
No. 12 3-4 4,1-5,4
M-10 28-40 38-54
1/4-20 5-7 6,8-9,5
M-12 50-71 68-96
5/16-18 12-14 16-19
M-14 80-114 108-155
3/8-16 20-25 27-34
7/16-14 32-40 43-54
Pound-inches x 0.11298 = newton-meters N m •
Pound-feet x 1.3558 = newton-meters N m •
Battery Cable Requirements

The battery should be mounted as close to the engine as practical to
cut down on battery cable lengths. Follow the recommendations be-
low.
• 0-10 Feet 0 Gauge

• 10-15 Feet 2/0 Gauge
• 15-20 Feet 4/0 Gauge
These specifications do not apply to aluminum battery cables.
Volvo Penta does not recommend the use of aluminum battery cables.
To prevent possible explosion or fire, do not substitute au-
tomotive parts for the following marine components: starter, al-
ternator, distributor and related ignition parts, spark plug leads,
solenoids, carburetor (and related parts), fuel pump or fuel filter
canister. These components have been specifically designed not
to emit fuel vapors or to cause ignition of fuel vapors in the bilge.

METRIC CONVERSION CHART
LINEAR ENERGY OR WORK

inches X 25.4 = millimeters (mm) foot-pounds X 1.3558 = joules (j)
feet X 0.3048 = meters (m) calories X 4.187 = joules (j)
yards X 0.9144 = meters (m) Btu X 1055 = joules (j)
miles X 1.6093 = kilometers (km) watt-hours X 3500 = joules (j)
inches X 2.54 = centimeters (cm) kilowatt - hrs X 3.600 = megajoules (MJ)
AREA FUEL ECONOMY AND FUEL CONSUMPTION

inches2 X 645.16 = millimeters2 (mm2) miles/gal X 0.42514 = kilometers/liter (km/l)
inches2 X 6.452 = centimeters2 (cm2) Note:
feet2 X 0.0929 = meters2 (m2) 235.2/(mi/gal) = liters/100 km
2 2 2
yards X 0.8361 = meters (m ) 235.2/(Iiters/100 km) = mi/gal
4 2
acres X 0.4047 = hectares (10 m ) (ha) LIGHT
2
miles X 2.590 = kilometers 2 (km2) footcandles X 10.76 = lumens/meter2 (lm/m2)
VOLUME PRESSURE OR STRESS
inches3 X 16387 = millimeters3 (mm3) inches HG (60°F) X 3.377 = kilopascals (kPa)
inches3 X 16.387 = centimeters3 (cm3) pounds/sq in X 6.895 = kilopascals (kPa)
inches3 X 0.01639 = liters (l) inches H2O (60°F) X 0.2488 = kilopascals (kPa)
quarts X 0.94635 = liters (l) bars X 100 = kilopascals (kPa)
gallons X 3.7854 = liters (l) pounds/sq ft X 47.88 = pascals(Pa)
feet3 X 28.317 = liters (l)
POWER
feet3 X 0.02832 = meters3 (m3)
horsepower X 0.746 = kilowatts (kW)
fluid oz X 29.57 = milliliters (ml)
ft-lbf/min X 0.0226 = watts (W)
yards3 X 0.7646 = meters3 (m3)
TEMPERATURE
MASS
°Celsius = 0.556 X (°F -32)
ounces (av) X 28.35 = grams (g)
°Fahrenheit = (1.8 X °C) +32
pounds (av) X 0.4536 = kilograms (kg)
tons (2000 lb) X 907.18 = kilograms (kg) TORQUE
tons (2000 lb) X 0.90718 = metric tons (t) pound-inches X 0.11299 = newton-meters (N m) •
pound-feet X 1.3558 = newton-meters (N m) •
FORCE
ounces - f (av) X 0.278 = newtons (N) VELOCITY
pounds - f (av) X 4.448 = newtons (N) miles/hour X 1.6093 = kilometers/hour (km/h)
kilograms - f X 9.807 = newtons (N) feet/sec X 0.3048 = meters/sec (m/s)

kilometers/hr X 0.27778 = meters/sec (m/s)
ACCELERATION
miles/hour X 0.4470 = meters/sec (m/s)
feet/sec2 X 0.3048 = meters/sec2 (m/S2)
inches/sec2 X 0.0254 = meters/sec 2 (m/S2)
Engine/eng 1-41
Drill Size Conversion Chart
SHOWING MILLIMETER SIZES, FRACTIONAL AND
DECIMAL INCH SIZES AND NUMBER DRILL SIZES
Milli- Dec. Fract- Num- Milli- Dec. Fract- Num- Milli- Dec. Fract- Num- Milli- Dec. Fract- Num- Milli- Dec. Fract-
Meter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional
.1 .0039 1.75 .0689 ... .1570 22 6.8 .2677 10.72 .4219 27/64
.15 .0059 ... .0700 50 4.0 .1575 6.9 .2716 11.0 .4330
.2 .0079 1.8 .0709 ... .1590 21 ... .2720 I 11.11 .4375 7/16
.25 .0098 1.85 .0728 ... .1610 20 7.0 .2756 11.5 .4528
.3 .0118 ... .0730 49 4.1 .1614 ... .2770 J 11.51 .4531 29/64
... .0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11.91 .4687 15/32
.35 .0138 ... .0760 48 ... .1660 19 ... .2811 K 12.0 .4724
... .0415 79 1.95 .0767 4.25 .1673 7.14 .2812 9/32 ... 12.30 .4843 31/64
.39 .0156 1/64 ... 1.98 .0781 5/64 ... 4.3 .1693 7.2 .2835 12.5 .4921
.4 .0157 ... .0785 47 ... .1695 18 7.25 .2854 12.7 .5000 1/2
... .0160 78 2.0 .0787 4.37 .1719 11/64 ... 7.3 .2874 13.0 .5118
.45 .0177 2.05 .0807 ... .1730 17 ... .2900 L 13.10 .5156 33/64
... .0180 77 ... .0810 46 4.4 .1732 7.4 .2913 13.49 .5312 17/32
.5 .0197 ... .0820 45 ... .1770 16 ... .2950 M 13.5 .5315
... .0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13.89 .5469 35/64
... .0210 75 2.15 .0846 ... .1800 15 7.54 .2968 19/64 ... 14.0 .5512
.55 .0217 ... .0860 44 4.6 .1811 7.6 .2992 14.29 .5624 9/16
... .0225 74 2.2 .0866 ... .1820 14 ... .3020 N 14.5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .3031 14.68 .5781 37/64
... .0240 73 ... .0890 43 4.75 .1870 7.75 .3051 15.0 .5906
... .0250 72 2.3 .0905 4.76 .1875 3/16 ... 7.8 .3071 15.08 .5937 19/32
.65 .0256 2.35 .0925 4.8 .1890 12 7.9 .3110 15.48 .6094 39/64
... .0260 71 ... .0935 42 ... .1910 11 7.94 .3125 5/16 ... 15.5 .6102
... .0280 70 2.38 .0937 3/32 ... 4.9 .1929 8.0 .3150 15.88 .6250 5/8
.7 .0276 2.4 .0945 ... .1935 10 ... .3160 O 16.0 .6299
... .0292 69 ... .0960 41 ... .1960 9 8.1 .3189 16.27 .6406 41/64
.75 .0295 2.45 .0964 5.0 .1968 8.2 .3228 16.5 .6496
... .0310 68 ... .0980 40 ... .1990 8 ... .3230 P 16.67 .6562 21/32
.79 .0312 1/32 ... 2.5 .0984 5.1 .2008 8.25 .3248 17.0 .6693
.8 .0315 ... .0995 39 ... .2010 7 8.3 .3268 17.06 .6719 43/64
... .0320 67 ... .1015 38 5.16 .2031 13/64 ... 8.33 .3281 21/64 ... 17.46 .6875 11/16
... .0330 66 2.6 .1024 ... .2040 6 8.4 .3307 17.5 .6890
.85 .0335 ... .1040 37 5.2 .2047 ... .3320 Q 17.86 .7031 45/64
... .0350 65 2.7 .1063 ... .2055 5 8.5 .3346 18.0 .7087
.9 .0354 ... .1065 36 5.25 .2067 8.6 .3386 18.26 .7187 23/32
... .0360 64 2.75 .1082 5.3 .2086 ... .3390 R 18.5 .7283
... .0370 63 2.78 .1094 7/64 ... ... .2090 4 8.7 .3425 18.65 .7344 47/64
.95 .0374 ... .1100 35 5.4 .2126 8.73 .3437 11/32 ... 19.0 .7480
... .0380 62 2.8 .1102 ... .2130 3 8.75 .3445 19.05 .7500 3/4
... .0390 61 ... .1110 34 5.5 .2165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 ... .1130 33 5.56 .2187 7/32 ... ... .3480 S 19.5 .7677
... .0400 60 2.9 .1141 5.6 .2205 8.9 .3504 19.84 .7812 25/32
... .0410 59 ... .1160 32 ... .2210 2 9.0 .3543 20.0 .7874
1.05 .0413 3.0 .1181 5.7 .2244 ... .3580 T 20.24 .7969 51/64
... .0420 58 ... .1200 31 5.75 .2263 9.1 .3583 20.5 .8071
... .0430 57 3.1 .1220 ... .2280 1 9.13 .3594 23/64 ... 20.64 .8125 13/16
1.1 .0433 3.18 .1250 1/8 ... 5.8 .2283 9.2 .3622 21.0 .8268
1.15 .0452 3.2 .1260 5.9 .2323 9.25 .3641 21.04 .8218 53/64
... .0465 56 3.25 .1279 ... .2340 A 9.3 .3661 21.43 .8437 27/32
1.19 .0469 3/64 ... ... .1285 30 5.95 .2344 15/64 ... ... .3680 U 21.5 .8465
1.2 .0472 3.3 .1299 6.0 .2362 9.4 .3701 21.83 .8594 55/64
1.25 .0492 3.4 .1338 ... .2380 B 9.5 .3740 22.0 .8661
1.3 .0512 ... .1360 29 6.1 .2401 9.53 .3750 3/8 ... 22.23 .8750 7/8
... .0520 55 3.5 .1378 ... .2420 C ... .3770 V 22.5 .8858
1.35 .0513 ... .1405 28 6.2 .2441 9.6 .3780 22.62 .8906 57/64
... .0550 54 3.57 .1406 9/64 ... 6.25 .2460 D 9.7 .3819 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23.02 .9062 29/32
1.45 .0570 ... .1440 27 6.35 .2500 1/4 E 9.8 .3858 23.42 .9219 59/64
1.5 .0591 3.7 .1457 6.4 .2520 ... .3860 W 23.5 .9252
... .0595 53 ... .1470 26 6.5 .2559 9.9 .3839 23.81 .9375 15/16
1.55 .0610 3.75 .1476 ... .2570 F 9.92 .3906 25/64 ... 24.0 .9449
1.59 .0625 1/16 ... ... .1495 25 6.6 .2598 10.0 .3937 24.21 .9531 61/64
1.6 .0629 3.8 .1496 ... .2610 G ... .3970 X 24.5 .9646
... .0635 52 ... .1520 24 6.7 .2638 ... .4040 Y 24.61 .9687 31/32
1.65 .0649 3.9 .1535 6.75 .2657 17/64 ... 10.32 .4062 13/32 ... 25.0 .9843
1.7 .0669 ... .1540 23 6.75 .2657 ... .4130 Z 25.03 .9844 63/64
... .0670 51 3.97 .1562 5/32 ... ... .2660 H 10.5 .4134 25.4 1.0000 1
DR2949-ENG
1-42 Engine/eng
SYMBOLS
Certain symbols or combinations of symbols may appear on your stern drive or on their accessories. It is very
important that you understand their meaning or purpose. If any symbol is not clearly understood, see your
authorized dealer.
Safety Warning Symbols
Risk of serious injury

Be Careful Poisonous
Follow instructions
Fire Hazard
Contents Under Pressure
Position Indicator Symbols

Shift Positions
NEUTRAL
Raise Lower FORWARD REVERSE
Condition Symbols
Voltmeter
Hour Meter Ammeter r/min Tachometer
- + Battery
Oil Filter Fuel Filter
Water Temperature Emergency Stop Oil Pressure
Instructional Symbols
Use unleaded gasoline Read Operator’s Manural

Pb Gasoline is present before operating product Oil Fill
DR3847
Engine/eng 1-43
Periodic Maintenance Chart
Items marked Safety Warning are safety related service points to prevent mechanical failures, fire and explo-
sion. Make sure the safety related service is performed at these points and at the intervals specified.
Engine
Service Point Every 25 Hours Every 50 Hours Recommendations

or as Specified or as Specified
Alternator Belt, Check belt for tension and Adjust tension to specifications. Replace
Power Steering Pump Belt deterioration. deteriorated belt. Keep spare on board.
Check for damage to grill Seasonally clean and inspect. If damaged, replace with specified Volvo
Flame Arrestor area. Must be firmly Damaged unit may allow backfire Penta or OMC parts. If dirty, clean in
attached. flame to enter engine compartment. solvent, and air dry before installation.
Crankcase Check oil level daily Drain and refill every 100 hours or See specifications.
once a year, whichever comes first.
Engine Alignment Seasonally Check engine alignment.
PCV Valve Check every 100 hours or once a Check for operation.
year.
Oil Filter Replace See parts catalog for part number.
Steering

Power Steering Pump Check reservoir fluid level. Use DuraPlusTM Power Trim/Tilt &
Steering Fluid or OMC Power Trim/Tilt
and Power Steering Fluid.
Steering Cable Ram Lubricate every 50 hours or every Use Volvo Penta Grease or OMC
60 days, whichever comes first. Triple-Guard grease.
Cooling

Engine Check for leaks. Check belts Seasonally check for hose Drain after operation in freezing
for correct tension. deterioration. Check supply pump temperatures, or during season lay up.
operation. Repair as required. Tighten connections. Replace supply
pump impeller every 2 years.
Transom Bracket Seasonally check for hose Drain after operation in freezing
deterioration. temperatures, or during seasonal lay up.
Vertical Drive Check water pickup screens Drain after operation in freezing
for obstructions. temperatures, or during seasonal lay up.

Periodic Maintenance Chart - Continued
Controls

Control Linkage Check operation. Check Adjust as required. Use Volvo Penta
adjustment and lubricate. Grease or OMC Triple-Guard grease.
Check for smooth shifting Seasonally or every 100 hours, Replace shift cable if necessary.
Shift System in and out of forward and check cable and shift assist for
reverse gears. proper operation.
Boat

Check for fuel fumes and Repair or replace defective

Bilge Area leaks. components.
Hull Check for marine growth. Clean boat bottom.
Preparation for Boating Season See Preparation for Boating.
Safety Equipment Check remote control and All boat safety equipment should be Be sure you have U.S.C.G. required
emergency stop switch, if checked for condition and proper equipment aboard (check Coat Guard
equipped, for proper operation. regulations).
operation.
Storage See Off-Season Storage.
Trailer Seasonally repack wheel bearings. Use OMC EP/Wheel Bearing grease
or equivalent.

Section 2
General Engine Mechanical
V6 and V8 Models
Table of Contents
Assembling Piston and Connecting Rod ............ 2-10

Camshaft
Cylinder Head
Assembly ............................................................ 2-18
2
Bearings .............................................................. 2-13 Cleaning and Inspection .................................... 2-15
Bearing Installation ............................................ 2-14 Disassembly ....................................................... 2-15
Bearing Removal ................................................ 2-13 Repair .................................................................. 2-17
Cleaning and Inspection .................................... 2-13 Reaming Valve Guides ................................... 2-17
Measurements .................................................... 2-14 Valve Grinding ................................................. 2-17
Cleanliness and Care .............................................. 2-2 Valve Seat Grinding ........................................ 2-17
Crankshaft and Connecting Rod Bearings Engine Gaskets, Replacing .................................... 2-4
Cleaning and Inspection .................................... 2-18 General Description ................................................ 2-2
Measuring Bearing Clearance ........................... 2-19 Piston and Connecting Rod ................................... 2-8
Connecting Rod Side Clearance .......................... 2-21 Measuring Piston to Pin Clearance ....................... 2-9
Crankshaft End Play ............................................. 2-21 Installing Piston Rings .......................................... 2-11
Crankshaft Runout ................................................ 2-21 Piston Selection .................................................... 2-10
Cylinder Bores RTV Sealer / Anaerobic Gasket Eliminator ............ 2-2
Boring ................................................................... 2-6 Special Tools ......................................................... 2-23
Honing ................................................................... 2-7 Thread Repair ........................................................ 2-22
Measuring Taper and Out-of-Round ................... 2-4
Reconditioning ..................................................... 2-5
Removing Ridge ................................................... 2-6
Safety Warnings
Before working on any part of the engine, read the Safety section
at the end of this manual.
Always use the correct fastener in the proper location. When you
replace a fastener, use ONLY the exact part number for that appli-
cation. The text will call out those fasteners that require replace-
ment after removal. The text will also call out the fasteners that
require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, do not use supplement coatings
(paints, greases, or other corrosion inhibitors) on threaded fas-
teners or fastener joint interfaces. Generally, such coatings ad-
versely affect the fastener torque and the joint clamping force,
and may damage the fastener.
When you install fasteners, use the correct tightening sequence
and tightening specifications. Following these instructions can
help you avoid damage to parts and systems.
Engine/eng 2-1
General Description
The engine repair information described in this section explains how
to clean, inspect, and measure certain engine components. Use this
section along with the proper engine repair section for the correct dis-
assembly 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 many machined, honed, polished, and
lapped surfaces with very close tolerances. Whenever valve train, cyl-
inder head, crankshaft, piston, and connecting rod components are
removed for 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 passage into the cylinder and cause extensive
damage when the engine is started.
When any internal engine parts are serviced, care and cleanliness are
important. Apply a liberal coating of engine oil to friction areas during
assembly to protect and lubricate the surfaces during initial operation.
Throughout this section, it should be understood that proper cleaning
and protection of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop practice even if
not specifically stated.
Use of RTV Sealer and Anaerobic Gasket

Eliminator
Two types of sealants are commonly used in the engines covered by
this manual. These are RTV sealer and anaerobic “gasket eliminator”
sealer.
It is important that these sealers be applied properly and in the proper
place to prevent oil leaks. THE TWO TYPES OF 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. Com-
mon examples are oil pans and valve rocker arm cov-
ers.
2-2 Engine/eng
Anaerobic gasket eliminator hardens in the absence of
air. This sealer is used where two rigid parts (such as
castings) are assembled together. When two rigid parts
are disassembled and no sealer or gasket is readily no-
ticeable, the parts were probably assembled using gas-
ket eliminator.
Using RTV Sealer
1. Do not use RTV in areas where extreme temperatures are expected,

such as exhaust manifold or head gaskets, or where gasket eliminator
is specified.
2. Use a rubber mallet to separate components sealed with RTV. Bump
the part sideways to shear the RTV sealer. Bumping should be done at
bends or reinforced areas to prevent distortion of parts. RTV is weaker
in shear (lateral) strength than in tensile (vertical) strength.
Attempting to pry or pull components apart may result in dam-
age to the part.
3. Remove all 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 recommendations and directions that are on the can. Do not use
any other method or technique to remove gasket 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. Abra-
sive pads also produce a fine grit that the oil filter cannot remove from
the oil. This grit is abrasive and has been known to cause internal en-
gine damage.
4. Apply RTV to one of the clean surfaces. Use a bead size as specified
in the procedure. Run the bead to 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 when the bolt is tightened.
5. Assemble components while RTV is still wet (within 3 minutes). Do
not wait for RTV to skin over.
6. Torque bolts to specifications. Do not overtighten.
Using Anaerobic Gasket Eliminator
1. Remove all 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 recommendations and directions that are on the can. Do not use
any other method or technique to rermove gasket material from a part.
Engine/eng 2-3
Do not use abrasive pads, sand paper or power tools to clean
gasket surfaces. These methods of cleaning can damage the part.
Abrasive pads also produce a fine grit that the oil filter cannot remove J 8087
from the oil. This grit is abrasive and has been known to cause internal
engine damage.
2. Apply a continuous bead of gasket eliminator to one flange. Sur-
faces 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. 1
DRC6507
4. Assemble parts in the normal manner and torque immediately to
specifications.
Important Anaerobic sealed joints that are partially torqued
and allowed to cure more than five minutes may result in incorrect
shimming of the joint.
Replacing Engine Gaskets

Composite-type head gaskets and intake manifold gaskets are
used in the engine assembly. The head gaskets have a thin metal core.
Some engine applications use a thin metal core for intake manifold
gaskets. Use caution when removing or handling gaskets to help
avoid personal injury.
Cylinder Bores
Measuring Cylinder Bore Taper and Out-of-Round
1 Tool Required: J 8087 Cylinder Bore Gauge

If one or more cylinder bores are rough, scored or worn
beyond limits, it will be necessary to smooth or true up
such bores to fit new pistons.
No attempt should be made to cut down oversize pis-
tons 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 cylin-
der bores should be honed to size for proper clear-
ances.
1. Refer to Engine Specifications in the proper engine repair section
for cylinder bore tolerances.
1 2. Depress plunger on tool 0.03 in. (0,76 mm) or until tool enters
cylinder bore.
1 3. Center the gauge in the cylinder and turn the dial to “0”.

,,
,,,,,
,,,,,
,,
1 4. Carefully work the gauge up and down the cylinder to determine
taper and turn it to different points around the cylinder wall to determine
,,
the out-of-round condition. Measure the bore both parallel to and at
right angles to the engine centerline. Measure at the top, middle, and
A
,,
bottom of the bore and note the readings.
B
,,
5. Recondition the cylinder bore as necessary. Refer to Cylinder Bore
Reconditioning in this section.
Cylinder Bore Reconditioning

2
DRC6508
Measure:
1. Cylinder bore for out-of-round and taper. J 8087
2 2. Wear at the top of the bore A

and the bottom B
. Refer to
Engine Specifications in the proper engine repair section for cylinder
bore tolerances.
3 Cylinder bores can be measured by setting the cylinder gauge dial
at zero in the cylinder at the point of desired measurement. Lock the
dial indicator at zero before removing it from the cylinder, and measure
across the gauge contact points with an outside micrometer, with the
gauge at the same zero setting when removed from the cylinder.
3
DRC6509
If cylinder bore taper or wear exceed specification, the cylinders must

be bored and honed to the smallest oversize. Refer to Engine Specifi-
cations in the proper repair section.
Fine vertical scratches made by ring ends will not, by themselves, cause
excessive oil consumption; therefore, honing to remove them is unnec-
essary.
If the bore is glazed but otherwise serviceable, break the glaze lightly
with a hone and replace the piston rings. Refer to Honing in this sec-
tion.
If honing is not required, the cylinder bores should be cleaned with a
hot water and detergent wash. Apply clean engine oil to the bore after
cleaning.

Removing Cylinder Bore Ridge J 24270
1 Tool Required: J 24270 Ridge Reamer
Important Do NOT remove excessive material from the cylin-

der bore. Excessive removal of material may require 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.
1
1 3. Perform the cutting operation with a J 24270 ridge reamer. DRC6510
Refer to the manufacturer’s instructions before using J 24270.

4. Remove J 24270 and rotate the crankshaft until the piston is at
TDC.
5. Remove the cloth and cuttings.
6. Repeat this procedure for each piston.
Boring
Important Refer to Engine Specifications in the proper en-

gine repair section for additional information.
1. Before the honing or boring operation is started, measure all new
pistons with the micrometer contacting at points exactly 90 degrees
from the piston pin centerline. Some pistons must be measured at 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 between pistons in a set may
provide 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 remove any dirt or burrs. This is very important. If not
checked, the boring bar may be tilted which would result in the rebored
cylinder wall not being at right angles to the crankshaft.
3. The instructions furnished by the manufacturer of the equipment
being used should be carefully followed.
4. When boring cylinders, all crankshaft bearing caps must be in place
and tightened to the proper torque to avoid distortion of bores in the
final assembly.
2-6 Engine/eng
5. When taking 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 between pistons, rings,
and cylinder bores is maintained).
Honing
1. When honing the cylinders, follow the hone manufacturer’s recom-

mendations for use, cleaning, and lubrication during honing. Use only
clean, sharp stones of the proper grade for the amount of material to be
removed. Dull, dirty stones cut unevenly and generate excessive heat.
When using coarse or medium grade stones, use care to leave suffi-
cient metal so that all stone marks may be removed with the fine stones
used for finishing to provide proper clearance.
186747
2. Occasionally, during the honing operation, the cylinder bore should
be thoroughly cleaned, and the piston selected for the individual cylin-
der checked for correct fit.
3. When honing to eliminate taper in the cylinder, make full strokes of
the hone in the cylinder. Also check measurement at 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. When finish honing a cylinder bore to fit a piston, move the hone up
and down at a sufficient speed to obtain very fine uniform surface finish
marks in a cross-hatch pattern at the specified angle (45 to 65 degrees).
5. The finish marks should be clean but not sharp, free from embedded
particles 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 specifica-
tion, the finish hone cylinder measurement can be determined. It is im-
portant that both the block and piston be measured at normal room
temperature.
7. Refer to Engine Specifications in the proper engine repair section.
8. It is of the greatest importance that refinished cylinder bores are trued
up to have less than the specified out-of-round or taper. Each bore must
be final honed to remove all stone or cutter marks and provide a smooth
surface.
Engine/eng 2-7
9. After final honing and before the piston is checked for fit, clean the
bores with hot water and detergent. Scrub with a stiff bristle brush and
rinse thoroughly with hot water. It is essential that a good cleaning J 3936-03
operation be performed. If any of the abrasive material is allowed to

remain in the cylinder bores, it will wear the new rings, 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 in the proper engine repair sec-
tion.
1
11. Permanently mark the piston for the cylinder to which it has been DRC6511
fitted.
12. Apply clean engine oil to each bore to prevent rusting.
Piston and Connecting Rod

Tools Required: J 24086-C Piston Pin Removal and Installation Set J 24086-C
Disassemble:
1 1. Piston rings. In most cases the rings should be discarded and

replaced with new rings at assembly.
2. Connecting rod bearings. If the bearings are to be reused, place
them in a rack so they may be reinstalled with the original connecting
rod and cap.
2 3. Piston pin.
a. Place the piston/connecting rod on support fixture J 24086-
C. Make sure the connecting rod is fully supported.
b. Place remover J 24086-C on the support fixture.
c. Press out the piston pin.
2
DRC6515
2-8 Engine/eng
Cleaning and Inspection
Clean: Piston
Remove all varnish and carbon deposits. DO NOT USE

A WIRE BRUSH.
Use an approved cleaning solution to remove carbon
build-up.
Remove the carbon from the ring grooves. Use a ring
groove cleaning tool.
Oil-control ring groove holes.
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. Connecting rod bearings for scratches or deep pitting.
4. Piston for:
Scratches, scuffing, and burrs

Ring land for cracking and wear
Ring grooves for burrs and nicks
Skirts and pin bosses for cracking
Skirts for scuffing
Measuring Piston Pin to Piston Clearance

Measure:
3 1. Piston pin diameter. Check against Engine Specifications in
the proper engine repair section.
3
2. Piston pin to piston clearance. DRC6512
4 a. Measure the piston pin hole diameter.

b. Subtract the piston pin diameter from the piston pin hole diam-
eter to obtain the clearance.
c. Replace the piston and piston pin if the clearance exceeds
specifications. The piston and piston pin are a matched set
and not available separately.
4
DRC6513
Engine/eng 2-9
Piston Selection
Check the used piston to cylinder bore clearance. J 8087
Measure:
1 1. Cylinder bore diameter. Use a telescoping bore gauge, located

2.56 in. (65 mm) below the top of the cylinder bore.
2 2. Piston diameter. Measure the piston skirt at a right angle to the
piston pin, at the centerline of the piston pin.
1
DRC6507
3. Subtract the piston diameter from the cylinder bore diameter to de-
termine piston to bore clearance.
to determine if piston clearance is within the acceptable range.
If the used piston is not acceptable, determine if a new piston will fit
the cylinder bore. If a new piston does not bring the clearance within
tolerances, the cylinder bore must be reconditioned. Mark the piston
to identify the cylinder for which it was fitted.
Assembling the Piston and Connecting Rod 2

DRC6514
3 Tool Required: J 24086-C Piston Pin Removal and Installation
Set
Assemble:
1. Piston and connecting rod.

a. The alignment mark on the top of the piston must face the J 24086-C
front of engine block. Connecting rod 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.
3
DRC6515
2-10 Engine/eng
c. Install the pin guide. Hold the piston and connecting rod to-
gether. Be sure to use the proper pin guide. Refer to the in-
structions supplied with the tool.
2. Piston pin:
a. Insert the piston pin into the piston pin hole.
3 b. Place the assembly on the support fixture.
3 c. Adjust the piston pin installer (J 24086-C) to the correct length,
using the letter-number scale on the installer adjuster. This is
necessary to ensure the piston pin is pressed into the piston
to the correct depth. Refer to the instructions supplied with the
tool for the proper setting.
d. Lock the adjuster in place with the lock ring.
After the installer hub bottoms on the support assembly, do not
exceed 5000 PSI (35,000 kPa) pressure, as this could cause damage
to the tool.
e. Place the adjuster in the support fixture. Press the piston pin
into place (until the adjustable installer bottoms in the support
fixture).
f. Remove the piston and connecting rod assembly from the tool
and check the piston for freedom of movement on the piston
pin.
Installing the Piston Rings

Measure:
4 Ring end gap as follows:

1. Select rings comparable in size to the piston being used.
2. Slip compression ring into the cylinder bore.
4
DRC6516
3. Use piston to square ring in cylinder wall.

4 Insert piston without rings upside down and guide the compres-
sion ring into the cylinder bore until ring is down about 1.499 in. (38,1
mm) below ring travel.
4 4. Space or gap between the ends of the ring with a feeler gauge.
Engine/eng 2-11
for correct gap.
6. If the gap between the ends of the ring is not as specified, remove
the ring and try another for fit.
Inspect:
Ring fit as follows:

1. Fit each compression ring to the piston on which it is going to be
used. 1
10755
1 2. Slip the outer surface of the top and second compression ring
into the respective piston ring groove, to make sure the ring is free. If
binding occurs at any point, the cause should be determined. If bind-
ing is caused by the ring groove, correct it by dressing the groove with
a fine cut file. If the binding is caused by a distorted ring, try a new
ring.
Assemble:
Refer to Piston Assembly in the proper engine repair section.

All compression rings are marked on the upper side of the ring. When
installing the compression rings, make sure the MARKED SIDE IS
TOWARD THE TOP OF THE PISTON.
The oil control rings are 3-piece assemblies, consisting of two rails
and an expander.
Expander
Lower rail
Upper rail
Lower compression ring
Upper compression ring
Flex all rings to make sure they are free. If binding occurs at any point
the cause should be determined. If binding is caused by the ring groove,
correct it by dressing the groove with a fine cut file. If binding is caused
by a distorted ring, try a new ring.
Ring gaps must be 180 degrees apart

Rail gaps must be 180 degrees apart
2-12 Engine/eng
Measure:
2 1. Ring clearance. Use a feeler gauge.

2. Compare with Engine Specifications in the proper engine repair
section.
Camshaft Bearings
Camshaft Bearing Removal
Disassemble:
2
DRC6517
3 Tool Required: J 33049 Camshaft Bearing Removal and Installa-

tion Set
1. Rear camshaft plug.
3 2. All camshaft bearings. Use J 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 block and into the first bear- 3
DRC6518
ing bore to center the tool.
d. Drive the bearing from the block.
e. Repeat this procedure to remove the remaining inner cam-
shaft bearings. Note that the rear bearing must be removed
from the front of the block and the front bearing should be
removed from the rear. This allows the tool to remain centered.
Clean:
Camshaft bearing bores in the block.

Inspect:
Camshaft bearings for scratches, pits, or loose fit in their

bores. Replace the camshaft bearings if necessary.
Camshaft lobes and journals for scratches, pitting, scor-
ing, and wear. Minor irregularities may be cleaned up
with emery cloth.
Engine/eng 2-13
Camshaft Measurements
1 Tool Required: J 7872 Dial Indicator or Equivalent
Important Whenever the camshaft needs to be replaced, a

new set of valve roller lifters must also be installed.
Measure:
1 1. Camshaft journal diameters using a micrometer. Compare with
Engine Specifications in the proper engine repair section. 1
DRC6519
2 2. Camshaft runout. Mount the camshaft in V-blocks or between
centers. Using J 7872, check the intermediate camshaft journal. Com- J 7872
pare camshaft runout specifications in the proper engine repair sec-
tion. If the camshaft is excessively bent, replace the camshaft and
camshaft bearings.
Camshaft Bearing Installation

3 Tool Required: J 33049 Camshaft Bearing Removal and Installa-
tion Set
The outer camshaft bearings must be installed first. These bearings 2
DRC6520
serve as guides for the tool, and help center the inner bearings during
the installation process.
Make sure to fit the correct cam bearing into the bore. The cam bear-
ing bores may vary in size.
Assemble:
3 1. Rear camshaft bearings. Drive the bearings into place using
J 33049 from front of engine.
Important Make sure the camshaft bearing lubrication hole

(or holes) align with the oil gallery hole (or holes) in the block. On 3
DRC6518
some engines, the oil holes may be difficult to see. Verify the holes are
lined up.
3 2. Front camshaft bearing using tool J 33049.
Important Make sure the camshaft bearing lubrication hole

(or holes) align with the oil hole (or holes) in the block.
2-14 Engine/eng
3 3. Inner camshaft bearings using J 33049. Reverse of removal
procedure.
4. Camshaft rear plug.
a. Coat a new camshaft plug with GM Sealer, P/N 12345493, or
equivalent.
b. Install the plug. The plug must be installed deep enough in
camshaft bore. Refer to the proper engine repair section for
camshaft plug installation.
Cylinder Head
Disassemble: J 8089
Valves and components. Refer to the proper engine repair section.
4 Tools Required: J 8089 Wire Brush

Clean:
4 1. Carbon from the combustion chambers, using J 8089. 4

DR3123
2. Valve stems and heads on a wire wheel.

3. Carbon and 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. 5
DR3124
Refer to Valve Grinding in this section. Check the valve stems for scor-
ing or excessive wear. Stems must not be bent.
3. Valve rocker arm studs for wear, damage, or improper fit.
4. Valve seats for pitting or other damage. Grind or reface as needed.
5. Rotators (if used). The rotators should rotate smoothly without bind-
ing.
Engine/eng 2-15
1 6. Cylinder head for surface flatness.
Measure:
2 4 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 ex-
cessive oil consumption and may damage components. Insufficient
clearance will result in noisy and sticky functioning of the valve and
1
DRC6521
interfere with engine smoothness.
2 a. Clamp a dial indicator J 8001 or equivalent on one side of the
cylinder head valve rocker arm cover gasket rail.
2 b. Observe dial indicator movement while moving valve from
side to side (crosswise to the head). The dial indicator mea-
surement must be taken just above the valve guide bore.
c. Drop the valve head about 0.063 in. (1,6 mm) off the valve
seat. J8001
d. Move the stem of the valve from side to side using light pres- 2
DR2101
sure to obtain a clearance reading. If clearance exceeds
specifications, it will be necessary to ream the valve guide
J 9666
bores for oversize valves as outlined later.
2. Valve spring tension, using J 9666 or equivalent.
3 a. Compress the 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.
4 b. Valve spring length. Replace the valve spring if valve spring
length exceeds specifications. Refer to Engine Specifica- 3
DR3122
tions in the proper engine repair section.
4
DRC6522
2-16 Engine/eng
Repair
Valve Grinding
5 Pitted valves must be refaced to the proper angle. Valve stems 204
that show excessive wear, or valves that are warped excessively must
be replaced. When an excessively warped valve head is refaced, a sharp 205
or thin valve margin may result because of the amount of metal that
206 207
must be removed. Undersize valve margins lead to breakage, burning,
or preignition due to heat localizing on this edge. Refer to Engine Speci-
fications in the proper engine repair section.
208
Several different types of equipment are available for refacing valves.
The manufacturer’s instructions for how to use the equipment should 209
be carefully followed to achieve proper results. Refer to Engine Speci- NEW VALVE WORN VALVE
fications in the proper engine repair section for valve face angle speci-
204 VALVE TIP 207 STEM-MOST WORN
fications. 205 KEY GROOVE SECTION
206 STEM-LEAST WORN 208 FACE
SECTION 209 MARGIN
Valve Seat Grinding
Reconditioning the valve seats is very important, because the seating

of the valves must be perfect for the engine to deliver the power and
performance it was designed to produce. 5
DRC6523
Another important factor is the cooling of the valve head. Good contact
between each valve and its seat ensures that heat will be carried away
properly.
Several different types of equipment are available for resurfacing valve
seats. Carefully follow the recommendations of the manufacturer of the
equipment being used to attain proper results.
Regardless of what type of equipment is 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 Engine Specifications in the proper
engine repair section for valve seat angle specifications.
6
DRC6524
Reaming Valve Guides
The valve guides used in engines covered by this manual are simply
holes bored into the cylinder head. The valve guides are not replace-
able.
If the valve stem-to-bore clearance as previously measured is exces-
sive, the valve guides should be reamed and a valve with an oversize
stem installed. Oversize valves are available. Refer to Engine Specifi-
cations in the proper engine repair section.
6 Select a reamer that will provide a straight, clean bore through the
entire length of the valve guide.
Engine/eng 2-17
Assembly
Valves and components. Refer to the proper engine repair section.
Measure:
Valve spring installed height of each valve spring as follows:

1 1.Valve installed height using a narrow thin scale. A cutaway scale
A may be helpful.
2 2. Spring seat in the cylinder head to the top of the valve spring 1
DRC6667
cap.
2 3. Certain engine applications use valve spring shims to adjust
valve spring installed height. If measurement B exceeds the amount
5
shown in Engine Specifications in the proper engine repair section,
4
install valve spring seat shims of 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.
2
1
Crankshaft and Connecting Rod Bearings
Cleaning and Inspection 2
DRC6668
Clean:
1. Crankshaft with solvent.
Do not scratch the bearing journals

Remove all sludge from the oil passages with com-
pressed air
2. Crankshaft bearings.
Wipe free of oil with a soft cloth.

Inspect:
Crankshaft for cracks.
Use the magnaflux method if available.

Crankshaft, crankshaft bearing journals, and thrust sur-
faces for scoring, nicks, or damage caused by lack of
lubrication.
2-18 Engine/eng
Crankshaft bearings for scoring or other damage. In gen-
eral, the lower crankshaft bearings (except the #1 bear-
ing) show the greatest wear and distress from fatigue.
Upon inspection, if a lower crankshaft bearing is suit-
able for reuse, it can be assumed that the upper crank-
shaft bearing is also satisfactory. If a lower crankshaft
bearing shows evidence of wear or damage, both the
upper and lower crankshaft bearings must be replaced.
Measuring Bearing Clearance
3
DRC6525
Crankshaft bearings are of the precision insert type and do not use
shims for adjustment. If clearances are excessive, new upper and lower
bearings will be required. Service bearings are available in standard
size and undersize. Refer to Crankshaft and Bearing Installation in
the proper engine repair section.
Selective fitting of crankshaft bearings are necessary in production to
obtain close tolerances. For example, you may find one-half of a stan-
dard crankshaft bearing with one-half of an undersize crankshaft bear-
ing.
To determine the correct replacement bearing size, the bearing clear-
ance must be measured accurately. Either of the following two methods
may be used, however, the micrometer method gives more reliable re-
sults and is preferred.
Micrometer Method
3 1. Measure the crankshaft journal diameter with a micrometer in

several places, approximately 90 degrees apart, and average the mea-
surements.
2. Compute taper and runout. Refer to Engine Specifications in the
proper engine repair section for allowable limits.
3. Install crankshaft bearings into the crankshaft cap and engine block.
4. Install crankshaft caps and bolts. Tighten bolts to the Torque Speci-
fications in the proper engine repair section.
5. Bearing inside diameter (I.D.) using an inside micrometer.
6. Compare crankshaft bearing clearance specifications using Engine
Specifications in the proper engine repair section.
7. If bearing clearances exceeds specifications, install new crankshaft
bearings.
a. Measure inside diameter with an inside micrometer. Place the
micrometer at 90 degrees to the split line of the crankshaft
bearing.
Engine/eng 2-19
b. Subtract journal diameter from bearing inside diameter to ob-
tain bearing clearance. Refer to Engine Specifications in
the proper engine repair section for bearing inside clearance.
Replace or repair the crankshaft if clearance exceeds specifi-
cations.
Plastic Gauge Method
1 1. Install all crankshaft bearings and crankshaft into block.

1 Install the crankshaft bearing caps and torque them to specifica- 1
tions. Remove the bearing caps and check the amount the gauging DRC6525
plastic has been compressed. Gauging plastic may adhere to either

the crankshaft bearing or crankshaft journal.
2 2. On the edge of the gauging plastic envelope there is a gradu-
ated scale. Without removing the gauging plastic, measure its com-
pressed width (at the widest point).
3. If the flattened gauging plastic tapers toward the middle or ends,
there is a difference in clearance indicating taper, low spot or other
irregularity of the bearing or journal.
4. Normally crankshaft bearing journals wear evenly and are not out- 2
of-round. However, if a bearing is being fitted to an out-of-round 0.001 DRC6527
in. (0.0254 mm) maximum journal, be sure to fit to the maximum diam-
eter of the journal. If the bearing is fitted to the minimum diameter and
the journal is excessively out-of-round, interference between the bear-
ing and the journal will result in rapid bearing failure.
5. If the bearing clearance is within specifications, the bearing is satis-
factory. If the clearance is not within specifications, replace the bear-
ing. Always replace both upper and lower bearings as a unit.
6. A standard or underside bearing combination may result in the proper
clearance. If the proper bearing clearance cannot be achieved using
standard or underside bearings, it will be necessary to replace the
crankshaft.
Crankshaft bearings must not be shimmed, scraped or filed.
Do not touch the bearing surface with bare fingers. Skin oil and acids
will etch the bearing surface.
7. Remove the flattened gaging plastic.
8. Measure remaining journals.
2-20 Engine/eng
Crankshaft Runout
Tools Required: J 7872 Magnetic Base Dial Indicator
Measure: Crankshaft
3 1. Mount the crankshaft in V-blocks at crankshaft journals 1 and 5.
3 2. Position a dial indicator pointer on the center main bearing and J 7872
rotate crankshaft.
3
for crankshaft runout specifications. DRC6528
Connecting Rod Side Clearance

Measure:
4 Connecting rod side clearance. Refer to Engine Specifications in
the proper engine repair section for clearance.
Crankshaft End Play

Measure:
4
DRC6529
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 sur-
faces.
5 2. With crankshaft wedged forward, measure at the front end of
the crankshaft bearing (thrust side) with a feeler gauge. Refer to En-
gine Specifications in the proper engine repair section for crankshaft
end play clearance.
3. If correct end play cannot be obtained, be certain that the correct
size crankshaft bearing has been installed. Some production engines 5
DRC6530
may use 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.
Engine/eng 2-21
Inspect:
Crankshaft for binding. Turn crankshaft to check for binding. If the crank-
shaft does not turn freely, loosen the crankshaft bearing bolts, one
pair at a time, until the tight bearing is located. Burrs on the bearing
cap, foreign matter between the bearing and the block or the bearing
cap, or a faulty bearing could cause a lack of clearance at the bearing.
Thread Repair
Damaged threads may be reconditioned by drilling out, rethreading, 1
DRC6572
and installing a suitable thread insert.
Wear safety glasses to avoid eye damage.
1. Determine size, pitch, and depth of damaged thread. If necessary,
adjust stop collars on cutting tool and tap to required depth.
Important Refer to the kit manufacturer’s instructions regard-

ing the size of drill and tap to be used.
1 2. Drill out damaged thread. Clean out chips.
2 3. Lubricate tap with light engine oil. Tap hole. Clean the thread. 2
DRC6573
Important Avoid buildup of chips. Back out the tap every few
turns and remove chips.
3 4. Thread the thread insert onto the mandrel of the installer. En-
gage the tang of the insert onto the end of the mandrel.
4 5. Lubricate the insert with light engine oil (except when installing
in aluminum) and install.
Important When correctly installed, the insert should be flush

to one turn below the surface.
3
6. If the tang of the insert does not break off when backing out the DRC6574
installer, break the tang off with a drift.
4
DRC6575
2-22 Engine/eng
J 33049
5 6 7
DRC6576 DRC6579 DRC6577
Special Tools
5 Cylinder Bore Gauge
6 Piston Pin Replacer Set
7 Camshaft Bearing Remover / Installer
8 Wire Brush
9 Dial Indicator
10 Valve Spring Tester
8
DRC6580
11 Ridge Reamer
9
DRC6578
10
DRC6581
11
DRC6582
Engine/eng 2-23
Section 3
3.0 GS Engines
Table of Contents
Camshaft ................................................................. 3-15 High-Rise Exhaust Elbow Replacement ............... 3-36

Camshaft Bearings ................................................. 3-17 Hydaulic Valve Lifter ................................................ 3-4
Circulating Pump .................................................... 3-33 Intake/Exhaust Manifold .......................................... 3-3
Connecting Rod Bearings ..................................... 3-20 Oil Filter Bypass Valve ........................................... 3-36
Crankshaft .............................................................. 3-19 Oil Pan Replacement .............................................. 3-34 3
Crankshaft Bearings .............................................. 3-21 Oil Pump ................................................................. 3-34
Cylinder Block ........................................................ 3-28 Oil Seal Replacement, Rear Main Bearing ........... 3-24
Cylinder Head ........................................................... 3-7 Oil Seal Retainer Replacement ............................. 3-24
Distributor Lower Bearing ..................................... 3-32 Piston Rings ........................................................... 3-26
Engine Coupler Replacement ................................ 3-38 Piston and Connecting Rod .................................. 3-24
Engine Specifications ............................................ 3-40 Timing Gear Cover ................................................. 3-13
Exhaust Hose Replacement .................................. 3-37 Torque Specifications ............................................ 3-43
General Motors Tools ............................................... 3-2 Valve Lash Adjustment ............................................ 3-5
Valve Spring and Seal Repair .................................. 3-6
Before removing cooling system hoses, it may be necessary

to remove boat from water to prevent flooding boat.
Safety Warnings
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 maintenance procedures, al-
ways make sure engine compartment is free of fuel vapors to pre-
vent possible fire and explosion.
When working 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, supply pump and circulating pump
belts, pulleys and other moving parts.
Engine/eng 3-1
General Motors Tools
Item Part #
Air Line Adaptor ....................................................................... J-23590

Bolt Guide Set ............................................................................ J-5239
Cam Lobe Lift Indicator ............................................................. J-8520
Camshaft Bearing Remover and Installer .......................... J-6098-01
Carbon Remover Brush ............................................................. J-8089
Crankshaft Pulley Installer ........................................................ J-8792
Cylinder Bore Checker .............................................................. J-8087
Distributor Bearing Installer ....................................................... J-9535
Distributor Bearing Remover ..................................................... J-9534
Engine Front Cover Aligner and Oil Seal Tool ........................ J-35468
Piston Pin Tool ......................................................................... J-24086
Piston Ring Tool ......................................................................... J-8037
Rear Crankshaft Seal Installer ................................................ J-35621
Rocker Arm Stud Hole Reamer (0.003 Oversize) .................... J-5715
Rocker Arm Stud Hole Reamer (0.013 Oversize) .................... J-6036
Rocker Arm Stud Installer .......................................................... J-6880
Rocker Arm Stud Remover .................................................. J-5802-01
Valve Guide Reamer Set ..................................................... J-5830-02
Valve Seal Tester ..................................................................... J-23994
Valve Spring Compressor .......................................................... J-8062
Valve Spring Tester .................................................................... J-9666
Vibration Damper and Crankshaft Gear Remover ............... J-6978-E
Order Directly from:

Kent-Moore Tool Division
28635 Mound Road
Warren, Ml 48092
(800) 345-2233
http://www.spxkentmoore.com
Price and ordering information are available from Kent-Moore Tool Di-
vision.
For additional service information not covered in this manual, obtain
the appropriate Chevrolet Engine Service Manual from:
Helm Inc.
P. O. Box 07130
Detroit, Ml 48207
(800) 782-4356
http://www.helminc.com
Material Required
Molykote Lubricant
Volvo Penta Gasket Sealing Compound
3M Adhesive
Permatex No. 2
GM Super Engine Oil Supplement
Plastigage (Green)
RTV Sealer
DuraPlusTM SAE 30 Heavy Duty Synthetic Motor Oil
3-2 Engine/eng
Intake/Exhaust Manifold
Removal
1. Disconnect battery cables at battery. Remove throttle cable

from anchor block and actuating bracket.
2. Drain water from block and exhaust manifold (see Cooling System
Section in this manual).
3. Remove carburetor from intake manifold. Follow the instructions in
Electrical/Ignition/Fuel Systems Service Manual.
1
45329
1 4. Disconnect water hose A running between manifold end cap

and thermostat housing.
2 5. Release tension from belt tensioner B and remove the serpen-
tine belt. Remove alternator and mounting bracket C .
3 6. Loosen upper hose clamps D

securing exhaust hose to high
rise elbow. Loosen and remove screws and lock washers E securing
elbow to manifold and remove the throttle linkage plate and elbow.
7. Remove six bolts securing manifold to cylinder head, then pull mani- 2
fold 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 new gasket 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 six bolts while holding the manifold in place. Tighten bolts fin-
ger tight, then alternately tighten to 20-25 ft. lb. (27-34 N m) working
from the center towards the ends.
•
3
22645A
3. Apply gasket sealer to a new elbow gasket and place it on the mani-
fold. Push the elbow into the exhaust hose, then install the elbow, throttle
linkage plate, lock washers, and screws. Tighten the screws to 12-14 ft.
lb. (16-19 N m).
•
4. Install carburetor using a new mounting gasket following the instruc-

tions in Electrical/Ignition/Fuel Systems Service Manual.
1 Install water hose from thermostat housing to manifold A .

1 5. Install alternator with mounting bracket A . Tighten screws B
to 26-30 ft. lb. (35-41 N m). Reinstall belt following the procedures found
•
in the General Information section of this manual. Tighten the alter-

nator screws C to 26-30 ft. lb. (35-41 N m). •
6. Reconnect throttle cable to anchor block and actuating bracket.

Secure with cotter pin.
7. Connect battery cables. Start engine and check for fuel
leaks.
1
Hydraulic Valve Lifter 45376
Removal
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. Disconnect ventilation hose, fuel line, and fuel pump overflow hose.
Remove circuit breaker bracket. Remove rocker arm cover.
3. Loosen rocker arm nuts and pivot the rocker arms free of the push
rods. 2
22477
4. Disconnect spark plug wires at plugs. Remove high tension lead

from coil. Remove both connectors from coil. Remove coil and mount-
ing bracket from cylinder head.
2 5. Remove both connectors at distributor. Take off cap, note dis-
tributor rotor position and remove distributor. (Mark distributor hous-
ing and block with chalk at point of rotor.)
6. From rear of block, take out screws that mount the shift bracket
assembly and move bracket away from push rod cover.
ROTATING - NORMAL, OK - NOT ROTATING
7. Remove push rod cover and gasket.
8. Remove push rods and lift out valve lifters that require service. Place
lifters in a wooden block having numbered holes, or use other suitable
means of identifying them according to original position in the engine.
9. If less than a complete set of lifters is being removed, immediately
disassemble and inspect one or two for presence of dirt or varnish. If GALLED - SHOULD BE REPLACED - SOFT, WORN
lifters contain dirt or varnish, it is advisable to replace all lifters. Other-

wise, it will be satisfactory to service only those lifters that are not
operating properly.
3 10. Examine the cam contact surface at lower end of lifter body. If
this surface is excessively worn, galled or otherwise damaged, dis- 3
860000
card the lifter assembly. In this case, also examine the mating cam-
shaft lobe for excessive wear or damage.
ROTATING - NORMAL, OK - NOT ROTATING

GALLED - SHOULD BE REPLACED - SOFT, WORN

Installation
Before installing any new lifters, coat the bottom of each lifter
with Molykote Lubricant or its equivalent.
1. Install valve lifters in cylinder block. If any new lifters or a new cam-
shaft has been installed, an additive containing EP lubricant such as
GM Engine Super Oil Supplement must be added to the crankcase oil
for break-in.
2. Install push rods onto lifters and install push rod cover with a new
gasket.
3. Install distributor (position rotor to mark on housing and block). In-
stall coil and bracket. Connect both connectors to coil. Install distributor
cap and attach spark plug and coil wires. Connect both connectors to
distributor.
4. Install shift bracket assembly.
5. Pivot rocker arms in place and turn adjusting nuts the amount neces-
sary to eliminate lash.
Valve Lash Adjustment

Adjust valve lash when lifter is on base circle of cam as follows:
1. Remove distributor cap and crank engine until distributor rotor points
to number one cylinder terminal. In this position the piston in number
one cylinder is at top center on compression stroke. Both lifters are on
base circle of cam and both valves can be adjusted.
4 2. Turn adjusting nut until all lash is removed from valve train. This
can be determined by checking push rod side play by hand while turn-
ing nut slowly. At this point, turn adjusting nut one more turn to place
the lifter plunger in center of its travel.
3. Follow steps 1 and 2 for each cylinder following firing order sequence
and adjust remaining valve one cylinder at a time. No further adjust-
ment is necessary.
Do not attempt to turn the adjusting nut one full turn while the 4
860001
engine is operating. Adjustment in this manner will not allow the lifters
to bleed down. This would result in valve train damage, probably bent
push rods. For those who prefer to adjust the valve lash while the en-
gine is running, the preferred method would be to find the “zero lash”
point as described above and then slowly turn the adjusting nut 1/4
turn. Wait for the lifter to bleed down (several engine revolutions) and
again turn adjusting nut 1/4 turn. Continue this adjust-and-wait cycle
until nut is one complete turn down from “zero lash” point. Repeat se-
quence on remaining valves.
Engine/eng 3-5
4. Install rocker cover gasket and cover. Connect fuel line and fuel
pump overflow hose to carburetor.
5. Install circuit breaker bracket. Connect crankcase ventilation hose.
6. Start engine and check for oil or fuel leaks and listen for
lifter noise. Check engine timing.
Valve Spring and Seal Repair

Removal
1. Remove rocker arm cover.

2. Remove spark plug, rocker arm, and push rod on the cylinder(s) to
be serviced.
3. Install Air Line Adapter tool J-23590 to spark plug port and apply
compressed air to hold the valves in place.
4. Using tool J-8062 to compress the valve spring, remove the valve
locks, valve cap and valve spring and damper.
5. Remove the valve stem oil seal.
Installation
1. Install seal over valve stem and seat against head.

2. Set the valve spring and damper, valve shield and valve cap in place.
Compress the spring with tool J-8062 and install oil seal in the lower
groove of the stem, making sure the seal is flat and not twisted.
A light coat of oil on the seal will help prevent twisting.
3. Install the valve locks and release the compressor tool making sure
the locks seat properly in the upper groove of the valve stem.
Grease may be used to hold the locks in place while releasing
the compressor tool.
4. Using Vacuum Pump J-23738-A, apply vacuum to the valve cap to
make sure no air leaks past the seal.
5. Install spark plug and tighten to 20 ft. lb. (27 N m).
•
6. Install and adjust valve mechanism as previously outlined.

Cylinder Head
The condition of the cylinder head and valve mechanism significantly
determines the power, performance and economy of the valve-in-head
engine. Extreme care should be exercised when conditioning the cylin-
der head and valves. Maintain correct valve stem to guide clearance,
correctly grind valves and valve seats, and properly adjust valves.
Removal
1. Remove intake and exhaust manifold as described under heading

Intake/Exhaust Manifold.
2. Disconnect coolant hoses at thermostat housing. Disconnect spark
plug wires and remove spark plugs.
3. Disconnect fuel line retaining clips at thermostat housing and cylin-
der head. Disconnect wire harness from the temperature sending unit,
leaving harness clear of clips on rocker arm cover. Remove thermostat
housing assembly from front of cylinder head. Disconnect fuel line at
the fuel pump and remove.
4. Remove the rocker arm cover. Next, back off the rocker arm nuts and
pivot the rocker arms to clear the push rods. Remove the push rods.
5. Remove the ignition coil and bracket.
6. Remove the cylinder head bolts, cylinder head, and gasket. Place
the cylinder head on two blocks of wood to prevent damage to the head.
Disassembly
1 1. Remove rocker arms nuts, ball seats and rocker arms. Use tool
J-8062, compress the valve springs and remove valve stem keys. Re-
lease the spring compressor tool and remove exhaust valve rotator or
intake valve cap, shield, spring and seals.
2. Remove valves from bottom of cylinder head and place them in a
rack in their proper sequence so they can be assembled in their original
positions. 1
860002
Engine/eng 3-7
Cleaning
1 1. Clean all carbon from combustion chambers and valve ports J 8089
using tool J-8089. Inspect the cylinder head for cracks in the exhaust
ports, combustion chambers, or external cracks to the water chamber.
Clean carbon deposits from head gasket mating surfaces.
2 2. Thoroughly clean the valve guides. 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.
1
860003
4. Wash all parts in cleaning solvent and dry them thoroughly. Check
fit of valve stems in their respective bores.
3 5. Measure valve stem clearance as follows: Clamp a dial indica-
tor on one side of the cylinder head rocker arm cover gasket rail, lo-
cating the indicator so that movement of the valve stem from side to
side (crosswise to the head) will cause a direct movement of the indi-
cator stem. The indicator stem must contact the side of the valve stem
just above the valve guide. With the valve head dropped about 1/16
in. off the valve seat; move the stem of the valve from side to side
using light pressure to obtain a clearance reading. If clearance ex-
ceeds specifications it will be necessary to ream valve guides for over-
size 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. 2
860004
Intake valve stem to bore clearance should be 0.001-0.0027 in. (0,025-
0,007 mm). Exhaust valve stem to bore clearance should be 0.0007-
0.0027 (0,01778-0,06858 mm). By using a 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 clear-
ance. If clearance is not within limits use next oversize valve and ream J 8520
bore to fit using suitable reamer.
4 6. Check valve spring tension with tool J-9666 spring tester.
On all models, springs should be compressed to 1.61 in. (40,89
mm) at which height it should check 100-110 pounds (444-490 N).
Weak springs affect power and economy and should be replaced.
3
860005
J 9666
4
860006
3-8 Engine/eng
7. Check valve lifters for free fit in block. The end that contacts the
camshaft should be smooth. If this surface is worn or rough, the lifter
should be replaced. If lifter is damaged, check the corresponding cam- J 4822
shaft lobe for damage.
Repair
5 1. Valve Guide Bore:
Valves with oversize stems are available for inlet and exhaust valves in
the following sizes: 0.0003 in., 0.015 in., and 0.030 in. Use the 11/32 in.
5
diameter reamer sizes from reamer tool set J-5830-02 which are: J- 860007
4822 standard; J-5830-1, 0.003 in oversize, J-5830-2, 0.015 in. over-

size and J-5830-3, 0.030 in. oversize to ream the bores for the new
valves.
2. Rocker Arm Studs J 5802-01
Rocker arm studs that have damaged threads may be replaced with
standard studs. If the studs are loose in the head, oversize studs (avail-
able in .003 in. or .013 in. oversize) may be installed after reaming the
holes as follows:
Do not attempt to install oversize stud without reaming stud 6
hole. 860008
6 a. Remove old stud by placing tool J-5802-01 over the stud. In-
stall nut and flat washer, and remove stud by turning nut.
7 b. Ream hole for oversize stud. Use tooI J-5715 for 0.003 in. J 5715
or
oversize and tool J-6036 for 0.013 in. oversize. J 6036
8 c. Coat press-fit area of stud with a hypoid axle lubricant. Install

new stud using tool J-6880. Tool should bottom on head.
3. Valve Seats:
Reconditioning the valve seats is very important, because the seating 7
of the valve must be perfect for the engine to deliver the power and 860009
performance built into it.

Another important factor is the cooling of the valve heads. Good con-
tact between each valve and its seat in the head is imperative to ensure
J 6880
that the heat in the valve head will be properly carried away.
Several different types of equipment are available for reseating valve
seats; the recommendations of the manufacturer of the equipment be-
ing used should be carefully followed to attain proper results.
8
860010
Engine/eng 3-9
Regardless of what type of equipment is used, however, it is essential
that valve guides be free from carbon or dirt to ensure proper center-
ing of pilot in the guide.
a. Install expanding pilot in the valve guide bore and expand
pilot by tightening nut on top of pilot.
b. Place roughing stone or forming stone over pilot and just clean
up the valve seat. Use a 46° stone for both the inlet and ex-
haust valve seats.
c. Remove roughing stone or forming stone from pilot, install
finishing stone on pilot and cut just enough metal from the
seat to provide a smooth finish.
d. Narrow down the valve seats to the proper width for the in-
take and exhaust. See Engine Specifications.
This operation is done by grinding the port side with a 30° J 8001
stone to lower seat and a 60° stone to raise seat.
e. Remove expanding pilot and clean cylinder head carefully to
remove all chips and grindings from above operations.
1 Valve seats should be concentric to within 0.002 in. total
indicator reading.
4. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stem on a valve refacing ma-
chine. Valve stems which show excessive wear, or valves that are
warped excessively should be replaced. When a valve head which is 1
860011
warped excessively is refaced, a knife edge will be ground on part or
all of the valve head due to the amount of metal that must be removed
to completely reface. Knife edges lead to breakage, burning or pre-
ignition due to heat localizing on this knife edge. If the edge of the
valve head is less than 1/32 in. thick after grinding, replace the valve.
a. If necessary, dress the valve refacing machine grinding wheel
to make sure it is smooth and true. Set chuck at 45° mark for
grinding valves.
b. Clamp the valve stem in the chuck of the machine.
c. Start the grinder and move the valve head out in line with the
grinder wheel by moving the lever to the left.
d. Turn the feed screw until the valve head just contacts wheel.
Move valve back and forth across the wheel and regulate the
feed screw to provide light valve contact.
3-10 Engine/eng
e. Continue grinding until the valve face is true and smooth all D
B
around valve. If this makes the valve thin the valve must be B
A
replaced as the valve will overheat and burn. A
C
C
f. Remove valve from chuck and place stem in “V” block. Feed
valve squarely against grinding wheel to grind any pit from
rocker arm end of stem.
Only the extreme end of the valve stem is hardened to resist
wear. Do not grind end of stem excessively.
g. After cleaning valve face and cylinder head valve seat of grind- 2
860012
ing particles, make pencil marks about 1/4 in. apart across the
valve face, place the valve in cylinder head and give the valve
4
one-half turn in each direction while exerting firm pressure on
face of valve.
3
h. Remove valve and check face carefully. If all pencil marks have
2
not been removed at the point of contact with the valve seat, it
will be necessary to repeat the refacing operation and again
1
1.65 in
recheck for proper seating.
i. Grind and check remaining valves in the same manner.
Assembly
3
DRC7544
2 1. Starting with number one cylinder, place the exhaust valve in

the port, and place the valve spring A and cap B in position. Place
spring and cap on exhaust valves. Then, using tool J-8062, compress
the spring and install the oil seal C and valve keys D . 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 valve springs in position with the closed coil end toward
the cylinder head.
2. Assemble the remaining valve, valve springs, spring caps, oil seals
and valve keys in the cylinder head using tool J-8062. Check seals by
placing a vacuum cup over valve stem and cap, squeeze vacuum cup
to make sure no oil leaks past oil seal.
3. Check the installed height of the valve springs using a narrow, thin
scale to measure from the top of the shim or spring seat in the head, to
the top of the valve spring cap. If this is found in excess of 1.65 in.
(41,91 mm), install a valve spring seat shim, approximately 1/16 in.
(1,858 mm) thick. At no time should the spring be shimmed to give an
installed height of less than 1.65 in. (41,91 mm).
If springs are to be changed with cylinder head installed, refer
to Valve Spring and Seal Repair, in this section.
Engine/eng 3-11
Installation
1. The gasket surfaces of both the head and the block must be clean
and free of any foreign matter, and free of nicks or heavy scratches.
2. Cylinder head bolt threads in the block must be cleaned as well as
the threads on the cylinder head bolts. Dirt will affect bolt torque.
1 3. Place a new cylinder head gasket in position over the dowel
pins in the cylinder block. On engines with a steel gasket coat both
sides of a new gasket with a thin, even coat of Volvo Penta Gasket
Sealing Compound. Too much sealer will hold the beads of the gasket
1
860014
away from the block or head.
The 3.0 Liter engine has a special marine head gasket. Do not
substitute an automotive head gasket.
2 4. Carefully guide cylinder head into place over dowel pins and
gasket. Coat threads of cylinder head bolts with Permatex No. 2. In-
stall the bolts and run them down to the block.
3 5. Tighten the cylinder head bolts, with a torque wrench, in three
progressive steps following the sequence shown.
Step 1 - 35 ft. lb. (47 N m)
• 2
860015
Step 2 - 65 ft. lb. (88 N m)
•
Step 3 - 90 ft. lb. (122 N m)

•
6. Install valve push rods down through openings in the cylinder head
8
7
and seat them in lifter sockets.
4 7. Install rocker arms, balls and nuts and tighten rocker arm nuts
until all push rod play is taken up.
4
3
8. Install thermostat housing using a new gasket. Attach coolant hoses.
9. Clean all spark plugs with abrasive-type cleaner, inspect for dam-
age (replace if necessary) and set the gap at 0.045 in. (1.14 mm) us-
1
2
ing a wire gauge. Install the spark plugs. Tighten spark plugs to 20 ft.
lb. (27 N m).
•
10. Install coil and connect both connectors to coil. Connect wire to
6
temperature sending unit.

11. Clean manifold gasket surfaces and install new gasket over mani-
fold studs. Position manifold and slide it into place over the studs,
10
making sure it seats against the gasket. Install bolts and nuts and
tighten as described under heading Intake/Exhaust Manifold.
3
860016
4
860017
3-12 Engine/eng
12. Adjust valve lash as outlined under heading Valve Lash Adjust-
ment. Install rocker arm cover and gasket. Tighten screws to 40 in. lb.
(5 N m).
•
13. Connect throttle linkage and adjust.

14. Connect fuel line and overflow hose to carburetor and install fuel
line support clamps (two). Clean and install flame arrestor.
15. Start engine and check for fuel, coolant, and exhaust leaks.
Timing Gear Cover

Removal
1. Drain coolant from block and exhaust manifold.

2. Securely support engine and remove front engine mount.
3. Remove alternator and power steering belts. Next remove harmonic
balancer and pulley assembly from pulley hub.
5 4. Install puller tool J-6978-E to pulley hub with three 3/8-24 x 2 in.
bolts and remove hub. Remove puller tool. J 24420-C
5. Remove circulating pump pulley. 5

860019
6. Remove crankcase oil drain tube cap and withdraw oil with a suction
pump. Disconnect oil drain tube and remove oil pan.
7. Remove timing gear cover attaching screws. Remove cover and gas-
ket.
Oil Seal Replacement
1. After removing timing gear cover, pry oil seal out of cover from front
with a large screwdriver.
6 2. Install new lip seal with lip (open side of seal) facing inside of
cover, and drive or press seal into place with tool J-35468.
Oil Nozzle Replacement

7 Remove old nozzle with pliers. Drive new nozzle in place using a
suitable light plastic or rubber hammer.
6
860020
7
860021

Timing Gear Cover Installation
1. Clean gasket surface on block and cover.

2. Install centering tool J-35468 over end of crankshaft.
3. Coat both sides of a new gasket with a light grease, and stick gas-
ket in position on block.
1 4. Place cover over centering tool and install cover screws. Tighten
screws to 27-35 in. lb. (3-4 N m) and remove centering tool.
•
5. Install oil pan using new gaskets. Tighten rear oil pan nuts to 165 in. 1
860022
lb. (18.6 N m), crankcase screws to 80 in. lb. (9 N m), and front cover
• •
screws to 45 in lb. (5 N m).

•
6. Connect oil drain tube to oil pan.
Harmonic Balancer Installation
2 3 1. Coat oil seal contact area on harmonic balancer with en-

X8 7 9 2 - 2
gine oil. Position hub over crankshaft and key, and start hub into posi-
tion with a mallet. Using tool J-8792, drive hub onto crankshaft until it
DRIVER
bottoms against crankshaft gear.
Crankshaft extends slightly through hub and a hollow tool is
necessary to drive hub completely into bottomed position. CLAMP
2. There are two 3/8 in. (9.925 mm) holes and one 5/16 in.
(7.938 mm) hole that must be matched on hub in order to properly PILOT
position timing mark.

3. Install circulating pump pulley.
4. Install alternator and power steering belts and adjust to specifica-
tions.
5. Install front engine mount.
6. Fill engine crankcase with proper amount of oil. 2
860023
7. Lake or tank test unit and check for leaks.
J 8792
3
860024
3-14 Engine/eng
Camshaft
Measuring Camshaft Lift
Remove both connectors from ignition coil.

If improper valve operation is indicated, measure the lift of each push
rod in consecutive order and record the readings.
1. Remove valve cover and rocker arms.
4 2. Position indicator with ball socket adapter (Tool J-8520) on push
rod.
3. Rotate crankshaft slowly in the direction of rotation until the lifter is
on the heel of the cam lobe. At this point, the push rod will be in its J 8520
lowest position.
0
10
4. Set dial indicator on zero. Rotate the crankshaft slowly, or attach an 90
80
20
auxiliary starter switch and “bump” the engine over, until the push rod is 70
30
40
60
in the fully raised position. 50
5. Compare the total lift recorded from the dial indicator with specifica-
tions. The correct lift is 0.25294 inch ± 0.001 inch (6,4247 ± 0,0254
mm).
6. Continue to rotate the crankshaft until the indicator reads zero. This
will be a check on the accuracy of the original indicator reading.
7. If camshaft readings for all lobes are within specifications, remove
dial indicator assembly. Install and adjust valve mechanism. 4
860026
Removal
1. Withdraw oil from crankcase. Drain coolant from block and exhaust
manifold.
2. Remove valve cover and gasket. Loosen valve rocker arm nuts and
pivot rocker arms clear of push rods.
3. After noting position of rotor, remove distributor.
4. Remove coil, side cover, and gasket. Remove push rods and valve
lifters.
5. Remove crankshaft pulley and hub. Disconnect oil drain tube. Re-
move oil pan and timing gear cover.
5 6. Remove two camshaft thrust plate screws by working through
holes in camshaft gear.
5
860027
Engine/eng 3-15
7. Remove the camshaft and gear assembly by pulling it out through
the front of the block.
Support shaft carefully when removing so as not to damage
camshaft bearings.
Inspection
The camshaft has three bearings, all with the same journal diameter
of 1.8677 in. to 1.8697 in. (47,440 to 47,490 mm). These dimensions
should be checked with a micrometer for an out-of- round condition. If
the journals exceed 0.001 in. (0,025 mm) out-of-round, the camshaft
should be replaced.
The camshaft should also be checked for alignment. The best method
is by use of “V” blocks and a dial indicator. The dial indicator will indi-
cate the exact amount that the camshaft is out of true. If it is out more
than 0.002 in. (0,051 mm) dial indicator reading, the camshaft should
be replaced. When checking, the high reading of the dial indicator in-
dicates the high point of the shaft. Examine the camshaft bearings
and if any bearing needs replacement, replace all bearings.
Gear and Thrust Plate
1 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 0.003 in. to 0.008 in. (0,0762 to 0.2032 mm).
Disassembly
2 If the inspection indicated that the shaft, gear or plate should be

replaced, the gear must be removed from the shaft. Support the cam-
shaft gear and press shaft out of gear.
Thrust plate must be positioned so that woodruff key in shaft
does not damage it when shaft is pressed out of gear. Also, support 1
the hub of the gear or the gear will be seriously damaged. 860028
Assembly
To assemble camshaft gear thrust plate and gear spacer ring to cam-
shaft, 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 woo-
druff key in shaft keyway.
2. Install camshaft gear and press it onto the shaft until it bottoms
J 791
against the gear spacer ring. The end clearance of the thrust plate
should be 0.003-0.008 in. (0,0762-0,2032 mm)
2
860029
3-16 Engine/eng
Camshaft Bearings
2
Removal J 6098-01
3
1
Camshaft bearings can be replaced while the engine is disassembled 4
for overhaul, or without complete disassembly of the engine after cam-

shaft and flywheel have been removed. Operation is easier if crank-
shaft is also removed. See Crankshaft in this section. 5
1. With camshaft and flywheel removed, drive out expansion plug for
rear cam bearing by driving from inside. 3
860030
2. Position bearing pilot in inner bearing. Install nut on puller screw far
enough so puller screw can be threaded into pilot while nut extends out
front of block.
3. Install remover section onto puller screw, and then install screw
through cam bore and thread it into pilot.
J 6098-01
3 4. Using two wrenches, hold screw shaft and turn puller nut to
remove bearing.
4 5. Remove pilot from shaft and install on drive handle with shoul-
der to handle. Drive out front and rear bearings from outside to inside of
block.
Installation
Inner bearing should be installed first to prevent damaging end bearing

with screw shaft. 4
860031
Bearing O.D.’s for number one and number two are 1.999-2.001
in. (5,077-5,083 cm) and number three is 2.009-2.011 in. (5,103-5,108
cm).
1. Remove handle from pilot. Install inner bearing on pilot.
2. Position inner bearing and pilot to rear of inner bearing bore. Install
screw shaft (with remover adapter on it) through the block from front of
engine into pilot.
3. Align oil hole on bearing with oil hole from oil gallery. Snug puller nut 2
J 6098-01
against adapter.
3
1
5 4. Using two wrenches, hold screw shaft and turn puller nut to pull 4
bearing into place.

Oil hole is on top side of bearing and cannot be seen during
5
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. 5
860032
Engine/eng 3-17
5. Attach drive handle to pilot, then place new number one bearing on
pilot.
1 6. Align oil hole on bearing with oil hole from oil gallery and drive J 6098-01
bearing in from front of engine.

2 The front bearing must be driven approximately 1/8 in.
behind front of cylinder block to uncover oil hole to timing gear oil
nozzle.
7. Repeat step (5) and (6) above to drive rear bearing into position
from rear of block. 1
860031
Rear bearing installed position is flush with inner edge of rear

cam bearing bore.
8. Install a new expansion plug at rear bearing.
Camshaft Installation
1. If crankshaft has been removed, install it at this time. Follow proce-

dures under the title Crankshaft in this section. If a new camshaft is to
be installed, coat cam lobes with GM Super Engine Oil Supplement
(G.M. P/N 1051858) and add rest of can to crankcase oil.
2
2. Install the camshaft assembly in the engine block, being careful not 860033
to damage bearings or cam.

3 3. Turn crankshaft and camshaft so that the valve timing marks
on the gear teeth will line up, then push camshaft into position. Install
camshaft thrust plate to block screws and tighten them to 80 in. lb. (9
TIMING
N.m). MARKS
4 4. Check camshaft and crankshaft gear runout with a dial indica-

tor. The camshaft gear runout should not exceed 0.004 in. (0.102 mm)
SCREW
and the crankshaft gear runout should not exceed 0.003 in. (0.076 ACCESS
HOLES
mm).
3
5. If gear runout is excessive, the gear will have to be removed, and 860034
any burrs cleaned from the shaft or the gear replaced.

5 6. Check the backlash between the timing gear teeth with a nar-
row feeler gauge or dial indicator. The backlash should not be less
than 0.004 in. (0,102 mm) nor more than 0.006 in. (0.152 mm). J 8001
7. Install timing gear cover with new gaskets. Install oil pan with new
gaskets and sealer. Connect oil drain tube.
60 70
50
8. Install harmonic balancer as described under title Timing Gear Cover

80
40
90
30
in this section. 20 10
0
4
860035
J 8001
0 10
20
90
30
80
40
70
60 50
5
860036
3-18 Engine/eng
9. Install valve lifters and push rods. Install side cover with a new gas-
ket and sealer. Attach coil and wires. Install distributor, positioning rotor
to reference mark.
10. Pivot rocker arms over push rods. Adjust valve lash as outlined un-
der heading Valve Lash Adjustment.
11. Add oil to engine. Install the alternator and power steering belts,
then adjust tension. Check and adjust timing.
Crankshaft
Removal and Installation
1. Remove main bearing caps and connecting rod caps and lift crank-
shaft out of cylinder block. Push pistons to top of bores.
2. Inspect the crankshaft:
Main bearing journals are ground to 2.979-2.994 in. (58,3666-58,4047
mm).
Crankpin journals are ground to 2.099-2.100 in. (53,315-53,340).
These dimensions should be checked with a micrometer for out-of-round,
taper or undersize. If the journals exceed 0.001 in. (0,025 mm) out-of-
round or taper, the crankshaft should be replaced or reconditioned to
an undersize figure that will enable the installation of undersize preci-
sion type bearings.
The crankshaft should also be checked for runout. To perform this op-
eration, support the crankshaft at the front and rear main bearing jour-
nals in “V” blocks, and indicate the runout of both the front center and
rear center journals using a dial indicator. The runout limit of each of
these journals is 0.002 in. (0,051 mm). If the runout exceeds 0.002 in.
(0,051 mm), the crankshaft must be repaired or replaced.
3. Remove rear main bearing oil seal.
4. Remove old bearings from cylinder block and caps. Install new bear-
ings in the cylinder block and caps.
Main bearings with oil holes are the upper halves of the bear-
ings and are inserted between the crankshaft and cylinder block.
5. Oil crankshaft journals and carefully place the crankshaft in the bear-
ings.
Engine/eng 3-19
6. Install all bearing caps and bolts. Tighten all main bearing cap bolts,
except the rear main bearing, to 55-70 ft. lb. (75-95 N m). When tight-
•
ening rear main bearing cap, tighten bolts to 10-12 ft. lb. (14-16 N m)
•
first, then tap end of crankshaft rearward with a lead hammer (this will
locate bearing cap and bearing). Then tap crankshaft forward (this will
line up both upper and lower crankshaft bearing thrust surfaces). Pro-
ceed with final tightening of rear main bearing cap bolts to 55-70 ft. lb.
(75-95 N m).
•
7. Check main bearing clearance and crankshaft end play. Install new
rear bearing oil seal. Install connecting rod bearings and caps.
Connecting Rod Bearings

1
Connecting rod bearings are available in standard sizes and undersizes
of 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (0.025, 0.051, 0.254,
0.508 mm). These bearings are not shimmed and when clearances
become excessive the next undersize bearing should be used.
Do not file rod or rod caps.
Removal and Inspection
1. Withdraw oil, disconnect oil drain tube and remove oil pan.
2. Remove the connecting rod bearing cap. Wipe bearing and crank-
pin clean of oil.
1 3. Place a piece of Plastigage gauging plastic the full width of the
bearing on crankpin (parallel to the crankshaft). 1
860037
4. Reinstall the bearing cap and evenly tighten the retaining nuts to 35
ft. lb. (47 N m).
•
Do not turn crankshaft with the gauging plastic installed.

2 5. Remove the bearing cap and, without removing the gauging
plastic, check its width at the widest point with the Plastigage scale.
If the crankpin is out-of-round be sure to fit the bearing to the
maximum diameter of the crankpin. If the flattened plastic is not uni-
form from end to end in its width, the crankpin or bearing is tapered,
has a low spot or some other irregularity. Check the crankpin with a
micrometer for taper if the flattened gauging plastic indicates more
than 0.001 in. (0,025 mm) difference.
2
860038
3-20 Engine/eng
6. If the 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, replace the bearing with the proper under-
size bearing.
The bearings are not adjustable and no attempt should be made
to adjust by filing or shimming the bearing caps.
Installation
New bearing clearance should be 0.0017-0.0027 in. (0,04318-0.06858

mm).
1. Rotate the crankshaft after bearing adjustment to be sure the bear-
ings are not too tight.
3 2. Check connecting rod end clearance between connecting rod
cap and side of crankpin. See Engine Specifications for clearance.
3. Install oil pan with new gaskets and seals. Connect oil drain tube.
Refill with engine oil.
Crankshaft Bearings
The main bearings are of the precision insert type and do not utilize
3
860039
shims for adjustment. If the clearances are found to be excessive, a
new standard or oversize bearing, both upper and lower halves, will be
required.
If, for any reason, main bearing caps are replaced, shimming
may be necessary. Laminated shims for each cap are available for ser-
vice. Shim requirements will be determined by bearing clearance.
The clearance may be checked by using Plastigage gauging plastic.
When one 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 when replaced in sets.
Main bearings may be replaced without removing the crank-
shaft.
1. Withdraw oil from crankcase. Disconnect oil drain tube. Remove the
oil pan.
Engine/eng 3-21
2. Remove the spark plugs.
3. Remove cap on main bearing requiring replacement and remove
bearing from cap. Install a main bearing removing and installing tool in
the oil hole in the crankshaft.
A cotter pin may be bent as required to do the job.
4. Rotate the crankshaft clockwise as viewed from the front of the en-
gine. This will roll upper bearing out of engine.
5. Oil new upper bearing and insert plain (unnotched) end of the bear-
ing between crankshaft and indented or notched side. Rotate the bear-
ing into place.
6. Install new bearing in bearing cap. The rear main bearing journal
has no oil hole drilling. To remove the upper bearing half proceed as
follows after cap is removed:
a. Use a small drift punch and hammer to start the bearing ro-
tating out of block.
1 b. Use a pair of pliers to hold the bearing thrust surface to the
oil slinger, and rotate the crankshaft to pull bearing out.
c. To install, start the bearing (side not notched) into notched
side of block by hand, then use pliers as before to turn bear-
ing half into place.
d. The last 1/4 in. (6,35 mm) movement may be done by hold-
ing 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 gauging plastic is a wax-like plastic material which will com-

press evenly between the bearing and journal surfaces without dam-
aging either surface. To obtain the most accurate results with gauging
plastic, certain precautions should be observed. If the engine is up-
side down, the crankshaft will rest on the upper bearings and it can be
assumed that the total clearance can be measured between the cap 1
860040
bearing and journal.
To ensure the proper seating of the crankshaft, the rear main
bearing oil seal should be removed and 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, remove bearing cap.
Wipe oil from journal and bearing cap before applying gauging
plastic.
3-22 Engine/eng
2 2. Place a piece of plastigage the full width of the bearing (parallel 1
to the crankshaft) on the journal.
Do not rotate the crankshaft while the gauging plastic is be-
tween the bearing and journal.
3. Install the bearing cap and evenly tighten the retaining bolts to 55-70
ft. lb. (75-95 N m).
•
4. Remove bearing cap. The flattened gauging plastic will be found ad-
hering to either the bearing or journal. On the edge of gauging plastic
packing envelope there is a graduated scale measuring in thousandths 2
860041
of an inch.
3 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-of- round journal
be sure to fit to the maximum diameter of the journal. If the bearing is
fitted to the minimum diameter of the journal, and the journal is out-of-
round 0.001 in. (0.025 mm) or more, interference between the 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 clear-
ance 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 mm) (worn) or
0.003 in. (0.076 mm) (new), or less than 0.001 in. (0.025 mm), the bear-
ing is satisfactory. If the clearance is not within these limits replace the
bearing.
If a new bearing cap is being installed and clearance is less
than 0.001 in. (0.025 mm), check for burrs or nicks; if none are found 3
then install shims as required. 860042
7. A 0.002 in. (0.051 mm) undersize bearing may produce the proper
clearance. If not, it will be necessary to regrind the crankshaft journal
for use with the next undersize bearing.
Bearings are available in standard sizes and various undersizes.
See your parts catalog.
8. Oil new bearings 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.
Engine/eng 3-23
1 9. Check the end play by forcing the crankshaft to its extreme
front position. Check at the front side of the rear main bearing with a
feeler gauge. This clearance should be from 0.002-0.006 in. (0,051-
0,152 mm).
10. Install a new rear main bearing oil seal in the cylinder block and
main bearing oil cap as described below.
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.
2 1.Insert a screwdriver into the notches provided in the seal re-
tainer and pry the seal out. Take care not to damage the crankshaft
sealing surface.
1
860043
2. Inspect chamfer on crankshaft for grit, loose rust, and burrs. Clean
seal running surface on the crankshaft with a non-abrasive cleaner.
3 3. Lubricate the inner and outer diameter of new seal with engine
oil. Install the seal on J-35621. Position J-35621 against the crank-
shaft. Thread the attaching screws into the tapped holes in the crank-
shaft.
4. Tighten screws securely. 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. Remove Flywheel and oil pan. Remove screws, nuts and seal re-
tainer. Remove gasket.
2. Remove rear crankcase oil seal as previously stated and clean gas-
ket surfaces on block and seal retainer.
Whenever seal retainer is removed, a new retainer gasket and 2
DR1878
rear crankshaft oil seal must be installed.
3. Attach gasket to block. No sealer is required. Install seal retainer,
screws and nuts. Tighten to 135 in. lb. (15 N m).
•
4. Install oil pan. Install rear crankshaft oil seal as outlined previously.
J 35621
Install flywheel.
Piston and Connecting Rod

Piston and Rod Removal
1. Withdraw crankcase oil. Disconnect oil drain tube. Remove oil pan. 3
DR1879
2. Drain coolant from block and exhaust manifold, then remove cylin-
der head.
3-24 Engine/eng
3. Remove any ridge and/or deposits from the upper end of the cylinder
bores with a ridge reamer.
Move piston to the bottom of its travel 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 the top of its stroke and carefully re-
move cloth with the cuttings.
4. Check connecting rods and pistons for cylinder number identification
and if necessary, mark them.
5. Remove connecting 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 away from crankshaft and out of the
cylinders.
It will be necessary to turn the crankshaft slightly to disconnect
some of the rods and push them out of the cylinder.
Piston and Rod Disassembly
1. Install pilot of piston pin removing and installing tool J-24086 on pis-
ton pin.
4 2. Install piston and connecting rod assembly on support and place
J 24086-C
assembly in an arbor press. Press pin out of connecting rod.
3. Remove assembly from press. Remove piston pin from support and
remove tool from piston and rod.
4. Piston pins are a matched fit to the piston and not available sepa-
rately. Piston pins will not become loose enough to cause a knock or
tapping until after prolonged use. In such cases a new piston and pin
assembly should be installed.
Piston pins should be capable of supporting their own weight in either
pin boss when coated with light engine oil at 60° F (16° C). Higher or
lower temperatures will cause false indications. Pistons and pins are
serviced as assemblies.
Check fit of used piston pins. Use a dial bore gauge or telescoping
snap gauge for the bore, and a micrometer for the pin. Wear limit on
4
860046
piston pin is production clearance plus 0.001 in. (0,025 mm). Replace
piston and pin assembly if wear is excessive.
Clean varnish from piston skirts and pins with a cleaning solvent. DO
NOT WIRE BRUSH THE PISTON SKIRT. Clean the ring grooves with a
groove cleaner, and make sure oil ring holes and slots are clean.
Engine/eng 3-25
Inspect the piston for cracked ring lands, skirts or pin bosses, wavy
worn ring lands, scuffed or damaged skirts, or eroded areas at top of
the piston. Replace pistons that are damaged or otherwise show signs
of excessive wear.
Piston and Rod Assembly
1. Lubricate piston pin holes in piston and connecting rod to facilitate

installation of pin.
2. Position connecting rod in its respective piston so that flange or
heavy side of rod at the bearing end will be towards front of piston
(cast depression in top of piston head).
1 3. Install piston pin, pilot spring and pilot in installer J24086C. J 24086-C
4. Place installer on arbor press, start pin into piston and press on
installer until pin pilot bottoms.
5. Remove installer and support assembly from piston and connecting
rod assembly. Check piston pin for freedom of movement in piston
bore.
Piston Rings 1
860047
Piston rings are furnished in standard sizes as well as several oversizes.
See your parts catalog.
Oil control rings used on all engines consist of two segments (rails)
and a spacer.
Compression rings in all engines are the deep section twist type,
0.0775-0.0780 in. (1,969-1,981 mm) wide.
This type compression ring takes its name, twist type, from its installed
position which is cocked or twisted. It assumes and maintains this po-
sition for life because the upper edge of its diameter is chamfered,
making the ring unbalanced in cross section.
All compression rings are marked on the upper side of the
ring. When installing compression rings, make sure the marked side is
toward the top of the piston.
Removal
1. Remove piston rings by expanding them and sliding them off the
ends of the piston.
3-26 Engine/eng
2. Check piston ring grooves by carefully removing all particles of car-
bon. Also check for burrs or nicks that might cause rings to hang up.
Installation
1. Select rings comparable in 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 place the ring square with the
cylinder walls.
2 3. Check the space or gap between the ends of the ring with a
feeler gauge.
4. If the gap between the ends of the ring is below specifications, re-
move the ring and try another for fit.
5. Fit each ring separately to the cylinder in which it is going to be used.
6. New pistons, rings and cylinder bores wear considerably during seat- 2
860048
ing and gaps widen quickly; however, engine operation will not become
seriously affected if ring gaps do not become greater that 1/32 in. (0,792
mm).
3 7. Slip the outer surface of the compression ring into the piston
ring groove. Roll the ring entirely around the groove to make sure that
the ring is free and does not bind in the groove at any point. If binding
occurs, the cause should be determined and removed by carefully dress-
ing with a fine cut file. However, if the binding is caused by a distorted
ring, install a new ring.
8. Install the oil ring spacer in the oil ring groove and position gap in line 3
860049
with piston hole. Hold spacer ends butted 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.
9. Flex the oil ring assembly in its groove to make sure ring is free and
does not bind in the groove at any point. If binding occurs, the cause
should be determined and removed by carefully dressing with a fine cut
file. However, if the binding is caused by a distorted ring, install a new
ring.
Engine/eng 3-27
1 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, when fitting new rings, the clear-
ances between the top and bottom surfaces of the ring grooves should
be inspected.
1 11. The compression rings should be fitted so that the clearance
is 0.0012-0.0029 in. (0,03048-0,07366 mm).
12. Assemble the rings to the pistons as they are fitted and make a
final test of the ring fit in the grooves by repeating the fitting procedure 1
860050
given above.
Expander ends must not align with the ring gap.
Piston and Rod Installation
1. Lightly coat pistons, rings and cylinder walls with light engine oil.
2 2. With bearing caps removed, install tool J-5239 on bearing cap
bolts. FACING FRONT OF
ENGINE BLOCK
2 3 3. Install each piston in its respective bore, using tool J-
8037 on each assembly. The side of the piston with the cast depres-
sion in the head should be to the front of the cylinder block and the oil
hole on connecting rod toward the camshaft side of the engine. Guide
the connecting rod bearing into place on the crankshaft journals with
the long detail of tool J-5239. Use J-8037 to compress piston rings.
4. Oil bearings and install bearing caps. Install cap retaining screws
and nuts. Tighten nuts to 45 ft. lb. (61 N m). Check the bearing clear-
•
ance as described previously.

J 5239
5. Install oil pan gaskets, seals and oil pan. See Oil Pan. Connect oil
drain tube.
6. Install cylinder head gasket and head. See Cylinder Head Installa- 2
tion. 860051
7. Refill crankcase and check for leaks. Lake or tank test unit and
check for coolant leaks.
Cylinder Block
Inspection
1. Check the cylinder block for cracks in the cylinder walls, water jacket J 8037
and main bearing webs.
3
860052
3-28 Engine/eng
4 2. Check the 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 gauge so that the thrust pin must be forced in
about 1/4in. (6,35 mm) to enter gauge in cylinder bore. Center gauge in
cylinder and turn dial to “O”. Carefully work gauge up and down cylinder
J 8087
to determine taper and turn it to different points around cylinder wall to
determine the out-of-round condition. If cylinders were found to have
more than 0.002 in. (0,051 mm) out-of-round, boring will be necessary.
Repair
The performance of the following operations is contingent upon engine

condition at time of repair.
If the cylinder block inspection indicated that the block was suitable for
continued use except for out-of-round or tapered cylinders, they can be
conditioned by honing, or boring and honing.
4
860053
If the cylinders were found to have less than 0.005 in. (0,127 mm) taper
or wear, they can be conditioned with a hone and 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 may not entirely clean up when fitted to a 0.001 in.
(0,025 mm) oversize piston. If it is desired to entirely clean up the bore
in these cases, it will be necessary to rebore for an oversize piston. If
more than 0.005 in. taper or wear exists, they should be bored and
honed to the smallest oversize that will permit complete resurfacing of
all cylinders.
Piston Selection
Replacement pistons are available in two sizes, see the appropriate

parts catalog for part numbers. The size identification of the piston is
marked in 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 measured diam-
eter. Next locate this dimension on the Piston Selection Chart. The num-
ber shown on the chart in the box above the dimension is the marking
on the piston which should be used.
Engine/eng 3-29
Example “A”:
Cylinder Bore Measurement 4.002 in. (10,165 cm) (Worn Bore)
Base Cylinder Bore Diameter 4.000 in. (10,160 cm)
Difference 0.002 in. (0,051 mm)
The number in the box above 0.002 (0,051 mm) in is S7. Therefore, in
this case a 0.001 in. (0,025 mm) oversize piston marked S7 would be
used.
Example “B”:
Cylinder Bore Measurement 4.032 in. (10,241 cm) (Bored Out Bore)
Base Cylinder Bore Diameter 4.000 in. (10,160 cm)
Difference 0.032 in. (0,813 mm)
The number in the box above 0.032 in. (0,813 mm) is 4. In this ex-
ample, a 0.030 in. (0,762 mm) oversize piston marked 4 would be
used.
DR4649
Boring
1. Before using any type boring bar, the top of the cylinder block should
be dressed to remove any dirt or burrs. This is very important. Other-
wise, the boring bar may be tilted which would result in the rebored
cylinder wall not being at right angles to the crankshaft.
2. The piston to be fitted should be checked with a micrometer, mea-
suring just below the lower ring groove and at right angles to the pis-
ton pin. The cylinder should be bored to the same diameter as the
piston and honed to give a clearance of 0.0025-0.0035 in. (0,064-0,089
mm).
3. The instructions furnished by the manufacturer of the equipment
being used should be carefully followed.
3-30 Engine/eng
Honing and Piston Fit
1. When the cylinders are to be honed only for use of a standard piston
or for final finishing after they have been rebored to within 0.002 in.
(0,051 mm) of the desired size, they should be finished with a hone.
Rough stones may be used at first and fine stones for the final opera-
tion.
1 2. Place the hone into a cylinder bore and expand the stones until
the hone can just be turned by hand. Connect a 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 liberal amount of kerosene should be used as a
cutting fluid to keep the stones of the hone clean. Move hone slowly up
and down with rough stones, but move hone up and down rapidly enough
with the fine stones to produce a final bore finish of very fine surface
scratches in a cross-hatch pattern of approximately 45° to 60°. The marks
1
186747
should be clean but not sharp, and free from embedded particles or
torn or folded metal.
3. Expand the 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 should
be thoroughly cleaned and the piston selected for the individual cylin-
der checked for correct fit.
5. Check fit of the aluminum pistons in the following manner:
Thoroughly clean cylinder bores with soap and hot water to
remove all grit particles.
a. Measure the cylinder bore diameter with a telescope gauge
and micrometer 2-1/2 inches (6,35 cm) from top of cylinder
bore at 90° from crankshaft axis.
b. Next measure the diameter of the piston skirt just below the
lower ring groove and at right angles to the piston pin.
c. If the difference is greater than the maximum allowable (see
Boring, step 2), try another piston or lightly hone the cylinder
bore to obtain the proper fit.
d. Should the difference be less than the minimum allowable (see
Boring, step 2), try another piston. If proper fit cannot be ob-
tained, it will be necessary to rebore the cylinder to the next
oversize piston.
e. Mark each piston after fitting to correspond with the cylinder to
which it has been fitted. Proceed to hone cylinders and fit the
remaining pistons.
Engine/eng 3-31
Handle the pistons with care and do not attempt to force them
through the cylinder until the cylinder has been bored to correct size.
This type piston can be distorted through careless handling.
6. Thoroughly clean the cylinder bores with hot water and soap. Scrub
well with a stiff bristle brush and rinse thoroughly with hot water. It is
extremely essential that a good cleaning operation be performed. If
any of the abrasive material is allowed to remain in the cylinder bores,
it will rapidly wear the new rings and cylinder bores. In addition, the
bearing will be lubricated by the contaminated oil. The bores should 1
be swabbed several times with light engine oil and a clean cloth and 860054
then wiped with a clean dry cloth. Cylinder should not be cleaned with
kerosene or gasoline. Clean the remainder of the cylinder block to
remove the excess material spread during the honing operation.
Distributor Lower Bearing

The distributor lower bearing is a bronze bushing pressed into the lower
side of the engine block. Its upper inside diameter pilots the distributor
shaft, and the outside diameter extending below the block pilots the oil
pump.
Some engines have a thrust washer at the upper end of the bushing
bore. The thrust washer, where used, may be replaced at the same
time the bushing is replaced.
The lower bushing will ordinarily require only a clearance or wear check
during engine overhaul. When distributor shaft-to-bushing clearance 2
exceeds 0.0035 in. (0,0889 mm) the bushing should be replaced as 860055
follows with oil pump and distributor removed:

1 1. Install tool J-9534 into bushing and using a slide hammer, re-
move the bushing.
Protect your eyes from fragments. Wear safety glasses when
striking these tools, handles, drivers, etc. Tool end may mush-
room after being repeatedly struck. Always grind off any rolled
edges before using tool. Use soft face hammers whenever pos-
sible.
2 2. Using a drift up through bushing bore, drive thrust washer (if
installed) out of bore and remove from block.
3. Clean bushing bore in block and check for burrs or damage.
3 4. If thrust washer was removed, start new washer in position in
bore and drive into place using tool J-9535.
3 5. Using tool J-9535 with driver-bolt in driver handle, install driver
into new bushing from large inside diameter.
3
860056
4 6. Place bushing and driver on block and drive the bushing in po-
sition. Depth is determined by tool bottoming against the block.
7. Remove tool from bushing. It is possible that the bushing with mini-
mum I.D. will collapse enough, during installation, to slightly seize the
installer arbor. If this happens, remove installer tool using slide hammer
in driver bolt hole of driver handle.
This will not damage the bushing and the tool is designed for
this purpose, should it occur.
Circulating Pump
Removal
1. Remove drain plugs on port side and drain coolant from block and
exhaust manifold. Disconnect water hose from circulating pump.
2. Loosen four screws holding circulating pump pulley to circulating
pump.
3. Loosen alternator bracket bolts and remove alternator belt. Remove
circulating pump pulley and bolts. Unscrew bolts and remove the circu-
lating pump from the engine. 4
860057
Pull the pump straight out of the block first, to avoid damage to
impeller.
Inspection
If the seal is leaking replace the pump. If the bearing is rough or allows
excessive sideways movement of the shaft, replace the pump. If the
impeller has excessive erosion replace the pump.
Installation
This pump has a special shaft and bearing assembly and a

special seal assembly intended for marine service. Do not substitute
with an automotive pump.
1. Apply Volvo Penta Gasket Sealing Compound to a new pump to block
gasket. Install pump assembly on cylinder block and tighten bolts se-
curely.
2. Install circulating pump pulley. Attach alternator belt and adjust. Re-
fer to General Information section for specifications.
3. Connect coolant hoses to circulating pump. Install the drain plugs in
the engine block and exhaust manifold. Tighten the plugs securely. Lake
or tank test unit and check for leaks.
Engine/eng 3-33
Oil Pan Replacement
Removal
1. Remove oil using a suction pump.

2. Remove oil withdrawal tube. Remove screws, oil pan and gasket.
Installation
1. Thoroughly clean all gasket sealing surfaces. Apply RTV sealer to

the front and rear of the block.
2. Install gasket on the block. Install oil pan. Tighten crankcase screws
to 80 in. lb. (9 N m), front cover screws to 45 in. lb. (5 N m), and rear
• •
pan nuts to 165 in. lb. (18.6 N m). Install oil drain tube and fill crank-
•
case with engine oil.
Oil Pump
1 The oil pump consists of two gears A and a pressure relief valve
B C
enclosed in a two-piece housing . The pump is driven from the
distributor driveshaft which in turn is driven by a helix gear on the cam-
shaft.
The oil pump is flange mounted to 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 pump cover 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 pump
intake is of the fixed screen type. A mesh screen D filters out small
particles of dirt and sludge which may be present.
A baffle incorporated on the intake screen has been designed
to eliminate pressure loss due to sudden surging stops, turns, and
acceleration.
In the event that a screen becomes plugged a steel grommet opens
and bypasses oil to the pump.
Removal and Disassembly
1. Withdraw oil. Disconnect oil withdrawal tube. Remove screws, oil 1

860058
pan and gasket. Remove oil withdrawal tube fitting from oil pan.
2. Remove oil pickup tube clamp bolt. Remove two flange mounting
bolts. Remove pump and screen as an assembly.
3. Remove four cover attaching screws, cover, gasket, idler gear, and
drive gear and shaft.
3-34 Engine/eng
4. Remove pressure regulator valve and valve parts. If necessary, re-
move oil pump suction pipe and screen by pulling from pump housing.
Do not disturb oil pickup pipe on screen. This pipe is located at
assembly.
5. Wash all parts in cleaning solvent and dry using compressed air.
Inspection
Should any of the following conditions be found during inspection op-

erations, the defective parts should be replaced.
1. Inspect pump body for cracks and excessive wear. Inspect oil pump
gears for excessive wear or damage.
2. Check shaft for looseness in the housing. Check inside of cover for
wear that would permit oil to leak past the ends of gears.
3. Check the oil pick-up screen for damage to screen or relief grommet.
4. Check pressure regulator valve plunger for fit in cover.
Assembly and Installation
1. Place drive gear and shaft in pump body. Install idler gear so that
smooth side of gear will be toward the cover.
2. Install a new pump to cover gasket to ensure correct end clearance
of the gears.
3. Install suction pipe and screen assembly to pump body and install
cover and attaching screws. Tighten screws to 72 in. lb. (8 N m) and•
check to see that shaft turns freely.

4. Install regulator valve plunger, spring, retainer and pin.
5. Align oil pump driveshaft slot to match with distributor tang. Install oil
pump to block, positioning flange over distributor lower bushing. Use
no gasket.
Oil pump should slide easily into place. If not, remove and relo-
cate slot or determine other problem.
6. Attach and tighten oil pickup tube clamp.
7. Install oil pan using new gaskets and seals.
2 8. Install withdrawal tube fitting to pan; leave screw loose. Orient
fitting and attach withdrawal tube. Then tighten both fitting screw and
flare nut to 15-18 ft. lb. (20-24 N m).
•
9. Fill crankcase with oil.

2
31576
Engine/eng 3-35
Oil Filter Bypass Valve
Inspection
Remove the oil filter and check the spring and fiber valve for opera-
tion. Check for a cracked or broken valve.
Replacement
If replacement is necessary:
1. Remove the valve by prying it out with a screwdriver.
2. Install a new valve and seat it by tapping into place using a 9/16 in.
thin wall deep socket and hammer.
3. Install oil filter according to manufacturer’s instructions.
High-Rise Exhaust Elbow Replacement

Removal
1. Loosen all four hose clamps. Lubricate exhaust pipe with a soapy
water solution, and slide hose down off exhaust elbow.
2. Loosen hose clamp and disconnect cooling hose from inside of ex-
haust elbow. Then remove hose fitting.
1 3. Remove the two screws A and swing anchor bracket out of

the way. Then remove the two nuts and lock washers B . 1
34729
2 4. Loosen the elbow with a soft hammer, then lift it off the mani-
fold. Remove and discard the elbow gaskets. Retain the restrictor plate.
2
22649A
Safety Related
3-36 Engine/eng
Installation
1. Thoroughly clean the manifold and elbow gasket surfaces. Apply Volvo
Penta Gasket Sealing Compound to both sides two new gaskets. Sand-
wich the restrictor plate between the two new gaskets. The slot in the
restrictor plate should be positioned out away from the engine block.
Place the gaskets and restrictor plate on the manifold.
3 2. Mount the elbow on the manifold. Install the throttle anchor

bracket, and secure with the two screws A and the two nuts and lock
washers B .Tighten all four to 12-14 ft. lb. (16-19 N m). Slide the ex-
•
3
34728
haust hose all the way onto the elbow.
3. Install hose fitting on the inside of elbow and connect cooling hose.
4 4. Position the upper clamps in the top two channels and tighten
them securely. Position the two lower clamps in the channels and tighten
them securely.
5. Reconnect throttle cable to carburetor and throttle linkage plate.
Secure with cotter pin.
Exhaust Hose Replacement 4

34727
Removal
1. Remove high rise exhaust elbow following procedure in High-Rise

Exhaust Elbow Replacement.
5 2. Remove clamps and slide hose off exhaust pipe.

Installation
6 One end of exhaust hose has two ribs C around the cir-
cumference. Position this end up when installing hose to ensure secure
attachment.
5
22647A
1. Place two No. 64 hose clamps over exhaust pipe if they were re-
moved.
7 2. For ease of installation lubricate inside diameter of hose with a

soapy water solution, and slide hose all the way onto exhaust pipe. C
Place two No. 64 clamps around top section of hose.
6
16350
7
22646A

Engine Coupler Replacement
Removal
1. Remove engine from boat following instructions in Engine Removal

and Installation section.
If 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 Removal and Installation section.
2. Cut tie strap holding flywheel housing drain hose (if equipped) to
6
20034
starter motor.
6 7 3. Take out screws holding flywheel housing cover C , then
slide out cover.
8 4. Remove nut, lock washer, and ground leads from ground stud.
Remove inner nut, lock washer and washer. Remove similar ground
stud hardware on opposite side of block.
5. Remove screws and washers holding 10 pin connector and relay,
and move bracket aside.
6. Unscrew remaining flywheel housing bolts, lock washers and wash- 7
6676
ers. Note position of clamps so they can be installed in original position.
9 7. Lift flywheel housing off engine block and set aside.
10 8. Unscrew six locknuts, then pull coupler off flywheel.
8
6675
9
6710
10
6712
3-38 Engine/eng
Installation
1 1. Slide coupler onto crankshaft studs. Install locknuts. Use a

crowfoot wrench and tighten nuts to 40-45 ft. lb. (54-61 N m).
•
2 2. Install flywheel housing. Place clamps in their original posi-

tions, and attach 10 pin connector and relay bracket. Tighten screws
to 28-36 ft. lb. (38-49 N m).
•
3. Place washer, lock washer and nut on ground stud. Tighten

inner nut to 35-40 ft. lb. (47-54 N m). Attach electrical leads to ground
•
stud. Install lock washer and tighten outer nut securely. Install 1
6714
ground stud hardware on opposite side of block.
3 4. Slide flywheel cover up into place. Install screws and tighten
them to 60-84 in. lb. (7-9 N m).
•
4 5. Attach flywheel housing drain hose A (if equipped) to starter

motor with tie strap.
6. Install engine in boat following instructions in Engine Removal and
Installation section.
2
6711A
3
20034
4
14704

Engine Specifications
1. General Specifications
Type - No. of Cylinder ........................................................... 4 - In-line

Bore and Stroke .................................................................... 4.000 in. x 3.60 in. (101.6 mm x 91.44 mm)
Piston Displacement ............................................................. 181 Cu. In. (3.0 Liter)
Cylinder No. (front to rear) ................................................... 1 - 2 - 3 - 4
Firing Order ........................................................................... 1 - 3 - 4 - 2
Compression Ratio ............................................................... 9.3 to 1
Thermostat Opens at ............................................................ 160° F (71° C)
Full Throttle Operating Range .............................................. 4200-4600 RPM
2. Engine Dimensions. Fits and Adjustments
Pistons:
Type ................................................................................. Cast Aluminum

Clearance Limit at Top Land .......................................... 0.0255 - 0.0345 in. (0.6477 - 0.8763 mm)
Clearance Limit at Skirt .................................................. 0.0025 - 0.0035 in. (0.0635 - 0.0889 mm)
Compression Ring Groove Depth .................................. 0.209 - 0.211 in. (5.309 - 5.359 mm)
Oil Ring Groove Depth ................................................... 0.190 - 0.199 in. (4.826 - 5.055 mm)
Piston Rings:
Compression Ring
Material ..................................................................... Cast Iron
Type .......................................................................... Radius Face (Upper)
Tape Face (Lower)
Coating - Upper Ring ............................................... Molybdenum
Coating - Lower Ring ............................................... Wear Resistant
Width ........................................................................ 0.0775 - 0.0780 in. (1.9685 - 1.981 mm)
Gap ........................................................................... 0.010 - 0.020 in. (0.254 - 0.508 mm) (Upper)
0.013 - 0.025 in. (0.330 - 0.635 mm) (Lower)
Oil ring
Material ..................................................................... Flat Spring Steel
Type .......................................................................... Multi-piece Rail Expander and Spacer
Coating (rail) ............................................................ Chrome
Width (Piston Groove) ............................................. 0.188 - 0.189 in. (4.775 - 4.801 mm)
Gap (Ring) ................................................................ 0.015 - 0.055 in. (0.381 - 1.397 mm)
Width (Ring) ............................................................. 0.154 - 0.160 in. (3.912 - 4.064 mm)
Expanders ................................................................ One-Piece Expander-Spacer
Piston Pins:
Length ............................................................................. 2.990 - 3.010 in. (75.946 - 76.454 mm)

Diameter ......................................................................... 0.9270 - 0.9273 in. (23.5458 - 23.5534 mm)
Clearance in Piston (new) ............................................. 0.0003 - 0.0004 in. (0.0076 - 0.0101 mm)
Wear Limit in Piston ....................................................... 0.001 in. (0.025 mm)
Clearance in Rod ........................................................... 0.0008 - 0.0021 in. (0.0203 - 0.0533 mm)
3-40 Engine/eng
Connecting Rods:
Material ........................................................................... Drop Forged Steel

Length CL to CL ............................................................. 5.700 in. (144.780 mm)
Connecting Rod Bearing
Material ..................................................................... M400
Effective Length ....................................................... 0.792 - 0.822 in. (20.117 - 20.879 mm)
Clearance ................................................................. 0.00085 - 0.00135 in. (0.02158 - 0.03429 mm)
End Play ................................................................... 0.008 - 0.015 in. (0.203 - 0.381 mm)
Crankshaft:
Material ........................................................................... Nodular Cast Iron

End Play ......................................................................... 0.002 - 0.006 in. (0.051 - 0.152 mm)
End Thrust Taken By ...................................................... Rear Main Bearing
Crankpin Journal Diameter ............................................ 2.0989 - 2.0995 in. (53.2892 - 53.3273 mm)
Main Bearing
Type .......................................................................... Precision Removable
Journal Diameter ..................................................... 2.2979 - 2.2994 in. (58.3666 - 58.4047 mm)
Length ...................................................................... 0.822 in. (20.879 mm) (rear)
0.830 in. (21.082 mm) (others)
Clearance ................................................................. 0.0003 - 0.0029 in. (0.0076 - 0.0737 mm)
Camshaft:
Camshaft Bearing
Material ..................................................................... Steel Backed Babbitt
Journal Diameter ..................................................... 1.8677 - 1.8697 in. (47.440 - 47.490 mm)
Bearing Outer Diameter - Nos. 1 and 2 ................ 1.999 - 2.001 in. (50.775 - 50.825 mm)
Bearing Outer Diameter - No. 3 .............................. 2.009 - 2.011 in. (51.029 - 51.079 mm)
Type of Drive .................................................................. Gear
Crankshaft Gear Material .............................................. Helical Cut Nodular Cast Iron
Camshaft Gear Material ................................................. Helical Cut Bakelite and Fabric Composition
Lobe Lift .......................................................................... 0.253 in. ± 0.005 in. (6.426 mm ± 0.127 mm)
Valve Systems:
Lifter Type ....................................................................... Hydraulic

Rocker Arm Ratio ........................................................... 1.75 to 1
Valve Lash Adjustment -
Intake and Exhaust (hot) ......................................... 3/4 to 1 Turn Down From “Zero Lash” Point
Valve Face Angle ........................................................... 45°
Valve Seat Angle ............................................................ 46°
Stem to Guide Clearance -
Intake Valve .............................................................. 0.0010 - 0.0027 in. (0.0254 - 0.0686 mm)
Stem to Guide Clearance -
Exhaust Valve .......................................................... 0.0010 - 0.0027 in. (0.0254 - 0.0686 mm)
Recommended Valve Seat Width
Intake ........................................................................ 0.050 - 0.070 in. (1.27 - 1.778 mm)
Exhaust .................................................................... 0.060 - 0.080 in. (1.524 - 2.032 mm)
Engine/eng 3-41
Valve Systems (cont.):
Outer Valve Spring Free Length .................................... 2.06 in. (52.324 mm)
Outer Valve Spring Pressure Lb. (N) @ In. (mm) ........ 100 - 110 (444 - 490) @ 1.61 (40.89 mm)
Engine Lubrication:
Type Oil Pump ................................................................ Gear

Normal Oil Pressure ....................................................... 40-60 PSI (275.8 - 413.7 kPa) @ 2000 RPM
Crankcase Capacity - Quarts ........................................ 3-1/2 (4 with new filter)
Oil Grade Recommended: Service SG-Meeting GM Spec 6094
32°F (0° C) and Above ................................................... SAE 30

0° F (-18° C) to 32° F (0° C) .......................................... SAE 20W-20
Below 0° F (-18° C) ........................................................ SAE 10W
We recommend DuraPlusTM SAE 30 Heavy Duty Synthetic Motor Oil, which is specially formulated for heavy duty
marine use. DuraPlusTM SAE 30 Heavy Duty Synthetic Motor Oil provides superior anti-wear qualities, especially
important during prolonged high speed operation. It also neutralizes acids created in all internal combustion en-
gines. This motor oil is formulated to offer superior protection against corrosion and to resist oxidation and high
temperature sludge formation.
The use of multi-viscosity oils is not recommended. Disregard any reference to multi-viscosity oil printed on
engine. Such reference is intended for automotive use only, not marine use.
Fuel Grade Recommendation .................................................................................. See General Information section
3-42 Engine/eng
Torque Specifications
Use a reliable torque wrench to tighten theparts listed to prevent straining or distorting the parts or possibly damag-
ing the threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accu-
rate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to
any extent may damage threads, thus preventing proper torque from being obtained, requiring replacement or repair
of the damaged part.
ITEM FT. LB. IN. LB. Nm•
Screw
Adaptor - Oil Pressure Sender 10-14 - 14-19
Alternator - Bracket to Engine 26-30 - 35-41
Camshaft Thrust Plate - 80 9
Circulating Pump 13-17 - 18-23
Distributor Clamp 20 - 27
Exhaust Elbow 12-14 - 16-19
Flywheel Bellhousing 28-36 - 38-49
Flywheel Cover - 60-84 7-9
Front Mount - Port 48-56 - 65-76
Front Mount - Starboard 32-40 - 43-54
Oil Pan to Crankcase - 80 9
Oil Pan to Front Cover - 45 5
Oil Pump Cover - 72 8
Oil Withdrawal Tube Fitting 15-18 - 20-24
Power Steering Pump Bracket 26-30 - 35-41
Starter Motor 30-36 - 41-49
Starter Motor Bracket 16-19 - 22-26
Supply Pump Bracket 13-17 - 18-23
Thermostat Housing 12-16 - 16-22
Timing Chain Cover - 27-35 3-4
Valve Cover - 40 5
Engine/eng 3-43
Torque Specifications - (Cont.)
Nut
Connecting Rod Cap 45 - 61
Crankshaft Oil Seal Retainer - 150-180 17-20
Flame Arrestor Cover - 30-40 3,4-4,5
Flare - Oil Withdrawal Tube 15-18 - 20-24
Flywheel and Coupler 40-45 - 54-61
Intake/Exhaust Manifold 20-25 - 27-34
Bolt
Cylinder Head
Step 1 35 - 47
Step 2 65 - 88
Step 3 90 - 122
Intake/Exhaust Manifold 20-25 - 27-34
Main Bearing Cap (exc. rear) 55-70 - 75-95
Main Bearing Cap, Rear
Step 1 10-12 - 14-16
Step 2 55-70 - 75-95
Oil Pump - 120 14
Stud
Flame Arrestor to Carburetor - 65-80 7-9
Miscellaneous
Oil Filter One turn after contact
Retainer - Oil Pan Drain 15-18 - 20-24
Sender, Oil Pressure 10-14 - 14-19
Sender, Water Temperature 18-22 - 24-30
Spark Plugs 20 - 27
3-44 Engine/eng
Section 4
4.3 GL and Gi Engine
Table of Contents
Accessories .............................................................. 4-4 General Description ................................................. 4-2

Balance Shaft ......................................................... 4-23 Intake Manifold ......................................................... 4-7
Balancer, Crankshaft .............................................. 4-15 Intermediate Pipe Replacement ............................ 4-38
Camshaft ................................................................. 4-22 Materials Required ................................................... 4-3
Cleaning .................................................................... 4-4 Oil Pan ..................................................................... 4-16
Circulating Pump .................................................... 4-34 Oil Pump ................................................................. 4-17
Crankshaft and Bearings ....................................... 4-30 Pistons and Connecting Rods .............................. 4-25
Cylinder Block ........................................................ 4-31 Rear Oil Seal, Crankshaft ...................................... 4-29
Bylinder head .......................................................... 4-12 Rear Oil Seal Housing ............................................ 4-29
Engine Rocker Arm Cover .................................................... 4-9 4
Coupler Replacement ......................................... 4-39 Rocker Arm Stud Replacement ............................. 4-13
Draining ................................................................. 4-4 Special Tools - GM ................................................. 4-46
Front Cover .......................................................... 4-20 Specifications
Front Mount ......................................................... 4-35 Engine .................................................................. 4-43
Lubrication ............................................................ 4-5 Torque .................................................................. 4-41
Exhaust Timing Chain and Sprockets ................................. 4-21
Manifold ................................................................. 4-6 Tools and Shop Equipment ..................................... 4-3
High-Rise Elbow Replacement........................... 4-37 Valve Train .............................................................. 4-10
Hose Replacement .............................................. 4-38
Safety Warnings
Engine/eng 4-1
General Description
Engine Construction
The 4.3L engine is a liquid-cooled 90 degree V6 type with overhead

valves, a balance shaft, and cast-iron block and cylinder heads.
Cylinder Block
The cylinder block has 6 cylinders arranged in a “V” shape with 3 cyl-
inders in each bank. Starting at the front of the engine, cylinders in the
right bank are numbered 1-3-5 and cylinders in the left bank are num-
bered 2-4-6 (when viewed from the front). The firing order of the cylin-
ders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets.
Cylinder Heads
The cylinder heads have one intake and one exhaust valve for each
cylinder. A spark plug is located between the 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 number

four bearing at the rear of the engine is the end thrust bearing. The
bearings are retained by bearing caps that are machined with 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 made of cast-aluminum alloy using two compression

rings and one oil control ring assembly. Piston pins are offset 0.0354
in. (0,9 mm) toward the major thrust side (right side) to reduce piston
slap as the connecting rod travels from one side of the piston to the
other side after a stroke. The pins are a press fit in the connecting rod
and a floating fit in the piston.
Balance Shaft
The cast-iron balance shaft is mounted in the crankcase above and

inline with the camshaft. A camshaft gear drives the gear attached to
the balance shaft. The front end of the balance shaft is supported by a
ball-type bearing. The rear end of the balance shaft uses a sleeve-
type bearing.
4-2 Engine/eng
Valve Train
The valve train is a ball-pivot type. Motion is transmitted from the cam-
shaft through the valve lifter and valve push rod to the valve rocker arm.
The valve rocker arm pivots on its ball and transmits the camshaft mo-
tion to the valve. The valve lifters with roller followers keep all parts of
the valve train in constant contact. Each lifter acts as an automatic ad-
juster 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 made from 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 equip-
ment includes: a suitable parts cleaning tank, compressed air supply,
trays to keep parts and fasteners organized, and an adequate set of
hand tools. An approved engine repair stand will help aid with the work
and help prevent personal injury or component damage.
Special tools are listed and illustrated throughout this section with a
complete listing at the end of the section. These tools (or their equiva-
lents) are specially designed to quickly and safely accomplish the op-
erations for which they are intended. The use of these special tools will
also minimize possible damage to engine components. Some precision
measuring tools are required for inspection of certain critical compo-
nents. Torque wrenches are necessary for the correct assembly of vari-
ous parts.
Material Required
DuraPlusTM Synthetic Motor Oil

Volvo Penta Thread Sealing Agent
3M Scotch Grip Rubber Adhesive 1300
GM Adhesive, P/N 12346141
GM Engine Oil Supplement, P/N 1052367
GM Sealant, P/N 12346004
GM Threadlock, P/N 12345382
Loctite Primer
Black Neoprene Dip
Engine/eng 4-3
Accessories
The various procedures in this manual assume that the engine acces-
sories have been removed. These accessories include all of the fol-
lowing:
Power Steering Pump

Alternator
Distributor
Water Supply Pump
Accessory Brackets and Electrical Wiring
Starter Motor
Cleaning
Remove the engine accessories before cleaning to provide better ac-
cess to the engine’s exterior surfaces. After removing the distributor,
accessory brackets, etc., cover the openings with tape to prevent the
entry of contaminants.
Methods used to clean the engine will depend on the means which are
available. Steam cleaning, 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 contaminants from 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 Engine/eng
1
DRC6583
Engine Lubrication
1 Full pressure lubrication, through a full-flow oil fil- Filtered oil flows into the main gallery and then to the
ter is supplied by a gear-type oil pump. Oil is drawn up camshaft, balance shaft, rear bearing, and crankshaft
through the oil pump screen and passes through the bearings. The valve lifter oil gallery supplies oil to the
pump to the oil filter. The oil filter is a full-flow paper valve lifters. Oil flows from the valve lifters through the
element unit with an anti-drain back valve. An oil filter hollow valve push rods to the valve rocker arms. Oil
bypass valve is used to ensure adequate oil supply, in drains back to the crankcase through oil drain holes in
the event the filter becomes plugged or develops ex- the cylinder head. The camshaft timing chain is drip
cessive pressure drop. fed from the front camshaft bearing. The pistons and
piston pins are lubricated by oil splash.
Engine/eng 4-5
Exhaust Manifold
Removal
1. Drain water from exhaust manifolds.

2. Disconnect water hose from manifold.
3. Loosen upper exhaust hose clamps, then remove high rise elbow.
4. Remove manifold attaching screws, then remove the manifold.
Inspection
1. Inspect for cracks. A

1 2. To pressure check manifold, use a plate such as pictured, A B
and a new elbow gasket B to seal water passage in manifold. Be sure
to apply sealer to gasket. Install rubber drain caps to manifold and C
secure with clamps. Attach a Gearcase Pressure Tester C (such as
Stevens Company S-34) to the water inlet hose. A bushing can be
made to secure pressure tester to hose. With the pressure tester at-
tached to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks. Manifold should
not leak around clamps and plate. If so, retighten clamps or reseal
1
DR2642
plate. No drop in pressure should be realized.
Installation
2 1. Clean mating surfaces on manifold and head. Install new ex-

haust gasket, then install manifold and secure with screws. Tighten
screws D to 20-26 ft. lb. (27-35 N m).
•
2. Install a new gasket and high rise elbow to manifold. Tighten bolts
to 12-18 ft. lb. (16-24 N m).
•
3. Install exhaust hose and secure with clamps.

2
4. Connect water hose and secure with clamp. 28287A
5. Start engine and check for fuel leaks.

Intake Manifold
Removal
3 5 1. Drain coolant from manifolds and both sides of block.
6 2. Remove intake manifold drain plug E from front of intake mani-
fold.
3. Disconnect:
a. Battery cables from battery. 3
34091A
b. Coolant hoses at thermostat housing.
c. Throttle cable from carburetor and anchor block.
d. Crankcase ventilation hose from rocker arm covers (both
sides).
e. Wire at temperature gauge sender unit and engine wiring har-
ness from alternator.
f. Distributor high tension and ignition primary leads from coil.
4. Remove:
4
7 a. Distributor cap and mark the position of the rotor on the hous- 34102A
ing. Scribe a line on distributor housing and intake manifold

for reassembly in the same position. Remove the distributor.
b. Alternator and alternator mounting bracket from engine.
c. Carburetor fuel line from carburetor and fuel pump or fuel lines
from throttle body and fuel pump/vapor separator.
d. Oil pressure sending unit.
e. Manifold attaching bolts and solenoid bracket. Lift manifold
from engine. Discard front and rear seals and gaskets.
5
49459
f. If manifold is to be replaced, transfer: carburetor or throttle
body and ECM bracket, thermostat and housing (use new gas-
ket), throttle cable anchor block assembly, distributor clamp
and temperature sending unit. Transfer additional hardware
as required.
6
28546
7
25140

Clean:
Old pieces of gasket or RTV from the gasket surfaces.

Excessive carbon build-up in the intake passages of
the intake manifold.
Scale and deposits from the coolant passages of the
intake manifold.
Installation
1
Important Do NOT reuse intake manifold gaskets. DRC6590
Install or Connect:
1 1. Sealant to the intake manifold gasket, cylinder head side.

Care must be used to apply the correct amount of sealant onto
the gaskets. Applying excessive amounts of sealant may prohibit the
intake gaskets from sealing properly.
2 3 2. Gaskets onto the cylinder head.
a. Use gasket locator pins to properly seat gasket on cylinder
head.
2
DRC6591
b. Apply a 0.499 in. (13 mm) bead of GM Adhesive , P/N

12346141, or equivalent to the front and rear block sealant
areas.
c. Extend the sealer bead 0.157 in. (4 mm) onto each gasket.
3. GM Threadlock, P/N 12345382, or equivalent to the threads of the
eight lower intake mounting bolts.
4. Lower intake manifold onto engine block.
5. Lower intake manifold bolts.
3
Tighten: DRC6592
4 Bolts in three steps, using the following sequence:

a. Snug all bolts to 27 in. lb. (3 N m) to minimize shifting of in-
•
take.
b. Bolts to 106 in. lb. (12 N m). •
c. Bo Its to 11 ft. Ib. (15 N m).

•
4
DRC6593
4-8 Engine/eng
d. Distributor with rotor and aligned exactly as marked during re-
moval.
If engine was cranked while distributor was out, complete igni-
tion timing procedure must be followed. See the appropriate Ignition
Circuit in Electrical/Ignition/Fuel Systems Service Manual.
e. Alternator with mounting bracket.
f. Distributor cap and high tension leads. See the General In-
formation section in Electrical/Ignition/Fuel Service Manual
for correct firing order and spark plug wire routing.
g. Oil pressure sending unit.
3. Connect:
a. All electrical connections. Apply black neoprene dip, or
equivalent, on all exposed connections.
b. Fuel lines to carburetor and fuel pump or throttle body and
fuel pump/vapor separator.
c. Throttle cable.
d. All water hoses, and close all drain petcocks.
e. Both crankcase ventilation hoses.
f. Battery cables.
g. Start engine. Check ignition timing, carburetor idle speed and
mixture. Check for leaks.
Rocker Arm Cover

Removal
5 Remove or Disconnect:
1. Valve rocker arm cover bolts.
2. Valve rocker arm cover.
3. Gasket.
5
DRC6584

Clean:
Parts in solvent. Remove all sludge and varnish.

Old gaskets from the gasket surfaces.
Inspect:
Gasket flanges for bending or damage.

Rubber grommets and parts for deterioration.
Installation
1 Install or Connect: 1
DRC6584
1. New gasket.
Tighten:
Valve rocker arm cover bolts to 106 in. lb. (12 N m).
•
Valve Train
Removal 2
DRC6585
Important Store all reusable components in an exact order,

so they can be reassembled in the same wear pattern location from
which they were removed. Mark the front end of the retainer.
Remove or Disconnect:
2 1. Valve rocker arm nuts, balls, and valve rocker arms.
3 2. Valve push rods.
3 3. Bolts and valve lifter retainer.
4 4. Valve lifters. 3
DRC6588
Remove the lifters one at a time using J 9290-01/J 3049 or equivalent

and place them in an organizer rack.
Important Store all reusable components in an exact order,

so they may be reassembled in the same wear pattern location from
which they were removed.
4
DRC6586
4-10 Engine/eng
Clean:
All parts in clean solvent and dry them with compressed

air.
Make sure oil passages in valve push rods are clear.
Inspect:
Valve rocker arms and balls at their mating surfaces.

These surfaces should be free from wear or any dam-
age.
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 damage or 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.
Valve Lifters
This engine uses hydraulic valve lifters. Valve lifters are serviced only
as an assembly. No internal parts are available. Service is limited to a
disassembly and cleaning. Discard valve lifters that are excessively worn
or damaged.
Important Whenever the camshaft needs to be replaced, a new

set of valve lifters must also be installed.
Installation
Important Replace all valve roller lifters, change the engine oil
and filter, and add GM Engine Oil Supplement, P/N 1052367, or equiva-
lent to the engine oil whenever a new camshaft is installed.
Lubricate the valve lifter bodies and roller with GM Engine Oil
Supplement, P/N 1052367, or equivalent.
Install or Connect:
3 1. Valve lifters to the block.
3 2. Valve lifter guide.
Note previously made mark on valve lifter guide. Refer-
ence mark should be pointing toward front of engine.
Engine/eng 4-11
Tighten:
Bolts to 12 ft. lb. (16 N m). •

a. Seat the valve push rods into the socket of the valve lifters.
b. Coat the mating surfaces of the valve rocker arms and balls
with GM Engine Oil Supplement , P/N 1052365, or equiva-
lent.
2 4. Valve rocker arms with balls on to the proper stud. 1
DRC6588
2 5. Valve rocker arm nuts onto the studs.
Align the valve push rod into the valve rocker arm while
tightening valve rocker arm nut.
Important
No lash adjustment is needed. These models use
screw-in rocker arm studs with positive stop shoulders.
Tighten:
Valve rocker arm nuts to 20 ft. lb. (27 N m).
•
Cylinder Head 2
DRC6589
Cylinder Head Removal
1. Spark plugs.
2. Cylinder head bolts.
3. Cylinder heads.
4. Head gaskets.
Cylinder Head Disassembly 3

DRC6594
Tool Required: J 8062 Valve Spring Compressor

3 4 Remove or Disconnect:
1. Compress the springs with J 8062.
2. Keys 1 .
3. Tool J 8062.
4. Valve spring cap 2 .
5. Spring 4 .
3
4
6. Seal . DRC6595
7. Valves 5 and 6 .
Place the valves in an organizer rack so they can be replaced in their
original position at reassembly.
4-12 Engine/eng
Cleaning, Inspection, and Measurement
Refer to General Engine Mechanical section in this manual.
Rocker Arm Stud Replacement

Valve rocker arm stud by unscrewing.
Install or Connect:
Screw valve rocker arm stud into cylinder head.
Tighten:
Valve rocker arm stud to 35 ft. lb. (47 N m).
•
Cylinder Head Assembly

Tools Required: J 8062 Valve Spring Compressor
Install or Connect:
4 1. Valves 5 and 6 .
a. Lubricate the valve stems with clean engine oil.
b. Insert the valves into the proper valve guides until the face of
the valve contacts the valve seat.
4 2. Seal 3 .
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 it bottoms out against
the head.
4 3. Springs 4 .
4 4. Valve spring cap 2 .
3 a. Compress the valve spring using J 8062, enough so 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.
4 c. Assemble the two valve keys 1 into the upper groove using
the grease to hold them in place.
Engine/eng 4-13
1 d. Release the compressor tool J 8062, making sure the valve
keys 1 stay in place.
e. Repeat the preceding steps on the remaining valves.
Measure:
Refer to General Engine Mechanical section in this manual for
valve spring installed height.
Clean:
Gasket surfaces on the block and cylinder head. 1
DRC6595
Cylinder Head Installation

Tool Required: J 36660 Torque/Angle Meter or equivalent
Install or Connect:
1. Head gasket.
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 head into place over the 2
DRC6587
dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder head bolts with
GM Sealant , P/N 12346004, or equivalent and install fingertight.
2 Tighten:
a. Bolts in sequence to 22 ft. lb. (30 N m).
•
b. Bolts in sequence using J 36660 or equivalent to:
Short length bolt (11, 7, 3, 2, 6, 10) 55 degrees.

Medium length bolt (12, 13) 65 degrees.
Long length bolt (1, 4, 8, 5, 9) 75 degrees.
4. Spark plugs.
Tighten:
a. Spark plug into new cylinder head to 22 ft. lb. (30 N m). •
b. All other subsequent installations to 15 ft. lb. (20 N m).

•
4-14 Engine/eng
Crankshaft Balancer
Removal
Tool Required: J 39046 Crankshaft Balancer Remover

The inertial weight section of the crankshaft balancer is as-
sembled to the hub with a rubber sleeve. The removal procedures must
be followed (with the proper tools) or movement of the inertial weight
section of the hub will destroy the tuning of the crankshaft balancer and
the engine timing reference.
1. Crankshaft balancer bolt and washer.
2. Crankshaft balancer using J 39046.
3. Crankshaft key, (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 roughness or nicks. Replace the balancer if this con- 3
dition exists. If balancer is replaced, new balance weights of the same DRC6641
size must be installed on the new balancer in the same location as the
old balancer.
Installation
Tool Required: J 39046 Crankshaft Balancer Installer

4 Install or Connect:
1. Apply GM Adhesive , P/N 12346141, or equivalent to crankshaft key-
way.
2. Crankshaft key (if removed). 4
DRC6644
sembled to the hub with rubber type material. The correct installation
procedures (with the proper tool) must be followed or movement of the
inertial weight section of the hub will destroy the tuning of the crank-
shaft balancer.
3. Stud (part of J 39046) to the crankshaft. Thread stud 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.
5. Bearing, washer, and nut.
a. Turn the nut to pull the crankshaft balancer into place.
b. Remove the tool.
Engine/eng 4-15
Tighten:
Bolt to 74 ft. lb. (100 N m).
•
Oil Pan
Removal
1. Oil pan nuts.
2. Oil pan bolts.
3. Oil pan.
4. Gasket.
Clean:

Old gaskets and sealant from the gasket surfaces.
Inspect:
1
DRC6642
Oil pan for damage or cracks.

Oil pan deflector for lack of fit.
Drain plug threads for stripping.
Installation
Tool Required: J 34673 Straight Edge or Equivalent
Important The alignment between the rear of the oil pan and
rear of the block flange is critical. The two surfaces must be flush to 2
DRC6639
provide a rigid engine-to-transom bracket alignment.
Install or Connect:
2 3 Apply GM Adhesive, 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 direc-
tions from each of the four corners.
1. Oil pan gasket onto pan.
3
DRC6640
4-16 Engine/eng
4 2. Oil pan against cylinder block.
5 3. Slide oil pan back against straight edge using J 34673 or equiva-
lent.
4. Oil pan bolts and nuts but do not tighten.
Measure:
5 Use a feeler gauge to check the clearance between the three oil
pan-to-transmission bell housing contact points as shown. If clearance
exceeds 0.010 in. (0,254 mm) at any of the three points repeat steps 2 4
DRC6642
and 3 until the clearance is within specification.
If the clearance is more than 0.010 in. (0,254 mm), powertrain
durability may be affected.
6 Tighten:
Bolts to 18 ft. lb. (25 N m) in the sequence shown.
•
Nuts to 17 ft. lb. (23 N m).

•
Measure:
Clearance between the three oil pan-to-transom bracket 5

contact points to verify proper alignment. DRC6646
5. Lubricate new oil filter seal with clean engine oil.

6. New oil filter.
Oil Pump
Removal
1. Bolt from oil pump to crankshaft bearing cap.
2. Oil pump assembly.
6
DRC6645
3. Driveshaft and retainer.
7
DRC6643
Engine/eng 4-17
1 Disassemble:
1. Driveshaft 9 and retainer 8 .
Do not remove the oil pump screen unless replacement is re-
quired. The oil pump screen has a press fit in to the pump cover. Do
not remove the screen from the pipe 6 . The oil pump screen is ser-
viced as a complete assembly only.
2. Oil pump screen pickup 6 .
3. Bolts 5 .
4. Pump cover 4 .
Mark where the idler gear and drive gear and shaft mesh to-
gether, so they can be reinstalled with the same gear teeth indexed.
5. Idler gear and drive gear and shaft 7 .
6. Retaining pin 1 .
7. Pressure regulator spring 2 .
8. Pressure regulator valve 3 .
Clean: 1
DRC6624
All parts in clean solvent and dry them with compressed air.
1 Inspect:
Important The pump gears, cover, and body are not serviced
separately. If any of the parts are damaged or worn, the entire oil pump
assembly must be replaced.
Pump body 10 for cracks, wear, or other damage.
Inside of the cover 4 for cracks and wear that would

permit oil to leak past the ends of the gears.
Idler and drive gear 7 for wear.

Drive gear and shaft for lack of fit in the pump body.
Oil pump screen for damage to the screen or loose fit
of the pipe.
Pressure regulator valve 3

for fit. The regulator valve
should slide freely in its bore without sticking or bind-
ing.
4-18 Engine/eng
Assemble
1. Pressure regulator valve 3 into the pump cover 4 .
Important Replace the pressure relief valve spring 2 when re-

using the oil pump assembly.
2. Pressure regulator spring 2 into the pump cover 4 .
3. Retaining pin 1 into the pump cover 4 .
4. Drive gear and shaft 7 into the pump body 10 .
5. Idler gear 7 into the pump body 10 .
Match together the index marks on the two gears made during
disassembly.
6. Pump cover 4 .
7. Bolts 5 .
Tighten:
Bolts 5 to 106 i n. Ib. (12 N•m).
With the driveshaft 9 installed on the pump, turn the driveshaft by hand
to check for smooth operation.
Be careful of twisting, shearing, or collapsing the pipe when
installing it to the pump. A damaged pipe can cause lack of lubrication
and engine failure.
Oil Pump Screen Installation
a. The oil pump screen assembly 6 should be replaced with a
new part. Loss of press fit condition could result in an air leak
and loss of oil pressure.
b. Mount the oil pump in a soft jawed vise.
c. Apply sealer to the end of the pipe.
d. Tap the pickup screen and pipe into place, using J 21882 and
a hammer.
e. The oil pump screen must be parallel with the bottom of the oil
pan when installed.
1 2. Oil pump driveshaft 9 and retainer 8 .
2
DRC6625
Engine/eng 4-19
Oil Pump Installation
1. Oil pump to the engine.
a. Align the slot in the oil pump shaft with the tang on the dis-
tributor shaft.
b. The oil pump should slide easily into place.
c. No gasket is used.
1
2. Oil pump and bolt onto crankshaft bearing cap. DRC6643
Tighten:
•
Engine Front Cover

Removal
Important Once the composite engine front cover is removed

DO NOT reinstall it. Always install a new engine front cover.
1. Engine front cover bolts.
2. Engine front cover.
Installation
Install or Connect:
1. Engine front cover to engine.
Tighten:
Bolts to 106 in. lb. (12 N m).
•
4-20 Engine/eng
Timing Chain and Sprockets
Tool Required: J 5825-A Crankshaft Sprocket Puller
Measure:
Check camshaft timing chain free play. If the camshaft timing chain can
be moved back and forth in excess of 0.625 in. (16 mm), make a note
that the camshaft timing chain should be replaced during assembly.
Removal
2
2 Remove or Disconnect: DRC6633
1. Camshaft sprocket bolts 1 .

2. Camshaft sprocket 2 and camshaft timing chain 3 together.
The sprocket has a light interference fit on the camshaft. Tap
the sprocket on its lower edge to loosen it.
3. Balance shaft drive gear.
2 3 4. Crankshaft sprocket 4 using J 5825-A.
5. Key 5 (if damaged).
3
DRC6615
Engine/eng 4-21
Inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new chain.
2. Camshaft timing chain for damage.
An excessively worn chain will rapidly wear a new set of sprock-
ets.
Installation
1
DRC6694
Tool Required: J 5590 Crankshaft Sprocket Installer
Install or Connect:
1. Crankshaft key (if removed).
1 2. Crankshaft sprocket using J 5590.
3. Balance shaft drive gear.
4. Camshaft sprocket and camshaft timing chain.
2 Important Line up the sprocket alignment marks on the

camshaft sprocket and crankshaft sprocket. 2
DRC6634
The number 4 cylinder is at top dead center of the com-
pression stroke with the timing marks in this position.
3 5. Camshaft sprocket bolts 1 .
Tighten:
Bolts 21 ft. lb. (28 N m).
•
Camshaft
Removal
3
Remove or Disconnect: DRC6633
1. Camshaft retainer bolts and camshaft retainer.

2. Camshaft.
4 a. Install three 5/16 - 18 (4.0 in.) long into the camshafts threaded
holes. Use these bolts to handle the camshaft.
4 b. Pull the camshaft out from the block being careful to prevent
damage to the camshaft bearings.
4
DRC6635
4-22 Engine/eng
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in
this manual.
Bearings
Refer to General Engine Mechanical section in this manual for cam-

shaft bearing disassembly, cleaning, inspection, and assembly.
Installation
Install or Connect:
Coat the camshaft lobes and journals with a high quality GM
Engine Oil Supplement , P/N 1052367, or equivalent. Apply GM Engine
Oil Supplement, P/N 1052367, or equivalent to all the teeth on the dis-
tributor drive gear.
4 1. Two or three 5/16 - 18 (4.0 in.) long bolts into the camshaft
threaded holes. Use these bolts to handle the camshaft.
4 2. Camshaft into the engine. Handle the camshaft carefully to pre-
vent damage to the camshaft bearings.
3. Camshaft retainer and retainer bolts.
Coat camshaft retainer plate with GM Engine Oil Supple-

ment, P/N 1052367, or equivalent.
Tighten:
Bolts to 124 in. lb. (14 N m). •
Balance Shaft
Removal
Tools Required: J 38834 Balance Shaft Bearing Service Kit 5

DRC6631
J 26941 Rear Balance Shaft Bearing Remover
1. Bolt 1 .
2. Driven gear 2 .
3. Retainer bolts 5 .
4. Retainer 3 .
5 6 5. Balance shaft 4 using a soft faced hammer.
7 6. Balance shaft rear bearing using J 38834 and J 26941. 6
DRC6617
7
DRC6618
Engine/eng 4-23
Inspect:
Balance shaft front roller bearing and rear sleeve bear-

ing for damage or excessive wear. The bearings are
serviced as an assembly. Use the proper tools for prop-
erly servicing the bearings.
Balance shaft drive and driven gears for nicks or burrs.
Replace gears that are damaged.
Front and rear bearing journal diameters. Replace the
balance shaft if the diameter exceeds the specifications.
1
DRC6629
Refer to Specifications in this section.
Rear sleeve bearing journal clearance. Replace the bal-
ance shaft if the clearance exceeds the specification.
Refer to Specifications in this section.
Installation
Tools Required: J 38834 Balance Shaft Bearing Service Kit

J 36996 Balance Shaft Installer
J 8092 Driver Handle 2
DRC6618
J 36660 Torque/Angle Meter or equivalent
Install or Connect:
1. Dip bearing in clean engine oil before installation.
1 2 2. Balance shaft rear bearing using J 38834.
3 3. Balance shaft into block using J 36996 and J 8092.
a. Dip the front balance shaft bearing into clean engine oil be-
fore assembly.
b. Retaining ring on balance shaft front bearing must be seated
on case.
3
DRC6630
4 4. Install balance shaft bearing retainer 3 and bolts 5 .

Tighten:
4 Balance shaft retainer bolts 5 to 124 in. lb. (14 N m). •
4 5. Balance shaft driven gear 2 and bolt 1 .

Tighten:
4 Balance shaft driven gear bolt 1
to 15 ft. lb. (20 N m) plus an
•
additional turn of 35 degrees using J 36660 or equivalent.

4 Rotate balance shaft 4 by hand to make sure there is
4
DRC6631
clearance between the 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 Engine/eng
5 • Turn the camshaft with the balance shaft drive gear tem-
porarily installed. The timing mark on the drive gear must
be straight up.
5 • With the balance shaft drive gear removed, turn the bal-
ance shaft so the timing mark on the driven gear points
straight down.
6. Balance shaft drive gear onto camshaft.
Important Make sure the timing marks on the balance shaft drive 5
DRC6632
gear and driven gear line up.

Removal
Tool Required: J 5239 Guide Set

Before attempting to remove piston, refer to General Engine
Mechanical section in this manual for cylinder bore ridge reamer pro-
cedures.
1. Mark the cylinder numbers on 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 numbered 1-3-5

The left bank is numbered 2-4-6
2. Check the connecting rod and cap for identification marks. If reusing
the connecting rods, mark the parts in the same way as the pistons.
Important Store the connecting rod and cap together as mating

parts, so they may be reassembled in the same wear pattern and bal-
ance in which they were removed.
3. Connecting rod nuts, cap and bearings.
Important If reusing bearings, keep bearings with their original

connecting rod and cap.
Engine/eng 4-25
4. Connecting rod and piston.
1 a. Attach J 5239 to the connecting rod bolts.
1 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

and connecting rod assembly.
Bearing Selection
Important Connecting rod bearings are of the precision insert

type and do not use shims for adjustment. DO NOT FILE RODS OR
ROD CAPS.
If clearances are excessive, install a new bearing. Service bearings 1
DRC6619
are available in standard size 0.001 in. (0,0254 mm) and 0.002 in.
(0,0508 mm) undersize for use with new and used standard size crank-
shafts. For reconditioned crankshafts 0.010 in. (0,254 mm) and 0.020
in. (0,508 mm) undersize bearings are available.
J 8087
Piston Selection
Measuring the Piston
Check the used piston to cylinder bore clearance, as follows:

2.5 in. (65 mm) below the top of the cylinder bore. 2
DRC6507
3 2. Piston diameter. Measure the skirt at a right angle to the piston
pin hole, 1.0 in. (25 mm) below the oil ring groove.
3
DRC6514
4-26 Engine/eng
Measure piston diameter at 70 degrees F (20 degrees C).
4. Locate the piston-to-bore clearance, refer to Engine Specifications.
Determine if the piston-to-bore clearance is within the acceptable range.
Piston Ring End Gap and Fit
Important The numbers on the connecting rod and bearing cap

must be on the same side when installed in the cylinder bore. If a con-
necting rod is ever transposed from one block or cylinder to another,
new connecting rod bearings should be fitted and the connecting rod
should be renumbered to correspond with the new cylinder number.
Installation
Tools Required: J 5239 Connecting Rod Bolt Guide Set

J 8037 Ring Compressor
Install or Connect:
1. Lubricate the cylinder walls lightly with engine oil.
2. Make sure the piston is installed in the matching cylinder.
3. Connecting rod bearings.
a. Make sure the crankshaft bearings are the proper size.
b. Install the crankshaft bearings in the connecting rod and con-
necting rod cap.
c. Lubricate the bearings with engine oil.
Engine/eng 4-27
4. Piston and connecting rod into the proper bore.
1 a. With the connecting rod cap removed, install J 5239 onto the
connecting rod bolts.
2 b. Locate the piston ring end gaps. Lubricate the piston and
rings with engine oil.
3 c. Without disturbing the ring end gap location, install J 8037
over the piston and compression rings.
2 d. The piston must be installed so that the notch in the piston
faces the front of the engine.
1 e. Place the piston in its matching bore. The connecting rod bear-
ing tang slots must be on the side opposite the camshaft.
Using light blows with a hammer handle, tap the piston down
into its bore. At the same time, from beneath the engine, guide
the connecting rod on to the crankpin with J 5239. Hold the
ring compressor against the block until all rings have entered
the cylinder bore.
1 f. Remove J 5239 from the connecting rod bolts.
1
Important Each connecting rod and bearing cap should be
DRC6619
marked, beginning at the front of the engine. Cylinders 1, 3, and 5 are FORWARD
the right bank and 2, 4, and 6 are the left bank (when viewed from the
B
front). The numbers on the connecting rod and bearing cap must be
on the same side when installed in the cylinder bore. If a connecting C A D
rod is ever transposed from one block or cylinder to another, new con-
necting rod bearings should be fitted and the connecting rod should B
be numbered to correspond with the new cylinder number. A - POSITION OF THE GAP FOR THE
SPACER OF THE OIL RING
B - POSITION OF THE GAP FOR THE
5. Connecting rod cap with crankshaft bearing. OIL RING
C - POSITION OF THE GAP FOR THE
LOWER COMPRESSION RING
6. Connecting rod bolt nuts. 2 D - POSITION OF THE GAP FOR THE

UPPER COMPRESSION RING
DRC6627
Tighten:
Connecting rod bolt nuts to 20 ft. lb. (27 N m).

•
J 8037
Connecting rod bolt nuts an additional 70 degrees us-

ing J 36660 or equivalent.
Measure:
Refer to General Engine Mechanical section in this manual for con-
necting rod side clearance procedure.
3
DRC6628
4-28 Engine/eng
Crankshaft Rear Oil Seal
Removal
Take care when removing the rear crankshaft oil seal so as not
to damage the crankshaft sealing surface.
4 Insert a screwdriver into the notches provided in the seal retainer
and pry the seal out.
4
DRC6658
Installation
Tool Required: J 35621 Crankshaft Rear Oil Seal Installer

1. Lubricate the inner and outer diameter of the oil seal with clean J 35621
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.
5
4. Tighten the screws securely with a screwdriver. This will en- DRC6626
sure that the seal is installed squarely over the crankshaft.

5. Turn the handle until it bottoms.
6. Remove J 35621.
Crankshaft Rear Oil Seal Housing

Removal
1. Bolts and nuts. 6
DRC6657
2. Oil seal housing.

3. Gasket.
Clean:
Gasket surfaces on the block and seal retainer.
Engine/eng 4-29
Installation
1. New gasket to the block.
It is not necessary to use sealant to hold the gasket in place.
2. Oil seal retainer.
3. Screws and nuts.
Tighten:
1
DRC6657
Screws and nuts to 11 ft. lb. (15 N m).
•
Crankshaft and Bearings

Removal
The crankshaft need not be removed for replacement of the rear oil
seal or crankshaft bearings. Those procedures are covered in other
parts of this section.
Important Check the crankshaft bearing caps for location mark-

ings. Mark the caps if necessary. The caps must be returned to their
original locations during assembly.
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 damage to crankshaft journals and thrust flange surfaces.
4. Upper crankshaft bearings.
Refer to General Engine Mechanical section in this manual
for cleaning, inspection, and measurements.
Installation
Install or Connect:
1. Upper crankshaft bearing to the block.
Important 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 Engine/eng
Measure:
crankshaft bearing clearance procedures.
4. Apply engine oil to the crankshaft bearings. Install crankshaft bear-
ing caps (except rear cap) and bolts to the block.
Tighten:
Crankshaft bearing cap bolts to 77 ft. lb. (105 N m). •
5. Rear crankshaft bearing cap. Apply engine oil to the crankshaft bear-
ings.
6. Rear crankshaft bearing cap bolts.
Tighten:
Rear crankshaft bearing cap bolts to 124 in. lb. (14 N m). •
Measure:
crankshaft end play procedure.
Tighten:
Finally tighten rear crankshaft bearing cap bolts to 77 ft. lb. (105
N m).
•
Cylinder Block
Disassembly
1. Coolant drain fittings.
2. Camshaft and balance shaft cup plugs.
2 3. Front oil gallery cup plugs.
2
DRC6623
3 4. Port side oil gallery plugs.

4 5. Rear oil gallery plugs.
Clean:
1. Sealing material from mating surfaces.
2. Boil cylinder block in caustic solution.
Flush with clean water or steam.

3
DRC6621
4
DRC6622
Engine/eng 4-31
3. Cylinder bores.
4. Threaded holes.
5. Oil galleries and passages.
6. Scale deposits from coolant passages.
7. Spray or wipe cylinder bores and machined surfaces with engine
oil.
Inspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaft lifter bores for deep scratches and deposits.
3. Cracks in the block
Cylinder walls.
Water jackets.
Engine mount bosses.
Crankshaft bearing webs.
Crankshaft bearing bores and caps.
All crankshaft bearing bores should be rounded and
uniform in inside diameter (I.D.) at all of the bearing
supports.
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.
1 4. Cylinder block head mounting surface for flatness, using a pre-
cision straight edge and feeler gauge.
a. Set the straight edge on the sealing surface to be inspected.
b. Take the feeler gauge and at various locations, check the
gap between the 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 sealing location, the block
must be replaced.
1
DRC6620
4-32 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 sus-
pected, then the minor irregularities may be carefully machined from
the block.
Oil pan and intake manifold mounting surfaces for nicks.

Minor irregularities may be cleaned up with a flat file.
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 Me-
chanical section in this manual.
Measure:
Cylinder Block Assembly
Install or Connect:
1. Front oil gallery plugs. Coat plug outside diameter with GM Sealant,
P/N 12346004, or equivalent.
2 3 4 2. Rear oil gallery plugs.
Tighten:
Left rear plug to 15 ft. lb. (20 N m).

•
Right rear plug to 18 ft. lb. (25 N m).

•
2
DRC6623
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 GM Sealant , P/N 12346004, or equivalent.
Important Do not allow residue on camshaft bearing or seizure

may result.
3
DRC6621
4
DRC6622
Engine/eng 4-33
Circulating Pump
Description
The circulating pump is manufactured specially for marine use. It is

serviced only as an assembly. Do not replace with an automotive cir-
culating pump.
Inspection
1. Remove alternator and power steering belts.

2. Grasp circulating pump pulley and check end and side play. Turn
pulley to check for drag.
3. Look for water leaking from indicator hole beneath pump shaft be-
hind pulley, Replace pump if play, drag, or leakage are evident.
1. Drain water from block and disconnect water hose from circulating
pump.
2. Remove pulley. Remove circulating pump bolts, pump and gaskets.
3. Use new pump to block gaskets and sealer. Install new pump as-
sembly on cylinder block and tighten bolts as specified.
4. Install pulley. Install alternator and power steering belts, then adjust
tension.
5. Install hose to circulating pump.
4-34 Engine/eng
Front Engine Mounts
Removal
1 1. Remove two lag screws A and washers from mounts.
2. Lift engine with a hoist capable of lifting at least 1500 lb.
(680 kg) to allow removal of front mount and bracket.
2 3. Remove three mount screws and lock washers B . Note screw
lengths and location.
1
3 Prior to disassembly of front mount assembly, measure 25929
distance and record measurement between large washer and flat on

upper mount bracket.
Disassembly
4 1. Remove three nuts C

and engine mount bracket D from mount
bolt while holding bolt secure with socket E .
5 2. Remove two flat washers, one large F and one smaller G .
Remove lock washer H, and engine mount bolt I from mount.
2
25917
3
11980
4
11979
5
11978

Reassembly
1 1. Place small washer A

on mount bolt and insert bolt up through
mount. Install large washer and secure with nut B . Tighten to 60-75 ft.
lb. (81-102 N m).
•
2 2. Install upper inner nut and place engine mount bracket C on

engine mount bolt.
Measure distance between large washer and flat on upper
mount bracket. Adjust distance to recorded measurement.
1
3. Install lock washer and top nut. Tighten nut to 100-120 ft. lb. (136- 11983
163 N m).
•
Installation
3 1. Spray the engine mount screw threads with Loctite Primer N

and allow to air dry. Apply Volvo Penta Thread Sealing Agent P/N
1161053 to the screws. Attach engine mount assembly to engine with
three screws and washers D . Tighten to 32-40 ft. lb. (43-54 N m).•
4 2. Install washers and lag screws E and tighten securely.
Height Adjustment 2
11979
5 1. To change engine height, tighten or loosen nuts F and G as
required.
(680 kg). Position engine at desired height.
5 3. After setting mount position, turn nut G up against underside
of engine bracket and hold nut with a wrench. Tighten nut F to 100-
120 ft. lb. (136-163 N m).
•
Any large adjustments to engine height should be followed by

a check of engine alignment. Failure to check alignment could result in 3
rapid engine coupler failure. See Drive Removal and Installation sec- 25917
tion of the Vertical Drive/Transom Bracket Service Manual for align-

ment procedures.
4
21929
5
2953
Removal
6 1. Loosen two clamps securing upper hose to elbow. Lubricate
inside of hose with a soapy water solution.
7 2. Starboard Elbow: Remove four screws, flat washers, and lock
washers mounting high-rise elbow. Remove circuit breaker bracket H
and set aside.
3. Port Elbow - EFI Models Only: Remove fuel reservoir water hose
6
34719
and set aside. Remove four screws, flat washers, and lock washers
mounting high-rise elbow.
8 9 4. Use a soft hammer to free elbow from manifold. Use a
twisting motion to pull elbow from hose. Remove and discard the elbow
gasket.
Installation
1. Thoroughly clean manifold gasket surface. Apply Volvo Penta Gas-

ket Sealing Compound to both sides of a new manifold gasket and place
it on the exhaust manifold. 7
49464
9 10 2. Lubricate the inside of the exhaust hose with a soapy wa-
ter solution. Insert the high-rise elbow into the hose with a twisting mo-
tion, and push it into hose as far as it will go.
8
34718
9
34716
10
34717
Engine/eng 4-37
1 3. Position elbow on manifold. Secure elbows and brackets with
four screws, flat washers, and lock washers. Tighten screws to 12-18
ft. lb. (16-24 N m). Starboard Elbow: Install circuit breaker bracket
•
A . Port Elbow: Install fuel reservoir water hose. Tighten clamp se-
curely.
2 4. Slide clamps B up onto hose and position them in the
two surface channels. Tighten clamps securely.
Exhaust Hose & Intermediate Pipe 1

Replacement 49464
Removal
3 1. Loosen eight clamps that secure the upper C and lower D

exhaust hoses.
4 2. Lubricate inside of lower hose with a soapy water solution, and
slide lower hose down onto exhaust Y-pipe.
5 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-
2
32371
pipe.
3
32374
4
32375
5
32363
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.
7 The inside diameter of both the upper and lower hoses
has a step E 1.5 in. (3.81 cm) from one end. The stepped end of the
hose must face the intermediate pipe when installed.
2. Slide hose onto high-rise elbow until it seats.
If hose is not properly positioned, it will not completely engage 6
the high-rise elbow or allow secure attachment. 32370
3 5 3. Place four No. 68 clamps on upper hose. With a twist-

ing 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 hose up until it’s halfway onto the inter-
mediate pipe. Position clamps in channels and tighten clamps se-
curely.

Removal 7
32366
1. Remove engine from boat.
If coupler is being replaced due to coupler failure (rubber hub of
splined hub), check engine alignment after installing new coupler. See
Drive Removal and Installation section of the Vertical Drive/Tran-
som Bracket Service Manual.
2. Disconnect all wires, lines and connectors from bellhousing.
8 9 3. Remove screws securing bellhousing cover, and slide cover

out. 8
20034
9
19085

1 4. Pull drain hose out of bellhousing if equipped.
2 5. Unscrew bolts and nuts retaining bellhousing. Disconnect ground

wires. Remove power steering cooler bracket.
6. Remove bellhousing from engine block.
3 7. Unscrew six nuts securing coupler and remove coupler from

studs.
8. Remove old gasket from bellhousing cover. Clean gasket surface 1
19842
thoroughly.
Installation
4 1. Install coupler and secure with six locknuts. Use a suitable adap-
tor and tighten to 40-45 ft. lb. (54-61 N m).
•
5 2. Install bellhousing and attach power steering cooler. Tighten

nuts and bolts to 32-40 ft. lb. (43-54 N m). Attach ground wires and
•
tighten nuts to 15-20 ft. lb. (20-27 N m).

•
3. Push drain hose into bellhousing if equipped. 2

6710
4. Apply Volvo Penta Gasket Sealing Compound P/N 591247 to both
sides of a new bellhousing gasket and position it on cover.
5 5. Clean seven self-tapping screws with a wire brush. Install

bellhousing cover and screws. Tighten to 60-84 in. lb. (7-9 N m).
•
6. Connect all wires, lines and connectors to bellhousing.

7. Install engine in boat.
3
6712
4
6714
5
19996
4-40 Engine/eng
Balance Shaft Driven Gear Bolt ............................................................................ 15 ft. lb. (20 N m) (Plus 35 degrees)
•
Balance Shaft Retainer Bolts ............................................................................................................ 124 in. lb. (14 N m) •
Bell Housing Cover Screws .......................................................................................................... 60-84 in. lb. (7-9 N m) •
Bell Housing Nuts and Bolts ....................................................................................................... 32-40 ft. lb. 43-54 N m) •
Block Drain Plug ................................................................................................................................... 15 ft. lb. (20 N m)

•
Block Oil Gallery Plug, Left Rear ......................................................................................................... 15 ft. lb. (20 N m) •
Block Oil Gallery Plug, Right Rear ...................................................................................................... 18 ft. lb. (25 N m) •
Block Oil Gallery Plug, Left Side Rear ................................................................................................. 15 ft. lb. (20 N m) •
Camshaft Retainer Bolt ..................................................................................................................... 124 in. lb. (14 N m) •
Camshaft Sprocket Bolts ...................................................................................................................... 21 ft. lb. (28 N m) •
Connecting Rod Nut ............................................................................................... 20 ft. lb. (27 N m) (Plus 70 degrees)

•
Crankshaft Balancer Bolt .................................................................................................................... 74 ft. lb. (100 N m) •
Crankshaft Bearing Cap Bolt .............................................................................................................. 77 ft. lb. (105 N m) •
Crankshaft Rear Oil Seal Housing Nut and Bolt ................................................................................. 11 ft. lb. (15 N m) •
Cylinder Head Bolt

First Pass ........................................................................................................................................ 22 ft. lb. (30 N m)
•
Second Pass Torque Angle all Bolts in Sequence:

Short Length Bolt .............................................................................................................................. 55 degrees
Medium Length Bolt .......................................................................................................................... 65 degrees
Long Length Bolt ............................................................................................................................... 75 degrees
Engine Coupler Nuts .................................................................................................................. 40-45 ft. lb. (54-61 N m) •
Engine Mount Screws ................................................................................................................ 32-40 ft. lb. (43-54 N m) •
Exhaust Manifold Screws .......................................................................................................... 20-26 ft. lb. (27-35 N m) •
Front Cover Bolt ................................................................................................................................. 106 in. lb. (12 N m)•
Front Mount Nut

Lower .................................................................................................................................. 60-75 ft. lb. (81-102 N m)
•
Upper ........................................................................................................................... 100-120 ft. lb. (136-163 N m) •
Engine/eng 4-41
High Rise Elbow Nuts ................................................................................................................ 12-18 ft. lb. (16-24 N m) •
Intake Manifold Bolts

First Pass ......................................................................................................................................... 27 in. lb. (3 N m)
•
Second Pass ................................................................................................................................ 106 in. lb. (12 N m) •
Final Pass ....................................................................................................................................... 11 ft. lb. (15 N m)

•
Oil Pan
Nuts ................................................................................................................................................. 17 ft. lb. (23 N m)
•
Bolts ................................................................................................................................................ 18 ft. lb. (25 N m)

•
Studs in Engine Block .................................................................................................................... 18 ft. lb. (25 N m) •
Oil Pump Bolt ........................................................................................................................................ 66 ft. lb. (90 N m)•
Oil Pump Cover Bolt .......................................................................................................................... 106 in. lb. (12 N m) •
Spark Plugs
Cylinder Head (New) ...................................................................................................................... 22 ft. lb. (30 N m) •
Cylinder Head (All Subsequent Installation) ................................................................................. 15 ft. lb. (20 N m) •
Valve Lifter Guide Retainer Bolt ........................................................................................................... 12 ft. lb. (16 N m) •
Valve Rocker Arm Cover Bolts .......................................................................................................... 106 in. lb. (12 N m) •
Valve Rocker Arm Nut ........................................................................................................................... 20 ft. lb. (27 N m) •
Valve Rocker Arm Stud ......................................................................................................................... 35 ft. lb. (47 N m) •
4-42 Engine/eng
ENGINE
Type ....................................................................................................................................................... 90 Degree V6
Displacement ....................................................................................................................................... 4.3L (262 CID)
Bore .............................................................................................................................................. 4.00 in. (101.6 mm)
Stroke ......................................................................................................................................... 3.480 in. (88.39 mm)
Compression Ratio .............................................................................................................................................. 9.2:1
Firing Order ............................................................................................................................................... 1-6-5-4-3-2
LUBRICATION SYSTEM
Oil Capacity
Without Filter Change ..................................................................................................................... 4 Qt. (3.75 Liters)
With Filter Change Add............................................................................................................ 0.42 Qt. (0.398 Liters)
Oil Pressure (Minimum Hot) ....................................................................... 6.0 PSI (41.4 kPa) at 1,000 engine RPM
18.0 PSI (24.1 kPa) at 2,000 engine RPM
24.0 PSI (165.5 kPa) at 4,000 engine RPM
Oil Filter System ............................................................................................................................................... Full Flow
Oil Pump Type ............................................................................................................................................. Gear Driven
CYLINDER BORE
Diameter .............................................................................................. 4.0007 - 4.0017 in. (101.618 - 101.643 mm)
Out-of-Round ................................................................................................................ 0.002 in. (0.0508 mm) MAX.
Taper .............................................................................................................................. 0.001 in. (0.0254 mm) MAX.
PISTON
Piston Bore Clearance .............................................................................................. 0.0024 in. (0.06096 mm) MAX.
PISTON RINGS
Piston Compression Ring
Groove Clearance ............................................................................................................... 0.0042 in. (0.10668 mm)
Gap .................................................................................................................................. 0.035 in. (0.889 mm) MAX.
Piston Oil Ring

Groove Clearance ......................................................................................................... 0.008 in. (0.2032 mm) MAX.
Gap ............................................................................................................................................. 0.065 in. (1.651 mm)
OIL PAN
Engine Block Clearance
Tolerance ......................................................................................................................... 0.010 in. (0.254 mm) MAX.
Engine/eng 4-43
PISTON PIN
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
INTAKE MANIFOLD
Surface Flatness ............................................................................................................ 0.010 in. (0.254 mm) MAX.
CYLINDER HEAD
Surface Flatness .......................................................................................................... 0.004 in. (0.1016 mm) MAX.
CRANKSHAFT
Crankshaft Journal
Diameter #1 ............................................................................................ 2.4488 - 2.4495 in. (62.199 - 62.217 mm)
Diameter #2, #3 ...................................................................................... 2.4485 - 2.4494 in. (62.192 - 62.215 mm)
Diameter #4 ........................................................................................... 2.4480 - 2.4489 in. (62.180 - 62.202 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................. 0.0010 in. (0.0254 mm) MAX.
Crankshaft Bearing Clearance

Bearing #1 ............................................................................................... 0.0010 - 0.0015 in. (0.0254 - 0.0381 mm)
Bearings #2, #3 ...................................................................................... 0.0010 - 0.0025 in. (0.0254 - 0.0635 mm)
Bearing #4 ............................................................................................... 0.0025 - 0.0035 in. (0.0635 - 0.0889 mm)
Crankshaft End Play ....................................................................................... 0.002 - 0.008 in. (0.0508 - 0.2032 mm)
CONNECTING ROD
Connecting Rod Journal
Diameter .................................................................................................. 2.2487 - 2.2497 in. (57.117 - 57.142 mm)
Taper ............................................................................................................................ 0.001 in. (0.0254 mm) MAX.
Out-of-Round ............................................................................................................... 0.001 in. (0.0254 mm) MAX.
Rod Bearing Clearance .......................................................................... 0.0010 - 0.0030 in. (0.0254 - 0.0762 mm)
Rod Side Clearance .................................................................................. 0. 006 - 0.017 in. (0.1524 - 0.4318 mm)
CAMSHAFT
Journal Diameter ......................................................................................... 1.8677 - 1.8697 in. (47.440 - 47.490 mm)
End Play ........................................................................................................... 0.001 - 0.009 in. (0.0254 - 0.2286 mm)
Lobe Lift ................................................................................................................................. ± 0.002 in. (± 0.051 mm)

Intake .................................................................................................................................... 0.2763 in. (0.7180 mm)
Exhaust ................................................................................................................................ 0.2855 in. (0.7252 mm)
BALANCE SHAFT
Front Bearing Journal Diameter ............................................................ 2.1648 - 2.1654 in. (55.985 - 55.001 mm)
Rear Bearing Journal Diameter ............................................................... 1.4994 - 1.500 in. (38.084 - 38.100 mm)
Rear Bearing Journal Clearance ........................................................... 0.001 - 0.0036 in. (0.0254 - 0.09144 mm)
4-44 Engine/eng
VALVE SYSTEM
Valve Lifter ........................................................................................................................................ Hydraulic Roller
Valve Rocker Arm Ratio ................................................................................................................................... 1.50:1
Valve Lash Net Lash .......................................................................................................................... No Adjustment
Face Angle ................................................................................................................................................. 45 degree
Seat Angle .................................................................................................................................................. 46 degree
Seat Runout ................................................................................................................. 0.002 in. (0.0508 mm) MAX.
Seat Width
Intake ............................................................................................................... 0.040 - 0.065 in. (1.016 - 1.651 mm)
Exhaust ........................................................................................................... 0.065 - 0.098 in. (1.651 - 2.489 mm)
Stem Clearance
Intake .............................................................................................. High Limit Production + 0.001 in. (0.0257 mm)
Exhaust .......................................................................................... High Limit Production + 0.002 in. (0.0508 mm)
Valve Spring
Free Length ...................................................................................................................................... 2.03 in. (52 mm)
Installed Height ............................................................................................... 1.690 - 1.710 in. (42.92 - 43.43 mm)
Spring Pressure
Closed ............................................................................................... 76 - 84 lb. at 1.70 in. (338 - 374 N at 43 mm)
Open .............................................................................................. 832 - 187 - 203 lb. at 1.27 in. (903 N at 32 mm)
Valve Lift
Intake ......................................................................................................................................... 0.414 in. (10.51 mm)
Exhaust ..................................................................................................................................... 0.428 in. (10.87 mm)
Engine Lubrication:
Oil Grade Recommended
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
We recommend DuraPlusTM Synthetic Motor Oil, which is specially for-

mulated for heavy duty marine use, and ideal for stern drive engines. It
provides better antiwear qualities, especially during long high speed
operation. In addition, it neutralizes acids caused in all internal com-
bustion engines, offers superior corrosion protection, and is formulated
to offer better resistance to oxidation and high temperature sludge for-
mation.
Fuel Recommendation ................... See General Information Section
Engine/eng 4-45
GM Special Tools
1 2 3
DRC6596 DRC6597 DRC6598
4 5 6
DRC6599 DRC6600 DRC6601
1 Pliers, Valve Lifter Remover

2 Connecting Rod Bolt Guide Set
3 Crankshaft Sprocket Installer
4 Crankshaft Sprocket Remover
5 Dial Indicator Set
6 Piston Ring Compressor
7 Valve Spring Compressor
7
8 Driver Handle DRC6602
8
DRC6603
4-46 Engine/eng
GM Special Tools
1 2 3
DRC6604 DRC6605 DRC6606
4 5 6
DRC6607 DRC6608 DRC6609
1 Hydraulic Valve Lifter Remover

2 Oil Suction Pipe Installer
3 Straight Edge
4 Rear Main Seal Installer
5 Torque/Angle Meter or equivalent
6 Balance Shaft Installer
7 Balance Shaft Bearing Service Kit
7
8 Harmonic Balancer Remover/Installer DRC6610
8
DRC6611
Engine/eng 4-47
4-48 Engine/eng
Section 5
5.0 GL and Gi Engines
5.7 GS and GSi Engines
Table of Contents
Accessories .............................................................. 5-6 General Description ................................................. 5-2

Balancer, Crankshaft .............................................. 5-17 GM Special Tools .................................................... 5-50
Camshaft ................................................................. 5-25 Intake Manifold ......................................................... 5-8
Circulating Pump .................................................... 5-38 Intermediate Pipe Replacement ............................ 5-41
Cleaning .................................................................... 5-4 Material Required ..................................................... 5-3
Crankshaft and Bearings ....................................... 5-31 Oil Filter ................................................................... 5-20
Cylinder Block ........................................................ 5-35 Oil Pan ..................................................................... 5-18
Cylinder Head ......................................................... 5-14 Oil Pump ................................................................. 5-20
Engine Pistons and Connecting Rods .............................. 5-27
Coupler Replacement ......................................... 5-42 Rear Oil Seal, Crankshaft ...................................... 5-30 5
Draining ................................................................. 5-6 Rear Oil Seal Housing, Crankshaft ....................... 5-31
Front Cover .......................................................... 5-23 Rocker Arm Cover .................................................. 5-10
Front Mounts ....................................................... 5-39 Rocker Arm Stud Replacement ............................. 5-15
Lubrication ............................................................ 5-4 Specifications
Exhaust Engine .................................................................. 5-46
High-Rise Elbow Replacement ........................... 5-40 Torque .................................................................. 5-44
Hose Replacement .............................................. 5-41 Timing Chain and Sprockets ................................. 5-24
Manifold ................................................................. 5-7 Tools and Shop Equipment ..................................... 5-6
Valve Train .............................................................. 5-11
Safety Warnings
Engine/eng 5-1
General Description
Cylinder Block
The engine block is made of cast iron and has eight cylinders arranged
in a “V” shape with four cylinders in each bank. It is a one piece cast-
ing with the cylinders encircled by coolant jackets.
Cylinder Head
The cylinder heads are cast iron. The valve guides and valve seats
are machined surfaces integral to the head. The spark plugs are lo-
cated between the intake and exhaust ports.
Camshaft
A steel camshaft is supported by five bearings pressed into the engine

block. The camshaft sprocket, mounted to the front of the camshaft is
driven by the crankshaft sprocket through a camshaft timing chain.
Motion from the camshaft is transmitted to the valves by hydraulic roller
valve lifters, valve push rods, and ball-pivot type rocker arms.
Crankshaft
The crankshaft is made of cast nodular iron. It is supported by five

crankshaft bearings that are retained by crankshaft bearing caps which
are machined with the block for proper alignment and clearances. Light
duty 5.0L and 5.7L engines have two bolts per cap. Heavy duty 5.7L
engines have four bolts per cap on caps two, three, and four. The
number five crankshaft bearing at the rear of the engine is the end
thrust bearing. Four connecting rod journals (two rods per journal) are
spaced 90 degrees apart.
The pistons are cast aluminum that use two compression rings and
one oil control ring assembly. The piston is a low-friction, lightweight
design with a flat top and barrel-shaped skirt. The piston pins are chro-
mium steel. They have a floating fit in the piston and are retained by a
press fit in the connecting rod assembly. The connecting rods are made
out of either forged powdered metal or forged steel. They are machined
with the rod cap installed for proper clearances and alignment.
Lubrication
The gear-type oil pump is driven through an extension driveshaft. The

extension driveshaft is driven by the distributor which is gear driven by
the camshaft. The oil is drawn from the oil pan through a pickup screen
and tube. Pressurized oil is delivered through internal passages to
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 arms and ball
pivots. Oil returning to the oil pan from the cylinder heads and the front
camshaft bearing, lubricates the camshaft timing chain and crankshaft
and camshaft sprockets.
5-2 Engine/eng
Valve Train
The valve train is a ball pivot type. Motion is 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
open the valve. The hydraulic roller valve lifters keep all parts of the
valve train in constant contact.
The valve rocker arm ball is retained on the valve rocker arm stud with
a locking nut. The valve rocker arm studs are pressed into the cylinder
head.
Intake Manifold
The intake manifold is a single piece design. It supports either a throttle

body or multiple injectors to meter and distribute fuel to each engine
cylinder.
Materials Required
DuraPlusTM Synthetic Motor Oil
Loctite Primer
Black Neoprene Dip
Engine/eng 5-3
Cleaning
Before cleaning the engine, remove the engine accessories to provide
better access to the engine’s exterior surfaces. After removing the
throttle body, distributor, etc., cover the openings with tape to prevent
the entry of coolant, solvent, or dirt.
Methods used to clean the engine will depend on what equipment is
available. Steam cleaning, pressure washing, or solvent cleaning are
some acceptable 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.
Engine Lubrication
1 3 Full pressure lubrication, through a full-flow oil filter is
supplied by a gear-type oil pump. Oil is drawn up through the oil pump
screen and passes through the pump to the oil filter. The oil filter is a
full-flow paper element unit with an anti-drain back valve. An oil filter
bypass valve is used to ensure adequate oil supply, in the event the
filter becomes plugged or develops excessive pressure drop.
Filtered oil flows into the main gallery and then to the camshaft, rear
bearing, and crankshaft bearings. The valve lifter oil gallery supplies
oil to the valve lifters. Oil flows from the valve lifters through the hollow
valve push rods to the valve rocker arms. Oil drains back to the crank-
case through oil drain holes in the cylinder head. The camshaft timing
chain is drip fed from the front camshaft bearing. The pistons and pis-
ton pins are lubricated by oil splash.
5-4 Engine/eng
1 2
DRC6612 DRC6614
Front View Rear View
3
Stbd View DRC6613
Engine/eng 5-5
A clean, well lit work area should be available. Other necessary equip-
hand tools.
An approved engine repair stand will help prevent personal injury or
damage to engine components.
Special tools are illustrated throughout this section and listed at its
end. These tools (or their equivalents) are specially designed to quickly
and safely accomplish the operations for which they are intended. The
use of these tools will also minimize possible damage to engine com-
ponents.
Some precision measuring tools are required for inspection of certain
critical components. Torque wrenches will be necessary to correctly
tighten various fasteners. Those fasteners 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
Accessory Brackets and Electrical Wiring
Starter Motor
It is beyond the scope of this section to detail the many different ac-
cessory installations. Refer to the proper Service Manual for this infor-
mation. Diagrams of vacuum hose routing, wiring harness routing, ac-
cessory drive belt layout, etc., should be made before removing these
components.
Draining The Engine

Follow the procedures in Section 1, General Information of this
manual to drain crankcase engine oil and the cooling system.
5-6 Engine/eng
Exhaust Manifold
Removal
1. Drain water from exhaust manifolds.

2. Disconnect water hose from manifold.
3. Loosen upper exhaust hose clamps, then remove high rise elbow.
4. Remove manifold attaching screws. Remove manifold.
Inspection
1. Inspect for cracks. A

1 2. To pressure check manifold, use a plate such as pictured A and B
a new elbow gasket B to seal water passage in manifold. Be sure to
apply sealer to gasket. Install rubber drain caps to manifold and secure C
with clamps. Attach a Gearcase Pressure Tester C (such as Stevens
Company S-34) to the water inlet hose. A bushing can be made to se-
cure pressure tester to hose. With the pressure tester attached to the
manifold, submerge manifold in water. Pressurize the manifold to 10-15
PSI (22-25 kPa) and check for leaks. Manifold should not leak around
clamps and plate. If so, retighten clamps or reseal plate. No drop in
1
DR2642
pressure should be realized.
Installation
2 1. Clean mating surfaces on manifold and head. Install new ex-

haust gasket, then install manifold and secure with screws. Tighten
screws D to 20-26 ft. lb. (27-35 N m).
•
2. Install a new gasket and high rise elbow to manifold. Tighten bolts to
12-18 ft. lb. (16-24 N m).
•
3. Install exhaust hose and secure with clamps.

2
4. Connect water hose. 49463
5. Start engine and check for fuel leaks.

Intake Manifold
Removal
1 2 1. Drain coolant from manifolds and both sides of block.

2. Disconnect:
a. Battery cables from battery.
b. Coolant hoses at thermostat housing.
c. Throttle cable from throttle body and anchor block.
1
49460
d. Crankcase ventilation hose and PCV Valve from rocker arm

covers (both sides).
e. Wire at temperature gauge sender unit and engine wiring har-
ness from alternator.
f. Distributor high tension and ignition primary leads from coil.
3. Remove:
3 a. Distributor cap and mark the position of the rotor on the hous-
ing. Scribe a line on distributor housing and intake manifold
for reassembly in the same position. Remove the distributor.
2
49461
b. Alternator and alternator mounting bracket from engine.

c. Fuel lines from throttle body and fuel pump/vapor separator
assembly.
d. Oil pressure sending unit.
e. Manifold attaching bolts. Lift manifold from engine. Discard
front and rear seals and gaskets.
f. If manifold is to be replaced, transfer: throttle body and ECM
bracket, thermostat and housing (use new gasket), throttle
cable anchor block assembly, distributor clamp and tempera-
3
25140
ture sending unit. Transfer additional hardware as required.

Clean:
Old pieces of gasket or RTV from the gasket surfaces.

Excessive carbon build-up in the intake passages of the
intake manifold.
Scale and deposits from the coolant passages of the
intake manifold.
Installation
3
DRC6591
Important Do NOT reuse intake manifold gaskets.
Install or Connect:
1. Sealant to the intake manifold gasket, cylinder head side.
Care must be used to apply the correct amount of sealant onto
the gasket. Applying excessive amounts of sealant may prohibit the in-
take gasket from sealing properly.
3 4 2. Gaskets onto the cylinder head.
a. Use gasket locator pins to properly seat gasket on the cylinder 4
head. DRC6592
b. Apply a 0.499 in. (13 mm) bead of GM Adhesive, P/N 12346141,

or equivalent to the front and rear block sealant areas.
5 c. Extend the sealer bead 0.157 in. (4 mm) onto each gasket.
3. GM Threadlock, P/N 12345382, or equivalent to the threads of the
eight lower intake mounting bolts.
4. Lower intake manifold onto engine block.
5. Lower intake manifold bolts.
Tighten: 5
DRC6590
6 Bolts in three steps, using the following sequence.
a. The first pass to 27 in. lb. (3 N m). Snug all bolts to minimize
•
shifting of the intake.

b. The second pass to 106 in. lb. (12 N m).
•
c. Final pass to 11 ft. lb. (15 N m).

•
6
DRC6593
Engine/eng 5-9
d. Distributor with rotor and aligned exactly as marked during
removal.
If engine was cranked while distributor was out, complete igni-
tion timing procedure must be followed. See the appropriate Ignition
Circuit in Electrical/Ignition/Fuel Systems Service Manual.
e. Alternator with mounting bracket.
f. Distributor cap and high tension leads. See the General In-
formation section in Electrical/Ignition/Fuel Service
Manual for correct firing order and spark plug wire routing.
g. Oil pressure sending unit.
6. Connect:
a. All electrical connections. Apply Black Neoprene Dip or
equivalent on all exposed connections.
b. Fuel lines to throttle body and fuel pump/vapor separator.
c. Throttle cable.
d. All water hoses, and close all drain plugs.
e. Crankcase ventilation hose and PCV Valve.
f. Battery cables.
g. Start engine. Check ignition timing. Check for leaks.
Rocker Arm Cover

Removal
3. Gasket.
1
DRC6647

Clean:

Old gaskets from the gasket surfaces.
Inspect:

Rubber grommets and parts for deterioration.
Installation
1. New gasket.
Tighten:
Bolts to 106 in. lb. (12 N m)
•
Valve Train
Removal
Important Store all reusable components in an exact order, so

they can be reassembled in the same wear pattern location from which
they were removed. Mark the front end of the retainer.
Tools Required: J 3049-A Valve Lifter Removal (Plier Type)
J 9290-01 Valve Lifter Removal (Slide Hammer Type)
Every effort should be made to ensure that the mating parts are in-
stalled in their original locations during assembly. A simple valve train
component organizer rack can be made from a piece of wood.
2 1. Valve rocker arm nuts, balls, and valve rocker arms.
2
DRC6648
3
DRC6650
Engine/eng 5-11
1 3. Valve lifter guide retainer and bolts.
1 4. Valve lifter guides.
5. Valve lifters.
Remove the valve lifters one at a time using a magnet. Place the valve
lifters in the organizer rack, or tag them in a way to ensure they can be
returned to the valve lifter bore from which they were removed.
2 3 Some valve lifters may be stuck in their bores due to gum or
varnish deposits. These valve lifters can be removed using either J 1
DRC6649
3049-A or J 9290-01.
Clean:
Parts in solvent. Blow dry with compressed air.

Make sure 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 scor-
ing or other damage. 2
DRC6651
Valve rocker arms areas that contact the valve stems

and the sockets that contact the valve push rods. These
areas should be smooth and free of damage and wear.
Valve rocker arm nuts or bolts.
Important All engines use 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 arm studs. If not, it is possible that the nut(s) could back
off during engine operation causing a loss of lash and create valve
train noise. 3
DRC6586
5-12 Engine/eng
Installation
Important Replace all valve roller lifters, change the engine oil
and filter, and add GM Engine Oil Supplement, P/N 1052367, or equiva-
lent to the engine oil whenever a new camshaft is installed.
Lubricate the valve lifter bodies and roller with GM Engine Oil
Install or Connect:
1. Valve lifters in same location from which they were removed.
1 2. Valve lifter guides, valve lifter guide retainer and valve lifter guide
retainer bolts.
Valve lifter guide retainer must contact all valve lifter guides. If
valve lifter guide retainer is bent it must be replaced.
Tighten:
Bolts to 18 ft. lb. (25 N m).
•
3. Coat valve rocker arm and rocker arm ball bearing surfaces with
prelube, GM Engine Oil Supplement , P/N 1052367, or equivalent, when
installing. Keep these components and valve push rods in same se-
quence to ensure their return to the original position from which they
were removed.
4 4. Valve push rods. Make sure valve push rods seat in valve lifter
sockets.
5 5. Valve rocker arms, balls, and nuts.
Valve Adjustment
Adjust:
1. Valve rocker arm nuts until all lash is eliminated.
4
DRC6650
2. Turn crankshaft until cast arrow on crankshaft balancer hub is in 12

o’clock position and number 1 cylinder is in firing position (top dead
center).
Watch number 1 cylinder valves as crankshaft balancer

hub arrow approaches 12 o’clock position. If a valve
moves as arrow moves to position, engine assembly is
in number 6 cylinder firing position. Crankshaft must then
be turned one more time to reach number 1 cylinder fir-
ing position.
5
DRC6648
Engine/eng 5-13
3. With engine assembly in number 1 cylinder firing position, following
valves can be adjusted.
Exhaust 1, 3, 4, 8
Intake 1, 2, 5, 7
1 4. Back off valve rocker arm nut until lash is felt in valve push rod.
Then tighten 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.
5. When all free play has been removed, tighten valve rocker arm nut 1
DRC6673
one additional turn (360 degrees).
6. Turn crankshaft one revolution until hub arrow is again at 12 o’clock
position. This is number 6 cylinder firing position. Following valves can
now be adjusted:
Exhaust 2, 5, 6, 7
Intake 3, 4, 6, 8
Cylinder Head
1. Spark plugs.
3. Cylinder heads.
4. Head gaskets.
Important Use care when handling the cylinder heads, to

prevent damage to the gasket sealing surfaces. 2
DRC6595
Cylinder Head Disassembly
2 3 1. Valve keys. Compress the valve springs with J 8062. Re-
move the valve keys and tool J 8062.
3
DRC6663
5-14 Engine/eng
2 2. Caps and springs.
3. Valve stem oil seals, valves, and components. Place them in a rack
so they can be returned to their original position at assembly.
J 5802-01
Rocker Arm Stud Replacement
Tools Required: J 5802-01 Valve Rocker Arm Stud Removal 4

DRC6664
J 5715 Reamer 0.003 in. (0.0762 mm) oversize)
J 6036 Reamer 0.013 in. (0.3302 mm) oversize)
J 6880 Valve Rocker Arm Stud Installation
Valve rocker arm studs that have damaged threads or are loose in cyl- J 5715
or
inder heads should be replaced. New studs are available in 0.003 in. J 6036
(0.0762 mm) and 0.013 in. (0.3302 mm) oversize.

4 1. Place J 5802-01 over the stud to be removed. Install a nut and
flat washer. Remove the stud by turning the nut.
5 2. Ream the hole to the proper size for the replacement oversize
stud. Use J 5715 for 0.003 in. (0.0762 mm) oversize studs, J 6036 for
5
DRC6665
0.013 in. (0.3302 mm) oversize studs.
6 3. Coat lower end (press-fit area) of stud with hypoid axle lubri-
cant. Drive the stud into place with a hammer and J 6880. Stud is in-
stalled to proper depth when the tool bottoms on the cylinder head.
Cylinder Head Assembly
Tools Required: J 8062 Valve Spring Compressor

J 6880
Install or Connect:
1. Valves.
Lubricate the valve stems with clean engine oil.

Insert the valves into their proper location.
2. Oil seals. lnstall the oil sealsover the valve stems and seat them
against the cylinder head.
3. Valve springs.
6
DRC6666
Engine/eng 5-15
4. Valve Keys.
1 a. Compress the valve spring, using J 8062. Compress the
spring enough so the lower valve stem grooves can be clearly
seen.
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. Make sure the keys seat properly in
the valve stem grooves.
c. Release the compressor tool. Make sure the valve keys stay 1
DRC6663
in place.
d. Repeat the preceding steps on the remaining valves.
Measure:
1. Valve spring installed height of each valve spring as follows:
2 2. Use a narrow, thin scale. A cut away scale A may be helpful.
3 3. Measure from the cylinder head spring seat to the top of the
cap.
Cylinder Head Installation 2

DRC6667
Tool Required: J 36660 Torque/Angle Meter or equivalent
Clean:
5
Gasket surfaces on block and cylinder head.
4
Inspect:
1. Head gasket onto engine block.
2
1
2. Place the gasket in position over the cylinder head dowel pins align-
ing the gasket locating mark facing up.
3. Cylinder head onto block. Carefully guide the cylinder head into 3
DRC6668
place over the dowel pins and head gasket.
5-16 Engine/eng
4. Coat threads of cylinder head bolts with GM Sealant, P/N 12346004,
or equivalent.
Tighten:
4 1. In sequence first pass to 22 ft. lb. (30 N m).
•
4 2. In sequence final pass using J 36660 or equivalent to:

Short bolts - (3,4,7,8,11,12,15,16) 55 degrees.
Medium bolts - (14,17) 65 degrees.
Long bolts - (1,2,5,6,9,10,13) 75 degrees.
Crankshaft Balancer
Removal
Tool Required: J 39046 Crankshaft Balancer Remover

sembled to the hub with a rubber sleeve. The removal procedures must
be followed (with the proper tools) or movement of the inertial weight 4
section of the hub will destroy the tuning of the crankshaft balancer and DRC6672
the engine timing reference.

5 2. Crankshaft balancer using J 39046.
3. Crankshaft key (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 5
DRC6671
crankshaft seal for roughness or nicks. Replace the balancer if this con-
dition exists. If balancer is replaced, new balance weights of the same
size must be installed on the new balancer in the same location as the
old balancer.
Engine/eng 5-17
Installation
Tool Required: J 39046 Crankshaft Balancer Installer

Install or Connect:
sembled to the hub with a rubber type material. The correct installa-
tion procedures (with the proper tool) must be followed or movement
of the inertial weight section of the hub will destroy the tuning of the
crankshaft balancer.
1
1. Use a small amount of RTV sealant to seal the balancer keyway to DRC6671
crankshaft joint.
1 2. Crankshaft balancer hub, until completely seated using J 39046.
3. Remove tool J 39046.
4. Bolt and washer into front of crankshaft.
Tighten:
•
Oil Pan
Removal
1. Oil pan bolts, nuts, and studs.
2. Oil pan reinforcements.
3. Oil pan.
4. Oil pan gasket.
Clean:
2
Parts in solvent. Remove all sludge and varnish. DRC6637
Old gaskets and RTV sealant from the gasket surfaces.
5-18 Engine/eng
Inspect:

Oil pan for damage or cracks.
Drain plug threads for stripping.
Installation
Install or Connect:
3 4 1. Apply a small amount of GM Adhesive , P/N 12346141, or 3
DRC6639
equivalent, to engine front cover and engine block junction, and to crank-
shaft rear oil seal housing and engine block junction. Apply sealer 1.0
in. (25 mm) in either direction of radius cavity of junctions.
2. Oil pan gasket, oil pan and reinforcements.
3. Oil pan nuts, bolts and studs.
Tighten:
2 Corner bolts or stud, and nuts to 15 ft. lb. (20 N m). Remainder of
•
bolts and studs to 106 in. lb. (12 N m).

•
4. Oil pan drain plug and gasket. 4

DRC6640
Tighten:
Oil pan drain plug to 18 ft. lb. (25 N m).
•
Engine/eng 5-19
Oil Filter
Removal
1. Oil filter.
2. Oil filter adapter bolts and washers.
3. Oil filter adapter and oil filter adapter gasket.
Inspect:
Oil filter adapter bypass valve and spring for opera-

tion.
For cracked or broken bypass valve.
Installation
Oil filter adapter and bypass valve must be replaced as a unit.

1. Oil filter adapter and oil filter adapter gasket.
2. Oil filter adapter bolts and washers. 1
DRC6638
Tighten:
Oil filter adapter bolts to 18 ft. lb. (25 N m).
•
3. Oil filter.
Tighten:
Oil filter to 12 ft. lb. (16 N m).
•
Oil Pump
Removal
1. Crankshaft oil deflector nuts.
2. Crankshaft oil deflector.
2
DRC6654
5-20 Engine/eng
3. Bolt attaching oil pump to rear crankshaft bearing cap.
4. Oil pump, retainer, and driveshaftfrom rear crankshaft bearing cap.
3 Disassemble:
1. Driveshaft 9 and retainer 8 .
Do not remove the oil pump screen unless replacement is re-
quired. The oil pump screen has a press fit in to the pump cover. Do not
remove the screen from the pipe 6 . The oil pump screen is serviced as
a complete assembly only.
3. Bolts 5 and pump cover 4 .
Mark where the idler gear and drive gear and shaft 7 mesh
together, so they can be reinstalled with the same gear teeth indexed.
4. Idler gear and drive gear and shaft 7 .
5. Retaining pin 1 .
6. Pressure regulator spring 2 and valve 3 .
Clean: 3
DRC6624
All parts in clean solvent and dry them with compressed air.
3 Inspect:
Important The pump gears, cover, and body are not serviced
separately. The pressure relief valve spring is the only serviceable
component. If any of the parts are damaged or worn, the entire oil pump
assembly must be replaced.
Pump body 10 for cracks, wear, or other damage.
Inside of the cover 4

for cracks and wear that would
permit oil to leak past the ends of the gears.
Idler and drive gear 7 for wear.

Drive gear and shaft for lack of fit in the pump body.
Oil pump screen for damage to the screen or loose fit of
the pipe.
Pressure regulator valve 3

for fit. The regulator valve
should slide freely in its bore without sticking or binding.
Engine/eng 5-21
Assemble:
1. Pressure regulator valve 3 into the pump cover 4 .
Important Replace the pressure relief valve spring when

reusing the oil pump assembly.
2. Pressure regulator spring 2 into the pump cover 4 .
3. Retaining pin 1 into the pump cover 4 .
4. Drive gear and shaft 7 into the pump body 10 .
5. Idler gear 7 into the pump body 10 .
Match together the index marks on the two gears made during
disassembly.
6. Pump cover 4 .
Tighten:
Bolts 5 to 106 in. lb. (12 N m). •
7. With the driveshaft 9 installed on the pump, turn the driveshaft by 1

DRC6624
hand to check for smooth operation.
Be careful of twisting, shearing, or collapsing the pipe when
installing it to the pump. A damaged pipe can cause lack of lubrication
and engine failure.
Oil Pump Screen Installation
Install:
1. Oil pump screen pickup.
a. The oil pump screen assembly should be replaced with a new
part. Loss of press fit condition could result in an air leak and
2
DRC6625
loss of oil pressure.
b. Mount the oil pump in a soft jawed vise.
c. Apply sealer to the end of the pipe.
2 d. Tap the pickup screen and pipe into place, using J 21882
and a hammer.
e. The oil pump screen must be parallel with the bottom of the
oil pan when installed.
5-22 Engine/eng
Install:
1 1. Oil pump driveshaft 9 and retainer 8 .
2. Oil pump to the engine.
a. Align the slot in the oil pump shaft with the tang on the dis-
tributor shaft.
b. The oil pump should slide easily into place.
c. No gasket is used.
3 3. Oil pump and bolt onto crankshaft bearing cap.
Tighten:
•
3 4. Crankshaft oil deflector.

Tighten:
Nuts to 30 ft. lb. (40 N m).•
Engine Front Cover 3

DRC6654
Removal
4 The composite engine front cover and gasket are NOT

REUSABLE.
2. Engine front cover.
Installation
4
Lubricate the sealing surface of the crankshaft front oil DRC6655
seal with clean engine oil.

Install or Connect:
A new composite engine front cover and gasket must be
installed on 5.0L and 5.7L engines. DO NOT reuse the composite
engine front cover.
4 1. Engine front cover and gasket.
Engine/eng 5-23
2. Install bolts.
Tighten:
Bolts to 106 in. lb. (12 N m).
•
Timing Chain and Sprockets

Tool Required: J 5825-A Crankshaft Sprocket Puller
Removal
To prevent damage to pistons or valves, do not turn the crank-

1
DRC6656
shaft after the camshaft timing chain has been removed.

1. Camshaft sprocket bolts.
2. Camshaft sprocket and camshaft timing chain together.
The sprocket has a light interference fit on the camshaft. Tap
the sprocket on its lower edge to loosen it.
2 3. Crankshaft sprocket using J 5825-A.
4. Key (if damaged). 2
DRC6615
Inspect:
1. Sprockets for chipped teeth and wear.
Excessively worn sprockets will rapidly wear a new chain.
2. Camshaft timing chain for damage.
An excessively worn chain will rapidly wear a new set of sprock-
ets.
3. Crankshaft sprocket for wear in the keyway area.
4. Crankshaft sprocket key for wear.
5-24 Engine/eng
Installation
Tool Required: J 5590 Crankshaft Sprocket Installer

Inspect:
1. Crankshaft key (if removed).
3 2. Crankshaft sprocket using J 5590.
Important Make sure the sprocket alignment mark faces away

from the engine block. Make sure the sprocket is fully seated against 3
DRC6669
the crank shoulder.
4 3. Camshaft timing chain to the camshaft sprocket.
4 4. Camshaft sprocket and camshaft timing chain to the front of
camshaft.
Important
5 • Make sure that camshaft and crankshaft timing marks

align. 4
DRC6633
The number 6 cylinder is at top dead center of the com-
pression stroke with the timing marks in this position.
Make sure the camshaft dowel pin and camshaft sprock-

et hole are properly aligned
Gears and chain mesh.
5. Camshaft sprocket bolts. Use the bolts to draw the camshaft sprocket
onto the camshaft. DO NOT ATTEMPT TO HAMMER THE CAMSHAFT
SPROCKET ONTO THE CAMSHAFT. TO DO SO MAY DISLODGE THE
REAR CAMSHAFT PLUG AND/OR DAMAGE THE CAMSHAFT. 5
DRC6670
Tighten:
•
Camshaft
Removal
All camshaft journals are the same diameter so care must be
used in removing the camshaft to avoid damage to the bearings.
Engine/eng 5-25
2. Camshaft.
1 a. Install three 5/16 - 18 x 4.0 in. long into the camshafts threaded
holes. Use these bolts to handle the camshaft.
1 b. Pull the camshaft out from the block being careful to prevent
damage to the camshaft bearings.
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in 1
DRC6636
this manual. Do not attempt to repair the camshaft. Replace the cam-
shaft if damaged. Whenever the camshaft needs to be replaced, a
new set of valve lifters must also be installed.
Bearings

Installation
Install or Connect:
Coat the camshaft lobes and journals with a high quality GM
Engine Oil Supplement , P/N 1052367, or equivalent. Apply GM En-
gine Oil Supplement, P/N 1052367, or equivalent to all the teeth on
the distributor drive gear.
1 1. Two or three 5/16 - 18 (4.0 in.) bolts long into the camshaft
threaded holes. Use these bolts to handle the camshaft.
1 2. Camshaft into the engine. Handle the camshaft carefully to
prevent damage to the camshaft bearings.
3. Camshaft retainer and retainer bolts.
Coat camshaft retainer plate with GM Engine Oil

Tighten:
•
5-26 Engine/eng
Removal
Tool Required: J 5239 Guide Set

1. Before attempting to remove piston, remove cylinder bore ridge as
necessary.
for cylinder bore ridge reamer procedures.
2. Mark the cylinder numbers on 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 numbered 1-3-5-7

The left bank is numbered 2-4-6-8
3. Check the connecting rod and cap for identification marks. If none,
place match marks or numbers on connecting rods and caps. Mark the
parts from the front to the rear, with the engine in an upright position
and viewed from the front. Connecting rod caps must be assembled to
their original connecting rods.
Important Store the connecting rod and cap together as mating

parts, so they may be reassembled in the same wear pattern and balance
in which they were removed.
4. Connecting rod nuts, cap and bearings.
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.
2 a. Attach J 5239 to the connecting rod bolts.
2 b. Use the long guide rod J 5239 to push the connecting rods
and pistons out of the top of the engine block.
Disassembly

and connecting rod disassembly. 2
DRC6619
Assembly

Engine/eng 5-27
Piston Selection
Measuring the Piston

J 8087
Check the used piston to cylinder bore clearance, as follows:
2.5 in. (65 mm) below the top of the cylinder bore.
2 2. Piston diameter. Measure the skirt at a right angle to the piston
pin hole, 1.0 in. (25 mm) below the oil ring groove.
1
Measure piston diameter at 70° F (20° C). DRC6507
4. Locate the piston-to-bore clearance, refer to Engine Specifications.
Determine if the piston-to-bore clearance is within the acceptable range.
Piston Ring End Gap and Fit
Important The numbers on the connecting rod and bearing cap 2

DRC6514
must be on the same side when installed in the cylinder bore. If a
connecting rod is ever transposed from one block or cylinder to another,
should be renumbered to correspond with the new cylinder number.
Installation
Tools Required: J 5239 Connecting Rod Bolt Guide Set

J 8037 Ring Compressor
Install or Connect:
2. Make sure the piston is installed in the matching cylinder.
3. Connecting rod bearings.
a. Make sure the crankshaft bearings are the proper size.
b. Install crankshaft bearings in connecting rod and cap.
c. Lubricate the bearings with engine oil.
5-28 Engine/eng
4. Piston and connecting rod into the proper bore.
3 a. With the connecting rod cap removed, install J 5239 onto the
connecting rod bolts.
4 b. Locate the piston ring end gaps. Lubricate the piston and rings
with engine oil.
5 c. Without disturbing the ring end gap location, install J 8037 over
the piston and compress the rings.
d. Place the piston in its matching bore. The connecting rod bear- 3
ing tang slots must be on the side opposite the camshaft. Us- DRC6619
ing light blows with a hammer handle, tap the piston down into FORWARD
its bore. At the same time, from beneath the engine, guide the
connecting rod onto the crankpin with J 5239, Hold the ring B
compressor against the block until all rings have entered the
C A D
cylinder bore.
e. Remove J 5239 from the connecting rod bolts. B
A - POSITION OF THE GAP FOR THE

B - POSITION OF THE GAP FOR THE
OIL RING
marked, beginning at the front of the engine. Cylinders 1, 3, and 5 are 4 D - POSITION OF THE GAP FOR THE
the right bank and 2, 4, and 6 are the left bank (when viewed from the DRC6627
front). The numbers on the connecting rod and bearing cap must be on
the same side when installed in the cylinder bore. If a connecting rod is
ever transposed from one block or cylinder to another, new connecting J 8037
rod bearings should be fitted and the connecting rod should be numbered
to correspond with the new cylinder number.
5. Connecting rod cap with crankshaft bearing.
6. Connecting rod bolt nuts.
Tighten:
Rod bolt nuts to 20 ft. lb. (27 N m) plus an additional 55 degrees
• 5
DRC6628
using J 36660 or equivalent.
Measure:
Refer to General Engine Mechanical section in this manual for con-
necting rod side clearance procedure.
Engine/eng 5-29
Crankshaft Rear Oil Seal
Removal
Take care when removing the rear crankshaft oil seal so as

not to damage the crankshaft sealing surface.
1 Insert a screwdriver into the notches provided in the oil seal hous-
ing and remove the oil seal.
1
DRC6658
Installation

1. Lubricate the inner and outer diameter of the oil seal with clean J 35621
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.
2
4. Tighten the screws securely with a screwdriver. This will ensure that DRC6626
the seal is installed squarely over the crankshaft.

5. Turn the handle until it bottoms.
6. Remove J 35621.
5-30 Engine/eng
Crankshaft Rear Oil Seal Housing
Removal
1. Bolts and nuts.
2. Oil seal housing.
3. Gasket.
Clean:
3
DRC6657
Gasket surfaces on the block and seal retainer.
Installation
• Always use new crankshaft rear oil seal and new hous-
ing gasket during installation of rear oil seal housing.
1. New gasket to the block.
It is not necessary to use sealant to hold the gasket in place.
2. Oil seal retainer.
3. Screws and nuts.
Tighten:
Screws and nuts to 106 in. lb. (12 N m).•
Crankshaft And Bearings

Removal
The crankshaft need not be removed for replacement of the rear oil
seal or crankshaft bearings. Those procedures are covered in other
parts of this section.
Important Check the crankshaft bearing caps for location

markings. Mark the caps if necessary. The caps must be returned to
their original locations during assembly.
Engine/eng 5-31
1 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 damage to crankshaft journals and thrust flange surfaces.
4. Upper crankshaft bearings.
Cleaning, Inspection, and Repair

The following is the recommended gasket cleaning procedure for Gen-
eral Motors engine components:
Carefully remove all gasket material from the part using a plastic or
wood scraper. Use Loctite brand “Chisel Gasket Remover” (P/N 4MA)
or equivalent. Do not use any other method or technique to remove
gasket 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. Abrasive pads also produce a fine grit that the oil 1
filter cannot remove from the oil. This grit is abrasive and has been DRC6659
known to cause internal engine damage.

If the engine is damaged internally and needs to be rebuilt, make sure
all foreign material is completely flushed out of the cooling and lubri-
cation systems. Failure to rid the oil or cooling systems of debris can
result in damage to the rebuilt engine.
Measure:
Crankshaft bearing vertical inside diameter (I.D.). Use an inside mi-
crometer. This dimension should be the same as the other crankshaft
bearing bore vertical diameters.
Clean:
Use care not to scratch crankshaft journals.
• Crankshaft with solvent.

• Blow all debris from the oil passages with compressed
air.
• Crankshaft bearings. Wipe free of oil with a soft cloth.
• Oil seal surfaces with a non-abrasive cleaner.
5-32 Engine/eng
Installation
Important Crankshaft bearings are the precision insert type and

do not use shims for adjustment. If clearances are excessive, a new
bearing 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
mm) is available for 5.7L engines only.
Selective fitting of both connecting rod and crankshaft bearings is nec-
essary to obtain close tolerances. For this reason you may use, for ex-
ample, one half of a 0.001 in. (0,0254 mm) undersize bearing which will
decrease the clearance 0.0005 in. (0,0127 mm) from using a full stan-
dard bearing.
Undersize Crankshaft Journals
When a production crankshaft cannot be precision fit by the method

described previously, it is then ground 0.009 in. (0,2286 mm) under-
size. GRIND ONLY THOSE CRANKSHAFT JOURNALS THAT CANNOT
BE PROPERLY FITTED. ALL JOURNALS WILL NOT NECESSARILY
BE GROUND.
A 0.009 in. (0,2286 mm) undersize bearing or 0.010 in. (0,254 mm)
undersize bearing will then be used for precision fitting in the same
manner as previously described.
Oversize Rear Crankshaft Bearing Thrust Faces
Some production engines may have rear crankshaft bearings that are
0.008 in. (0,2032 mm) wider than standard across the thrust faces. The
crankshaft on these engines can be identified by “.008” stamped on 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.
1. Upper crankshaft bearing to the block.
Important If any undersized bearings are used, they must be

fitted to the proper journals.
2. Crankshaft.
Measure:
crankshaft bearing clearance procedures.
Engine/eng 5-33
4. Apply engine oil to the crankshaft bearings. Install crankshaft bear-
ing caps and bolts to the block. DO NOT install the rear crankshaft
bearing cap at this time.
In order to prevent the possibility of cylinder block and/or crank-
shaft bearing cap damage, the crankshaft bearing caps are to be lightly
tapped into their cylinder block cavity using a brass or leather mallet
before attaching bolts are installed. DO NOT USE ATTACHING BOLTS
TO PULL CAPS INTO THEIR SEAT.
Important The arrows on the crankshaft bearing caps must be

facing the front of the engine.
Tighten:
Crankshaft main bearing cap bolts to:
• All inboard bolts 77 ft. lb. (105 N m).

•
• Outboard bolts (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:
1 1. Firmly thrust the crankshaft first rearward then forward. This
will line up the rear crankshaft bearing and crankshaft thrust surfaces.
2. Install rear crankshaft bearing cap bolts.
Tighten:
Rear crankshaft bearing cap bolts to 77 ft. lb. (105 N m).
•
1
DRC6530
5-34 Engine/eng
3. With the crankshaft wedged forward, measure at 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).
4. If correct end play cannot be obtained, make sure the correct size
rear crankshaft bearing has been installed. Production engines may
have rear crankshaft bearings that are 0.008 in. (0,2032 mm) wider
across the thrust faces than standard, as explained previously.
Inspect:
Crankshaft for binding. Try turning the crankshaft to check for binding. 2
DRC6660
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 between the bearing and the block or the
bearing cap, or a faulty bearing could cause a lack of clearance at the
bearing.
• A bent crankshaft could cause binding. Make sure the

steps outlined in General Engine Mechanical section
have been performed when checking for a bent crank-
shaft.
Cylinder Block 3
DRC6661
Disassembly
2 4 2. Cooling jacket plugs. 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:
4
DRC6662
1. Sealing material from mating surfaces.

2. Boil cylinder block in caustic solution.
3. Flush with clean water or steam.
4. Cylinder bores.
5. Threaded holes.
Engine/eng 5-35
6. Oil galleries and passages.
7. Scale deposits from coolant passages.
8. Spray or wipe cylinder bores and machined surfaces with engine
oil.
Inspect:
1. All block core plugs for lack of fit or leakage.
2. Camshaft lifter bores for deep scratches and deposits.
3. Cracks in the block
a. Cylinder walls.
b. Water jackets.
c. Engine mount bosses.
d. Crankshaft bearing webs.
e. Crankshaft bearing bores and caps.
• All crankshaft bearing bores should be rounded and

uniform in inside diameter (I.D.) at all of the bearing
supports.
• The area where the crankshaft bearings contact the
crankshaft bearing bore should be smooth.
• If a crankshaft bearing cap is found to be damaged,
replace the cap and line bore the block.
1 4. Cylinder block head mounting surface for flatness, using a pre-
cision straight edge and feeler gauge.
a. Set the straight edge on the sealing surface to be inspected.
b. Take the feeler gauge and at various locations, check the
gap between the straight edge and the sealing surface. 1
DRC6521
c. If the gap is found to be greater than 0.004 in. (0,1016 mm)
within 5.984 in. (152 mm) at any sealing location, the block
must be replaced.
d. If the gap is found to be less than 0.004 in. (0,1016 mm)
within 5.984 in. (152 mm) at any sealing location and a cause
for leakage is suspected, then the minor irregularities may
be carefully machined from the block.
• Oil pan and intake manifold mounting surfaces for nicks.

Minor irregularities may be cleaned up with a flat file.
5-36 Engine/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

2
DRC6660
Measure:
2 4 Install or Connect:
1. Oil gallery plugs. Coat plug outside diameter with GM Sealant, P/N
12346004, or equivalent.
2. Camshaft cup plugs to proper depth. Coat bore inside diameter with
GM Sealant , P/N 12346004, or equivalent.
3
DRC6661
Important Do not allow residue on camshaft bearing or seizure

may result.
4
DRC6662
Engine/eng 5-37
Circulating Pump
Description
The circulating pump is manufactured specially for marine use. It is

serviced only as an assembly. Do not replace with an automotive cir-
culating pump.
Inspection
1. Remove alternator and power steering belts.

2. Grasp circulating pump pulley and check end and side play. Turn
pulley to check for drag.
3. Look for water leaking from indicator hole beneath pump shaft be-
hind pulley. Replace pump if play, drag, or leakage are evident.
pump.
2. Remove pulley. Remove circulating pump bolts, pump and gaskets.
sembly on cylinder block and tighten bolts as specified.
4. Install pulley. Install alternator and power steering belts, then adjust
tension.
5. Install drain plugs in block and large hose to circulating pump.
5-38 Engine/eng
1 2 3
25929 25917 11980
Front Engine Mounts

Removal

(680 kg) to allow removal of front mount and bracket.
2 3. Remove three mount screws and lock washers B . Note screw
lengths and location. 4
11979
3 Prior to disassembly of front mount assembly, measure
distance and record measurement between large washer and flat on
upper mount bracket.
Disassembly
4 1. Remove three nuts C and engine mount bracket D from mount

bolt while holding bolt secure with socket E .
5 2. Remove two flat washers, one large F
and one smaller G .
Remove lock washer H , and engine mount bolt I from mount.
Reassembly
5
11978
6 1. Place small washer G on mount bolt and insert bolt up through

mount. Install large washer and secure with nut C . Tighten to 60-75 ft.
lb. (81-102 N m).
•
4 2. Install upper inner nut and place engine mount bracket D on

engine mount bolt.
Measure distance between large washer and flat on upper mount
bracket. Adjust distance to recorded measurement.
3. Install lock washer and top nut. Tighten nut to 100-120 ft. lb. (136-
163 N m).
•
6
11983

Installation
1 1. Spray the engine mount screw threads with Loctite Primer and
allow to air dry. Apply Volvo Penta Thread Sealing Agent to the screws.
Attach engine mount assembly to engine with three screws and wash-
ers A . Tighten to 32-40 ft. lb. (43-54 N m).
•
2 2. Install washers and lag screws B and tighten securely.
Height Adjustment
3 1. To change engine height, tighten or loosen nuts C and D as 1
25917
required.
(680 kg). Position engine at desired height.
3 3. After setting mount position, turn nut D
up against underside
of engine bracket and hold nut with a wrench. Tighten nut C to 100-
120 ft. lb. (136-163 N m).
•
Any large adjustments to engine height should be followed by

a check of engine alignment. Failure to check alignment could result in
rapid engine coupler failure. See Drive Removal and Installation sec-
tion of the Vertical Drive/Transom Bracket Service Manual for align-
2
25929
ment procedures.

Removal
4 1. Loosen two clamps securing upper hose to elbow. Lubricate

inside of hose with a soapy water solution.
5 2. Starboard Elbow: Remove circuit breaker bracket E and set
aside. Remove four screws, flat washers, and lock washers mounting
high-rise elbow. 3
2953
3. Port Elbow - EFI Models Only: Remove fuel reservoir water hose
and set aside. Remove four screws, flat washers, and lock washers
mounting high-rise elbow.
4
49540
5
49464
6 7 8
49541 49542 49543
6 7 4. Use a soft hammer to free elbow from manifold. Use a

twisting motion to pull elbow from hose. Remove and discard the elbow
gasket.
Installation
1. Thoroughly clean manifold gasket surface. Apply Volvo Penta Gas-

ket Sealing Compound to both sides of a new manifold gasket and place
it on the exhaust manifold.
7 8 2. Lubricate the inside of the exhaust hose with a soapy wa- 9
49544
ter solution. Insert the high-rise elbow into the hose with a twisting mo-
tion, and push it into hose as far as it will go.
5 3. Position elbow on manifold. Secure elbows and brackets with
four screws, flat washers, and lock washers. Tighten screws to 12-18 ft.
lb. (16-24 N m). Starboard Elbow: Install circuit breaker bracket E .
•
Port Elbow: Install fuel reservoir water hose. Tighten clamp securely.
9 4. Slide clamps F up onto hose and position them in the two
surface channels. Tighten clamps securely.
Exhaust Hose & Intermediate Pipe 10

Replacement 49545
Removal
10 1. Loosen eight clamps that secure the upper G and lower H
exhaust hoses.
slide lower hose down onto exhaust Y-pipe.
12 3. Twist intermediate pipe out of upper hose. Lubricate inside of
upper hose if necessary to ease removal.
11
4. Slide upper hose off high-rise elbow. Slide lower hose off exhaust Y- 49546
pipe.
12
49547

1 2 3
32370 32366 49547
Installation
1 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.
2 The inside diameter of both the upper and lower hoses
has a step A 1.5 in. (3.81 cm) from one end. The stepped end of the
hose must face the intermediate pipe when installed. 4
49545
2. Slide hose onto high-rise elbow until it seats.
If hose is not properly positioned, it will not completely engage
the high-rise elbow or allow secure attachment.
3 4 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 hose up until it’s halfway onto the
intermediate pipe. Position clamps in channels and tighten clamps
securely.
5
20034
Removal

If coupler is being replaced due to coupler failure (rubber hub
of splined hub), check engine alignment after installing new coupler.
See Drive Removal and Installation section of the Vertical Drive/
Transom Bracket Service Manual.
6
5 6 3. Remove screws securing bellhousing cover, and slide 19085
cover out.

1 4. Pull drain hose out of bellhousing, if equipped.
2 5. Unscrew bolts and nuts retaining bellhousing. Disconnect
ground wires. Remove power steering cooler bracket.
6. Remove bellhousing from engine block.
3 7. Unscrew six nuts securing coupler and remove coupler from
studs.
8. Remove old gasket from bellhousing cover. Clean gasket surface
thoroughly. 1
19842
Installation
4 1. Install coupler and secure with six locknuts. Use a suitable

adaptor and tighten to 40-45 ft. lb. (54-61 N m).
•
3 2. Install bellhousing and attach power steering cooler. Tighten

nuts and bolts to 32-40 ft. lb. (43-54 N m). Attach ground wires and
•
tighten nuts to 15-20 ft. lb. (20-27 N m).

•
3. Push drain hose into bellhousing, if equipped.

4. Apply Volvo Penta Gasket Sealing Compound to both sides of a
new belihousing gasket and position it on cover.
2
6710

bellhousing cover and screws. Tighten to 60-84 in. lb. (7-9 N m).
•
6. Connect all wires, lines and connectors to bellhousing.

7. Install engine in boat.
3
6712
4
6714
5
19996
Engine/eng 5-43
Torque Specifications - All Models
Bell Housing Cover Screws ....................................................................................................... 60-84 in. lb. (7-9 N m) •
Bell Housing Nuts and Bolts .................................................................................................. 32-40 ft. lb. (43-54 N m) •
Camshaft Retainer Bolt ................................................................................................................... 106 in. lb. (12 N m) •
Camshaft Sprocket Bolt ..................................................................................................................... 18 ft. lb. (25 N m) •
Connecting Rod Nut ........................................................................ 20 ft. lb. (27 N m) plus an additional 55 degrees
•
Crankshaft Balancer Bolt ................................................................................................................ 74 ft. Ib. (100 N m) •
Crankshaft Bearing Cap

Inboard Bolt .................................................................................................................................... 77 ft. lb. (105 N m)
•
Outboard Bolt (Four Bolt Caps) ...................................................................................................... 67 ft. lb. (90 N m) •
Crankshaft Oil Deflector Nut ............................................................................................................. 30 ft. lb. (40 N m) •
Crankshaft Rear Oil Seal Housing Screws and Nuts ................................................................. 106 in. lb. (12 N m) •
Cylinder Head Bolt

First Pass all Bolt in Sequence ....................................................................................................... 22 ft. lb. (30 N m) •
Final Pass all Bolts in Sequence:

Short Bolt ........................................................................................................................................... 55 degrees
Medium Bolt ....................................................................................................................................... 65 degrees
Long Bolt ........................................................................................................................................... 75 degrees
Distributor Clamp Bolt ....................................................................................................................... 18 ft. lb. (25 N m) •
Engine Block
Drain Plug ......................................................................................................................................... 15 ft. lb. (20 N m)
•
Oil Gallery Plug ................................................................................................................................ 15 ft. lb. (20 N m)

•
Engine Coupler Nuts ............................................................................................................... 40-45 ft. Ib. (54-61 N m) •
Engine Mount Screws .............................................................................................................. 32-40 ft. lb. (43-54 N m) •
Exhaust Manifold Screws ....................................................................................................... 20-26 ft. lb. (27-35 N m) •
Front Cover Bolt ............................................................................................................................... 106 in. lb. (12 N m) •
Front Mount
Lower Nut ............................................................................................................................ 60-75 ft. lb. (81-102 N m) •
Upper Nut ..................................................................................................................... 100-120 ft. lb. (136-163 N m) •
5-44 Engine/eng
Torque Specifications - All Models
Fuel Pump Opening Cover
Upper Bolt ....................................................................................................................................... 30 ft. lb. (40 N m)
•
Lower Bolt .................................................................................................................................... 106 in. lb. (12 N m) •
Intake Manifold
First Pass ......................................................................................................................................... 27 in. lb. (3 N m)
•
Second Pass ................................................................................................................................ 106 in. lb. (12 N m) •
Final Pass ....................................................................................................................................... 11 ft. Ib. (15 N m)

•
Oil Filter Bypass Valve Bolt ............................................................................................................... 20 ft. lb. (26 N m) •
Oil Level Indicator Tube Bolt .......................................................................................................... 106 in. lb. (12 N m) •
Oil Pan
Corner Nut or Stud ......................................................................................................................... 15 ft. lb. (20 N m) •
Side Reinforcement Bolt or Stud ................................................................................................ 106 in. lb. (12 N m) •
Drain Plug ....................................................................................................................................... 18 ft. lb. (25 N m)

•
Oil Filter ................................................................................................................................................ 12 ft. lb. (16 N m)

•
Oil Pump
Bolt-to-Rear Crankshaft Bearing Cap ........................................................................................... 66 ft. lb. (90 N m) •
Cover Bolt .................................................................................................................................... 106 in. lb. (12 N m) •
Spark Plugs
Spark Plugs (cylinder head - new) ................................................................................................ 22 ft. lb. (30 N m) •
Spark Plugs (cylinder head - all subsequent installations) .......................................................... 15 ft. lb. (20 N m) •
Valve Lifter Guide Retainer Bolt ...................................................................................................... 18 ft. Ib. (25 N m) •
Valve Rocker Arm Cover Bolt ......................................................................................................... 106 in. lb. (12 N m) •
Engine/eng 5-45
ENGINE
Type ........................................................................................................................................................................ 90° V8
Displacement
............................................................................................................................................................. 5.0L (305 CID)
............................................................................................................................................................. 5.7L (350 CID)
Bore
5.0L ........................................................................................................................................... 3.736 in. (94.89 mm)
5.7L ............................................................................................................................................. 4.00 in. (101.6 mm)
Stroke ............................................................................................................................................ 3.480 in. (88.39 mm)
Compression Ratio ................................................................................................................................................... 9.4:1
Firing Order .............................................................................................................................................. 1-8-4-3-6-5-7-2
Oil Pressure (Minimum) ................................................................................................. 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
CYLINDER BORE
Diameter
5.0L ................................................................................................................ 3.735 - 3.7384 (94.881 - 94.958 mm)
5.7 L ................................................................................................... 4.0007 - 4.0017 in. (101.618 - 101.643 mm)
Out-of-Round
Production ...................................................................................................................... 0.001 in. (0.025 mm) MAX.
Service Limit ..................................................................................................................... 0.002 in. (0.05 mm) MAX.
Taper
Production
Thrust Side ............................................................................................................ 0.0005 in. (0.012 mm) MAX.
Relief Side ............................................................................................................. 0.001 in. (0.0254 mm) MAX.
Service Limit ................................................................................................................ 0.001 in. (0.0254 mm) MAX.
PISTON
Piston Bore Clearance
Production ................................................................................................... 0.0007 - 0.0021 in. (0.018 - 0.053 mm)
Service Limit ............................................................................................... 0.0007 - 0.0026 in. (0.018 - 0.068 mm)
PISTON RINGS
Piston Compression Ring
Groove Clearance
Production Top ..................................................................................... 0.0012 - 0.0027 in. (0.030 - 0.070 mm)
Production 2nd ....................................................................................... 0.0015 - 0.003 in. (0.040 - 0.080 mm)
Service Limit ......................................................................................... 0.0012 - 0.0035 in. (0.030 - 0.090 mm)
Gap
Production Top ............................................................................................. 0.012 - 0.020 in. (0.30 - 0.51 mm)
Production 2nd ............................................................................................. 0.020 - 0.026 in. (0.51 - 0.66 mm)
Service Limit ................................................................................................. 0.012 - 0.025 in. (0.30 - 0.85 mm)
5-46 Engine/eng
PISTON RINGS (cont.)
Piston Oil Ring
Groove Clearance
Production .................................................................................................. 0.002 - 0.006 in. (0.051 - 0.17 mm)
Service Limit ........................................................................................... 0.002 - 0.0078 in. (0.051 - 0.195 mm)
Gap
Production .................................................................................................... 0.010 - 0.030 in. (0.25 - 0.76 mm)
Service Limit ........................................................................................... 0.010 - 0.030 in. (0.0254 - 0.785 mm)
PISTON PIN
Diameter ........................................................................................................ 0.9270 - 0.9271 in. (23.545 - 23.548 mm)
Clearance in Piston
Production ................................................................................................... 0.0005 - 0.0009 in. (0.013 - 0.023 mm)
Service Limit ................................................................................... 0.0005 - 0.0010 in. (0.013 - 0.0254 mm) MAX.
Fit In Connecting Rod .................................................................. 0.0008 - 0.0016 in. (0.021 - 0.040 mm) Interference
INTAKE MANIFOLD
Surface Flatness .................................................................................................................. 0.010 in. (0.254 mm) MAX.
CYLINDER HEAD
Surface Flatness .....................................................................................................................0.005 in. (0.10 mm) MAX.
CRANKSHAFT
Crankshaft Journal
Diameter #1 ........................................................................................... 2.4484 - 2.4493 in. (62.189 - 62.212 mm)
Diameter #2, #3, #4 ................................................................................ 2.4481 - 2.4491 in. (62.181 - 62.207 mm)
Diameter #5 ............................................................................................ 2.4479 - 2.4491 in. (62.177 - 62.207 mm)
Taper
Production ............................................................................................................. 0.0002 in. (0.005 mm) MAX.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) MAX.
Out-of-Round
Production ............................................................................................................. 0.0002 in. (0.005 mm) MAX.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) MAX.
Crankshaft Bearing Clearance
Production #1 .............................................................................................. 0.0007 - 0.0021 in. (0.018 - 0.053 mm)
Production #2, #3, #4 ................................................................................. 0.0009 - 0.0024 in. (0.022 - 0.061 mm)
Production #5 ............................................................................................ 0.0010 - 0.0027 in. (0.0254 - 0.069 mm)
Service Limit #1 ........................................................................................ 0.0010 - 0.0020 in. (0.0254 - 0.051 mm)
Service Limit #2, #3, #4 ........................................................................... 0.0010 - 0.0025 in. (0.0254 - 0.064 mm)
Service Limit #5 ........................................................................................... 0.001 5 - 0.003 in. (0.038 - 0.076 mm)
Crankshaft End Play ......................................................................................... 0.002 - 0.008 in. (0.0508 - 0.2032 mm)
Crankshaft Runout At Rear Flange ............................................................................................. 0.0015 in. (0.038 mm)
Engine/eng 5-47
CONNECTING ROD
Connecting Rod Journal
Diameter ............................................................................................. 2.0978 - 2.0998 in. (53.2840 - 53.3340 mm)
Taper
Production .................................................................................................................... 0.0003 in. (0.007 mm) MAX.
Out-of-Round
Production .................................................................................................................... 0.0003 in. (0.007 mm) MAX.
Rod Bearing Clearance
Production ................................................................................................... 0.0013 - 0.0035 in. (0.033 - 0.088 mm)
Service Limit ................................................................................................. 0.001 - 0.003 in. (0.0254 - 0.076 mm)
Rod Side Clearance .................................................................................................. 0.006 - 0.024 in. (0.16 - 0.61 mm)
CAMSHAFT
Journal Diameter ............................................................................................... 1.8677 - 1.8697 in. (47.44 - 47.49 mm)
End Play .................................................................................................................... 0.004 - 0.012 in. (0.11 - 0.30 mm)
Lobe Lift ............................................................................................................................................. 0.002 in. (0.05 mm)
Intake ................................................................................................................... 0.274 - 0.278 in. (9.97 - 7.07 mm)
Exhaust ................................................................................................................ 0.283 - 0.278 in. (7.20 - 7.30mm)
VALVE SYSTEM
Valve Lifter ............................................................................................................................................... Hydraulic Roller
Valve Rocker Arm Ratio .......................................................................................................................................... 1.50:1
Valve Lash ................................................................................................................... One Turn Down From Zero Lash
Face Angle ..................................................................................................................................................... 45 degrees
Seat Angle ...................................................................................................................................................... 46 degrees
Seat Runout ............................................................................................................................ 0.002 in. (0.05 mm) MAX.
Seat Width
Intake ................................................................................................................... 0.045 - 0.065 in. (1.14 - 1.65 mm)
Exhaust (Light Duty) ........................................................................................... 0.065 - 0.098 in. (1.65 - 2.49 mm)
Exhaust (Heavy Duty) ........................................................................................ 0.059 - 0.101 in. (1.50 - 2.56 mm)
Stem Clearance
Production
Intake .................................................................................................. 0.0010 - 0.0027 in. (0.0254 - 0.069 mm)
Exhaust ............................................................................................... 0.0010 - 0.0027 in. (0.0254 - 0.069 mm)
5-48 Engine/eng
VALVE SYSTEM (cont.)
Service
Intake ......................................................................................................... 0.0010 - 0.0037 in. (0.0254 - 0.094 mm)
Exhaust ........................................................................................................ 0.0010 - 0.037in. (0.0254 - 0.094 mm)
Valve Spring
Free Length ................................................................................................................................... 2.02 in. (51.3 mm)
Pressure
Closed ...................................................................................... 76 - 84 lb. at 1.70 in. (338 - 374 N at 43.2 mm)
Open .................................................................................... 187 - 203 lb. at 1.27 in. (832 - 903 N at 32.3 mm)
Installed Height ......................................................................................................... 1.69 - 1.70 in. (42.92 - 43.43 mm)
Engine Lubrication:
Type Oil Pump .................................................................................................................................................... Gear
Crankcase Capacity ........................................................... Approx. 5 qt. (4.73 liters); 6 qt. (5.68 liters) with Filter
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
mation.
Fuel Recommendation ................. See General Information Section
Engine/eng 5-49
GM Special Tools
1 2 3
DRC6674 DRC6675 DRC6676
4 5 6
DRC6677 DRC6579 DRC6582
7 8 9
DRC6678 DRC6607 DRC6608
1 Rocker Arm Stud Bore Reamer 0.003 in. (0,0762 mm) O.S.
2 Rocker Arm Stud Bore Reamer 0.013 in. (0,3302 mm) O.S.
3 Rocker Arm Stud Remover
4 Rocker Arm Stud Installer
5 Piston Pin Remover / Installer
6 Cylinder Bore Ridge Reamer
7 Front Cover Aligner / Oil Seal Installer
10
DRC6611
8 Crankshaft Rear Oil Seal Installer

9 Torque Angle Meter or equivalent
10 Crankshaft Balancer Remover / Installer
5-50 Engine/eng
GM Special Tools
1 2 3
DRC6596 DRC6597 DRC6598
4 5 6
DRC6599 DRC6601 DRC6602
7 8 9
DRC6680 DRC6604 DRC6605
1 Valve Lifter Remover (plier type)

2 Connecting Rod Guide Tool
3 Crankshaft Sprocket Installer
5 Piston Ring Compressor
6 Valve Spring Compressor
7 Carbon Removal Brush
10
DRC6681
8 Valve Lifter Remover (slide hammer type)

9 Oil Pump Screen Installer
10 Vacuum Pump
Engine/eng 5-51
5-52 Engine/eng
Section 6
7.4 Gi Engines
Table of Contents
Camshaft High-Rise Exhaust Elbow Replacement ............... 6-32

Installation ........................................................... 6-24 Intake Manifold
Removal ............................................................... 6-10 Installation ........................................................... 6-29
Circulating Pump .................................................... 6-31 Removal ................................................................. 6-7
Crankshaft Service ................................................................. 6-16
Bearing Cap and Bearing Removal .................... 6-12 Intermediate Pipe Replacement ............................ 6-34
Bearing Installation ............................................. 6-21 Material Required ..................................................... 6-3
Balancer Installation ........................................... 6-30 Oil Pan
Balancer Removal ................................................. 6-7 Installation ........................................................... 6-26
Rear Oil Seal Installation .................................... 6-23 Removal ................................................................. 6-9
Cylinder Block Oil Pump
Assembly ............................................................. 6-14 Installation ........................................................... 6-26
Clean and Inspect ................................................ 6-13 Removal ................................................................. 6-9
Disassembly ........................................................ 6-12 Service ................................................................. 6-18
Cylinder Head Piston, Connecting Rod, and Bearing
Installation ........................................................... 6-27 Installation ........................................................... 6-23 6
Removal ................................................................. 6-9 Removal ............................................................... 6-11
Service ................................................................. 6-20 Piston Selection ..................................................... 6-14
Engine Coupler Replacement ................................ 6-34 Timing Chain and Sprockets
Engine Front Cover Installation ........................................................... 6-25
Clean and Inspect ................................................ 6-15 Removal ............................................................... 6-10
Installation ........................................................... 6-26 Torque Specifications ............................................ 6-39
Removal ................................................................. 6-9 Valve Rocker ARm Cover
Engine Specification .............................................. 6-36 Installation ........................................................... 6-29
Exhaust Hose Replacement ................................... 6-34 Removal ................................................................. 6-7
Exhaust Manifold Replacement ............................... 6-6 Valve Rocker Arm and Push Rod
Front Engine Mount Replacement ........................ 6-31 Installation ........................................................... 6-28
General Description ................................................. 6-2 Removal ................................................................. 6-8
GM Special Tools .................................................... 6-41 Valve Train Components ........................................ 6-19
Engine/eng 6-1
Safety Warnings
Before working on any part of the engine, read the section called
Safety at the end of this manual.
UNLESS OTHERWISE SPECIFIED, do not use supplement coat-
ings (paints, greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally, such coatings ad-
and may damage the fastener,
General Description
Cylinder Block
The engine block is made of cast iron and has eight cylinders arranged
in a “V” shape with four cylinders in each bank. It is a one piece casting
with the cylinders encircled by coolant jackets.
Cylinder Head
The cylinder heads are cast iron and have parent metal inlet valve guides
and inlet valve seats. Cast iron exhaust valve guides and powered metal
valve seats are pressed into the exhaust ports.
Camshaft
A steel camshaft is supported by five bearings pressed into the engine

block. The camshaft sprocket, mounted to the front of the camshaft, is
driven by the crankshaft sprocket through a camshaft timing chain.
Motion from the camshaft is transmitted to the valves by hydraulic roller
valve lifters, valve push rods, and ball-pivot type rocker arms.
Crankshaft
The crankshaft is made of cast nodular iron. The crankshaft is sup-

ported by five crankshaft bearings. The crankshaft bearings are re-
tained by the crankshaft bearing caps which are machined with the
block for proper alignment and clearances. The engine crankshaft bear-
ing caps are retained by four bolts each. The number five crankshaft
bearing at the rear of the engine is the end thrust bearing. Four con-
necting rod journals (two rods per journal) are spaced 90 degrees apart.
6-2 Engine/eng
The pistons are cast aluminum that use two compression rings and one
oil control ring assembly. The piston pins are a floating fit in the pistons
and are retained by a press fit in the connecting rod assembly. Connect-
ing rods are forged steel, with precision type insert crankpin bearings.
Lubrication
The gear-type oil pump is driven through an extension driveshaft. The

extension driveshaft is driven by the distributor which is gear driven by
the camshaft. The oil is drawn from the oil pan through a pickup screen
and tube. Pressurized oil is delivered through internal passages to lubri-
cate 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 arms and ball pivots.
Oil returning to the oil pan from the cylinder heads and the front cam-
shaft bearing, lubricates the camshaft timing chain and crankshaft and
camshaft sprockets.
Valve Train
The valve train is a ball pivot type. Motion is transmitted from the cam-
shaft through hydraulic roller valve lifters and tubular valve push rods to
the valve rocker arms. The valve rocker arm pivots on a ball to open the
valve. The hydraulic roller valve lifters keep all parts of the valve train in
constant contact. The valve rocker arm and balls are retained by bolts.
Material Required
GM Engine Oil Supplement , P/N 1052367
Loctite Primer
Engine/eng 6-3
1
DRC6932
Engine Lubrication Cleaning
1 Full pressure lubrication, through a full-flow oil fil- Before cleaning the engine, remove the engine acces-
ter is supplied by a gear-type oil pump. Oil is drawn up sories to provide better access to the engine’s exterior
through the oil pump screen and passes through the surfaces. After removing the throttle body, distributor,
pump to the oil filter. The oil filter is a full-flow paper etc., cover the openings with tape to prevent the entry
element unit with an anti-drain back valve. An oil filter of coolant, solvent, or dirt.
bypass valve is used to ensure adequate oil supply, in
Methods used to clean the engine will depend on what
the event the filter becomes plugged or develops ex-
equipment is available. Steam cleaning, pressure wash-
cessive pressure drop.
ing, or solvent cleaning are some acceptable methods.
Filtered oil flows into the main gallery and then to the Allow the engine to dry before beginning the work.
camshaft, rear bearing, and crankshaft bearings. The
It is important that the engine be as clean as possible to
valve lifter oil gallery supplies oil to the valve lifters. Oil
prevent dirt from entering critical areas during disassem-
flows from the valve lifters through the hollow valve push
bly.
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 cam-
shaft bearing. The pistons and piston pins are lubricated
by oil splash.
6-4 Engine/eng
A clean, well lit work area should be available. Other necessary equip-
hand tools.
An approved engine repair stand will help prevent personal injury or dam-
age to engine components.
Special tools are illustrated throughout this section and listed at its end.
These tools (or their equivalents) are specially designed to quickly and
safely accomplish the operations for which they are intended. The use
of these tools will also minimize possible damage to engine components.
Some precision measuring tools are required for inspection of certain
critical components. Torque wrenches will be necessary to correctly
tighten various fasteners. Those fasteners 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
• Accessory Brackets and Electrical Wiring
• Starter Motor
It is beyond the scope of this section to detail the many different acces-
sory installations. Refer to the proper Service Manual for this informa-
tion. Diagrams of vacuum hose routing, wiring harness routing, acces-
sory drive belt layout, etc., should be made before removing these com-
ponents.
Draining The Engine
Follow the procedures in Section 1, General Information of this manual

to drain crankcase engine oil and the cooling system.
Engine/eng 6-5
Exhaust Manifold Replacement
Removal
Drain water from respective exhaust manifold before begin-

ning procedure.
1. Remove high-rise exhaust elbow following procedure under High-
Rise Exhaust Elbow Replacement.
2. Carefully pull wires off spark plugs.
3. Loosen hose clamp at front of manifold, and pull off water hose.
4. Remove manifold attaching screws, nuts and washers. Discard nuts. C
Remove manifold and discard manifold gasket.
A
Cleaning
Clean mating surfaces on manifold and cylinder head. Clean the threads B
on the exhaust manifold bolts.
Inspection
1 Inspect for cracks. To pressure check manifold, use a plate A 1

such as shown, and a new elbow gasket B to seal water passage in DR2875
manifold. Be sure to apply sealer to gasket. Install rubber drain cap to

manifold and secure with clamp. Attach a gearcase pressure tester C
(such as Stevens Company S-34) to the water inlet hose. A bushing
can be made to secure pressure tester to hose. With the pressure tester
attached to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks.
Installation
1. Install a new exhaust manifold gasket.

2 3 2. Install manifold and secure with bolts and washers. Tighten 2
18946
bolts to 24-28 ft. lb. (33-38 N m).
•
3. Attach water hose to nipple at front of manifold and tighten clamp.

4. Attach spark plug wires to plugs. Make sure firing order is correct.
5. Install high-rise exhaust elbow following procedure under High-Rise
6. Start engine and check for water and exhaust leaks.
3
18944

Crankshaft Balancer Removal
Tools Required: J 23523-F Crankshaft Balancer Remover/Installer
1. Crankshaft balancer retaining bolt and washer.
4 2. Crankshaft balancer using Special Tool P/N J 23523-F Crank-
shaft Balancer Remover/Installer.
Intake Manifold Removal 4

DRC6913
5 1. Upper intake manifold bolts.
2. Upper intake manifold and gaskets. Discard the gaskets.
6 3. Lower intake manifold bolts.
Important Do not attempt to loosen the manifold by prying under
the gasket surface with any tool. The lower intake manifold gaskets are
reusable.
4. Lower intake manifold by pulling up on the manifold.
5
DRC6891
5. Lower intake manifold gaskets and seals.
Valve Rocker Arm Cover Removal

7 1. Valve rocker arm cover bolts.
2. Valve rocker arm cover and gasket. Discard the gasket.
6
DRC6893
7
DRC6895
Engine/eng 6-7
Valve Rocker Arm and Push Rod Removal
Tools Required:J 3049-A Valve Lifter Removal (Plier Type)
J 9290-01 Valve Lifter Removal (Slide Hammer Type)
Important Every effort shou Id be made to ensure that the

mating parts are installed in their original locations during assembly.
1 1. Valve rocker arm bolts, balls, rocker arms and push rod guides. 1
DRC6896
2 2. Valve push rods. Note: The exhaust valve push rods are longer
than the intake valve push rods.
3 3. Splash shield.
4 4. Valve lifter guide retainer bolts and retainer.
5 5. Lifter guides.
6. Valve lifters
a. Use a magnet in order to remove the valve lifters one at a
time. 2
DRC6897
b. Tag the valve lifters in a way to ensure they can be returned
to the valve lifter bore from which they were removed.
c. Some valve lifters may be stuck in their bore due to gum or
varnish deposits. These valve lifters can be removed by us-
ing either J 3049-A Valve Lifter Removal (Plier Type), or J
9290-01 Valve Lifter Removal (Slide Hammer Type).
3
DRC6914
4
DRC6915
5
DRC6916
6-8 Engine/eng
6 1. Cylinder head bolts.
2. Cylinder Head. Note: Handle the cylinder heads carefully to prevent
damage to the gasket sealing surfaces.
3. Cylinder head gasket. Discard the gasket.
Oil Pan Removal 6

DRC6907
7 1. Oil pan bolts.
2. Oil pan.
3. Oil pan gasket. Discard the gasket.
Oil Pump Removal

8 1. Bolts that attach the oil pump to the rear crankshaft bearing cap. 7
DRC6909
2. Oil pump, the retainer, and the driveshaft from the rear crankshaft
bearing cap.
Engine Front Cover Removal

9 1. Engine front cover bolts.
2. Engine front cover and gasket. Note: The engine front cover gasket is
reusable.
8
DRC6910
9
DRC6901
Engine/eng 6-9
Timing Chain and Sprockets Removal
Tools Required: J 28509-A Crankshaft Sprocket Remover
Measure:The camshaft timing chain free play. If the chain can be
moved back and forth in excess of 0.625 in. (16 mm), make a note
that the camshaft timing chain and sprockets must be replaced
during assembly.
1 1. Camshaft sprocket bolts. 1
DRC6903
2. Camshaft sprocket and camshaft timing chain.

2 3. Crankshaft sprocket using J 28509-A Crankshaft Sprocket Re-
mover.
4. Crankshaft key, if necessary.
Camshaft Removal
2
2. Install three 5/16 - 18 x 4 in. bolts in the camshaft front bolt holes. DRC6904
3. Carefully rotate and pull the camshaft out of the engine block.
3
DRC6906
6-10 Engine/eng
Piston, Connecting Rod, and Bearing Removal
Tools Required: J 24270 Ridge Reamer
J 5239 Connecting Rod Guide Tool
Important Do not remove excessive material from the cylinder

bore. Excessive removal of material may require cylinder boring to the
next oversize.
4 1. Cylinder bore ridge as necessary.
a. Rotate the crankshaft until the piston is at BDC. J 24270
b. Place a cloth on top of the piston.

c. Perform the cutting operation using J 24270 Ridge Reamer.
Refer to the manufacturer’s instructions before using the tool.
d. Remove the special tool.
e. Rotate the piston to TDC and remove the cloth and cuttings
f. Repeat the procedure for the remaining pistons. 4
DRC6510
Important Place the match marks or numbers on the connecting
rods and the connecting rod caps. The rod caps must be assembled to
their original connecting rods.
2. Connecting rod nuts.
Important If reusing keep the bearings with their original

connecting rods and rod caps. Wipe the oil from the bearings and crank
pins.
3. Connecting rod caps and bearings.
5 4. Connecting rod and piston out of the top of the engine block
5
DRC6619
using J 5239 Connecting Rod Guide Tool.
5. Remaining piston and connecting rod assemblies from the engine
block.
Engine/eng 6-11
Crankshaft Bearing Cap and Bearing Removal
Important Check the crankshaft bearing caps for location
markings. Mark the caps if necessary. The caps must be returned to
the original locations with the arrow pointing forward during assembly.
1 1. Crankshaft bearing cap bolts.
2. Crankshaft bearing caps. 1
DRC6917
3. Crankshaft.
4. Crankshaft upper bearings from the engine block.
5. Crankshaft lower bearings from the crankshaft bearing caps.
6. Rear crankshaft oil seal from the crankshaft. Discard the seal.
Cylinder Block Disassembly

2 1. Cooling jacket plugs by using the following procedure:
a. Obtain a suitable self-threading screw.
b. Drill a hole into the plug.
c. Install the self-threading screw.
d. Remove the jacket plug
2. Oil gallery plugs.
3. Oil pump switch.
4. Knock Sensors.
5. Oil bypass valves. Discard the valves. 2
DRC6918
6-12 Engine/eng
Cylinder Block Clean and Inspect
Clean:
1. Sealing material from the mating surfaces.
2. Boil the cylinder block in a caustic solution.
3. Flush the cylinder block with clean water or steam.
4. Cylinder bores.
5. Oil galleries and the passages.
6. Scale deposits from the cooling system passages.
7. After cleaning the engine block, spray or wipe the cylinder bores and
machined surfaces with clean engine oil.
Inspect:
1. Valve lifter bores for deep scratches and varnish deposits.
2. Check the bores for cracks.
3. Cylinder walls for scoring.
4. Cooling jackets.
5. Crankshaft bearing webs.
6. Engine mounting bosses.
7. Crankshaft bearing bores and the crankshaft bearing caps for the
following:
8. All crankshaft bearing bores must be round and uniform in inside di-
ameter (ID) at all the bearing supports.
a. The area where the crankshaft bearings contact the crankshaft
bearing bore must be smooth.
b. Note if a crankshaft bearing cap is damaged and requires re-
placement. Refer to Crankshaft and Bearings Clean and In-
spect.
3 9. Check cylinder head gasket surfaces for flatness using a straight
edge and a feeler gauge. The surface must be flat within 0.004 in. (0,10
mm).
3
DRC6620
Engine/eng 6-13
Tools Required: J 35748 Fuel Pump/Oil Pressure Switch Installation
Socket
Install or Connect:
1. New oil bypass valves.
2. Knock Sensors into cylinder block after applying GM Sealant, P/N
12346004 to the sensor threads.
Tighten:
Knock Sensors to 14 ft. lb. (19 N m).•
3. Apply GM Sealant, P/N 12346004to oil pressure switch threads. Oil

pressure switch using J 35748 Fuel Pump/Oil Pressure Switch Instal-
lation Socket.
1 4. Oil gallery plugs after applying GM Sealant, P/N 12346004.
Tighten:
Oil gallery plugs to 15 ft. lb. (20 N m).•
5. Cooling jacket plugs.

6. Cylinder block cooling drain plugs after applying GM Sealant, P/N
12346004.
Tighten:
Cylinder block drain plugs to 15 ft. lb. (20 N m).
•
Piston Selection
Measure:
Check the used piston-to cylinder bore clearance in the following man-
ner: 1
DRC6918
2 1. Using a telescoping bore gauge located 2.5 in. (65 mm) below
the top of the cylinder bore, measure the cylinder bore diameter.
3 2. Piston diameter at 70° F (20° C).
J 8087
3. Skirt at a right angle to the piston pin hole, 1 in. (25 mm) below the oil
ring groove.
2
DRC6507
3
DRC6514
6-14 Engine/eng
4. Subtract the pistondiameter from thecylinder borediameter in order to
determine the piston-to-bore clearance.
5. Determine if the piston-to-bore clearance is within the acceptable
range. Refer to Specifications found elsewhere in this section.
6. If the used piston is not acceptable, determine if a new piston will fit
the cylinder bore.
7. If the new piston will not bring the clearance within tolerances, the
cylinder must be reconditioned. Refer to Cylinder Boring and Honing
found in the General Engine Mechanical section in this manual.
8. Mark the piston to identify the cylinder for which it was fitted.
Engine Front Cover - Clean and Inspect

Disassemble:
4 Remove the crankshaft front oil seal. Drive the seal out with mul-
tiple hits on the inside of the seal from the inside of the cover.
Clean:
Sealer from the front cover and engine case.
Inspect:
1. Timing tab marker.
2. Front cover.
Assembly:
Tools Required: J 22102 Crankshaft Seal Installer
5 1. Coat the seal lips with grease.
2. Place the open end of the seal toward the inside of the front cover.
Use J 22102 Crankshaft Seal Installer to install the seal.
4
DRC6921
5
DRC6900
Engine/eng 6-15
Intake Manifold Service
Upper Intake Manifold Disassembly
1 1. Throttle body nuts.
2 2. Throttle body.
3 3. Throttle body gasket and studs.
Lower Intake Manifold Disassembly
1
DRC6922
4 1. MAP Sensor nut, retainer and the MAP Sensor.
2. Fuel rail bolts and stud.
5 3. Fuel rail.
4. Coolant housing bolts, coolant housing, and thermostat from lower
intake manifold.
5. Coolant Temperature Sensor from the lower intake manifold.
2
Clean and Inspect: DRC6923
1. Gasket surfaces.
2. Intake passages of the intake manifold.
3. Coolant passages of the intake manifold.
Lower Intake Manifold Assembly
Important Do not install the thermostat without the rubber O-

ring seal. Omitting the rubber O-ring seal may result in poor engine
warm-up.
3
Install or Connect: DRC6924
1. Thermostat, coolant housing and bolts to lower intake manifold.

Tighten:
•
4
DRC6925
5
DRC6926
6-16 Engine/eng
2. Coolant Temperature sensor to lower intake manifold after applying
GM Sealant, P/N 12346004.
Tighten:
Sensor to 15 ft. lb. (20 N m). •
Important Lubricate the injector O-ring seals with clean engine

oil and install on the spray tip end of each injector.
5 3. Fuel rail assembly in the intake manifold. Tilt the rail assembly to
install the injectors.
4 4. Fuel rail attaching bolts and stud.
Tighten:
Bolts to 89 in. lb. (10 N m) •
Stud to 18 ft. lb. (25 N m).

•
5. MAP Sensor, retainer, and nut to the lower intake manifold.

Tighten:
Nut to 18 ft. lb. (25 N m).
•
Upper Intake Manifold Assembly
Install or Connect:
3 1. Throttle body studs.
Tighten:
Studs to 106 in. lb. (12 N m). •
2. Throttle body gasket.

2 3. Throttle body.
1 4. Throttle body nuts.
Tighten:
Nuts to 89 in. lb. (10 N m). •
Engine/eng 6-17
Oil Pump Service
Disassembly
Important Do not remove the pick up screen and pipe. They

are only serviced as part of the oil pump.
1 1. Oil pump shaft and retainer.
2. Oil pump body screws.
1
DRC6927
3. Oil pump body cover.
Important Mark the gear teeth so the pump can be installed

with the same gear teeth indexed.
4. Drive gear and shaft.
5. Idler gear.
6. Pressure relief valve spring retaining pin.
7. Pressure relief valve spring.
8. Pressure relief valve.
Clean and Inspect:
Important The oil pump is serviced as an assembly. Do not

attempt to service the individual components. The pressure relief valve
spring is the only serviceable component. Replace the pump if any wear
to the pump gears or housing exists.
1. Oil pump housing and cover for cracks, scoring, casting imperfec-
tions and damaged threads.
2. Drive gear shaft. If the shaft is loose in the pump housing, replace
the oil pump.
3. Pressure relief valve for scoring and sticking Burrs may be removed
with a fine stone.
4. Oil pump screen for broken wire mesh or looseness.
5. Gears for chipping, galling and wear.
6-18 Engine/eng
Assembly
Install or Connect:
1. Pressure relief valve.
2. Pressure relief valve spring.
3. Pressure relief valve spring retaining pin.
4. Drive gear and shaft.
5. Idler gear.
6. Oil pump body cover.
7. Oil pump body screws.
Tighten:
Oil pump body screws to 106 in. lb. (12 N m).
•
8. Oil pump driveshaft and retainer. Turn the driveshaft by hand to check
for smooth operation.
Valve Train Components

Clean:
1. All parts in solvent.
2. Blow dry the parts with compressed air.
Inspect:
1. Valve rocker arms and balls atthe mating surfaces. These parts should
be smooth and free from scoring or other damage.
2. Valve rocker arm areas that Contact the valve stems and the sockets
that contact the push rods. These areas should be smooth and free of
damage and wear.
3. Valve rocker are bolts for signs of cracking at the bolt shoulder. Re-
place as necessary.
4. Valve push rods for bending. Roll the push rod on a flat surface in
order to determine if it is bent. Replace as necessary.
5. Ends of the valve push rods for scoring or roughness.
6. Valve push rod oil passage for restrictions.
Engine/eng 6-19
Cylinder Head Service
Disassembly
1. Spark plugs.
2. Valve keys 1 as follows:
a. Compress the valve springs using J 8062 Valve Spring Com-
1
DRC6663
pressor
b. Remove the valve keys,
c. Remove the valve spring compressor.
2 3. Caps 2 , springs 4 and rotators.
4. Valve stem oil seals 3 .
5. Valves 5 6 . Place valves in a rack to ensure that they will be re-
turned to their original locations at assembly.
6. Remaining valves and components. 2
DRC6595
Assembly

1 2 Install or Connect:
1. Lubricate the valve stem with clean engine oil.
2. Valves 5 6 into their proper location.
3. Oil seals 3 over the valve stems.
4. Rotators.
5. Valve springs 4 .
6-20 Engine/eng
6. Valve keys as follows:
a. Compress the valve spring using J 8062 Valve Spring Com-
pressor. Compress the spring enough to clearly see the valve
stem groove.
b. Apply a small amount of grease to the valve keys to hold them
in place. Make sure the keys are properly seated in the valve
stem grooves.
c. Remove the compressor tool. Make sure the valve keys stay in
place.
d. Repeat the procedure on the remaining valves.
3 7. Measure the installed height of each valve spring using the fol-
5
lowing procedure:
4
4 a. Use a narrow, thin scale. A cut away scale may be helpful.
b. Measure from the cylinder head spring seat to the top of the
2
cap. If this measurement exceeds the amount given under
1
Specifications found in this manual, install the valve spring
shims of sufficient thickness between the rotator and the cylin-
der head in order to give the desired measurement. 3
DRC6668
Important Never shim the spring so as to give an installed

height under the specified amount.
Crankshaft Bearing Installation

Important If undersized bearings are used, ensurethatthe
bearings are fitted to the proper journals.
Install or Connect:
5 1. Upper crankshaft bearings to the block. 4
DRC6667
3. Lubricate the crankshaft bearings with clean engine oil.
4. Crankshaft.
In order to prevent the possibility of cylinder block or crankshaft
bearing cap damage, the crankshaft bearing caps are tapped into the
cylinder block cavity using a brass, lead, or a leather mallet before the
attaching bolts are installed. Do not use the attaching bolts to pull the
crankshaft bearing caps into the seats. Failure to observe this informa-
tion may damage a cylinder block or a bearing cap.
5
DRC6917
Engine/eng 6-21
1 5. Crankshaft bearing caps and the bolts. Ensure that the arrows
on the crankshaft bearing caps are facing the front of the engine. Do
not install the rear crankshaft bearing cap at this time.
Important Tighten the inside bearing cap bolts first and the
outside bearing cap bolts last.
Tighten:
Crankshaft bearing cap bolts to 100 ft. lb. (135 N m).
•
2 6. Apply GM Adhesive, P/N 12346141 to the rear bearing cap 1

DRC6917
sealing face or to the rear bearing cap channel of the engine block,
from the corner of the rear thrust bearing pocket to the edge of the
channel.
7. Rear crankshaft bearing cap and bolts to the rear of the engine block.
Temporarily tighten the bolts to 35 in. lb. 94 N m).
•
3 8. Measure the crankshaft end play as follows:

a. Firmly thrust the crankshaft first rearward then forward. This
will line up the rear crankshaft thrust surfaces.
Important
2
Tighten the inside bearing cap bolts first and the DRC6929
outside bearing cap bolts last.

Tighten:
Rear crankshaft bearing cap bolts to 100 ft. lb. (135 N m).•
b. With the crankshaft wedged forward, measure at the front

end to the rear crankshaft bearing with a feeler gauge. the
proper clearance is 0.002-0.010 in. (0,0508-0,2540 mm).
9. Inspect the crankshaft for binding as follows:
a. Try turning the crankshaft to check for binding. 3
DRC6530
b. If the crankshaft does not turn freely, loosen the crankshaft
bearing cap bolts on one cap at a time until the tight bearing is
located.
c. A bent crankshaft or a lack of bearing clearance could cause
binding.
10. A lack of bearing clearance may be caused by the following condi-
tions:
• Burrs on the bearing cap.

• Foreign matter between the bearing and the block.
• Foreign matter between the bearing and the bearing cap.
6-22 Engine/eng
Crankshaft Rear Oil Seal Installation
1. Make sure the crankshaft rear chamfer is free of grit, loose rust, and
burrs. Correct as needed.
2. Lubricate the inner and outer diameter of the seal with engine oil.
4 3. Install the seal on J 38841 Crankshaft Rear Oil Seal Installer.
4. Position J 38841 Crankshaft Rear Oil Seal Installer against the crank-
shaft. Thread the attaching screws into the tapped holes in the crank-
shaft.
5. Tighten the screws securely with a screwdriver in order to ensure that
the seal is installed squarely over the crankshaft.
6. Turn the handle until it bottoms. J 35621
7. Remove J 38841 Crankshaft Rear Oil Seal Installer.
Piston, Connecting Rod, and Bearing

Installation
4
Tools Required:J 5239 Connecting Rod Guide Tool DRC6939
J 8037 Piston Ring Compressor

In order to determine the correct replacement bearing size, the bearing
clearance must be measured accurately. Either the micrometer or plas-
tic gauge method may be used, however the micrometer method gives
more reliable results and is preferred. Refer to Crankshaft and Con-
necting Rod Bearings, Cleaning and Inspection found in this manual
for either procedure.
Do not shim, scrape, or file bearing inserts. Do not touch the
bearing surface of the insert with bare fingers. Skin oil and acids will 5
etch the bearing surface. DRC6619
Install or Connect: FORWARD
1. Connecting rod bearings to the connecting rods and connecting rod B
caps.
C A D
5 3. J 5239 Connecting Rod Guide Tool onto the connecting rod bolts. B
A - POSITION OF THE GAP FOR THE

6 4. Align the piston ring end gaps. B - POSITION OF THE GAP FOR THE
OIL RING
6 D - POSITION OF THE GAP FOR THE

DRC6627
Engine/eng 6-23
5. Lubricate the piston and the rings with engine oil.
1 6. J 8037 Piston Ring Compressor over the piston and rings as- J 8037
sembly without disturbing the eng gap locations.

7. Compress the piston rings.
2 8. Ensure that the dimple faces the front of the block.

marked for proper location and orientation. Cylinder 1, 3, 5, and 7 are
the right bank and 2, 4, 6, and 8 are the left bank (when viewed from 1
DRC6628
the front of the engine). The numbers on the connecting rod and bearing
cap must be on the same side when installed in the cylinder bore. If a
connecting rod is ever transposed from one block or cylinder to another,
should be numbered to correspond with the new cylinder number.
1 9. Piston and connecting rod into proper cylinder bore.
10. Use a hammer to lightly tap the piston down into the cylinder bore.
11. Guide the connecting rod into position on the crankpin, while tap-
ping the piston into the bore.
2
12. Coat the connecting rod bearings with clean engine oil. DRC6919
13. Coat the crankpin with clean engine oil.

14. Connecting rod cap with the bearing and connecting rod nuts.
Tighten:
Connecting rod nuts to 45 ft. lb. (61 N m).
•
Camshaft Installation
Install or Connect
3
1. Camshaft as follows: DRC6906
3 a. Install three 5/16 - 19 X 4 in. bolts into the camshaft front bolt
holes in order to handle the camshaft.
b. Use care to avoid damaging the camshaft bearings.
c. Remove the three bolts after the camshaft is installed.
6-24 Engine/eng
2. Camshaft retainer and bolts.
Tighten:
Camshaft retainer bolts to 10 ft. lb. (14 N m).
•
Timing Chain and Sprockets Installation

Tools Required: J 22102 Crankshaft Sprocket Installer
Install or Connect
1. Crankshaft key, as necessary.
Important Ensure that the sprocket alignment mark faces away

from the engine block. Ensure that the sprocket is fully seated against
the crank shoulder.
4 2. Crankshaft sprocket using J 22102 Crankshaft Sprocket Installer.
Important Ensure the following conditions exist:

a. The camshaft and crankshaft timing marks are aligned.
b. The camshaft dowel pin and camshaft sprocket hole are prop-
erly aligned.
c. The gears and timing chain mesh.
3. Camshaft timing chain to the camshaft sprocket.
5 4. Camshaft sprocket and the camshaft timing chain to the front of
the camshaft.
Do not hammer the camshaft sprocket onto the camshaft. To do
so may dislodge the rear camshaft plug and damage the camshaft.
5. Camshaft sprocket bolts. Use the bolts to draw the camshaft sprocket
onto the camshaft. 4
DRC6905
Tighten:
Camshaft sprocket bolts to 25 ft. lb. (34 N m).•
5
DRC6902
Engine/eng 6-25
Engine Front Cover Installation
Install or Connect:
1 1. Lubricate the sealing surface of the crankcase front oil seal
with clean engine oil.
2. Apply GM Adhesive, P/N 12345739, or the equivalent in two places
where the front cover meets the oil pan rail.
2 3. Engine front cover.
1
4. Engine front cover screws. DRC6921
Tighten:
Engine front cover screws to 106 in. lb. (12 N m).
•

Install or Connect:
3 1. Oil pump driveshaft and retainer.
2. Oil pump.
3. Oil pump bolt.
2
DRC6901
Tighten:
Oil pump bolt to 65 ft. lb. (90 N m).
•
Oil Pan Installation

Important Install the oil pan within 10 minutes of the adhesive
application.
Install or Connect:
4 1. Apply GM Adhesive , P/N 12345739, or the equivalent in four 3
DRC6910
places where the front and rear crankshaft bearing caps meet the en-
gine block.
2. Oil pan gasket to the engine block.
4
DRC6909
6-26 Engine/eng
3. Oil pan. Ensure that the oil pan gasket stays in place.
4. Oil pan bolts.
Tighten:
Oil pan bolts to 18 ft. lb. (25 N m).
•
5. Oil pan drain plug.

Tighten:
Oil pan drain plug to 20 ft. lb. (28 N m).
•
Cylinder Head Installation

Install or Connect
5 1. Cylinder head gasket onto the engine block.
Important Do not use sealer on any engines that use a

composition gasket.
2. Align the gasket locating mark to face up.
3. Cylinder head onto the block. Guide the cylinder head carefully into 5
place over the dowel pins and head gasket. DRC6907
4. Coat the threads of the cylinder head bolts with GM Sealant , P/N
6 5. Cylinder head bolts and tighten in the following three F6 sequen-
tial steps:
Tighten:
a. First pass to 30 ft. lb. (40 N m).
•
b. Second pass to 60 ft.lb.(80 N m). •
c. Third pass to 85 ft. lb. (115 N m).

• 6
DRC6908
6. Spark plugs.
Tighten:
• New cylinder heads to 22 ft. lb. (30 N m).

•
• Subsequent installations to 15 ft. lb. (20 N m).

•
Engine/eng 6-27
Valve Rocker Arm and Push Rod Installation
Important If a new camshaft is installed, replace all the valve
lifters.
Install or Connect:
1. Coat the valve lifter rollers and inside of the valve lifter guides with
GM Engine Oil Supplement, P/N 1052367, or equivalent.
1 2. Valve lifters in the same location from which they were removed. 1
DRC6916
3. Valve lifter guides.
Important The valve lifter guide retainer must contact all of

the valve lifter guides. If the valve lifter guide retainer is bent, the valve
lifter guide must be replaced.
2 4. Valve lifter guide retainer.
5. Valve lifter guide retainer bolts.
Tighten:
•
2
DRC6915
The 7.4 L engine uses different length intake and exhaust valve push
rods. The exhaust valve push rods are longer than the intake valve
push rods.
3 6. Valve push rods. Bring the #1 piston to TDC compression stroke
and the timing indicator on 0°. Torque the intake rocker arm bolts 1, 2,
5, and 7; and exhaust rocker arm bolts 1, 3, 4, and 8 to 40 ft. lb. (54
N•m) while holding the rocker arm centered over the valve stem. Ro-
tate the crankshaft 360°, then torque intake rocker arm bolts 3, 4, 6,
and 8; and exhaust rocker arm bolts 2, 5, 6, and 7 to 40 ft. lb. (54 N•m)
while holding the rocker arm centered over the valve stem.
3
Be sure that the valve push rods seat in the valve lifter sockets. DRC6897
7. Valve rocker arms, balls and the bolts.

Tighten:
Bolts to 40 ft. lb.. (54 N m).
•
4 8. Splash shield.
4
DRC6914
6-28 Engine/eng
Valve Rocker Arm Cover Installation
Install or Connect:
5 5. Valve rocker arm cover and gasket.
Tighten:
Valve rocker arm cover bolts to 72 in. lb. (8 N m).
•
Intake Manifold Installation 5

DRC6895
Install or Connect
6 1. Seals on the cylinder block.

2. Gasket onto the cylinder head.
3. Lower intake manifold onto the engine block.
4. Coat the lower intake manifold bolts with GM Threadlock , P/N
7 5. Lower intake manifold bolts. 6
DRC6893
Tighten:
Bolts in sequence to 30 ft. lb. (40 N m).
•
8 6. Upper inake manifold gaskets.

7. Upper intake manifold.
8. Cover a minimum of eight threads of the upper intake manifold bolts
with GM Threadlock, P/N 12345493, or equivalent.
7
DRC6894
8
DRC6891
Engine/eng 6-29
1 9. Upper intake manifold bolts and tighten in the following two
sequential steps:
Tighten:
a. First pass to 72 in. lb. (8 N m).
•
b. Second pass to 10 ft. lb. (14 N m). •
Crankshaft Balancer Installation

Tools Required: J 23523-F Crankshaft Balancer Installer 1
DRC6892
Inspect:
1. Crankshaft balancer weight for signs of shifting on the hub. Replace
the crankshaft balancer if the weight has shifted.
2. Crankshaft balancer hub sealing surfaces for grooves, nicks, or dam-
age. Replace the crankshaft balancer if any of the above conditions
exist.
Important The inertial weight section of the crankshaft

balancer is assembled to the hub with a rubber material. You must follow
the installation procedures carefully, using the proper tool, or movement
2
DRC6982
of the inertial weight section of the hub will destroy the tuning of the
crankshaft balancer.
Install or Connect:
3. Use a small amount of GM Adhesive, P/N 12345739, to seal the
balancer key to the crankshaft keyway groove.
4. Key into the crankshaft keyway, if the key has been removed.
2 5. Crankshaft balancer hub, until the hub is completely seated
against the crankshaft ridge using J 23523-F Crankshaft Balancer In-
staller.
6. Remove the J 23523-F Crankshaft Balancer Installer.
7. Bolt and washer into the front of the crankshaft.
Tighten:
•
6-30 Engine/eng
Circulating Pump
The circulating pump is manufactured specially for marine use.
It is serviced only as an assembly. Do not replace with an automotive
circulating pump.
Inspection
Remove alternator and power steering belts. Grasp circulating pump

pulley and checkend and side play. Turn pulleyto checkfor drag. Look
for water leaking from indicator hole beneath pump shaft behind pulley. 3
11982
Replace pump if play, drag, or leakage are evident.
pump. Remove pulley. Remove circulating pump bolts, pump and gas-
kets.
2. Use new pump to block gaskets and sealer. Install new pump assem-
bly on cylinder block and tighten bolts as specified. Install pulley. Install
alternator and power steering belts, then adjust tension. Connect hose
to circulating pump. Lake or tank test unit and check for leaks. 4
11981
Front Engine Mount Replacement
Removal
4 2. Lift engine with 1500 lb. (680 kg) minimum capacity
hoist to allow removal of front mount and bracket. Remove three
mount screws and lock washers B .
distance between large washer and flat on upper mount bracket. 5
11980
Disassembly
6 1. Remove three nuts C , one lock washer, and engine mount
bracket D from mount bolt E while holding bolt secure with socket.
6
11979

1 2. Remove one large washer A , one small washer B and engine
mount bolt C from mount.
Reassembly
2 1. Place small washer B on mount bolt and insert bolt up through

mount. Install large washer A and secure with nut D . Tighten to 60-75
ft. lb. (81-102 N m).
•
1 2. Install upper inner nut and place engine mount bracket G on

engine mount bolt. NOTE: Measure distance between large washer 1
11978
and flat on upper mount bracket. Distance must be the same as that
prior to disassembly.
3. Install lock washer and lower nut. Tighten nut to 50-70 ft. lb. (68-95
N m).
•
Installation
1. Spray the engine mount screws threads with Loctite Primer and al-
low to air dry. Apply Volvo Penta Thread Sealing Agent to the screws.
ers. Tighten to 32-40 ft. lb. (43-54 N m). •
2
11983
2. Install lag screws and tighten securely.
Height Adjustment
3 1. To change engine height, tighten or loosen nuts F and G as

required.
2. Lift engine with 1500 lb. (680 kg) minimum capacity hoist.
Position engine at desired height.
3 3. After setting mount position, turn nut G
up against underside of
engine bracket and hold nut with a wrench. Tighten upper nut F to
100-120 ft. lb. (136-163 N m).
•
3
2953

Removal
Drain water from respective exhaust manifold.

1. Loosen two clamps securing upper hose to elbow.

2. Port Elbow - Remove four thru-bolts, lock washers, and washers.
Move remote oil filter aside.
• Move crankcase oil filler bracket aside.

4 3. Starboard Elbow - Remove two thru-bolts H,
lock washers, and
washers attaching circuit breaker bracket. Set bracket assembly aside.
5 4. Lubricate inside of exhaust hose with a soapy water solution,
then remove remaining elbow bolt. Tap elbow with a soft hammer to free
it, then twist it out of the hose. Remove and discard the manifold gasket.
4
Installation DR6451
6 2. Apply Volvo Penta Gasket Sealing Compound to both sides of a

new gasket I , and place it on the manifold. Lubricate inside of exhaust
hose with a soapy water solution to ease elbow installation.
3. Twist elbow into hose and position it on the gasket. Install the outer
rearthru-bolt, washer, and lock washer, and turn it in finger tight.
4. Port Elbow - Position remote oil filter at front of elbow.
• Mount oil filter bracket on elbow.

Install four thru-bolts, washers, and lock washers finger tight. Tighten 5
28265
small screw securely.
4 5. Starboard Elbow - Position circuit breaker assembly at front of
elbow. Install two thru-bolts H, washers, and lock washers finger tight.
6. Tighten all elbow thru-bolts to 12-18 ft. lb. (16-24 N m).•
7. Properly position the two exhaust hose clamps and tighten them
securely.
6
28266

Exhaust Hose and Intermediate Pipe
Replacement
Removal
1. Loosen eight clamps that attach the upper and lower exhaust hoses,
and slide clamps down onto exhaust Y-pipe.
push lower hose down onto exhaust Y-pipe.
1
2 3. Twist intermediate pipe out of upper hose. Lubricate inside of 19377A
upper hose with a soapy water solution for ease of removal.

pipe.
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.
3 2. On the 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. The ribbed end of the hose 2
must face the intermediate pipe (rearward) when it’s installed. Slide 28264
hose onto high-rise elbow until it seats. NOTE: If hose is not properly
positioned, it will not completely engage the high-rise elbow or allow
secure attachment.
2 3. With a twisting motion, insert intermediate pipe all the way into
the upper hose. Slide the lower hose up until it’s halfway onto the inter-
mediate pipe.
4. Slide four No. 68 clamps up onto the upper hose. Slide four No.
64 clamps up onto lower hose. Position clamps in their proper chan-
nels and tighten them securely.
3
16041
Removal

4 5 3. Remove seven screws securing bellhousing cover and
slide cover off.
4
20034
5
19996

6 4. Pull drain hose out of bellhousing if equipped.
5. Remove bolts and nuts retaining bellhousing. Disconnect ground
wires and oil cooler bracket. Note oil cooler orientation.
6. Remove bell housing.
7 7. Use an offset box end wrench to remove the six nuts securing
the coupler, and slide coupler off studs.
thoroughly. 6
19842
Installation
8 1. Install coupler and attach six locknuts. Use a suitable adaptor
and tighten nuts to 40-45 ft. lb. (54-61 N m).
•
2. Install bell housing. Attach oil cooler with same orientation as noted
in a previous step. Tighten nuts and bolts to 32-40 ft. lb. (43-54 N m). •
Attach ground wires and tighten nuts to 15-20 ft. lb. (20-27 N m).
•
3. Push drain hose into bellhousing, if equipped.

new bellhousing gasket and position it on cover.
7
6712

bellhousing cover and screws and tighten to 60-84 in. lb. (7-9 N m). •
6. Connect all wires, lines and connectors to bellhousing. Install en-

gine in boat.
8
6714
9
19083
Engine/eng 6-35
General Information:
Type - No. of Cylinder ................................................................................................................................... 90° - V-8
Valve Arrangement ......................................................................................................................................... In head
Bore and Stroke ........................................................................................... 4.250 x 4.000 in. (107,95 x 101,6 mm)
Piston Displacement ........................................................................................................ 7.4 Litre/454 Cubic Inches
Cylinder Numbers - Front to Rear
Starboard Bank ......................................................................................................................................... 2-4-6-8
Port Bank .................................................................................................................................................. 1-3-5-7
Firing Order ........................................................................................................................................ 1-8-4-3-6-5-7-2
Compression Ratio ................................................................................................................................................ 8:1
Water Temperature Control ..................................................................................................................... Thermostat
Thermostat Opens at .......................................................................................................................... 140° F. (60° C)
Alternator Belt Adjustment .................................................................................... 1/4-1/2 in. give w/finger pressure
Full Throttle Operation Range ....................................................................................................... 4200 - 4600 RPM
Pistons:
Production Clearance ............................................................................. 0.0018 - 0.0030 in. (0,0457 - 0,0762 mm)
Service Limit .................................................................................... 0.0018 - 0.0048 in. (0,0457 - 0,219 mm) Max.
Piston Rings, Compression:
Production Groove Clearance
Top ......................................................................................................... 0.0012 - 0.0029 in. (0,031 - 0,074 mm)
2nd ......................................................................................................... 0.0012 - 0.0029 in. (0,031 - 0,074 mm)
Service Groove Clearance (both) ............................................................ 0.0012 - 0.0039 in. (0,031 - 0,0991 mm)
Gap
Top ............................................................................................................. 0.010 - 0.018 in. (0,254 - 0,475 mm)
2nd ............................................................................................................. 0.016 - 0.024 in. (0,406 - 0,609 mm)
Service (both) .................................................................................................. 0.016 - 0.034 in. (0,406 - 0,863 mm)
Piston Rings, Oil:
Groove Clearance
Production ................................................................................................ 0.005 - 0.0065 in. (0,127 - 0,165 mm)
Service ................................................................................................... 0.0050 - 0.0075 in. (0,127 - 0,191 mm)
Gap
Production .................................................................................................. 0.010 - 0.030 in. (0,254 - 0,762 mm)
Service ...................................................................................................... 0.01 0 - 0.040 in. (0,254 - 1,016 mm)
6-36 Engine/eng
Piston Pins:
Diameter .................................................................................................. 0.9895 - 0.9897 in. (25,132 - 25,137 mm)
Clearance in Piston
Production .............................................................................................. 0.0002 - 0.0007 in. (0,005 - 0,017 mm)
Service Limit ..........................................................................................0.0002 - 0.0001 in. (0,005 - 0,025 mm)
Rod Fit ..................................................................................... 0.0031 - 0.0021 in. (0,078 - 0,053 mm) lnterference
Connecting Rods:
Bearing Clearance
Production ............................................................................................ 0.001 1 - 0.0029 in. (0,028 - 0,074 mm)
Service Limit ........................................................................................ 0.001 1 - 0.0039 in. (0,028 - 0,099 mm)
Side Clearance ............................................................................................ 0.0013 - 0.0230 in. (0,033 - 0,584 mm)
Crankshaft:
End Play ............................................................................................................ 0.005 - o.ol I in. (0,127 - 0,279 mm)
Main Journal Diameter
No. 1, 2, 3, 4, 5 ................................................................................. 2.7482 - 2.7489 in. (69,804 - 69,822 mm)
Taper
Production ................................................................................................................ 0.0004 in. (0,010 mm) Max.
Service Limit ............................................................................................................ 0.0010 in. (0,025 mm) Max.
Out -of-Round
Production ................................................................................................................ 0.0004 in. (0,010 mm) Max.
Service Limit ............................................................................................................ 0.0010 in. (0,025 mm) Max.
Mai n Bearing Clearance, Production
No. 1 ......................................................................................................0.0017 - 0.0030 in. (0,043 - 0,076 mm)
No. 2 ,3 , 4 ........................................................................................... 0.001 1 - 0.0024 in. (0,028 - 0,061 mm)
No. 5 ......................................................................................................0.0025 - 0.0038 in. (0,063 - 0,096 mm)
Main Bearing Clearance, Service
No. 1, 2, 3, 4 ..........................................................................................0.0010 - 0.0030 in. (0,025 - 0,076 mm)
No. 5 ......................................................................................................0.0025 - 0.0040 in. (0,063 - 0,101 mm)
Crankpin Diameter .................................................................................. 2.1990 - 2.1996 in. (55,854 - 55,869 mm)
Taper
Production ....................................................................................................... 0.0005 in. (0,0127 mm) Max.
Service Limit ...................................................................................................... 0.0010 in. (0,025 mm) Max.
Out-of-Round
Production ......................................................................................................... 0.0005 in. (0,013 mm) Max.
Service Limit ...................................................................................................... 0.0010 in. (0,025 mm) Max.
Camshaft:
Camshaft Bearing Journal Diameter ...................................................... 1.9477 - 1.9497 in. (49,471 - 49,522 mm)
Lobe Lift + 0.002 in. (0,05 mm)
Intake ................................................................................................................................ 0.2821 in. (7,165 mm)
Exhaust ............................................................................................................................. 0.2843 in. (7,221 mm)
Engine/eng 6-37
Valve Systems:
Lifter Type ....................................................................................................................... Hydraulic, Roller Followers
Rocker Arm Ratio .......................................................................................................................................... 1.70 to 1
Valve Lash - Intake and Exhaust .................................................................................................................. Net lash
Valve Face Angle (I & E) ....................................................................................................................................... 45°
Valve Seat Angle (I & E) ........................................................................................................................................ 46°
Valve Seat Runout (I & E) ............................................................................................... 0.002 in. (0,051 mm) Max.
Stem to Guide Clearance
Intake, Production .............................................................................. 0.0010 - 0.0029 in. (0,025 - 0,0737 mm)
Exhaust, Production .............................................................................. 0.0012 - 0.0031 in. (0,030 - 0,077 mm)
Intake, Service ....................................................................................... 0.0010 - 0.0037 in. (0,025 - 0,094 mm)
Exhaust, Service ................................................................................... 0.0012 - 0.0049 in. (0,030 - 0,124 mm)
Intake ........................................................................................................... 1/32 to 1/16 in. (0,794 - 1,587 mm)
Exhaust ........................................................................................................ 1/16 to 3/32 in. (1,587 - 2,381 mm)
Valve Spring Installed Height ± 0.0312 in. (± 0,794 mm) ..................................................... 1.838 in. (46,685 mm)
Valve Spring Pressure
Lb. @ In. (N @ mm) Closed ................................................................. 71 - 79 @ 1.838 (316 - 351 @ 46,685)
Lb. @ In. (N @ mm) Open ............................................................ 238 - 262 @ 1.347 (1059 - 1165 @ 34,213)
Installed Height ± 1/32 in. (0,794 mm)
Engine Lubrication:
Normal Pressure, Warm Engine ........................................................................... 10 PSI (86,65 kPa) @ 600 RPM
25 PSI (172,37 kPa) @ 2000 RPM
Crankcase Capacity ..................................................................... Approx. 8 qts. (7,57 1); 9 qts. (8,51 I) with Filter
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) .......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
We recommend DuraPlus TM Synthetic Motor Oil, which is specially for-
provides better antiwear qualities, especially during long high speed op-
eration. In addition, it neutralizes acids caused in all internal combus-
tion engines, offers superior corrosion protection, and is formulated to
offer better resistance to oxidation and high temperature sludge forma-
tion.
Fuel Recommendation ................... See General Information Section
6-38 Engine/eng
Use a reliable torque wrench to tighten theparts listed to prevent straining or distorting the parts or possibly damag-
Bolts
Camshaft Sprocket 25 - 34
Circulating Pump 30 - 40
Cylinder Head
Step 1 30 - 40
Step 2 60 - 80
Step 3 85 - 115
Dipstick Tube Fitting 15-18 - 20-24
Exhaust Manifold 24-28 - 33-38
Flywheel to Crankshaft 70 - 95
Front Mount 65-75 - 81-102
Front Mount Bracket to Block 32-40 - 43-54
Fuel Rail - 89 10
Harmonic Balancer 110 - 149
High-Rise Elbow 12-18 - 16-24
Intake Manifold
Lower 30 - 40
Upper 10 - 14
Main Bearing Cap (All) 100 - 135
Oil Pan to Block 18 - 25
Oil Pump 65 - 90
Remote Oil Filter Adaptor (to block) 20-25 - 27-34
Rocker Arm 40 - 54
Timing Chain Cover - 106 12
Thermostat Housing 30 - 40
Water Pump 30 - 40
Vibration Damper 110 -149
Engine/eng 6-39
Torque Specifications (cont.)
ITEM FT. LB. IN. LB. Nm

•
Nut
Connecting Rod Cap 45 - 61
Flame Arrestor - 22-35 2,8-4,0
Flare-Dipstick Tube 15-18 - 2,8-4,0
Front Mount (upper) 100-120 0 136-163
MAP Sensor 18 - 25
Throttle Body - 89 10
Stud
Fuel Rail 18 - 25
Power Steering Pump 13-15 - 18-20
Throttle Body - 106 12
Miscellaneous
Oil Filter one turn after contact
Spark Plugs 22 - 30
New Cylinder Head 22 - 30
Subsequent Installations 15 - 20
6-40 Engine/eng
GM Special Tools
1 2 3
DRC6596 DRC6597 DRC6601
4 5 6
DRC6602 DRC6680 DRC6604
7 8 9
DRC6936 DRC6582 DRC6938
1 Valve Lifter Remover (Plier Type)

2 Connecting Rod Guide Tool
3 Piston Ring Compressor J 35621
4 Valve Spring Compressors

5 Carbon Remover Brush
6 Valve Lifter Remover (Slide Hammer Type)
7 Crankshaft Oil Seal and Sprocket Installer 10
DRC6939
8 Cylinder Ridge Remover
10 Crankshaft Rear Main Seal Installer
Engine/eng 6-41
6-42 Engine/eng
Section 7
7.4 GSi and 8.2 GSi Engines
Table of Contents
Camshaft ........................................................................................... 7-15

Camshaft Lobe Lift, Measuring ....................................................... 7-19
Circulating Pump .............................................................................. 7-24
Connecting Rod Bearing Replacement .......................................... 7-21
Crankshaft ........................................................................................ 7-20
Cylinder Block .................................................................................. 7-23
Cylinder Head ..................................................................................... 7-9
Engine Coupler Replacement.......................................................... 7-27
Engine Specifications ...................................................................... 7-29
Exhaust Hose and Intermediate Pipe Replacement ...................... 7-27
Exhaust Manifold Replacement ........................................................ 7-5
Front Engine Mount Replacement .................................................. 7-24
GM Special Tools ................................................................................ 7-2
High-Rise Exhaust Elbow Replacement ......................................... 7-25
Intake Manifold ................................................................................... 7-3
Lubrication System .......................................................................... 7-16
Material Required ............................................................................... 7-2
Oil Pan ............................................................................................... 7-17
Oil Pump ........................................................................................... 7-17 7
Oil Seal Replacement, Rear Main Bearing ..................................... 7-19
Piston, Ring and Connecting Rod .................................................. 7-22
Remote Engine Oil Filter .................................................................. 7-16
Timing Chain, Cover and Seal ......................................................... 7-12
Torque Specifications ...................................................................... 7-32
Valve Lifter, Hydraulic ........................................................................ 7-6
Valve Spring and Seal Repair ............................................................ 7-8
Safety Warnings
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 maintenance procedures, al-
ways make sure engine compartment is free of fuel vapors to pre-
vent possible fire and explosion.
the alternator, power steering and circulating pump belts, pulleys
and other moving parts.
Engine/eng 7-1
GM Special Tools
Part
Item Number
Air Line Adaptor ....................................................................... J-23590

Camshaft Lobe Lift Indicator ..................................................... J-8520
Dial Indicator Set ........................................................................ J-5239
Crankshaft Seal/Sprocket Installer ......................................... J-22102
Crankshaft Sprocket Puller ........................................................ J-1619
Hydraulic Lifter Remover ..................................................... J-9290-01
Hydraulic Lifter Remover ....................................................... J-3049-A
Main Bearing Replacer .............................................................. J-8080
Ring Compressor ....................................................................... J-8037
Seal Installer ............................................................................ J-35468
Seal Installer ............................................................................ J-38841
Spring Compressor ................................................................ J-5892-C
Torsional Damper Puller ...................................................... J-23523-E
Valve Spring Compressor .......................................................... J-8062
Order Directly from:

Kent-Moore Tool Division
28635 Mound Road
Warren, MI 48092
(800) 345-2233
http://www.spxkentmoore.com
Price and ordering information is available from Kent-Moore Tool Divi-

sion.
Material Required
DuraPlus TM Synthetic Motor Oil
GM Sealer, P/N 1052289
GM Silicone Rubber Sealer, P/N 1052366
Loctite Primer
Molykote Lubricant
Plastigage (Green)
For additional service information not covered in this manual, obtain

the appropriate Chevrolet Engine Service Manual from:
Helm Inc.
P.O. Box 07130
Detroit, MI 48207
(800) 782-4356
http://www.helminc.com
7-2 Engine/eng
Intake Manifold
Removal
See On-Board Service section of GM EFI Diagnistics Manual for re-

moval of components from intake manifold.
1 2 1. Disconnect battery cables at battery, and drain
coolant from both sides of block and manifolds.
2. Remove alternator. If electrical leads are not disconnected, tie alter- 1
nator to oil hoses to prevent alternator weight damaging leads. 46200A
3. Remove thermostat housing.

4. Remove main electrical harness from clamps on port side of mani-
fold and at front of manifold. Disconnect other wire connections as nec-
essary.
3 5. Remove distributor cap Aand mark the position of the rotor on
the housing. Scribe a line on the distributor housing and intake mani-
fold for reassembly in the same position. Remove the distributor.
6. Unscrew attaching bolts, and remove intake manifold. NOTE: If nec-
essary to pry manifold away from cylinder heads, do not damage gas- 2
46199A
ket sealing surfaces.
7. Remove and discard intake manifold gaskets and seals.
Cleaning
Remove all gasket material and clean the sealing surfaces of the mani-
fold, block and thermostat housing. Remove excessive carbon depos-
its from exhaust passages, scale and deposits from cooling passages.
Clean the manifold in a suitable solvent and dry it with compressed air.
Inspection
3
Inspect the manifold for cracks, damaged gasket surfaces, or other de- 31841
fects that would make it unfit for further service. Replace all studs that
are stripped or otherwise damaged. Remove all filings and foreign
matter that may have entered the manifold as a result of repairs.

Installation
1. Install new manifold seals on block, and new gaskets on cylinder

heads. Use only side gaskets having metal inserts covering the
center exhaust passage. Use sealer at water passages and where
seals butt to gaskets.
1 2. Install intake manifold. Tighten bolts in the sequence shown,
7.4 GSi: 30 ft. lb. (40 N m), 8.2 GSi: 35 ft. lb. (47 N m).
• •
Check torque of the intake manifold screws annually. The cen-

ter screws can become loose under normal usage.
3. Install distributor with rotor and align exactly as marked during re-
moval. Install clamp and tighten screw to 25 ft. lb. (34 N m). NOTE: If
•
engine was cranked while distributor was out, complete ignition timing
procedure must be followed.
4. Install distributor cap and high tension leads.
5. Place main wire harness under clamps on port side of manifold and
at front of manifold. Make other wire connections as necessary.
6. Apply Volvo Penta Gasket Sealing Compound to both sides of
a new thermostat housing gasket and place it on manifold. Place lift- 1
DRC6869
ing eye on long bolt, then install and tighten both screws to 12-16
ft. lb. (16-22 N m).
•
7. Install alternator and properly tension belt. Tighten mounting screws

securely.
8. Attach battery cables at battery. Start engine and check for
fuel and water leaks.

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 spark plugs.
3. Loosen hose clamp at front of manifold, and pull off water hose.
4. Remove manifold attaching screws, nuts and washers. Discard nuts. C
Remove manifold and discard manifold gasket.
A
Cleaning
Clean mating surfaces on manifold and cylinder head. Clean the threads B
on the exhaust manifold bolts.
Inspection
2 Inspect for cracks. To pressure check manifold, use a plate A 2

such as shown and a new elbow gasket B to seal water passage in DR2875
manifold. Be sure to apply sealer to gasket. Install rubber drain cap to

manifold and secure with clamp. Attach a gearcase pressure tester C
(such as Stevens Company S-34) to the water inlet hose. A bushing can
be made to secure pressure tester to hose. With the pressure tester
attached to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks.
Installation
1. Install a new exhaust manifold gasket.

3 4 2. Install manifold and secure with bolts, washers and new 3
18946
locknuts. Tighten nuts to 20-26 ft. lb. (27-35 N m). Tighten bolts to 24-
•
28 ft. lb. (33-38 N m).

•
3. Attach water hose to nipple at front of manifold and tighten clamp.

4. Attach spark plug wires to plugs. Make sure firing order is correct.
5. Install high-rise exhaust elbow following procedure under High-Rise
6. Start engine and check for water and exhaust leaks.
4
18944

Hydraulic Valve Lifter
Checking Hydraulic Valve Lifter
When checking hydraulic valve lifters, rememberthat grit, sludge, var-

nish, or other foreign matter will seriously affect their operation. If any
foreign substance is found in the lifters or engine where it may be
circulated by the lubrication system, a thorough cleaning job must be
done to avoid a repetition of lifter trouble.
To help prevent lifter trouble, the engine oil and oil filter must be changed
as recommended in General Information Section. The engine oil must
be heavy-duty type (for Service SG) and must also conform to Gen-
eral Motors Standard 6094-M to avoid detrimental formation of sludge
and varnish. We recommend DuraPlusTM Synthetic Motor Oil. The boat
owner should be specifically advised of these requirements when the
unit is delivered. Faulty valve lifter operation usually appears under
one of the following conditions:
1. Rapping Noise Only When Engine is Started:
When the engine is stopped, any lifter on a camshaft lobe is under
pressure of the valve spring; therefore, leak down or escape of oil
from the lower chamber can occur. When the engine is started, a few
seconds may be required to fill the lifter, particularly in colder weather.
If noise occurs only occasionally, it may be considered normal, requir-
ing no correction. If noise occurs frequently, however, check for either
oil too heavy for prevailing temperatures, or excessive varnish in lifters.
2. Intermittent Rapping Noise:
An intermittent rapping noise that appears and disappears every few
seconds indicates leakage at check ball seat due to foreign particles,
varnish, or defective surface of check ball or seat.
3. Noise at Idle and Low Speed:
If one or more valve lifters are noisy at idle speed and up to approxi-
mately 1200 RPM, but quiet at higher speeds, it indicates excessive
leakdown rate orfaultycheckball seatorplunger.With engine idling, lifters
with excessive leak down rate may be spotted by pressing down on
each rocker arm above the push rod with equal pressure. Recondition
or replace noisy lifters.
7-6 Engine/eng
4. Generally Noisy at All Speeds:
Check for low or high oil level in crankcase. High oil levels will cause oil
foaming from the crankshaft and will force air bubbles into the lifters.
Low oil levels allow pump to pump air at high speed. With engine idling,
strike each rocker arm above the push rod several sharp blows with a
mallet; if noise disappears, it indicates that foreign material was keep-
ing check ball from seating. Stop engine and place lifters on camshaft
base circle. If there is lash clearance in any valve linkage, it indicates a
stuck lifter plunger, worn lifter roller, or worn camshaft lobe.
1
5. Loud Noise at Normal Operating Temperature Only: 11508
If a lifter develops a loud noise when the engine is at normal operating

temperature, but is quiet when engine is below normal temperature, it
indicates an excessively fast leak down rate of scored lifter plunger.
Recondition or 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
2. Remove intake manifold. Remove exhaust manifolds. 11509
3. Remove rocker arm covers. Do not pry. If covers stick use rubber
mallet and strike cover end to jar loose. Loosen rocker arm nuts and
pivot the rocker arm free of the push rods.
1 2 4. Remove push rods. Remove the hydraulic lifter guides and
lifters that require service one at a time and place them in an organizer
rack. The lifters must be installed in the same bore from which they
were removed.
3 4 A stuck hydraulic lifter can be removed using Tool J-3049-A
(plier type) or Tool J-9290-01 (slide hammer type). 3
31350
5. If less than a complete set of lifters is being removed, immediately is
assemble one or two for presence of dirt or varnish. If lifters contain dirt
or varnish, it is advisable to remove all lifters for replacement. Other-
wise, it will be satisfactory to service only those lifters that are not oper- J 9290-1
ating properly.
5 6. Examine the cam roller (4) of the lifter. If this surface is exces-
sively worn, galled or otherwise damaged, discard the lifter assembly.
In this case, also examine the mating camshaft lobe for excessive wear
or damage.
Installation
4
GR970297
Before installing any new lifters, coat the bottom of the lifter
with Molykote or its equivalent.
5
178485
Engine/eng 7-7
1. Install valve lifters in cylinder block. If any new lifters or a new cam-
shaft has been installed, an additive containing EP lubricant such as
GM Engine Oil Supplement must be added to the crankcase oil for
break-in.
2. Install push rods onto lifters. Install intake manifold.
3. Pivot rocker arms in place and install rocker arm bolts. Tighten bolts
to 40 ft. lb. (54 N m).
•
4. Install rocker arm covers, using GM Sealer No. 1052289, and tighten
nuts to 115 in. lb. (13 N m).
•
5. Install exhaust manifold. Start engine and check for oil leaks at rocker
arm covers.
Valve Spring and Seal Repair

Removal
1 1. Remove rocker arm cover.

2. Remove spark plug, rocker arm, and push rod on the cylinder(s) to
be serviced.
2 3. Install Air Line Adaptertool J-23590 to spark plug port and ap-
ply compressed air to hold the valves in place.
2 4. LJsing tool J-5892-C, compress the valve spring and remove
the valve locks. Release and remove tool. Remove valve cap and shield,
and valve spring and damper.
5. Remove the valve stem oil seal.
Installation
1. Install seal over valve stem and seat against head.

2. Set the valve spring and damper, valve shield and valve cap in place. 1
DR3796
Compress the spring with tool J-5892-C and install oil seal in the lower
groove of the stem, making sure 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 compressor tool making sure
the locks seat properly in the upper groove of the valve stem. NOTE:
Grease may be used to hold the locks in place while releasing the
compressor tool.
4. Install spark plug and tighten to 22 ft. lb. (30 N m).
•
5. Install rocker arm cover. Tighten nuts to 115 in. lb. (13 N m).
•
2
DR3794
7-8 Engine/eng
Cylinder Head
Removal
1. Drain water from block and exhaust manifolds. Remove intake and
exhaust manifolds.
2. Remove valve covers and spark plugs.
3. Loosen rocker arm bolts and turn rocker arms aside. Remove push
rods. If lifters are to be serviced, remove them at this point. Otherwise
protect the lifters and the camshaft from the entrance of dirt by covering
the area with clean cloths.
4. Remove cylinder head bolts, cylinder heads and gasket. Place cylin-
der heads on bench, supporting them at each end on blocks of wood to
prevent damage to gasket faces of heads.
Disassembly
1. Remove rocker arm bolts, ball seats and rocker arms.

3 2. Using tool J-8062, compress the valve springs and remove the
valve keys. Release the compressor tool, and remove rotators, springs 3
and spring dampers, then remove oil seals. DR3125
3. Remove valve from bottom of cylinder heads and place them and
their respective valve springs in a rack in their proper sequence so they
can be assembled in their original positions.
Refer to General Engine Mechanical section in this manual for cylin-

der 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 power and
performance built into it.
Another important factor is the cooling of the valve heads. Good con-
tact between each valve and its seat in the head is imperative to ensure
that the heat in the valve head will be properly carried away.
Engine/eng 7-9
Several different types of equipment are available for resealing valve
seats; the recommendations of the manufacturer of the equipment be-
ing 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 center-
ing of pilot in the guide.
a. Install expanding pilot in the valve guide bore and expand
pilot by tightening nut on top of pilot.
b. Place roughing stone orforming stone over pilot and just clean
up the valve seat. Use a 46° stone for both the inlet and ex-
haust valve seats.
c. Remove roughing stone or forming stone from pilot, install
finishing stone on pilot and cut just enough metal from the
seat to provide a smooth finish.
d. Narrow down the valve seats to the proper width for the in-
take and exhaust. See Specifications at the end of this sec-
tion.
This operation is done by grinding the port side with a 30°
stone to lower seat and a 60° stone to raise seat.
e. Remove expanding pilot and clean cylinder head carefully to
remove all chips and grindings from above operations.
1 Valve seats should be concentric to within 0.002 in.
(0,0508 mm) total indicator reading.
J 8001
2. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stern on a valve refacing ma-
chine. Valve stems which show excessive wear, or valves that are
warped excessively should be replaced. When a valve head which is
warped excessively is refaced, a knife edge will be ground on part or
all of the valve head due to the amount of metal that must be removed
to completely reface. Knife edges lead to breakage, burning or pre-
ignition due to heat localizing on this knife edge. If the edge of the
valve head is less than 1/32 in. (0.792 mm) thick after grinding, re-
place the valve. 1
10425

a. If necessary, dress the valve refacing machine grinding wheel
to make sure it is smooth and true. Set chuck at 45° mark for
grinding valves.
b. Clamp the valve stem in the chuck of the machine.
c. Start the grinder and move the valve head out in line with the
grinder wheel by moving the lever to the left.
d. Turn the feed screw until the valve head just contacts wheel.
Move valve back and forth across the wheel and regulate the
feed screw to provide light valve contact.
e. Continue grinding until the valve face is true and smooth all
around valve. If this makes the valve thin, the valve must be
replaced as the valve will overheat and burn.
f. Remove valve from chuck and place stem in “V” block. Feed
valve squarely against grinding wheel to grind any pit from
rocker arm end of stem. NOTE: Only the extreme end of the
valve stem is hardened to resist wear. Do not grind end of
stern excessively.
g. After cleaning valve face and cylinder head valve seat of grind-
ing particles, make pencil marks about 1/4 in. (6,35 mm) 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 check face carefully. If all pencil marks have
not been removed at the point of contact with the valve seat, it
will be necessary to repeat the refacing operation and recheck
for proper seating.
i. Grind and check remaining valves in the same manner.
Assembly
When replacing valve springs, refer to the latest parts catalog

for ordering information.
2 Starting with number 1 cylinder, place the valves in the designated
ports and assemble all but the seal and locks. Then, using tool J-5892-
C, compress the spring A and install the seal B and locks C . See that
the seal is flat and not twisted in the valve stem groove, and that the
locks seat properly in the valve stern groove.
2
DR3795
Engine/eng 7-11
Place valve spring in position with the closed coil end toward
the cylinder head.
Installation
1. Wipe off engine block gasket surface and be certain no foreign ma-
terial has fallen into the cylinder bores, bolt holes, or the valve lifter
area. It is good practice to clean out bolt holes with an air hose.
This engine has special marine head gaskets. Do not substi-
tute automotive head gaskets.
2. Install new head gasket on cylinder block. Dowels in the block will
holdthe gasket in position. Always handle gaskets carefully to avoid
kinking or damage to the surface treatment of the gaskets. DO NOT
use any type of sealing material on head gaskets. The gaskets are
coated with a special lacquer to provide a good seal, once the parts
have warmed up.
3. Carefully set in place on the engine block dowel pins.
4. Clean and lubricate the head bolts with Volvo Penta Gasket Sealing
Compound . Install bolts.
1 5. Tighten the head bolts with a torque wrench, in three progres-
sive steps, following the sequence shown.
Step 1 - 35 ft. lb. (47 N m)
•
Step 2 - 65 ft. lb. (88 N m)

•
Step 3 - 85 ft. lb. (115 N m)•
Damage to the cylinder block threads can result if bolts are

not lubricated with Volvo Penta Gasket Sealing Compound prior to
installation or if the bolts are tightened excessively. Use an accurate
torque wrench when installing head bolts and do not overtightens Un-
even tightening of the cylinder head bolts can distort the cylinder bores, 1
DR2905
causing compression loss and excessive oil consumption.
Timing Chain, Cover and Seal

Harmonic Balancer Removal
1. Remove alternator and power steering belts, and crankshaft pulley.

2 2. Attach tool J-23523-E to balancer, and turn puller screw to
remove balancer from crankshaft.
The timing chain cover is made of composit material with an 2

integral seal. The seal and gasket is not serviceable. Onece the cover DR3573
is removed it must be replaced by a new timing chain cover.
7-12 Engine/eng
Timing Chain Cover Removal
1. Remove circulating pump pulley, alternator brace, and power steer-

ing pump.
2. Drain cooling system and remove hose at circulating pump. Discon-
nect temperature sender wire, then remove circulating pump and dis-
card gaskets.
3. Remove oil pan. See Oil Pan in this section.
4. Remove the front cover-to-block attaching screws. Remove front cover 3
DR3579
and gasket.
Timing Chain and Sprocket Replacement

3 1. Crank engine until “0” marks on camshaft and crankshaft sprock-
ets are in alignment. In this position, engine is timed to fire No. 6
cylinder.
2. Remove camshaft sprocket bolts. Remove sprocket and timing chain
together. Sprocket is a slight press-fit for approximately 1/8 inch. If
sprocket does not come off easily, a light blow with a plastic-faced ham-
mer on the lower edge of the camshaft sprocket should dislodge it. 4
DR3574
4 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.
5 4. Install crank sprocket using tool J-22102 to drive it into place
over keyway.
3 5. Install timing chain on camshaft sprocket. Hold the sprocket
vertical with the chain hanging below. Align the cam and crank sprocket
timing marks, and attach the chain to the crank sprocket.
5
DR3577
Engine/eng 7-13
6. Align dowel in camshaft with dowel hole 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 oil.
Timing Chain Cover Installation
1. Clean gasket surface on block and crankcase front cover.

2. Install new oil pan gasket and oil pan. See Oil Pan in this section.
3. Coat the gasket with sealer and place in position on cover. Apply a
1/8 in. (3.175 mm) bead of GM Silicone Rubber Sealer, P/N 1052366
(or equivalent), to the joint formed at the oil pan and cylinder block.
4. Position crankcase front cover over crankshaft. Press cover down-
ward against oil pan until cover is aligned and installed over dowel
pins on block.
5. Install the front cover-to-block attaching screws.
6. Tighten front cover to block bolts. See Torque Specifications at
the end of this section for the torque figure.
Harmonic Balancer Installation
1. Coat machined outer surface of balancer hub with engine oil. Align
keyway and start balancer onto crankshaft.
1 2. Using appropriate end of tool J-23523-E threaded into crank-
shaft, 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.
2 3. Remove installing tool. Install crankshaft pulley and tighten 1
DR3576
screws securely. Thread 7/16-20 x 2 in. bolt and thick washer into crank-
shaft and tighten. See Torque Specifications at the end of this sec-
tion for the torque figure.
4. Install circulating pump and pulley, and tighten screws securely. At-
tach water hose to pump.
5. Install alternator and power steering pump brackets. Install alterna-
tor and power steering belts and adjust tension to specifications.
2
24965
7-14 Engine/eng
Camshaft
Removal
3 1. Remove distributor A . Remove intake manifold and circulating

pump.
2. Remove rocker arm covers, loosen rocker arms, then remove push
rods and valve lifters.
3. Remove crankshaft pulley, harmonic balancer, timing chain cover,
3
timing chain, and camshaft sprocket. 28257
4 4. Install two or three 5/16-18 x 4 in. bolts in camshaft sprocket

bolt holes and carefully pull out camshaft. Use care not to damage cam-
shaft bearings.
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in
this manual. Do not attempt to repair the camshaft. Replace the cam-
shaft if damaged. Whenever the camshaft needs to be replaced, a new
set of valve lifters must also be installed.
Bearings
4
DR3790

Installation
1. Lubricate camshaft journals with engine oil.

Whenever a new camshaft is installed, lubricate the camshaft
lobes with Molykote Lubricant or its equivalent. Also add one can of GM
Engine Oil Supplement to crankcase oil.
2. Install three 5/16-18 x 4 in. bolts in camshaft bolt holes. Install cam-
shaft, being careful not to damage bearings.
3. Install cam sprocket (making sure timing marks face outward), timing
chain, and timing chain cover.
4. Install harmonic balancer and crankshaft pulley. Install circulating
pump and connect coolant hose.
5. Install valve lifters, push rods, rocker arms, and intake manifold. In-
stall rocker arm covers.
6. Install distributor and set initial timing.
Engine/eng 7-15
Lubrication System
Description and Operation
The oil pump consists of two gears and a pressure relief valve en-
closed 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 pump is flange mounted to the cylinder block with two bolts. The
pump cover is equipped with a pressure regulator valve that regulates
oil pressure at approximately 40-60 PSI (275.8-413.7 kPa) at 2000
RPM. The pump intake is of the fixed screen type. A mesh screen
filters out small particles of dirt and sludge which may be present.
A baffle incorporated in the intake screen has been designed
to eliminate pressure loss due to sudden surging stops. In the event
that a screen becomes plugged, a steel grommet opens and bypasses
oil to the pump. Oil passes through an opening in the mounting flange
to the cylinder block, then into an oil filter adapter.
The main oil galleries run the full length of the crankcase and cut into
the valve lifter guide holes to supply oil at full pressure to the lifters.
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 pas-
sages in the cylinder head and block.
Connecting passages drilled in the crankcase permit delivery of oil at
full pressure to all crankshaft and camshaft bearings, distributor drive
gear, and shaft, and the timing chain.
Holes drilled in the crankshaft carry oil from the crankshaft bearings to
the connecting rod bearings. Pistons and cylinder walls are lubricated
by oil forced through a small notch in the bearing parting surface on
the connecting rod, which registers with the hole in the crankpin once
every revolution. Piston pins are lubricated by splash. 1
28256
Remote Engine Oil Filter
1 2 A full flow oil filter A is mounted to a bracket attached to the
port exhaust elbow. Two hoses connect it to an oil cooler and an en-
gine block adaptor B .
1 2 Oil exits the block through the outboard opening C of the
adaptor, and travels through a hose to the rear oil cooler fitting. It leaves
the front cooler fitting, and travels through a hose that connects to the
filter bracket inner (starboard) opening D . Return oil leaves the filter
bracket at the outer (port) opening E travels through a hose and re- 2
enters the engine at the forward opening F of the adaptor. 19046A
If hoses are improperly attached at adaptor or filter bracket, oil

flow will be reversed. Oil pressure will drop and engine damage may
result.
7-16 Engine/eng
3 Normally, all engine oil passes from the block through an OEM
filter adapter G . If the remote oil filter or lines become restricted, a
spring loaded bypass valve H opens in the adaptor and circulates oil
back into the block.
3 Inspect bypass valve spring and valve disc H for proper operation
or damage. If replacement of bypass valve is necessary, remove bolts
and adaptor. Clean valve chamber in block and replace adaptor.
Oil Pan 3
DR2906
Removal
1. Remove timing chain cover. See Timing Chain, Cover and Seal in
this section.
2. Remove oil 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.
Installation
1. Thoroughly clean all gasket sealing surfaces.

4
DR3788
4 2. Apply GM Silicone Rubber Sealer, P/N 1052366 to the front and

rear corners of the block.
4 3. Attach gasket to block. Install rear portion of oil pan seal in groove
in rear main bearing cap.
4 4. Install front portion of oil pan seal by pressing the corners into
sealer applied to block.
5. Install oil pan and tighten screws. See Torque Specifications at the
end of this section for the torque figure.
5 6. Install dipstick tube fitting to pan; leave screw loose. Orient fit- 5
31576
ting and attach dipstick tube. Then tighten fitting screw and flare nut.
See Torque Specifications at the end of this section for the torque
figure.
7. Fill crankcase with specified engine oil. See Crankcase Oil in the
General Information Section.
Oil Pump
Removal and Disassembly
1. Remove oil pan. 6

DR3580
6 2. Remove pump to rear main bearing cap bolt, and remove pump,
extension shaft, and collar. NOTE: Baffle nuts have to be loosened.
Engine/eng 7-17
3. Disconnect pump shaft from extension. Remove four cover attach-
ing screws, cover, gasket, idler gear and drive gear, and shaft.
4. Remove pressure regulator valve and valve parts.
5. If the pickup screen or pipe need replacing, replace the entire pump
and pickup screen assembly.
6. Wash all parts in cleaning solvent and dry using compressed air.
Inspection
Should any of the following conditions be found during inspection op-

erations, the pump and pickup screen assembly should be replaced.
1. Inspect pump body for cracks or excessive wear. Inspect oil pump
gears for excessive wear or damage.
2. Check shaft for looseness in the housing. Check inside of cover for
wear that would permit oil to leak past the ends of gears.
3. Check the oil pickup screen for damage to screen or relief grommet.
Check for oil in the air chamber.
4. Check pressure regulator valve plunger for fit in cover.
Assembly and Installation
1. Place drive gear and shaft in pump body. Install idler gear so that
smooth side of gear will be toward the cover.
2. Install a new pump to cover gasket to ensure correct end clearance
of the gears.
3. Install cover and attaching screws. Tighten screws to 80 in. lb. (9
N m), and check to see that shaft turns freely.
•
4. Install regulator valve plunger, spring, retainer, and pin.

5. Assemble collar end of extension shaft assembly over pump
driveshaft, aligning tang of extension shaft with slot in end of pump
driveshaft.
6. Assemble pump and extension shaft to rear main bearing cap, align-
ing slot on top end of extension shaft with drive tang on lower end of
distributor shaft. NOTE: Oil pump should slide easily into place. If not,
remove and relocate slot or locate other problem. Install mounting
screws and tighten. See Torque Specifications at the end of this sec-
tion for the torque figure.
7. Tighten baffle nuts.
8. Install oil pan using new gasket. Connect oil drain tube.
7-18 Engine/eng
Measuring Camshaft Lobe Lift
1 1. Remove rocker arm covers. Loosen rocker arms and pivot away
from push rods. Position indicator with ball socket adapter (Tool J-8520)
on push rod. Make sure push rod is in the lifter socket.
2. Rotate the crankshaft slowly in the direction of rotation until the lifter
is on the heel of the cam lobe. At this point, the push rod will be in its
lowest position.
3. Set dial indicator on zero, then rotate the crankshaft slowly, or attach 1
an auxiliary starter switch and “bump” the engine over, until the push DR3791
rod is fully raised position.

Whenever the engine is cranked:
2 Remove gray and black connectors from ignition coil to prevent
accidental starting of engine.
4. Compare the total lift recorded from the dial indicator with specifica-
tions. If camshaft readings for all lobes are within specifications, re-
move dial indicator assembly.
5. Install valve mechanism as outlined. Install rocker arm covers.
2
DR5655
Rear Main Bearing Oil Seal Replacement
Removal
Pry out rear crankcase oil seal. NOTE: Care should be taken when
removing the rear crankcase oil seal so as not to nick the crankcase
seal surface.
Clean sealing surface on crankshaft with a non-abrasive cleaner. In-

spect chamfer on crankshaft for grit, loose rust, and burrs. Correct as 3
necessary. DR1979
Installation
1. Lubricate the inner and outer diameter of the seal with engine oil.
3 2. Position the seal onto tool J-38841 A so seal lip will face the
block.
4 3. Position tool J-38841 against the crankshaft. Thread the attach-
ing screws into the tapped holes in the crankshaft and tighten securely.
This will ensure that the seal B is installed squarely overthe crank-
shaft. Turn the handle until it bottomsthen remove the tool. 4
DR3789

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 bear-
ing, both upper and lower halves, will be required. Bearings are avail-
able in standard size and 0.001 in. (0.0254 mm), 0.002 in. (0.0508
mm), 0.010 in. (0.245 mm) and 0.020 in. (0.508 mm) undersize.
Selective fitting of both rod and main bearing inserts is necessary in
production in order to obtain close tolerances. For this reason you
may find one-half of a standard insert with one-half of a 0.001 in. (0.0254
mm) undersize insert which will decrease the clearance 0.0005 in.
(0.0127 mm) from using a full standard bearing.
When a production crankshaft cannot be precision fitted by this method,
it is then ground 0.009 in. (0.2286 mm) undersize on only those main
journals that cannot be properly fitted. All journals will not necessarily
be ground undersize. A 0.009 in. (0.2286 mm) undersize bearing and
0.010 in. (0.245 mm) undersize bearing may be used for precision
fitting in the same manner as 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

In general, (except No. 1 bearing) the lower half of the bearing shows
a 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. If the lower half shows evidence of wear or dam-
age, both upper and lower halves should be replaced. Never replace
one half without replacing the other half.
These dimensions should be checked with a micrometer for out-of-
round, taper or undersize. If the journals exceed 0.001 in. (0.0254 mm)
out-of-round, or taper, the crankshaft should be replaced or recondi-
tioned to an undersize figure that will enable the installation of under-
size precision type bearings.
The crankshaft should also be checked for runout. To perform this op-
eration, support the crankshaft at the front and rear main bearing jour-
nals in “V” blocks, and indicate the runout of both the rear intermedi-
ate and front intermediate journals, using a dial indicator. The runout
limit of each of these journals is 0.002 in. (0.0508 mm). If the runout
exceeds 0.002 in. (0.0508 mm), the crankshaft must be repaired or
replaced.
7-20 Engine/eng
Main Bearing Replacement
1 1. Install a main bearing removing and installing tool J-8080 A

in
oil hole in crankshaft journal. NOTE: If such a tool is not available, a
cotter pin may be bent as required to do the job.
2. Rotate the crankshaft clockwise as viewed from the front of engine.
This will roll upper bearing out of block.
3. Oil new selected size upper bearing and insert plain (unnotched) end
between crankshaft and indented or notched side of block. Rotate the
bearing into place, and remove tool from oil hole in crankshaft journal.
1
DR2916
4. Oil new lower bearing and install in bearing cap. Install main bearing
cap with arrows pointing toward front of engine. Torque main bearing
cap bolts to specifications.
Measure:
Refer to General Engine Mechanical section in this manual for crank-
shaft bearing clearance procedures.
Connecting Rod Bearing Replacement

Connecting rod bearings are of the precision insert type and do not
utilize shims for adjustment. DO NOT FILE RODS OR 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 pump removed, remove the connecting rod cap
and bearing.
2. Wipe the bearings and crankpin clean of oil. Inspect the bearing for
evidence of wear or damage.
3. Measure the crankpin for out-of-round or taper with a micrometer. If
not within specifications, replace or recondition the crankshaft. If within
specifications and a new bearing is to be installed, measure the maxi-
mum diameter of the crankpin to determine new bearing size required.
4. If within specifications, measure new 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 minimum diameter and the crankpin is out-of-round 0.001 in., inter-
ference 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.)
Engine/eng 7-21
b. Install the bearing in the connecting rod and cap.
c. Install the bearing cap and evenly tighten nuts to specifica-
tions.
Do not turn the crankshaft with the gauging plastic in-
stalled.
d. Remove the bearing cap and using the scale on the gauging
plastic envelope, measure the gauging plastic width at the
widest point.
5. If the clearance exceeds specifications select a new, correct size
bearing and remeasure the clearance.
6. Coat the bearing surface with oil, install the rod cap and tighten nuts
to specifications.
7. When all connecting rod bearings have been installed tap each rod
lightly (parallel to the crankpin) to make sure they have clearance.
1 8. Measure all connecting rod side clearances (see Specifica-
tions at end of this section), between connecting rod caps.
Piston, Ring and Connecting Rod 1

47427
Piston and Rod Removal
1. Remove oil pan, oil pump, and cylinder head. Turn crankshaft until
piston is at bottom of stroke. Place a cloth on top of piston to collect
cuttings.
2. Before attempting to remove piston, remove cylinder bore ridge as
necessary.
for cylinder bore ridge reamer procedures.
3. Inspect connecting rods and connecting rod caps for cylinder iden-
2
DR3792
tification. If necessary mark them.
2 4. Remove connecting 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 discon-
nect some of the connecting rod and piston assemblies and push them
out of the cylinder.
Disassembly

and connecting rod disassembly.
7-22 Engine/eng
Assembly

Piston and Rod Installation
1. Lightly coat pistons, rings and cylinder walls with light engine oil.
2. With bearing caps removed, install tool J-5239 on bearing cap bolts.
Check position of ring end gaps. They must be aligned with 3
each other as described previously. See General Engine Mechanical. 47437
3. Install each piston in its respective bore, using tool J-5239 on each
assembly. For valve clearance, 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.
3 4. Use tool J-8037 A to compress the piston rings.
5. Install bearing caps and check the bearing clearance. Refer to Gen-
eral Engine Mechanical section in this manual for connecting rod side
clearance procedure.
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
Measure:
Piston Selection
1. Check USED piston to cylinder bore clearance as follows:

a. Measure the “Cylinder Bore Diameter” with a telescope gauge
2 1/2 in. (64 mm) from top of cylinder bore.
b. Measure the “Piston Diameter” (at skirt across centerline of
piston pin).
Engine/eng 7-23
c. Subtract piston diameter from cylinder bore diameter to de-
termine “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, check if a new piston can be se-
lected to fit cylinder bore within the acceptable range.
3. If cylinder bore must be reconditioned, measure new piston diam-
eter (across centerline of piston pin), then hone cylinder bore to cor-
rect clearance (preferable range). Mark the piston to identify the cylin-
der for which it was fitted.
Handle the pistons with care, and do not attempt to force them
through the cylinder until the cylinder has been bored to correct size
as this type piston can be distorted through careless handling.
Circulating Pump
The circulating pump is manufactured specially for marine use.
It is serviced only as an assembly. Do not replace with an automotive
circulating pump.
Inspection
Remove alternator and power steering belts. Grasp circulating pump

pulley and check end and side play. Turn pulley to check for drag.
Look for water leaking from indicator hole beneath pump shaft behind
pulley. Replace pump if play, drag, or leakage are evident.
pump. Remove pulley. Remove circulating pump bolts, pump and gas-
kets.
sembly on cylinder block and tighten bolts as specified. Install pulley.
Install alternator and power steering belts, then adjust tension. Con-
nect hose to circulating pump. Lake or tank test unit and check for
leaks.
Front Engine Mount Replacement

Removal

2
1
2. Lift engine with 1500 lb. (680 kg) minimum capacity 11982
hoist to allow removal of front mount and bracket. Remove three
mount screws and lock washers B .
2
11981
distance between large washer and flat on upper mount bracket.
Disassembly
4 1. Remove three nuts C, one lock washer, and engine mount

bracket D from mount bolt E while holding bolt secure with socket.
5 2. Remove one large washer F , one small washer G and engine
mount bolt E from mount.
Reassembly
3
11980
6 1. Place small washer G on mount bolt and insert bolt up through

mount. Install large washer F and secure with nut C . Tighten to 60-75
ft. lb. (81-102 N m). •
4 2. Install upper inner nut and place engine mount bracket on D

engine mount bolt. NOTE: Measure distance between large washer and
flat on upper mount bracket. Distance must be the same as that prior to
disassembly.
3. Install lock washer and lower nut. Tighten nut to 50-70 ft. lb. (68-95
N m).
•
4
11979
Installation
1. Spray the engine mount screws threads with Loctite Primer and al-
low to air dry. Apply Volvo Penta Thread Sealing Agent to the screws.
ers. Tighten to 32-40 ft. lb. (43-54 N m). •
2. Install lag screws and tighten securely.
Height Adjustment
7 1. To change engine height, tighten or loosen nuts H and I as 5
required. 11978
2. Lift engine with 1500 lb.(680 kg) minimum capacity hoist.

Position engine at desired height.
7 3. After setting mount position, turn nut I up against underside of
engine bracket and hold nut with a wrench. Tighten upper nut H to 100-
120 ft. lb. (136-163 N m). •

Removal
6
Drain water from respective exhaust manifold. 11983
1. Loosen two clamps securing upper hose to elbow.
7
2953

2. Port Elbow - Remove four thru-bolts, lock washers, and washers.
Move remote oil filter aside.
• Move crankcase oil filter bracket aside.

1 3. Starboard Elbow - Remove two thru-bolts , lock washers,
A
and washers attaching circuit breaker bracket. Set bracket assembly
aside.
2 4. Lubricate inside of exhaust hose with a soapy water solution,
then remove remaining elbow bolt. Tap elbow with a soft hammer to
free it, then twist it out of the hose. Remove and discard the manifold 1
DR6451
gasket.
Installation
3 2. Apply Volvo Penta Gasket Sealing Compound to both sides of
a new gasket B , and place it on the manifold. Lubricate inside of ex-
haust hose with a soapy water solution to ease elbow installation.
3. Twist elbow into hose and position it on the gasket. Install the outer
rear thru-bolt, washer, and lock washer, and turn it in finger tight.
4. Port Elbow - Position remote oil filter at front of elbow.
2
28265
• Mount oil filter bracket on elbow.
Install four thru-bolts, washers, and lock washers finger tight. Tighten
small screw securely.
1 5. Starboard Elbow - Position circuit breaker assembly at front
of elbow. Install two thru-bolts A , washers, and lock washers finger
tight.
6. Tighten all elbow thru-bolts to 12-18 ft. lb. (16-24 N m).
•
7. Properly position the two exhaust hose clamps and tighten

them securely.
3
28266

Exhaust Hose and Intermediate Pipe
Replacement
Removal
1. Loosen eight clamps that attach the upper and lower exhaust hoses,
and slide clamps down onto exhaust Y-pipe.
push lower hose down onto exhaust Y-pipe.
4
5 3. Twist intermediate pipe out of upper hose. Lubricate inside of 19377A
upper hose with a soapy water solution for ease of removal.

pipe.
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.
6 2. On the 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. The ribbed end of the hose 5
must face the intermediate pipe (rearward) when it’s installed. Slide 28264
hose onto high-rise elbow until it seats. NOTE: If hose is not properly
positioned, it will not completely engage the high-rise elbow or allow
secure attachment.
5 3. With a twisting motion, insert intermediate pipe all the way into
the upper hose. Slide the lower hose up until it’s halfway onto the inter-
mediate pipe.
4. Slide four No. 68 clamps up onto the upper hose. Slide four No.
64 clamps up onto lower hose. Position clamps in their proper chan-
nels and tighten them securely.
6
16041
Removal

7 8 3. Remove seven screws securing bellhousing cover and slide
cover off.
7
20034
8
19996

1 4. Pull drain hose out of bellhotising if equipped.
5. Remove bolts and nuts retaining bellhousing. Disconnect ground
wires and oil cooler bracket. Note oil cooler orientation.
6. Remove bell housing.
2 7. Use an offset box end wrench to remove the six nuts securing
the coupler, and slide coupler off studs.
thoroughly. 1
19842
Installation
3 1. Install coupler and attach six locknuts. Use a suitable adaptor

and tighten nuts to 40-45 ft. lb. (54-61 N m).
•
2. Install bellhousing. Attach oil cooler with same orientation as noted

in a previous step. Tighten nuts and bolts to 32-40 ft. lb. (43-54 N m).•
Attach ground wires and tighten nuts to 15-20 ft. lb. (20-27 N m).
•
3. Push drain hose into bellhousing if equipped.

new bellhousing gasket and position it on cover.
2
6712

bellhousing cover and screws and tighten to 60-84 in. lb. (7-9 N m).•
6. Connect all wires, lines and connectors to bellhousing. Install en-

gine in boat.
3
6714
4
19083
7-28 Engine/eng
7.4 GSi and 8.2 GSi Models
General Information:
Type - No. of Cylinder .................................................................................................................................. 90° - V-8
Valve Arrangement ......................................................................................................................................... In head
Bore and Stroke
7.4 GSi ................................................................................................... 4.250 x 4.000 in. (107.95 x 101.6 mm)
8.2 GSi .................................................................................................. 4.468 x 4.000 in. (1 13.48 x 101.6 mm)
Piston Displacement
7.4 GSi ........................................................................................................................ 7.4 liter/454 Cubic Inches
8.2 GSi ..................................................................................................................... 8.2 Liters/502 Cubic Inches
Cylinder Numbers - Front to Rear
Starboard Bank ........................................................................................................................................ 2-4-6-8
Port Bank .................................................................................................................................................. 1-3-5-7
Firing Order ........................................................................................................................................ 1-8-4-3-6-5-7-2
Compression Ratio
7.4 GSi .......................................................................................................................................................... 8.6:1
8.2 GSi .......................................................................................................................................................... 8.8:1
Water Temperature Control .................................................................................................................... Thermostat
Thermostat Opens at .......................................................................................................................... 140° F (60° C)
Alternator Belt Adjustment ................................................................................... 1/4-1/2 in. give w/finger pressure
Full Throttle Operation Range
7.4 GSi ..................................................................................................................................... 4800 - 5200 RPM
8.2 GSi ..................................................................................................................................... 4600 - 5000 RPM
Pistons:
Production Clearance
7.4 GSi .................................................................................................. 0.003 - 0.004 in. (0.0762 - 0.1016 mm)
8.2 GSi .................................................................................................. 0.004 - 0.005 in. (0.1016 - 0.1270 mm)
Service Limit ................................................................................................................... 0.005 in. (0.127 mm) Max.
Piston Rings. Compression:
Production Groove Clearance
Top .................................................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
2nd .................................................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
Service Groove Clearance (both) ................................................................................... + 0.001 in. (+0.0254 mm)
Gap
Top ........................................................................................................... 0.010 - 0.018 in. (0.254 - 0.475 mm)
2nd ............................................................................................................ 0.016 - 0.024 in. (0.406 - 0.609 mm)
Service (both) ..................................................................................................................... + 0.010 in. (+0.254 mm)
Piston Rings. Oil:
Groove Clearance
Production ............................................................................................ 0.005 - 0.0065 in. (0.127 - 0.1651 mm)
Service ........................................................................................................................ + 0.001 in. (+0.0254 mm)
Gap
Production ................................................................................................ 0.010 - 0.030 in. (0.254 - 0.762 mm)
Service .......................................................................................................................... + 0.010 in. (+0.254 mm)
Engine/eng 7-29
Piston Pins:
Diameter .................................................................................................. 0.9895 - 0.9897 in. (25.133 - 25.138 mm)
Clearance in Piston
Production ........................................................................................ 0.0002 - 0.0007 in. (0.0050 - 0.0177 mm)
Service Limit .................................................................................................................... 0.001 in. (0.0254 mm)
Rod Fit ................................................................................ 0.0031 - 0.0021 in. (0.0787 - 0.0533 mm) lnterference
Connecting Rods:
Bearing Clearance
Production ...................................................................................... 0.0011 - 0.0029 in. (0.0279 - 0.07366 mm)
Service Limit .................................................................................................................... 0.003 in. (0.0762 mm)
Side Clearance ......................................................................................... 0.0013 - 0.023 in. (0.0330 - 0.5842 mm)
Crankshaft:
End Play ........................................................................................................ 0.006 - 0.010 in. (0.1524 - 0.254 mm)
Main Journal Diameter
No. 1, 2, 3, 4, 5 ............................................................................ 2.7482 - 2.7489 in. (69.8042 - 69.8220 mm)
Taper
Production ............................................................................................................ 0.0002 in. (0.0051 mm) Max.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) Max.
Out-of-Round
Production ........................................................................................................... 0.0002 in. (0.0051 mm) Max.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) Max.
Main Bearing Clearance. Production
No. 1, 2, 3, 4 .................................................................................... 0.0017 - 0.0030 in. (0.0432 - 0.0762 rnm)
No. 5 ................................................................................................. 0.0025 - 0.0040 in. (0.0635 - 0.0965 mm)
Main Bearing Clearance. Service
No. 1, 2, 3, 4 ..................................................................................... 0.0010 - 0.0030 in. (0.0254 - 0.0762 mm)
No. 5 ................................................................................................. 0.0025 - 0.0040 in. (0.0635 - 0.0965 mm)
Crankpin Diameter
7.4 GSi .............................................................................................. 2.199 - 2.1996 in. (55.854 - 55.8698 mm)
8.2 GSi .................................................................................................................................. 2.20 in. (55.88 mm)
Taper
Production ................................................................................................ 0.0005 in. (0.0127 mm) Max.
Service Limit .............................................................................................. 0.001 in. (0.0254 mm) Max.
Out-of-Round
Production ................................................................................................ 0.0005 in. (0.0127 mm) Max.
Service Limit .............................................................................................. 0.001 in. (0.0254 mm) Max.
Camshaft:
Camshaft Bearing Journal Diameter ..................................................... 1.9482 - 1.9492 in. (49.484 - 49.509 mm)
Lobe Lift - 0.002 in. (0.0508 mm)
7.4 GSi
Intake ....................................................................................................................... 0.2343 in. (5.9512 mm)
Exhaust ................................................................................................................... 0.2530 in. (6.4262 mm)
8.2 GSi
Intake ......................................................................................................................... 0.510 in. (12.954 mm)
Exhaust ..................................................................................................................... 0.510 in. (12.954 mm)
7-30 Engine/eng
Valve Systems:
Lifter Type .................................................................................................................................................... Hydraulic
Rocker Arm Ratio
7.4 GSi ...................................................................................................................................................... 1.7 to 1
8.2 GSi ...................................................................................................................................................... 1.7 to 1
Valve Lash - Intake and Exhaust ............................................................................................. zero lash + one turn
Valve Face Angle (I & E) ....................................................................................................................................... 45°
Valve Seat Angle (I & E) ..................................................................................................................................... 46°
Valve Seat Runout (I & E) ............................................................................................ 0.002 in. (0.0508 mm) Max.
Stem to Guide Clearance
Intake, Production ............................................................................ 0.0010 - 0.0027 in. (0.0254 - 0.0270 mm)
Exhaust, Production ......................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
Intake, Service ............................................................................. Hi Limit Production + 0.001 in. (0.0254 mm)
Exhaust, Service .......................................................................... Hi Limit Production + 0.002 in. (0.0508 mm)
Intake .......................................................................................................... 1/32 to 1/16 in. (0.794 - 1.587 mm)
Exhaust ....................................................................................................... 1/16 to 3/32 in. (1.587 - 2.381 mm)
Valve Spring Free Length .......................................................................................................... 2.15 in. (54.41 mm)
Valve Spring Installed Height ............................................................................................. 1 51/64 in. (45.641 mm)
Valve Spring Pressure
Lb. @ In. (kg @ mm) Closed .................................................................. 74-86 @ 1.80 in. (33.5 - 39 @ 45.72)
Lb. @ In. (kg @ mm) Open ............................................................ 195-215 @ 1.40 in. (88.4 - 97.5 @ 35.56)
Installed Height ± 1/32 in. (0.794 mm)
Valve Spring Fit In Damper ................................................................................ 0.042 - 0.094 in. (1.06 - 2.38 mm)
Engine Lubrication:
Normal Pressure. Warm Engine ............................................................................. 10 PSI (70.3 kPa) @ 500 RPM
40-60 PSI (281 - 422 kPa) @ 2000 RPM
Crankcase Capacity
7.4 GSi .......................................................................... Approx. 8 qt. (7.57 liters); 9 qt. (8.51 liters) with Filter
8.2 GSi .......................................................................... Approx. 8 qt. (7.57 liters); 9 qt. (8.51 liters) with Filter
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
mation.
Fuel Recommendation ................. See General Information Section
Engine/eng 7-31
Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or possibly damag-
Screw
Camshaft Sprocket
7.4 GSi 20 - 27
8.2 GSi 25 - 34
Circulating Pump 30 - 40
Dipstick Tube Fitting 15-18 - 20-24
Front Mount Bracket to Block 32-40 - 43-54
Oil Pan to Block - 200 22
Oil Pan to Front Cover 70 7,9
Thermostat Housing 12-16 - 16-22
Timing Chain Cover
7.4 GSi - 106 12
8.2 GSi - 120 13,6
Water Pump
7.4 GSi 30 - 40
8.2 GSi 35 - 47
7-32 Engine/eng
Torque Specifications (cont.)
ITEM FT. LB. IN. LB. Nm

•
Nut
Connecting Rod Cap
7.4 GSi 48 - 65
8.2 GSi 73 - 99
Flame Arrestor - 25-35 2,8-4,0
Flare-Dipstick Tube 15-18 - 20-24
Front Mount (upper) 100-120 - 136-163
Rocker Arm Cover - 115 13
Bolt
Cylinder Head
Step 1 35 - 47
Step 2 65 - 88
Step 3 85 - 115
Flywheel to Crankshaft 70 - 95
Front Mount 65-75 - 81-102
Harmonic Balancer
7.4 GSi 85 - 115
8.2 GSi 90 - 122
High-Rise Elbow 12-18 - 16-24
Intake Manifold
7.4 GSi 30 - 40
8.2 GSi 35 - 47
Main Bearing Cap (All)
7.4 GSi 100 - 135
8.2 GSi 110 - 149
Oil Pump
7.4 GSi 65 - 90
8.2 GSi 70 - 95
Remote Oil Filter Adaptor (to block) 20-25 - 27-34
Rocker Arm 40 - 54
Vibration Damper 24 - 33
Stud
Power Steering Pump 13-15 - 18-20
Rocker Arm Cover - 60-90 7-10
Miscellaneous
Oil Filter one turn after contact
Spark Plugs
(cylinder head - new) 22 - 30
(cylinder head - all subsequent installations) 15 - 20
Engine/eng 7-33
7-34 Engine/eng
Section 8
Steering System
Table of Contents
Mechanical (Nonpower) Steering System ........................................ 8-3

Cable Installation ............................................................................. 8-3
Cable Removal ................................................................................ 8-3
Description ...................................................................................... 8-3
Lubrication ....................................................................................... 8-4
Sealants, Lubricants and Adhesives ............................................. 8-2
Special Tools ................................................................................... 8-2
Steering Tube Replacement ........................................................... 8-4
Trim Tab Adjustment ..................................................................... 8-17
Power Steering System ...................................................................... 8-5

Cable Installation ........................................................................... 8-15
Cable Installation Problems ......................................................... 8-23
Checking Fluid Level .................................................................... 8-10
Cylinder Installation ...................................................................... 8-14
Cylinder Removal .......................................................................... 8-13
Cylinder Servicing ......................................................................... 8-14
Description ...................................................................................... 8-5
Diagnosis Chart ............................................................................. 8-19
External Leakage ........................................................................... 8-21
Feedback To Helm ......................................................................... 8-24
Hoses ............................................................................................. 8-16 8
Hydraulic Fluid .............................................................................. 8-10
Lubrication ..................................................................................... 8-16
Pump Belt Adjustment .................................................................. 8-12
Pump Installation ............................................................................ 8-9
Pump Leakage ............................................................................... 8-22
Pump Operation .............................................................................. 8-6
Pump Pressure Test ...................................................................... 8-22
Pump Removal ................................................................................ 8-9
Purging Air From Steering System .............................................. 8-11
Sealants, Lubricants and Adhesives ............................................. 8-2
Special Tools ................................................................................... 8-2
Specifications - Torque ................................................................. 8-25
Steering Cylinder ........................................................................... 8-13
Steering Without Power Assist ...................................................... 8-8
System Diagnosis ......................................................................... 8-16
System Operation ........................................................................... 8-7
Tie Bar Adjustment - Twin Engine Installations .......................... 8-18
Trim Tab Adjustment ..................................................................... 8-17
Engine/eng 8-1
Special Tools
Rod Holder 3854367-4

Pump Pulley Installer 9995444-8
Pump Pulley Remover 9995443-0
Kent-Moore Special Tools
Pressure Gauge J-5176-E

Thermometer J-5421
Sealants, Lubricants and Adhesives

Cleaning Solvent
Volvo Penta Grease
Volvo Penta Power Trim/Tilt & Steering Fluid
GM Power Steering Fluid
Dexron, or Dexron II
Loctite Primer
Safety Warnings
Before working on any part of the steering system, read the Safety
section at the end of this manual.
When replacement parts are required, use genuine Volvo Penta or
parts with equivalent characteristics including type, strength and
material. Failure to do so may result in product malfunction and
possible injury to the operator and/or passengers.
the alternator, power steering supply pump and circulating pump
belts, pulleys and other moving parts.
8-2 Engine/eng
5
5
4
1 2 3
CO2740 18638 18640
Mechanical (Nonpower) Steering System

Description
1 The mechanical steering system consists of a helm assembly A ,

the steering cable B , and attaching hardware C that connect the steer-
ing system to the inner transom bracket and steering arm.
Steering Cable Removal
The steering cable is serviced as an assembly.

4
6825
2 3 1. To remove the steering cable, remove the cotter pin and D

steering arm pin E securing the cable ram to the steering arm F . Re-
move both steering arm bushings G .
2. Turn the helm to the port full lock position.
4 3. Loosen the cable anchor nut H, and remove the cable.
Steering Cable Installation
Steering tube position in the anchor block is preset at the fac-

tory for proper centering of the steering system. Do not loosen the jam 5 D
nut or change the position of the steering tube. 31837
5 1. Turn the steering wheel to fully extend the steering cable

ram to its maximum extension. Lubricate the full length of the steer-
ing cable ram with Volvo Penta Grease .
2. Install the steering cable ram through the steering tube. B
3. While holding the steering cable in the steering tube, thread the steer-
ing cable anchor nut onto the steering tube until the steering cable an-
chor nut bottoms on the end of the steering tube.
6 4. Attach a crowfoot wrench I at a 90° angle to the torque
wrench. Tighten the steering cable anchor nut to 120 in. lb. (14 N m). •
6
2921

5. Insert bushings into steering arm. Install the steering arm pin through
the top hole in the steering arm and through the hole of the steering
cable ram.
6. Install the cotter pin through the steering arm pin and secure
by spreading the ends of the cotter pin.
7. Turn the steering wheel to fully extend and retract the steering cable
ram. The steering arm should move from stop to stop as the steering
ram moves from fully retracted to fully extended. Steering arm must
not contact inside of transom cutout in either direction. Check for equal 1
3253
clearance of steering arm. Center the steering wheel and check cen-
tering of steering arm. Readjust as necessary.
Steering System Lubrication
1 Lubricate the steering ram with Volvo Penta Grease ev-

ery 50 hours or 60 days, which ever comes first.
Due to local conditions, it may be necessary to lubricate your
steering ram at more frequent intervals.
Steering Tube Replacement

2
DR1726
1. Loosen the jam nut and screw the steering tube out of the anchor
block. Remove the jam nut from the steering tube.
2 2. Screw the jam nut A all the way onto a new steering tube.
2 3. Measure 3-1/4 in. (8,26 cm) B in from the end of the steering
tube. Clean the following 1-1/4 in. (3,18 cm) of thread C with Loctite
Primer and allow to air dry. Apply Volvo Penta Thread Sealing Agent to
the 1-1/4 in. (3,18 cm) thread area C .
3 4. Screw the anchor block onto the steering tube until the block is
3-5/32 in. (8,02 cm) D from the end. This dimension positions the steer-
ing tube for accurate centering of the steering system. 3
DR1727
5. Screw the jam nut up against the anchor block and tighten to 35-40
ft. lb. (47-54 N m). Do not disturb the anchor block position while tight-
•
ening the nut.

4 5 6. If the anchor block was removed from the transom
plate, apply a small mount of Volvo Penta Grease to both bushings.
Install the block with the original screws. Tighten both to 40-45 ft. lb.
(54-61 N m). Secure screws with two cotter pins.
•
Filling the bushing pockets with grease can cause the screws
to hydraulically lock and break the transom plate when tightened.
4
8012
5
8011
6
DR2959
Power Steering System • The oil cooler G is a heat exchanger that uses en-
gine cooling water to keep the hydraulic fluid cool.
Description
• A high pressure hydraulic hose H carries fluid from
The power steering system consists of a mechanical the pump to the control valve, and low pressure hoses
cable from the helm to the inner transom plate, an en- I and J carry the fluid from the valve to the oil cooler,
gine mounted pump, and a power cylinder to move the and back to the reservoir.
vertical drive steering arm.
• The steering cable casing K attaches to the steering
6 The hydraulic pump E is mounted on the front of cylinder valve.
the engine and is belt driven by the crankshaft pulley.
The reservoir fill cap has a dipstick attached. • The cable ram passes through the valve and attaches
to the clevis L . The drive steering arm M is also at-
• The control valve and cylinder Fis a single unit tached to the clevis.
mounted to the inner transom bracket.

1 2
DR3007 DR3008
Pump Operation
1 During normal operation, fluid is drawn into dual pump intake
ports A from the reservoir B . The reservoir is supplied by a low pres-
sure return line C from the power steering oil cooler. The pump output
is through ports D . The vanes E are held out against the pump bore
by pressure behind the vanes. The pump has sufficient output F to
allow quick boat maneuvers even at engine idle RPM. The pump out-
put at high RPM is limited to about 2.3 gallons per minute by a flow
restriction orifice G .
The pump output pressure is determined by the resistance to flow of
the system. When no steering changes are being made, the pressure
will be about 50-100 PSI. When there is steering input, the pressure
will be higher and will depend on the steering forces required due to
the boat attitude, drive trim position, throttle position and quickness of
the maneuver.
2 The pump is protected from the very high pressures by a pres-
sure relief valve H that is located in the pump body. If the steering load
becomes extremely high, the relief valve will open and limit the output
pressure I to about 1,000-1,100 PSI.
Internal damage to the pump will occur if the system is oper-
ated at relief valve pressure for more than a few seconds.
3 The pump has a metric output fitting. Use only a hose with a met-
ric fitting.
3
2635
8-6 Engine/eng
4 5
DR3508 DR3506
System Operation Steering To Port - Steering Wheel Turning To Left
No Steering Input - Steering Wheel Not Turning

5 When the helm is turned to port (either turning boat
to left or straightening from a right turn) the steering arm
4 When there is no steering input from the helm, the is pulled to starboard. The steering cable casing pushes
spring J in the control valve keeps the spool K cen- the valve spool K to port. Fluid from the pump enters
tered. Fluid from the pump enters the control valve the valve at L , is routed to the rod-end outlet N and to
through the pressure port L , flows past both cylinder the low volume side end of the cylinder Q . The pump
ports M and N with little restriction, then through the pressure moves the piston and steering arm to starboard.
return port O and back to the reservoir. There is a small Fluid in the high volume side of the cylinder P is forced
equal force at both ends P and Q of the cylinder and out through the valve from M to return port O and back
the cylinder does not move. to the reservoir. As long as the helm is turning to port
this motion continues, swinging the sterndrive to port.
With no steering input, the sterndrive is held in one po-
sition and the boat moves in a constant turn or in a When the helm input stops (steering wheel not turning),
straight line. the steering cable stops pulling the steering arm to star-
board, and the steering casing stops pushing the valve
spool to port. When the spring J moves the valve spool
to a “centered” position, hydraulic fluid is again routed
past both cylinder outlets. The steering cylinder has an
equal force at both ends and stops moving. The steer-
ing system is then back to the No Steering Input condi-
tion described previously.
STARBOARD STARBOARD
PORT PORT
Engine/eng 8-7
1 2
DR3007 DR3008
Steering To Starboard - Steering Wheel Turning To Steering Without Power Assist

Right
2 If the steering system is not providing power as-
1 When the helm is turned to starboard (either turn- sist, the operator may still steer the boat. Turning the
ing boat to right or straightening from a left turn), the steering wheel to port causes the steering cable to pull
steering arm is pushed to port. The steering cable cas- the steering arm to starboard. This causes the cable
ing pulls the valve spool A to starboard. Fluid from the casing to push the valve spool A to port against the
pump enters the valve at B and is routed to the piston- stop about 0.125 in. (3,18 mm). The steering cable then
end outlet C and to the high volume side of the cylinder transmits the full manual effort to pull the steering arm.
D . The pump pressure moves the piston and steering
The fluid D ahead of the piston is forced out of the cyl-
arm to port. Fluid at the low volume side of the cylinder
E is forced out and through the valve from F to return
inder through outlet C into the valve, and through re-
turn port G back to the reservoir. Additional fluid is drawn
port G and back to the reservoir. As long as the helm is
out of the reservoir through the pressure inlet B and F
turning to starboard this motion continues, swinging the
to the opposite side of the piston E .
sterndrive to starboard.
More steering effort is required since all of the power
When the helm input stops (steering wheel not turning),
required to steer the boat must be supplied by the op-
the steering cable stops pushing the steering arm to port,
erator, and additional force is required to move the fluid
and the steering casing stops pulling the valve spool to
through the system when the pump is not operating.
starboard. When the spring 0 moves the valve spool to
a “centered” position, hydraulic fluid is again routed past
both cylinder outlets. The steering cylinder has an equal
force at both ends and stops moving. The steering sys-
tem is then back at the No Steering Input condition
described previously.
8-8 Engine/eng
3 4 5
20497 23916A 20496A
Pump Removal
3 1. Place an oil drain pan under pump. Disconnect high pressure
hose I and return hose J at pump. Do not lose O-ring on pressure
hose fitting. Secure hose ends in a raised position to prevent fluid drain-
ing from hoses. Cap or tape ends of hoses to keep out dirt. Drain pump
completely before removing.
Serpentine Belt Models Only

4 On models with serpentine belt, release tension on the belt tensioner
6
20510
and remove the belt.
3.0GS, 4.3, 5.0Gi, 5.7GSi, 7.4Gi, GSi and 8.2GSi Models 4

V-Belt Models Only
5 6 2. Loosen pump bracket mounting screws and remove

drive belt.
4.3 GL, GS, 5.0GL, and 5.7GS Models 5
7.4 Gi, GSi and 8.2 GSi Models 6

7
20847
All Models
3. Take out mounting screws and remove pump from engine.
7 4. Remove pump pulley using Pulley Remover, Volvo Penta P/N
9995443-0, then remove mounting bracket.
Pump Installation
8 1. Attach mounting bracket to pump. Attach pulley using Pulley
Installer, Volvo Penta P/N 9995444-8.
8
2. Mount pump bracket loosely on the engine. 20846
3 3. Make sure O-ring is in place and in good condition, then connect

high pressure hose fitting I . Tighten fitting to 15-26 ft. lb. (20-35 N m).
•
3 4. Connect return hose J to reservoir. Tighten hose clamp to 12-

17 in. lb. (1,4-2,0 N m).
•
Engine/eng 8-9
5. Fill pump reservoir with Volvo Penta Power Trim/Tilt & Steering Fluid.
Bleed pump, hoses, and valve by turning pulley clockwise (as viewed
from front of engine) until reservoir no longer shows air bubbles. Keep
reservoir filled while purging air from system.
Serpentine Belt Models Only

Release belt tensioner and install belt.
V-Belt Models Only

6. Install drive belt and adjust belt tension as described under Belt 1
20509
Adjustment in this section. Do not pry against pump reservoir while
tightening belt.
7. Bleed entire system as outlined under Purging Air From Steering
System.
Hydraulic Fluid
Use an approved power steering fluid such as Volvo Penta Power Trim/
Tilt & Steering Fluid or GM Power Steering Fluid. If these fluids are not
available, any automatic transmission fluid labeled Dexron or Dexron II
may be used. 2
31839
Checking Fluid Level

1 1. Run engine and rotate steering wheel lock-to-lock for a rea-
sonably long period of time to warm up steering fluid, then shut engine
off. Remove reservoir filler cap and check if fluid level is at “HOT” mark
on dipstick.
2 2. If fluid level is low, add recommended hydraulic fluid to bring
fluid up to “HOT” mark on dipstick. Replace filler cap.
Do not overfill a cold reservoir. Fluid could overflow when sys-
tem reaches operating temperature.
Safety Related
8-10 Engine/eng
Purging Air From Steering System
When system components have been serviced, pump must be refilled
with fluid before engine is started. Perform the following steps to purge
air from the steering system.
Do not run pump even momentarily without fluid. Pump will be
ruined or severely damaged.
1. With engine “OFF,” turn helm all the way to port. Add power steering
fluid to bring fluid level to “COLD” mark on dipstick.
2. Start engine, run momentarily and shut off engine. Recheck fluid level
and fill to “COLD” mark. Repeat this step as necessary until system no
longer requires additional fluid.
3. Complete purging of air from system by starting engine and turning
wheel slowly lock-to-lock. Maintain fluid level above pump body in res-
ervoir.
4. Returning fluid with air in it will often be in the form of foam and will
have a light tan or red appearance. Maintain fluid level high enough so
foam is not drawn into pump inlet. All air must be eliminated from fluid
before normal steering action can be obtained. If excessive foam accu-
mulates in reservoir it must be removed, or let unit stand for an hour and
repeat steps above.
5. After all air has been purged, return wheel to centered position. Con-
tinue to run engine for several minutes and then shut engine off.
6. With engine “OFF” and with fluid at normal operating temperature,
recheck to make sure fluid level is at “HOT” mark on dipstick.
7. Water test the boat to make sure the steering functions normally and
is free from noise.
Engine/eng 8-11
Alt. Alt.
Circ.
Pump
Circ.
Pump
P/S P/S
C/S or Idler Crank
shaft
1 2 3
DR4933 DR4933A 23916A
Power Steering Pump Belt Adjustment

3.0GS, 4.3Gi, 5.0Gi, 5.7GSi 7.4Gi, GSi and 8.2GSi Models
1 2 These models have serpentine belts. The belt tension

is maintained by a belt tensioner. No adjustment is necessary.
4.3 GL, GS, Gi, 5.0 GL, Gi, and 5.7 GS Models
4 6 7 To increase belt tension: Loosen pump mounting

4
bracket screws, insert a 1/2 in. breaker bar into the square hole in the 24278
pump mounting bracket, and pivot pump away from engine as shown.
While maintaining pressure on pump, retighten all mounting screws.
Recheck belt tension.
4 7 With engine stopped, the belt should be tight enough
so that it will deflect 1/4 to 1/2 in. (6-13 mm) when pressed with the
finger at the point indicated 3 . If the belt is too tight, excessive belt
and bearing wear can occur. If it is too loose, slippage can occur, re-
sulting in belt wear and poor power steering operation. Belt tension
should be checked after 10 hours of service and every 50 hours there-
after. 5
DRC7451
1 Power Steering Pump Pulley
3 Belt Tension Check Point
Check power steering pump belt tension 3 midway between the circu-
lating pump pulley 2 and the power steering pump pulley 1 . Retighten
new belt, or check old belt, after 10 hours service and every 50 hours
thereafter.
When adjusting a power steering pump belt, never pry against
the pump reservoir or pull against the filler neck.
6
20510
8-12 Engine/eng
7 8 9
47507 16067 DR2959
Steering Cylinder 5 I
9 The steering cylinder assembly is a combination power cylinder
and control valve. A piston rod clevis A provides the attachment to the
steering arm and steering cable ram. The steering cable casing attaches
to the threaded valve B .
Cylinder Removal F 3
10 1. Turn helm to port full lock position. Remove the cotter pin C and 10
D 20572
the steering cable pin .
11 2. Hold steering tube with wrench. Loosen steering cable anchor
nut E and pull steering cable out of valve.
A
12 3. Remove cotter pin, then pull pin F out of clevis and steering
arm.
13 4. Remove both hose fittings G from the valve. Raise hoses and
cover the ends to keep out dirt.
Do not move cylinder rod in or out until cylinder has been
drained completely. A dangerous spray of fluid can discharge from 11
the cylinder ports if the rod is moved in or out. 20606
B 4 C
12
20504
13
20583

1 2 3
20503 20580 20579
1 5. Remove cotter pins Aand loosen both anchor screws B until

steering cylinder assembly can be removed.
Cylinder Servicing
2 1. Pry out steering pivot bushings C
if they are to be replaced. If
necessary they may be carefully drilled in two places with a 1/16 in.
(1,5 mm) drill bit and then removed.
2. New bushings should be lubricated and pushed into place. 4
20576
3 3. The cylinder rod should be wrapped with heavy paper or paste-
board and held in a vise with Rod Holder, Volvo Penta P/N 3854367-4,
D . To remove the clevis E , unscrew the 19 mm locknut F .
3 4. To reinstall clevis, tighten piston rod locknut F to 23-

28 ft. lb. (31-38 N m).
•
Cylinder Installation
4 1. Install anchor screws B flush with inside of inner transom
bracket.
5 2. Apply Volvo Penta Grease to both bushings.
5
31842
Filling the bushing pockets with grease can cause the screws
to hydraulically lock and break the transom plate when tightened.
6 3. Position steering cylinder assembly on inner transom
bracket. Align bushings of steering cylinder with screws. Hand start
both anchor screws to ensure alignment and engagement into bush-
ings. Tighten anchor screws to 40-45 ft. lb. (54-61 N m).
•
1 4. Install cotter pins A through holes in transom bracket

from transom side. Spread ends of cotter pins to secure.
Do not move cylinder rod if cylinder contains any fluid. A 6
20574
dangerous spray of fluid may discharge from the ports.
7
20573
B 4 C F
8 9 D 10
20504 31837 20570
7 5. Connect hoses to cylinder. Start each fitting by hand. Tighten

pressure fitting G to 10-12 ft. lb. (14-16 N m). Tighten return fitting H to
• G
15-17 ft. lb. (20-23 N m).
•
8 6. Pull steering arm I into hydraulic cylinder clevis J . Align

holes and install large pin K from top of arm. Secure large pin by
installing and spreading ends of cotter pin.
Cable Installation
9
11
1. Turn the steering wheel to fully extend the steering cable 20506
ram to its maximum extension. Lubricate the full length of the steer-
ing cable ram with Volvo Penta Grease
10 2. Retract steering cable ram L and insert ram through valve M . A
11 3. Hold steering cable anchor nut back on cable casing to make
certain the steering cable is completely seated in end of valve.
12 4. While holding steering cable tight against valve, thread steering
cable anchor nut N onto valve until snug.
10 13 5. Hold cable tube with a 22 mm wrench on the flat O .
Attach a crowfoot wrench at 90° to a torque wrench P and tighten the 12
20606
steering cable anchor nut to 120 in. lb. (14 N m). •
14 6. Align cable ram Q with steering cylinder clevis R and in-

stall small pin from top of clevis. Secure small pin by installing and H
spreading ends of cotter pin.
7. Fill system with fluid and remove all air. See Purging Air From Steer-
ing System.
13
20605
14
20507

Lubrication
1 Lubricate the steering ram with Volvo Penta Grease ev-
ery 50 hours or once a season, which ever comes first.
Due to local conditions, it may be necessary to lubricate your
steering ram at more frequent intervals.
Hoses
Do not start engine with any power steering hose disconnected. 1 D
31837
The pump output fitting has metric threads. Do not attach a hose
with SAE threads to the pump fitting.
After connecting power steering hoses, make sure that there’s ample
clearance between the hoses and drive belts and other components.
Hoses installed out of position may rub during operation and be dam-
aged.
If fluid return hose is removed at pump, be sure to use a “worm drive”
clamp when reinstalling it.
System Diagnosis
Complaints of faulty steering are frequently the result of problems other
than the steering cylinder assembly or pump. Conditions such as hard
or loose steering, or vibrations, are often related to such factors as the
drive belt; pump and cylinder mounting; fluid level; or incorrect installa-
tion of the steering cable. These factors should be checked and cor-
rected before disassembling or replacing parts of the steering system.
System Checks
Many factors affect power operation of the steering system. Some of

the most common problem areas are:
• Fluid level.
• Loose or worn drive belt, or oily belt.
• Steering cable jammed against something in boat at
stern.
• Steering cable too short or steering cable too long.
• Loosely mounted components.
• Loose pump pulley.
8-16 Engine/eng
After the problem has been found, determine the cause. For example, if
the fluid level in the reservoir is found to be low, refill and bleed the
system and check the entire hydraulic system for leaks. Just refilling the
reservoir will make the unit operate, but will not correct the condition
that caused the problem.
Trim Tab Adjustment

Models With Power Steering
Trim tab adjustment is not required on power steering installations.
Models Without Power Steering
Safety Warning: Improper trim tab adjustment can cause diffi-

cult steering.
An adjustable trim tab is provided to compensate for propeller torque
and allows you to balance steering effort in either direction. Test your
boat to see if further adjustment is needed.
• With a firm grip on the steering wheel and the weight in

the boat evenly distributed, run the boat at full throttle in
a straight line. Do this in an area where current and wind
will not be a factor.
• Turn the steering wheel to port and starboard. Determine
which direction requires the least amount of steering ef-
fort.
Safety Warning: When adjusting the trim tab, stop the engine
and raise the vertical drive out of the water.
• If less steering effort was required in a port turn, loosen

the trim tab screw and move the rear edge of the trim tab
slightly to the port. Tighten screw.
• If less steering effort was required in a starboard turn,
loosen trim tab screw and move the rear edge of the trim
tab slightly to the starboard. Tighten screw.
• Repeat the above procedure until steering effort is equal
D
2
in both directions.
• After adjustment is complete, tighten the trim tab screw
A
to a torque of 14-16 ft. lb. (19-22 N m). •
Set both trim tabs to the same position for twin engine installa-
tions where trim tabs are used.
C
2
34130B

Tie Bar Adjustment - Twin Engine Installation
1 2 On deep Vee shaped boat hulls, a toe-in condition should
D
be created for improved performance and efficiency. A commonly used
toe-in condition is one in which dimension A will be 1/4 to 3/8 in. (6,35
to 9,53 mm) less than dimension B . Remove the steering tie bar from
the port tiller arm. Loosen port jam nut C of the tie bar. Turn jam nut
out 1/16 to 3/32 in. (1,59 to 2,38 mm) D as required, and screw in port
steering tie bar end E . Retighten the jam nut C . E
Threads of the port tie bar must be visible through the in-
1
DR3026
spection hole F to insure adequate thread engagement between
the rod and tube. Failure to ensure proper threads engagement
could result in component failure resulting in possible loss of
steering control.
H G I
1 For DP-S sterndrive twin installation the vertical drive must be
adjusted so operation is free from ventilation. To adjust, measure the
distance A between the center line of the two transom brackets. Ad-
just tie bar so the distance B between the center of the anti-ventilation
plate is equal to distance A . F
Hold the vertical drive when measuring. 2
21085A
8-18 Engine/eng
Power Steering System Diagnosis Chart
Condition Possible Cause Correction
SYSTEM NOISE:
Pump noise "chirp." Loose belt.* Adjust belt tension to specification.*
Belt squeal. Loose belt.* Adjust belt tension to specification.*
"Hissing" sound. Some noise exists in all power steering None; a slight "hiss" is normal and in
systems. "Hiss" may be expected when no way affects steering.
turning the steering wheel, particularly at
low speed.
Rattle Pressure hose touching other parts of Adjust hose position.

powerhead.
Rattle or chuckle. Steering system looseness. Check cable nut and cylinder pivot
points for wear or looseness. Replace
bushings if necessary.
Groan Low fluid level. Find and repair leak. Fill reservoir and
bleed system.
Air in fluid. Fill reservoir, find and repair leak.

Check connections, bleed system.
Growl Excessive back pressure caused by hose Locate restriction and correct.
restriction. Replace part if necessary.
Pump growl. Incorrect steering cable adjustment. Cable Adjust cable per procedure. Eliminate
to boat interference. interference.
Whine in pump. Pump shaft bearing scored. Flush system, replace pump.
SYSTEM OPERATION:
Excessive wheel Steering cable attachment loose. Replace pin. Tighten steering cable
kickback or loose anchor nut.
steering (not boat
wander). Air in system. Add fluid to pump reservoir and bleed
system. Check all connections.
Steering wheel surges or Loose pump belt. Adjust tension to specification.

jerks when turning with
engine running, Air in fluid. Fill reservoir, find and repair leak.
especially during slow Bleed system.
speed operation.
Insufficient pump pressure. Replace pump if defective.
Momentary increase in Pump belt slipping. Tighten or replace belt. If oily, fix leak.
effort when turning wheel
fast to right or left. Low fluid level. Fill reservoir and bleed system.
High internal leakage. Replace pump if defective.
* Does not apply to

serpentine belts.
Engine/eng 8-19
Condition Possible Cause Correction
Hard steering or lack of High internal leakage. (Power cylinder or Replace pump is defective. Replace
assist. pump.) cylinder if defective.
Cable jacket movement restricted Do not clamp cable tight near output
(bulkhead, fuel tank, jammed against inside end. Eliminate interference.
of hull).
Adjust belt tension to specification.*
Loose pump belt.*
Fill to proper level. If excessively low,
Low fluid level in reservoir. check all lines and joints for evidence
of external leakage, torque to specs.
Lubricate, relubricate at proper

Lack of lubricant in lube points. intervals.
Find reason for excessive friction;

Excessive friction in steering linkage. relubricate or repair.
Eliminate small radius.

Cable has too tight a radius at output end.
Remove all cable anchors, tie straps,
Cable movement restricted by tie straps, etc. on cable between last bend and
anchors, attached wires, etc. valve attachment point.
Replace pump if defective.

Insufficient fluid pressure.
Hard steering to Cable too long or movement restricted by Replace cable, or eliminate restriction.
starboard. bulkhead, etc.
Hard steering to port. Cable too short or movement restricted by Replace cable, or eliminate restriction.
bulkhead, etc.
Low fluid pressure due to Check for kinks in hoses. Remove kink.
restriction in hoses.
Foreight object stuck in hose. Remove restricting object or replace
hose.
Low fluid pressure due to Loose belt. Adjust tension to specification.

steering pump.
Low fluid level. Find and repair leak. Fill reservoir and
bleed system.
Air in fluid. Fill reservoir, tighten fittins and hose

clamps. Bleed system.
Defective hoses. Correct as necessary.
Pump worn or damaged. Flush system, replace pump.
Foaming milky power Air in fluid and loss of fluid due to internal Check for leak and correct. Bleed
steering fluid, low level pump leakage causing foaming and system. Keep fluid level up when very
and possible low overflow. cold. If fluid level is correct and pump
pressure. still foams, replace pump.
* Does not apply to

serpentine belt models.
8-20 Engine/eng
External Leakage
General Procedure
1. Wipe suspected area dry.

2. Check for overfilled reservoir.
3. Check for fluid aeration and overflow.
4. Check hose connections - tighten if necessary.
5. Determine exact point of leakage.
6. When service is required, replace component.
Leakage Checks
Although some leaks are easily found, seepage type leaks may be dif-
ficult to pinpoint. Locate seepage leaks as follows:
1. With the engine off, wipe the complete power steering system dry
(pump, hoses, and connections).
2. Check the fluid level in the pump reservoir and adjust as directed.
3. Start the engine and turn the steering wheel from stop-to-stop several
times.
4. Find the exact area of leakage.
Easily Fixed Leaks
1. Loose clamp on pump return hose.

2. Loose pump or cylinder hose fitting. If fittings are not cross-threaded,
tighten to correct torque. See Torque Specifications.
3. Damaged O-ring on pump pressure fitting. Replace O-ring.
4. External leakage of power cylinder. Replace power cylinder.
5. Leakage of fluid in cooling water. Replace oil cooler.
6. Damage or cracked hose. Replace hose.
If the return hose is removed, the clamp must be replaced with a worm
drive clamp. Replace leaky hoses.
Engine/eng 8-21
1 2
DR3009 DR1443
Pump Leakage 2. Remove filler cap from pump reservoir and check fluid
level. Fill pump reservoir to full mark on dipstick. Start
1 1. An overfilled pump reservoir can cause a leak. engine, momentarily hold steering wheel against stop,
The fluid in the steering system expands as it heats up and check connections at tool for leakage.
during normal usage and fluid level rises in reservoir.
3. Bleed system as outlined under Purging Air From
Excess fluid is forced through the breather cap hole
Steering System.
where it may be sprayed over the engine by the drive
belt. 4. Insert Kent-Moore Thermometer Tool, J-5421 into res-
1 2. Install new O-ring. Tighten hose fitting A
ervoir filler opening. Start the engine and move steering
to 15-
wheel from stop-to-stop several times until thermometer
26 ft. lb. (20-35 N•m). If leakage persists, replace pump
indicates that hydraulic fluid has reached its normal op-
or hose as required.
erating temperature of approximately 150° to 190° F (65°
1 3. Check torque on fitting B . Tighten to 37-75 ft. to 88° C).
lb. (50-102 N•m). If fitting is not loose, replace pump.
5. Check fluid level; add fluid if required. When engine
1 4. Check fluid level C. If leakage persists with fluid is at normal operating temperature, the pressure read-
at correct level and cap tight, replace cap or pump. ing on the gauge (valve open) should be in the 50-100
1 5. Some non-repairable pump leakage areas are PSI (345-690 kPa) range. If pressure exceeds specifi-
marked with the oil-drop symbol. If leakage occurs in cations, check the hoses for restrictions.
these areas, replace pump. 6. Pump relief valve pressure can be checked by
momentarily closing the shutoff valve. Do not leave
Pump Pressure Test valve closed longer than it takes to read gauge; high
hydraulic pressures are developed. Relief valve pres-
2 1. With engine off, disconnect high pressure (out-
sure is approximately 1000-1100 PSI (6895-7584 kPa).
put) hose at pump. Use a spare pressure hose D to
install Kent-Moore Tool, J-5176-E E between pump and Replace pump if fluid pressures or temperature do not
steering cylinder pressure hose F . Gauge must be po- meet specifications.
sitioned between shutoff valve and pump. Connect steer-
ing cylinder pressure hose to shutoff valve. Open shut-
off valve.

Cable Installation Problems
The hydraulic valve reacts to steering cable casing movement. Total
valve movement is about 1/4 inch. This small motion is sufficient to op-
erate the valve and direct hydraulic pressure to the appropriate side of
the steering cylinder. Any restriction of movement of the steering cable
casing at the stern of the boat will limit or restrict the movement of the
valve and will result in hard steering in one or both directions.
When replacing the steering cable, the following points must be fol-
lowed for proper power steering system operation:
3
DR1450
3 1. Do not install a cable that is too short. Inadequate length 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 ten-
dency to self steer to starboard.
4 2. Do not install a cable that is too long. Excessive length will push
on the cable casing, and cause binding of the steering cable. This will
restrict valve movement, cause hard steering to starboard and a ten-
dency to self steer to port.
3. Do not position steering cable in a sharp bend of less than 6 in. ra- 4
dius. Tight bends will cause binding and limit control valve movement. DR1451
This will contribute to hard or uneven steering, or rough steering wheel

movement.
5 4. Do not jam anything against cable at the engine end. Do not bind
cable against inside of boat or against fuel tanks, battery boxes or flota-
tion blocks. Jamming the steering cable will restrict steering cable move-
ment and cause hard steering.
6 5. Do not interfere with or restrict steering cable movement through
the last 90° of bend to the engine. Cable retainers, clips, clamps or tie
straps should not be used in a manner that will restrict the cable move-
ment near the engine. Do not attach wiring harness or control cables to
5
DR1452
this end of the steering cable.
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 may hold the valve in one steering mode.
6
DR1453

Feedback To The Helm
The steering system requires at least a little friction in the helm (and
cable) to prevent hydrodynamic forces on the gear case from feeding
back and turning the steering wheel without the operator activating the
power assist system. This may happen on single engine installations
(or on twin engines having both drives rotating in the same direction).
Run the 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, momentarily release the steering
1
DR5643
wheel to see if the wheel is turned by the gear case, 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 power steering system to
hold the desired steering position.
1 2 If the helm always turns in one direction (when it turns), it
may be caused by a 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” A or for
“toe-out” B of the vertical drives. Refer to Tie Bar Adjustment found 2
DR5644
in this section.
Safety Related
8-24 Engine/eng
Specification
Power Steering Pump Relief Valve Pressure ......................................................... 1000-1100 psi (6895-7584 kPa)
Component Torque
Anchor Screw - Cylinder assy. to Transom Plate 40-45 ft. lbs. (54-61 N m)
•
Bolts - Power Steering Pump Mounting Bracket 25 ft. lbs. (34 N m)

•
Bolts - Power Steering Pump Mounting 25 ft. lbs. (34 N m)

•
Fitting - Power Steering Pump 37-75 ft. lbs. (50-102 N m) •
Fitting - Power Steering Pump Hose 15-26 ft. lbs. (20-35 N m)

•
Fitting - Inlet Control Valve Hose 10-12 ft. lbs. (14-16 N m)

•
Fitting - Outlet Control Valve Hose 15-17 ft. lbs. (20-23 N m)

•
Hose Clamps - Oil Cooler and Power Steering Pump 12-17 in. lbs. (1,4-2,0 N m) •
Jam Nut - Anchor Block 35-40 ft. lbs. (47-54 N m)

•
Locknut - Piston Rod To Clevis 23-28 ft. lbs. (31-38 N m)

•
Nut - Steering Cable Anchor 120 in. lbs. (14 N m)

•
Screw - Trim Tab 14-16 ft. lbs. (19-22 N m)

•
Safety Related
Engine/eng 8-25
8-26 Engine/eng
Section 9
Throttle and Shift Control Systems
Table of Contents
Check Remote Control Shift Cable Stroke ....................................... 9-4

Installation of SAE Cables to Engine/Drive ...................................... 9-5
Shift Cable to Vertical Drive ........................................................... 9-5
Throttle Cable to Engine ................................................................. 9-6
Installation of Shift and Throttle Cables ........................................... 9-3
Neutral Start Switch Tests ................................................................. 9-8
Removal of SAE Cables From Engine/Drive .................................... 9-9
Shift Cable from Vertical Drive ....................................................... 9-9
Throttle Cable from Engine ............................................................ 9-9
Sealants, Lubricants and Adhesives ................................................ 9-2
Engine/eng 9-1
Safety Warnings
Before working on any part of the steering system, read the Safety
section at the end of this manual.
Replace any locking type fastener (example: locknut or patch
screw) whose locking feature becomes weak. Definite resistance
to turning must be felt or locking fastener is not suitable for con-
tinued use. Replace only with authorized replacement part or
equivalent.

Volvo Penta Grease
9-2 Engine/eng
Installation of Shift and Throttle Cables
Shift cable should “PULL” for forward gear on right-hand rotation
SX and DP-S propeller applications. Shift cable should “PUSH” for for-
ward gear on left-hand rotation SX propeller applications. Throttle cable
should “Push” to close for Volvo Penta remote controls. Failure to do
so could result in loss of control of the boat and possible injury to
the boat occupants.
1. If the remote control shift and throttle cables are installed in the re-
mote controls, proceed to Check Remote Control Shift Cable Stroke.
2. If the remote control shift and throttle cables have not been installed,
the following procedure will permit you to order the correct length re-
mote control shift and throttle cables.
1 3. Measure the proposed route of the remote control shift and
throttle cables. All bends must have a radius greater than 6 inches (15,2
cm).
• Remote control shift cable: A

Add A + B plus 20 in. (50.8 cm), round up to next cable
length.
C
• Remote control throttle cable:
Add A + B + C plus 4 in. (10.1 cm), ( C is to center of
throttle arm pin). Round up to next cable length. B
When removing shift and throttle cables from the packing box, 1
DR4939
DO NOT bend the cables tighter than a 6 inch radius.

Check Remote Control Shift Cable Stroke
1 1. Move the remote control handle to the wide-open-throttle posi-
tion in the direction needed to retract the shift cable. Pull out cable
core wire to remove end play. Mark cable core wire at end of casing.
2 2. Return remote control shift handle to the neutral detent posi-
tion. Measure and record the distance between mark A and end of
casing.
3 3. Mark cable core wire at end of casing with control in the neu- 1
tral detent position. 36560
4 4. Move the remote control handle to the wide-open-throttle posi-

tion in the direction needed to extend the shift cable. Push in on cable
core wire to remove end play. Measure and record the distance be-
tween mark B and end of casing.
D
• The distance between forward and neutral must be no
less than 1¼ in. (31.8 mm) and no greater than 1 3/ 8 INCHES 1 2 3
in. (35.0 mm).

• The distance between neutral and reverse must be no
less than 1¼ in. (31.8 mm) and no greater than 1 3/ 8 2
36561
in. (35.0 mm).
Check your remote control installation instructions, if your mea-
surements are not within these specifications. Make sure the cables
are attached correctly inside the control box and move in the proper
direction for your application before continuing. Refer to the remote
control installation instructions for this information. All control boxes
must meet these minimum and maximum specifications in order for
the shift system to function properly.
3
36562
INCHES 1 2 3
4
36563
9-4 Engine/eng
Installation of SAE Cables to Engine/Drive
If the throttle cable is attached to the throttle arm and anchor
block, remove it from both. The throttle cable must be disconnected
from the throttle arm prior to shift cable installation and adjustment to F G
prevent “loading” the control box and adversely affecting shift adjust-
ments.
Before beginning, shift remote control handle into NEUTRAL detent po-
sition; the propellers should rotate freely.
5
Remote control shift and throttle cables must be SAE type 34045
cables.
Shift Cable to Vertical Drive

5 1. Note position of small seal and large seal D on the shift
C
cable, Remove and retain jam nut E , small seal, and large seal from
the shift cable.
6 2. Apply a light coat of Volvo Penta Grease to the end of the re-
mote control shift cable casing. Slide shift cable through shift cable tube
until it appears on the outside of the transom.
6
7 3. For ease of installation of shift cable, turn vertical drive to port. 34044
Reinstall the retained large seal D

and small seal C onto the shift
cable in the same position as noted in step 1.
8 4. Loosen cable clamp screw F and pull clamp out.
9 5. Slide shift cable through pivot housing and vertical drive.
Slide clamp in fully, engaging the shift cable anchor groove. Tighten G
clamp screw F securely.
F
7
47553
8 A
47554
9
34038

D
B
1 2 C 3
47131 47132 47130A
1 2 7. Rotate shift lever A

to extend bell crank B . Remove
cotter pin, flat washer, and anchor pin C .
3 8. Thread anchor pin halfway onto remote control cable end.
4 9. Rotate shift lever back to neutral detent position, then move
remote control handle to its neutral detent position. Turn anchor pin IN E
or OUT until it aligns with center of bell crank slot D .
5 10. Install anchor pin, flat washer, and cotter pin E . Spread
prongs of cotter to secure anchor pin. Install jam nut F and tighten 4
47133
securely against anchor pin.
6 11. Reinstall rear cover and secure with three original screws G .
Tighten screws to 108-132 in. lb. (12-15 N m).
•
Throttle Cable to Engine

G
Determine whether you have a “push-to-close” or “pull-to-
close” remote control system. Cable attachment point at throttle arm
is determined by direction of control cable movement. Incorrect at-
tachment may cause hazardous boat operation.
F
The remote control shift cable must be installed prior to throttle 5
47134A
cable installation. This will ensure proper throttle and shift system op-
eration when using single lever controls.
1. Position control handle in NEUTRAL and propeller should rotate
freely. Turn propeller shaft and shift into the FORWARD gear detent C
position, then pull handle HALFWAY BACK towards NEUTRAL. This
positions the control for proper throttle adjustment. Failure to follow
this procedure can result in “hard shifting” out of NEUTRAL.
2. Make sure throttle lever is against idle stop screw. C
7 3. Align internal bosses H of trunnion with throttle cable groove
I . Press trunnion on throttle cable until seated. 6
47557
E
7
34751
8 V6 and Small Block V8 Models Only: The engine throttle
5.0Gi
5.7GSi 4.3GL
4.3GS
cable anchor block bracket has several sets of anchor block holes. The
sets of holes marked with a “V” J are used for Volvo Penta engines. 5.0GL
The set of holes K marked “GSi” are for 5.0 and 5.7 Liter EFI models.
5.7GS
The set of holes L marked “43” are for 4.3 Liter 2V (2 barrel) and 4V (4
barrel) carburetor models. Holes M are for all 5.0 and 5.7 Liter, 2V (2
barrel) and 4V (4 barrel) carburetor models. The anchor block will be
set at the correct position from the factory for your particular engine.
9 3. Install open end N of trunnion in anchor block. Install screw 8
in anchor block and position throttle cable assembly in selected set of DRC7279
holes. Locknut O must be against the anchor bracket, tighten it

securely.
C D
10 4. Throttle arm connector P must have a minimum of 9
full turns or 1/4 in. (6,4 mm) of throttle cable thread engagement. B
Install throttle arm connector onto the throttle cable. Pull connector for- 4V
ward to remove all end play from throttle cable, then turn the connector A
in until hole aligns with the “push-to-close” Q or “pull-to-close” R
throttle arm stud.
If throttle arm connector hole cannot be adjusted to align with 9
the throttle arm, check for proper cable installation in the remote control DR4977
box.
11 12 5. Install connector onto appropriate throttle arm stud.
Install washer and cotter pin S , and secure by spreading end of
E
cotter pin. Tighten locknut T against connector.
• All Models Except 7.4 GSi and 8.2 GSi 11
• 7.4 GSi and 8.2 GSi Models Only 12 F

10
DR5095
G
11
DR5094
12
DR5707

Neutral Start Switch Tests
Electrical
1. All switches must be in the “OFF” position, then discon-

nect battery cables at the battery before servicing electrical sys-
tems. Failure to do so could result in injury from:
• shorted battery positive (B+), causing a burn or an

electrical fire.
• contact with moving parts, if the engine is acciden-
tally cranked or started.
2. Move the control handle to the NEUTRAL position. Disconnect the
yellow/red lead from the key switch and the yellow/red lead from the
instrument wiring harness.
3. To test the continuity, calibrate an ohmmeter on high ohms scale.
Connect the ohmmeter to the two leads. The meter should read zero
(0).
4. Move the remote control handle to the FORWARD gear position.
The meter should read infinity (¥). Move the remote control handle to
the REVERSE gear position. The meter should read infinity (¥).
5. If the meter does not show (¥), check the ohmmeter connections
and test again. Replace the neutral start switch if the meter still fails to
show (¥) when the remote control handle is in the FORWARD and
REVERSE gear position. Refer to the procedures in Disassembly of
Remote Control to replace the neutral safety switch.
Mechanical
1. With the boat in water and the remote control in NEUTRAL, turn the
ignition key to the start position. The engine should start.
2. Disengage the remote control handle and move it into the FOR-
WARD warm-up position. The engine should start.
3. Disengage the remote control handle and move it into the REVERSE
warm-up position. Again the engine should start. Move the remote con-
trol handle back into NEUTRAL.
4. Move the remote control handle to the FORWARD gear position.
The engine should NOT start. Move the handle to the REVERSE gear
position. Again the engine should NOT start.
5. If the engine starts when the remote control handle is in either the
FORWARD or REVERSE gear position, replace the neutral start switch.
Refer to the procedures in Disassembly of Remote Control to re-
place the neutral safety switch.
9-8 Engine/eng
Removal of SAE Remote Control Cables
H
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 of remote control cables.
Before beginning, shift remote control handle into NEUTRAL detent po-
sition; the propeller should rotate freely.
G
Throttle Cable From Engine
1 2 1. Remove cotter pin and flat washer A

1
from throttle arm. DR5094
• All Models Except 7.4 GSi and 8.2 GSi 1
• 7.4 GSi and 8.2 GSi Models Only 2

1 2 2. Loosen anchor retainer nut B and rotate retainer C away
from cable trunnion. Remove throttle cable from throttle arm and an-
chor bracket.
Shift Cable From Vertical Drive
3 1. Remove drive’s rear cover. Remove flat washer and cotter pin 2
D from anchor pin. Remove jam nut E from shift cable core wire. DR5707
4 2. Remove anchor pin F from bell crank slot. Unscrew anchor pin
from shift cable core wire.
5 3. Loosen screw and slide retainer out of shift cable anchor groove.
Pull the shift cable from drive and transom bracket cable tu be.
E
D C
3
47127
4
47133
5
34038
Engine/eng 9-9
Section 10
Cooling System
Table of Contents
Components
Circulating Pump - Engine ........................................................... 10-7
Hoses, Clamps and Drain Plugs .................................................. 10-6
Manifolds and Elbows ................................................................... 10-7
Supply Pump
3.0 GS Models Only .................................................................... 10-8
V6 and V8 Models Only .............................................................. 10-9
Thermostat ..................................................................................... 10-6
Description ........................................................................................ 10-2
Draining
Engine Block or Exhaust Manifold ............................................ 10-11
Pivot Housing .............................................................................. 10-14
Power Steering Coolers .............................................................. 10-13
Supply Pump
3.0 GS Models Only .................................................................. 10-13
V6 and V8 Models Only ............................................................ 10-14
Thermostat Replacement ............................................................... 10-14
Troubleshooting
Isolating Problem .......................................................................... 10-4
Possibilities to Consider .............................................................. 10-4
Quiz the Customer ........................................................................ 10-3
Water Flow Problem Checkpoints ................................................. 10-17
Water Flow Diagrams
Vertical Drive and Transom Bracket .......................................... 10-19
3.0 GS Models .............................................................................. 10-20
4.3 GL Models .............................................................................. 10-21
4.3 Gi Models ............................................................................... 10-22
5.0 GL Models .............................................................................. 10-23 10
5.0 Gi Models ............................................................................... 10-24
5.7 GS Models .............................................................................. 10-23
5.7 GSi Models ............................................................................. 10-24
7.4 Gi and GSi Models ................................................................. 10-25
8.2 GSi Models ............................................................................. 10-25
Safety Warnings
Before working on any part of the cooling system, read the section
called Safety at the end of this manual.
Engine/eng 10-1
Description
1 Water is supplied to the engine by means of an impeller type pump
(supply pump). The water supply pump is mounted on the engine. Wa-
ter supplied to the engine is circulated in the engine by means of a
centrifugal type pump (circulating pump).
All models use a crankshaft mounted pump. During low speed opera-
tion the impeller functions as a positive displacement pump. At higher
speeds it functions as a combination centrifugal and positive displace-
ment pump.
1
DRC7621
The shape of the housing and/or 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 pump is
sufficient to prevent the ends of the impeller blades from making con-
tact and following the inside perimeter of the pump housing. The blades
merely flex in toward the center of the impeller to perform as a combi-
nation centrifugal and positive displacement pump.
2 3 The circulating pump is mounted on the front of the cylinder
block. It has a pulley bolted to the pump shaft hub at its forward end.
This in turn is driven by means of a belt from the crankshaft pulley. The 2
DRC6871
pump shaft and bearing assembly is pressed in the water pump hous-
ing. The bearing is permanently lubricated during manufacture and
sealed to prevent loss of lubricant and entry of dirt. The pump is sealed
against coolant leakage by a non-adjustable seal assembly pressed
into the pump cover.
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
gearcase until 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 3
meets a nipple and hose attached to the pivot housing. Water is routed DRC6872
through the transom mount assembly to a tube that’s mounted on the

inside of the gimbal housing. From this tube the water is drawn through
a supply hose that’s connected to the inside nipple of the supply pump.
Water exits the outside nipple of the supply pump under pressure and
carried through a hose to the inlet nipple of the thermostat housing.
10-2 Engine/eng
All Models: The water is now carried downward through In the event the engine cooling water is cold, as in first
the thermostat housing where it enters the flexible hose starting up, the thermostat will be closed and will not
which attaches to the inlet pipe of the circulating pump. allow any of the water to pass through for eventual dis-
This inlet pipe is a part of the pump cover and feeds the charge overboard. Instead, the water will be carried via
coolant into a low pressure area located at the axis of the flexible hose back to the circulating pump for recir-
the impeller. Vanes on the rotating impeller cause the culation within the block. While the water within the block
coolant to be thrown outward and into the cylinder block. is recirculating, the supply pump is pumping water to
the block.
The cooling water flows rearward through the water
jacket which surrounds each cylinder and extends be- Since this water is not able to enter the cylinder block, it
low the lower limit of piston ring travel. After flowing the is necessary to provide a method of discharge. This is
full length of the cylinder block, the water is forced up- provided by the bypass passage within the thermostat
ward through two passages and into the cylinder head(s). housing. If this were not provided, the resulting water
The water now flows forward in the cylinder head(s) to pressure would be enough to force the thermostat off its
cool the combustion chamber areas. seat, resulting in a greatly increased warm-up period.
At the forward end of the cylinder head(s), the water
Cooling System Troubleshooting
enters the thermostat housing. If the water within the
block is sufficiently warmed up, the thermostat will be 1. Quiz Customer for the Following Information:
open and a portion of the water will be pumped upward
a. How old is unit, how many hours of operation?
past the thermostat. The remainder will be returned via
(Wear and corrosion.)
the flexible hose to the water pump for recirculation within
the powerhead. The water which was pumped upward b. How long has problem existed? (Gradual or
past the thermostat will enter the hose(s) connected to sudden.)
the thermostat housing outlet(s) and travel to the mani-
c. What were the operating conditions prior to
folds.
problem? (Fresh or salt water, silty or sandy
At this point the water flows rearward through the mani- water.)
fold passages and into the high-rise elbow. All of the
d. What previous repairs and service have been
water that enters the high-rise elbow is mixed with the
made on unit? (Tune-ups, impeller replace-
exhaust gases prior to entering the exhaust pipe(s) and
ment, etc.)
hose(s). This mixture of exhaust gases and water then
enters the exhaust passages of the gimbal housing, pivot e. At what RPM does problem occur? (Low, high.)
housing and vertical drive where it is discharged under
water.
Engine/eng 10-3
2. Possibilities To Consider:
a. Temperature Gauge Malfunction.
• Improper or defective sender unit

• Malfunctioning gauge - Check ground wire - substitute
good gauge.
b. Engine Water Circulation Pump Malfunction.
• Loose alternator belt

• Impeller vanes worn - replace pump.
• Impeller shaft seal failure - replace pump.
c. Water Intake Screens Blocked.
d. Ventilation - Marine growth on keel, hull deformities, etc.
e. Ignition Timing
• Running with retarded timing - Check timing.

3. Isolating Cooling Problem:
Air or exhaust gas entering cooling water:

a. Procedure - Replace water hose between thermostat hous-
ing and the supply pump with clear plastic hose. Operate unit
in test tank or boat in water at RPM at which overheat occurs.
If operating unit in test tank, run motor in neutral. Some test
tanks may not have sufficient water volume to 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. Check for - Defective lower gearcase water tube guide and
seals; damaged water tube grommet; leaking water passage
cover gasket or adaptor-to-gear housing gasket.
10-4 Engine/eng
Insufficient water supply:
a. Procedure - Disconnect water supply hose from transom
bracket at thermostat housing. Operate engine at specified idle
RPM. Hold end of hose level with the top of the flame arrestor.
b. Results and 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.
c. Check for - Blocked intake screens; damaged impeller hous-
ing O-ring or impeller plate gasket; broken or worn impeller;
defective pivot housing water passage O-ring or water drain
screw seal; loose pivot housing-to-gimbal housing water hose
clamps.
Thermostat malfunction - overheating or slow warm-up:

a. Procedure - Operate engine until indicated temperature ex-
ceeds 160°F (71° C). Touch hoses between thermostat and
exhaust manifolds.
b. Results and Conclusions - Hoses cold, thermostat is stuck
closed. Hoses warm or hot, thermostat is good.
c. Check for - Thermostat stuck open or closed, defective ther-
mostat O-ring, correct thermostat style for engine type, clear
thermostat housing bypass passage.
Engine head gasket leakage - overheating or hard starting (water in

cylinders):
a. Procedure - Allow engine to cool. Replace water hose(s) be-

tween thermostat housing and exhaust manifolds) with clear
plastic hose. Operate unit at RPM at which overheat occurs.
b. Results and Conclusions - No bubbles evident, head gas-
kets not leaking. Bubbles evident, head gaskets leaking.
c. Check for - Cylinder compression using appropriate tester, wa-
ter in engine oil, water in cylinders, spark plugs wet with water.
Engine/eng 10-5
Cooling System Components
Hoses, Clamps, and Drain Plugs
For all models. No special tools required.
Inspection Procedure: Examine all external cooling system compo-
nents for leaks, wear, deterioration, and damage. Check all connec-
tions for tightness. Inspect hoses for cracks, checking or deterioration.
Repair Procedure: Repair or replace as required.
Water supply hoses used for replacement must conform to
S.A.E. 20R3, class D-2.
Thermostat
• All Models Except 7.4 Gi, GSi and 8.2 GSi: A 160° F
(71° C) thermostat is standard.
• 7.4 Gi, GSi and 8.2 GSi Models: A 140° F (64° C) ther-
mostat is standard.
Inspection Procedure: Check for proper rating and style, corrosion,
restricted movement, or broken spring. 1
DR3232
1 2 Test Procedure - All Models Except 7.4 Gi, GSi and 8.2
GSi: Immerse the thermostat and a thermometer in a container of wa-
ter. Heat water. Thermostat should start to open between 157-163° F
(70-73° C), and should open to 5/32 in. (3,96 mm) minimum A at 182°
F (83° C).
2 Test Procedure: 7.4 Gi, GSi and 8.2 GSi Models: Immerse the
thermostat and a thermometer in a container of water. Heat water. Ther-
mostat should start to open between 138-142° F (59-61° C), and should
open to 5/32 in. (3,96 mm) minimum A at 162° F (72° C).
• 3.0 GS Models 1
2
DR3051
• All V-6 and V-8 Models 2

Repair Procedure: None, replace unit.
10-6 Engine/eng
Manifolds and Elbows
Inspection Procedure: Pressure check components for leaks. Disas-
semble and inspect for corrosion or accumulation of foreign material.
Repair Procedure: Rod out any accumulation of foreign matter built up
in water passages. If evidence of porosity between water passages and
exhaust chambers or exterior is found, replace component. Install new
gaskets on reassembly.
Circulating Pump - Engine

Inspection Procedure: Make sure belt tension is correct. With the en-
gine running, observe the rotation of the circulating pump pulley. If the
pulley does not run true it can cause excessive drive belt wear and dam-
age to the circulating pump itself.
If the leakage of water occurs at the circulating pump while the engine is
in operation, the pump may be loosely mounted to the engine, the shaft
seal in front of the pump may be bad, the backing plate gasket may be
defective, or the circulating pump mounting gaskets are leaking.
If the above inspections do not detect any defect, the pump must be
removed and inspected for internal corrosion, blockage, or damage. In-
spect 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 marine shaft seal
assembly. Do not replace with an automotive water pump.
Engine/eng 10-7
Supply Pump
Removal
1. Drain engine, refer to Draining Engine Block or Exhaust Manifold.

1 2. Loosen hose clamps and remove hoses from supply pump. Note:
The hose E is the inlet hose.
2 3. Loosen bracket mounting screws F and remove bracket.
Impeller Removal 1
49462
3 1. Remove the four screws G securing the housing.
4 5 2. Remove pump housing. Remove and discard O-ring A .
2
49465
3
49466
4
49467
5
49468
10-8 Engine/eng
6 3. Grasp impeller securely and pull from housing.
1. Clean all parts with solvent and blow dry thoroughly.

2. Clean sealing surfaces.
3. Inspect impeller housing wear, and housing for cracks and distortion
caused by freezing. Replace if necessary.
4. Inspect impeller; if blades are set in a bent position, cracked or bro- 6
ken, or show flat instead of rounded edges on the housing contact sur- 49469
faces, replace the impeller.

5. Check bearings for smooth operation.
Impeller Installation
7 1. Apply a light coat of Volvo Penta Grease grease to impeller

surfaces. Install impeller until seated in the housing.
8 2. Apply a light coat of Volvo Penta Grease grease to a new O-
ring A . Install the O-ring onto the pulley and shaft assembly B .
7
49470
8
49471
Engine/eng 10-9
1 2 3
49472 49473 49448
Installation
1 1. Install pump and secure with four screws C . Tighten screws to
19-24 in. lbs. (2,2-2,8 N m).
•
2 2. Orient pump assembly. Install bracket D and secure with screws

E . Tighten screws to 20-25 ft. lbs. (27-34 N m).
•
3 3. Attach the inlet hose F to large nipple and the outlet hose G to
the small nipple. Tighten hose clamps securely.
4
Draining Engine Block or Exhaust Manifold 23907
Some service work performed on the engine block and exhaust mani-
fold may require the complete drainage of those components.
3.0 GS Models
4 1. Disconnect and drain large hose I at water pump.

5 2. Remove the drain plugs from the cylinder block port side andJ
exhaust manifold K . Clear holes with a small wire to ensure complete
drainage.
5
46195
10-10 Engine/eng
4.3 Gi Models Only
6 1. Disconnect the small water by-pass hose A at the top of ther-

mostat housing.
7 2. Disconnect the water discharge hose Bat the port side ex-
haust elbow nipple. Lower to the front of the block. Blow out the water
trapped in the MOAS and lines by applying air to the by-pass hose.
All 4.3 Models

8 1. Remove the long water supply hose at the thermostat housing 6
49457
C . Lower it alongside block and drain it completely.
8 2. Disconnect and drain the large hose at the water pump D .
8 3. Remove intake manifold drain plug E and drain manifold. The
bow of the boat may have to be lowered to ensure complete drainage.
Reinstall the plug when draining is complete.
9 10 4. Remove drain plugs from the rear of the port and star-
board exhaust manifolds. Remove drain plugs on the port and star-
board side of the cylinder block. Clean holes with a small wire to en-
sure complete drainage.
7
44195
5.0 Gi and 5.7 GSi Models Only
6 1. Disconnect the small water by-pass hose A at the top of ther-
mostat housing.
7 2. Disconnect the water discharge hose Bat the port side ex-
haust elbow nipple. Lower to the rear of the block. Blow out the water
trapped in the vapor separator and lines by applying air to the by-pass
hose.
All 5.0 and 5.7 Models

8 1. Remove the long water supply hose at the thermostat housing 8
49458
C . Lower it alongside block and drain it completely.
9
49459
10
34102A
Engine/eng 10-11
1 2 3
49461 49460 42863
All 5.0 and 5.7 Models (continued)
1 2 3. Remove drain plugs F

at the rear of each port and star-
board exhaust manifold, and remove drain plugs G on both sides of the
cylinder block. Clear holes with a small wire to ensure complete drain-
age.
All 7.4 and 8.2 Models
3 1. Remove the long water supply hose at the thermostat housing

C . Lower it alongside the engine and drain it completely. 4
28283

3 3. Drain the small water by-pass hose H between MOAS the top of
thermostat housing. Disconnect the hose at the thermostat housing and
lower it alongside the engine and drain it completely.
4 5 4. Remove the rubber cap at the rear of each port and star-
board exhaust manifold. On 7.4Gi, remove drain plug on starboard side
and remove knock sensor on port side. On 7.4 and 8.2GSi Models re-
move drain plugs on both sides of the cylinder block. Clear holes with a
small wire to ensure complete drainage. 5
28284
Draining Supply Pump

6 1. Loosen and slide hose clamps back. Remove hoses A from the
pump and drain.
2. Crank the engine no more than 2 seconds (DO NOT START) to expel
any water trapped in water pump. Reattach hoses.
6
49462
10-12 Engine/eng
Thermostat Replacement
3.0 GS Models
7 1. Remove all hoses B from the thermostat housing.
8 2. Remove the engine coolant temperature sender nut, lead and
washers C from the sender.
9 3. Remove two screws E
securing thermostat housing to the cyl-
inder head. Remove the housing from the head. Clean all gasket sur-
faces.
7
45332
10 4. Remove thermostat O-ring F and thermostat G from the hous-

ing.
10 11 5. Install thermostat G
into the thermostat housing with the
pointed end H
facing into the housing. Place the O-ring F into posi-
tion in the O-ring groove to retain the thermostat.
8
45333
9
45335
10
45354
11
45355
Engine/eng 10-13
1 6. Place a new gasket I into position at the front of the head.
No sealer is required with this gasket.
2 7. Install the thermostat housing into position and secure with two
screws E . Tighten the screws to 12-16 ft. lbs. (16-22 N m).
•
3 8. Attach the engine coolant temperature sender washers, lead

and nut C to the sender. Tighten the nut securely. Install Temperature
switch lead onto switch terminal D . 1
45356
4 9. Install all hoses B and secure with clamps. Tighten the clamps
securely.
2
45357
3
45345
4
45344
10-14 Engine/eng
All V-6 and V-8 Models
5 6 1. Remove all water hoses from the thermostat housing.
• Carburetor Models: four hoses A 5
• EFI Models: five hoses B 6

7 2. Note position of lifting eye C
. Remove two screws D then
remove lifting eye and thermostat housing.
8 3. The thermostat E is held in place by an O-ring. Pry the O-ring 5
28546
out of its groove, then lift the thermostat out of the housing.
4. Discard the housing gasket and O-ring. Thoroughly clean the hous-
ing and manifold gasket surfaces.
8 5. Place the thermostat in the housing. The temperature sensing
element E must face you when installed. Install a new O-ring to seal
thermostat in housing. Make sure O-ring is completely seated in its
groove.
7 6. Coat both sides of a new gasket with Volvo Penta Gasket Seal-
ing Compound and place it on the manifold. Position thermostat hous-
ing and lifting eye on engine adapter as noted in Step 2. Install two lock
6
38259
washers and screws D . Tighten the screws to 20-25 ft. lbs. (27-34
N m).
•
9 7. Connect the water supply hose to nipple F

and tighten hose
clamp securely. Connect the three remaining water hoses and tighten
hose clamps securely. Make sure lifting eye C is positioned as shown.
If the water supply hose is attached to the wrong nipple, the
engine will overheat.
7
28548
8
14649
9
28547
Engine/eng 10-15
Water Flow Problem Checkpoints:
Numbers refer to Cooling System Flow Diagrams. 17 Cylinder Head - Corrosion, slag, blocked passages
1 or leaking gaskets.
Intake Screen - Blocked with debris.
2 18 Exhaust Manifold, Elbows, Gaskets, and Hoses
Water Tube Guide and Seal - Improperly sealed.
- Gaskets improperly installed; corrosion, sand, or
3 Water Tube - Plugged with debris. slag in manifold and elbows; hoses collapsed,
4 Grommet - Deteriorated, improperly seated. burned through, or leaking.
5 Upper Gear Housing - Debris blocking passage, 19 Exhaust Pipe and Seal - Improperly sealed or in-
freeze damaged. stalled, leaking.
6 Pivot Housing Seal - Damaged, out of position, 20 Bellows, Clamp, and Retainer - Loose clamp,
improperly sealed. detached or torn bellows.
7 Nipple O-ring - Out of position, improperly sealed, 21 Power Steering Cooler - Restricted, or cracked
damaged. and leaking.
8 Nipple - Blocked by debris, freeze cracked. 22 Intake Manifold - Cracked casting, or leaking
gasket(s).
9 Water Hose and Clamps - Clamps loose, hose
collapsed or leaking. 23 Engine Oil Cooler - Restricted, or cracked and
leaking.
10 Transom Mount Water Tube - Blocked by debris.
24 7.4 and 8.2 Models: Check Valve - Water By-pass
11 Supply Pump (Engine Mounted) - Failed seal, Hose - Plugged with debris.
corroded or bad bear ings, eroded impeller, leak-
ing mounting gaskets or backing plate. In addition, check:
12 Thermostat Housing - Corroded, restricted, or • Ignition Timing

leaking gasket. • Boat Hull - Condition of hull, marine
13 Thermostat - Defective thermostat, or wrong type growth, or under- hull equipment.
for engine; improperly seated or damaged O-ring. Fittings protruding through hull may cause air
14 Belts - Loose, or worn and slipping. bubble streams which can be picked up by the lower
gearcase and mixed with incoming cooling water to cause
15 Circulating Pump (Engine) - Failed seal, corroded an overheat condition.
or bad bearings, eroded impeller, leaking mount-
ing gaskets or backing plate.
16 Cylinder Block Water Passages - Corrosion, slag,
blocked passages, or leaking core plugs.
10-16 Engine/eng
A Water In
B To Thermostat Housing
C Return From Exhaust Pipe
D Exhaust and Water Out
Vertical Drive and Transom Bracket
All Models
DRC6252
Engine/eng 10-17
Warm water
C Bypass 21
Cold Water
Exhaust Water
er in rive
9 Wat Sternd
A from
11
9 13
18
12
19
18
22 17
Cold Engine
12 C
16
15
B
Warm Engine
14
D
3.0 GS Models
DRC6715
10-18 Engine/eng
4.3 GL Models
DRC7625
Engine/eng 10-19
4.3 Gi Models
DRC7626
10-20 Engine/eng
5.0 GL and 5.7 GS Models
DRC7627
Engine/eng 10-21
5.0 Gi and 5.7 GSi Models
DRC7628
10-22 Engine/eng
7.4 Gi, GSi and 8.2 GSi Models
DRC7629
Engine/eng 10-23
10-24 Engine/eng
Section 11
Engine Removal and Installation
Table of Contents
Engine
Alignment ...................................................................................... 11-7
Installation ..................................................................................... 11-6
Removal ......................................................................................... 11-2
Determining Minimum Engine Height ........................................... 11-12
Engine Mounts, Rear ...................................................................... 11-11
Exhaust Pipe Replacement ............................................................. 11-6
Safety Warnings
at end of this manual.
Proper installation is important for the safe, reliable operation of
all mechanical products. The procedures we recommend and de-
scribe in these instructions are effective methods to be followed
when removing or installing the engine. Some of these methods
require the use of tools specially designed for the purpose. The
special tools should be used when and as recommended.
Special Tools
Alignment Tool 3851083-0

Universal Handle 3850609-3 11

Volvo Penta Grease
3M Adhesive
Engine/eng 11-1
Engine Removal
Before removing engine, check engine height. See Determin-
ing Minimum Engine Height.
Check engine clearance between front of engine and engine compart-
ment bulkhead prior to starting work. If clearance is less than 6 in.
(15,2 cm), the vertical drive must be removed to disengage U-joint
shaft from engine coupler. See Vertical Drive and Transom Bracket
Service Manual.
1
When engine clearance is more than 6 in. (15.2 cm), the engine can 22703
be pulled forward to disengage the U-joint shaft from the flywheel cou-
pler, and be removed from the engine compartment.
The vertical drive can remain installed only if engine removal
does not require re-alignment of the engine. If the engine mounts, boat
stringers, or engine coupler are being repaired or replaced, remove
the vertical drive for engine alignment.
To prevent possible fire and explosion caused by ignition of
fuel vapors which may be present in the engine compartment,
remove the positive and negative cables from the battery. 2
22704
Disconnect Battery
All switches must be in the “OFF” position prior to discon-

necting the red (positive) and black (negative) cables from the
battery. This will safeguard against permanent damage to electri-
cal components.
Disconnect Power Steering Lines
1 1. Disconnect both power steering lines at the steering cylinder.

2 3 2. If the original fitting, P/N 3853315 A , is available, use it
to link both steering lines together. If the fitting is not used, cover both 3
22706
steering cylinder openings and line fittings to prevent fluid loss and
entry of contaminants. Tie lines onto engine higher than power steer-
ing pump to prevent damage and loss of oil during engine removal.
Disconnect Fuel Supply
4 Disconnect boat fuel line at the fuel filter inlet. Seal end of
fuel line and inlet opening.
Disconnect Electrical Cables
5 1. Disconnect the plastic two-wire trim/tilt motor connector B .

4
2913
5
38277
6 2. Remove wire retainer C and unplug rubber two-wire trim/tilt
sender connector. Cut tie strap D securing sender cable, if required.
7 3. Unscrew worm clamp and disconnect large rubber instrument
cable connector.
Disconnect Throttle Cable
Prior to disconnecting the remote control throttle cable, note

whether you have a “push-to-close” or “pull-to-close” throttle arm
attachment. 6
24208
8 9 1. Remove cotter pin and flat washer G from throttle arm.
8 9 2. Loosen anchor retainer nut H and rotate retainer I away
from cable trunnion. Remove throttle cable from throttle arm and an-
chor bracket.
• All Models (except 7.4 Gi, GSi and 8.2 GSi) 8
• 7.4 Gi, GSi and 8.2 GSi Models Only 9
7
33729
G
8
DR5094
9
DR5707
Engine/eng 11-3
Disconnect Exhaust Hose - 3.0 Models
1 1. Loosen four hose clamps.

2 2. For ease of moving hose, lubricate exhaust pipe.
3 3. To free exhaust hose from elbow, pry or twist hose. Slide hose
down onto exhaust pipe.
Disconnect Exhaust Hose - All V-6 and V-8 Models
4 1. Loosen four clamps A on lower exhaust hose. For ease of 1

moving lower hose, lubricate exhaust pipe. 6361
5 2. To free lower hose from intermediate pipe, pry or twist hose.

Slide hose down onto exhaust pipe B .
2
6362
3
6363
4
49449
5
49450
11-4 Engine/eng
Disconnect Water Hose
6 Loosen clamp and pull water supply hose off transom bracket wa-
ter tube.
Separate Engine Mounts

7 1. Attach a hoist to lifting brackets of engine. Hoist must
have a lifting capacity of at least 1500 lb. (680 kg).
8 2. Remove and retain both lock nuts C and both flat washers D
from rear engine mounts. 6
22698
9 3. Remove and retain lag screws from front engine mounts.
If vertical drive was removed, lift engine out of engine compartment. If
vertical drive was not removed, lift engine slightly and pull it forward to
disengage U-joint shaft and flywheel coupler. With U-joint shaft clear of
flywheel coupler, lift engine out of compartment. A
7
31444
8
12211
9
2933

Exhaust Pipe Replacement
Removal
1. Remove engine following previous procedure.

1 2. Remove and retain four exhaust pipe screws. Remove exhaust
pipe and discard seal A . Clean all material from transom bracket and
exhaust pipe seal surfaces.
Exhaust pipe mounting holes have locking Heli-Coilâ inserts.
1
Do not clean screw holes with a thread tapping tool, otherwise locking 22780
feature will be destroyed and Heli-Coil will have to be replaced.
Installation
2 1. Coat a new seal with 3M Scotch Grip Rubber Adhesive 1300

and place in transom bracket groove B .
2 2. Apply Volvo Penta Gasket Sealing Compound to the four ex-
haust pipe mounting screws C .
3 3. Secure exhaust pipe Dto transom bracket with four screws
C . Tighten to 20-25 ft. lb. (27-34 N m). Slide exhaust hoses and clamps
E
•
2
onto exhaust pipes if they were removed. 15048
4. Install engine.
Engine Installation
Attach Engine Mount
1. Lower engine into engine compartment:
4 • If vertical drive was not removed, and engine crank-

shaft was not rotated, engage U-joint shaft with engine
coupler and slide engine back onto rear mounts. If cou- 3
pler and U-joint shaft will not align, either the engine or 15047
U- oint shaft will have to be rotated to allow engage-

ment. If engine mount height was disturbed, engine
must be realigned as described later.
4 • If vertical drive has been removed, lower engine onto

rear mounts.
5 2. Install flat washers F into recesses of engine bracket and
secure engine to mount with lock nuts G . Tighten lock nuts to 28-30 ft.
lb. (38-40 N m).
•
Do not use an impact wrenc or power driving tool to install the 4

12212
lock nuts onto the studs.
5
12211
11-6 Engine/eng
6 3. Install forward engine mount lag screws and tighten them se-
curely.
If vertical drive was not removed, go on to Exhaust Hose Attachment.
If vertical drive was removed, continue with Engine Alignment sec-
tion.
Engine Alignment
Correct engine alignment is essential to long engine drive-train
life. The front engine mounts may need adjustment UP or DOWN to
6
2933
produce correct engine alignment. Use Alignment Tool, Volvo Penta P/
N 3851083-0, with Universal Handle, Volvo Penta P/N 3850609-31, to
check engine alignment. G
7 1. Slide alignment tool H through driveshaft gimbal bearing I .
The alignment tool must slide through the gimbal bearing and into en-
gine coupler with ease. If the alignment tool binds going into engine
coupler, make sure the gimbal bearing is properly aligned. If gimbal
bearing alignment is correct, the front engine mounts must be adjusted H
either UP or DOWN, as required, until alignment tool slides easily in
and out of engine coupler. 7
47547
8 2. To change engine height, tighten or loosen nuts J
and K as
required. See respective engine section, Front Mount Height Adjust-
ment.
3. After correct alignment has been made, the front mount(s) must be
tightened to maintain alignment.
• While holding one nut with an open-end wrench, tighten

the second adjusting nut to 100-120 ft. lb. (136-163 N m).
•
8
2953
Engine/eng 11-7
Connect Exhaust Hose
1 3.0 Models - Slide exhaust hose A up onto high-rise exhaust

elbow B .
2 V-6 and V-8 Models - Push lower hoses C up onto intermediate
exhaust pipes D .
3 Position and tighten all hose clamps securely between ribs of
exhaust hose(s) as shown.
3 DO NOT install hose clamps in expanded area E of 1
hose(s). Cooling will be restricted and engine damage will occur. 2945
Connect Throttle Cable
Determine whether you have a “push-to-close” or “pull- to-

close” remote control throttle cable. Position remote control handle in
NEUTRAL, propeller should rotate freely. Turn propeller shaft and shift
into the forward gear detent position, then pull handle HALFWAY BACK
towards NEUTRAL. This positions the control for proper throttle ad-
justment. Failure to follow this procedure can result in “hard shifting”
out of neutral.
4 1. Align internal bosses F
of trunnion with throttle cable groove
2
49451
G . Press trunnion on throttle cable until seated.
5 V6 and Small Block V8 Models Only: The engine throttle

cable anchor block bracket has several sets of anchor block holes.
The sets of holes marked with a “V” are used for Volvo Penta engines.
The set of holes marked “GSI” are for 5.0 and 5.7 Liter EFI models.
The set of holes marked “43” are for 4.3 Liter 2V (2 barrel) and 4V (4
barrel) carburetor models. Holes are for all 5.0 and 5.7 Liter, 2V (2
barrel) and 4V (4 barrel) carburetor models. The anchor block will be
set at the correct position from the factory for your particular engine.
6 2. Install open end of trunnion L in anchor block. Install 3
49449
screw in anchor block and position throttle cable assembly in selected
set of holes. Nut M must be against the anchor bracket, tighten it
securely. E
7 3. Throttle arm connector N must have a minimum of 9
full turns or 1/4 in. of throttle cable thread engagement. Install F
throttle arm connector onto the throttle cable. Pull connector N for-
ward to remove all end play from throttle cable, then turn the connec-
tor in until hole aligns with the “push-to-close” O or “pull-to-close”
P throttle arm stud.
E
If throttle arm connector hole cannot be adjusted to align with 4
the throttle arm, check for proper cable installation in the remote con- 34751
trol box. 5.0Gi

4.3GL
5.7GSi
4.3GS
5.0GL
5.7GS
5
DRC7279
C D E H
B
4V
A
F G
6 7 8
DR4977 DR5095 DR5094
8 9 4. Install connector onto throttle arm. Install wash er

and cotter pin Q , and spread cotter pin prongs. Tighten jam nut R
against connector.
For throttle and shift cable adjustment procedures, see Throttle
and Shift Control Systems section.
Connect Water Hose
10 1. Slide hose clamp S onto water inlet hose. Lightly lubricate in-
side of water inlet hose and push hose onto water inlet tube T .
9
DR5707
11 2. If inlet hose is not installed properly, underside of hose may

collapse. Check underside of hose for proper installation and adjust
hose as required. Tighten hose clamp securely.
Failure to install water inlet hose correctly can result in
powerhead damage from blockage of water circulation.
Connect Power Steering Lines
1. Remove tape or protective cover from small hydraulic hose fitting (or
unscrew steering line connector) and small steering cylinder opening.
10
12 2. Install small hose fitting into steering cylinder and tighten to 10- 22698
12 ft. lb. (14-16 N m).

•
3. Remove tape or protective cover from large hydraulic hose fitting

and large steering cylinder opening.
11
15864
12
22702

1 4. Install large hose fitting into steering cylinder and tighten to 15-
17 ft.lb. (20-23 N m).
•
Connect Electrical Cables
2 1. Connect plastic two-wire plug of engine harness to two-wire

receptacle of trim/tilt motor. Connectors should lock together.
3 2. Connect rubber two-wire trim/tilt sender plug to two-wire re-
ceptacle C of instrument harness. Secure connectors with wire re-
tainer and cable with a tie strap D . 1
22701
3. Route the instrument cable plug to join engine cable 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, and
contribute to fire and explosion in the engine compartment.
4. Apply a light coat of Volvo Penta Grease grease around large en-
gine plug.
5. Route trim/tilt cable behind shift bracket. Align the marks of the trim/
tilt plug and receptacle and press together. 2
4 6. Slide hose clamp over large engine receptacle. Align the two 31461
large terminals on plug and receptacle and press together. Slide hose
clamp over receptacle and tighten securely.
7. All switches must be in the “OFF” position prior to con-
necting battery cables to the battery. Be sure polarity is observed;
positive (+) cable to the positive terminal, and negative (-) cable to the
negative terminal.
3
24208
4
33729

Connect Fuel Supply
Attach boat’s fuel supply hose to fuel filter canister. On EFI models
connect to the MOAS. Tighten connection securely. Check for fuel
leaks when testing engine, and repair any leaks that might occur.
Rear Engine Mounts

Removal
1. Remove engine as previously described in this section. 4

6678
4 2. Unscrew two screws and washers, then lift mount assembly off
transom plate.
Disassembly
5 Hold square nut and remove screw. Mount assembly will break
down into components shown. Pay particular attention to the two mount
washers; their thickness, shape (concave or flat), and position in the
assembly (above or below the rubber mount).
Assembly
5
5 1. Slide lower washer F
onto mount bolt; make sure you choose 16348
the correct washer (as determined during the mount disassembly) forthis
position. Insert bolt into bottom (flat) side of rubber mount assembly,
and install remaining washer and square nut. Do not tighten nut at this
time.
If top and bottom washers are not installed in their original po-
sitions, mount may transmit excessive engine vibrations into boat and
cause undesirable operating conditions.
6 2. Turn mount assembly upside down and clamp square nut in
vise. Rotate rubber mount until mounting holes are positioned at 90° to
any side of square nut. Hold mount in this position and tighten center
6
6680
bolt to 44-52 ft. lb. (60-71 N m).
•
If 90° relationship between nut and mounting holes is not main-

tained, slot of engine mount pad cannot engage rear mount during in-
stallation.
Installation
7 1. Place mount assembly on transom plate. Install two screws and
washers, and tighten them to 20-25 ft. lb. (27-34 N m).
•
8 2. Install engine as previously described in this section. Make sure

mount pad slot engages square nut. Install both flat washers and lock-
7
6677
nuts, then tighten locknuts to 28-30 ft. lb. (38-41 N m).
•
8
12212
Engine/eng 11-11
B A
1
DR4960
Determining Minimum Engine Height

1 1. To determine minimum engine height, use a level A
placed on
top of the transom,measure from bottom of level to top of elbow B
and record distance.
1 2. Measure from bottom of level to static water line C and record
distance.
1 3. Subtract dimension B from dimension C and record result.
See engine height requirements below:
• 3.0 Models - Measurement C minus B should not be

less than 9 in. (22.8 cm).
• V-6 Models - Measurement C minus B should not be
less than 13 in. (33 cm).
• V-8 Models - Measurement C minus B should not be
less than 14 in. (35.6 cm).
4. When engine installations do not meet these specifications, an ex-
haust 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 Engine/eng
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) . . . boat will move opposite

unknown to operator, or engine will to direction intended by operator.
start in gear, boat will move unexpectedly.
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.
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.
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 . . .
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 pre-
use steering components which meet marine industry (BIA/ABYC) standards . . .
delivery Read, understand, and follow manufacturer's instructions.
inspection Assemble parts and make adjustments carefully . . .
and when Closely follow the warnings marked with ...
servicing 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
Why? Possible jamming of steering
turning steering wheel (Power
system.
assist models)
Engine stringer must not interfere

with power steering pump and pul-
ley
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 en-
gine.
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.
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 explo-
sions.
Safety
S-7
Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require-
ments. Most automotive parts do not, especially electrical components that must meet ignition protec-
tion requirements of the U.S. Coast Guard regulations.
When nonmetallic parts look to be in poor shape . . . replace them!
Torn Boots!
Wires Cracked!
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.
If you smell gasoline in the engine compartment . . .

STOP 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 compart-
ment. 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" electri-
cal 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

If solution gets
of water. . .
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 con-

necting 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 gas is explosive! battery posts. . . it's a sure
While charging or discharging, way to make lots of
remember. . . sparks. . .surrounded by battery gas
No Smoking
No Flames
No Sparks
Don't check battery condition After Charging. . .

by placing metal objects
across posts. Shut off charger
You're sure to make sparks Remove charger plug from wall socket
Then. . .
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

If the air around you is quiet . . . the pilot light in mixed with air
the heater may
ignite the heavy fumes 5 Parts
before your nose ever Gasoline
smells the fumes . .
100 Parts
Air
What Can you Do?
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:
Store in sturdy, Put out open flames, cigarettes, sparking devices
sealed gas can Wipe up spill or leak; get towels, rags outside fast
. . .and . . . Check lowest area for fumes; open doors or win-
keep outside dows
Safety
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 . . .
. . . yummmmmmmmmmm Keep containers away

from children
S-14 Safety
Part No. 7797353 © 1999. Volvo Penta of the Americas, Inc. Printed in U.S.A.
Volvo Penta of the Americas, Inc.

1300 Volvo Penta Drive
Chesapeake, Virginia 23320
U.S.A.

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• Engine Model Number 1 2 3

• Transom Bracket Model Number 4

• Vertical Drive Model Number 5

Battery Cable Requirements ........................................................... 1-40 1

Good Service Practice

Service required for stern drives is generally one of three kinds:

• Normal care and maintenance - which includes putting

Proper preparation is extremely helpful for efficient service work. A clean

It is a Volvo Penta policy to provide dealers with service knowledge so

Engine/eng Safety Related 1-3

When replacement parts are required, always use genuine Volvo

Parts Catalogs contain exploded views showing the correct assembly

Special Service Tools

Product References, Illustrations & Specifications

Volvo Penta reserves the right to make changes at anytime, without

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• Components affecting compression

Engine Compression Testing

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• All Models Except 5.0 GL and 5.7 GS: Remove (grey)

The indicated compression pressures are considered normal if the low-

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Compression Pressure Limit Chart

134 101 154 115 174 131 194 145

After checking cylinder compression, repairs should be made as necessary.

Ignition System Fuel System

• Spark Plugs • Fuel Tank Pickup and

Engine/eng Safety Related 1-7

1. Install a vacuum gauge to a good intake manifold source, following

1. A steady vacuum reading between 18 and 22 in. Hg. (60,7-74,3

Gasolines Containing Alcohol

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• The engine will operate leaner. This may cause engine

for recommended oil change intervals.

Draining and Filling the Engine Crankcase

Engine/eng Safety Related 1-11

THE FOLLOWING SAE

32° F (0° C) and above SAE 30

Disregard any reference to multi-viscosity oil printed on

Model Less Filter With Filter 3

Steering System Lubrication

Power Trim/Tilt-Fluid Level

• Level should be between the “MIN” and “MAX” marks on

There are nine steps that must be completed for off-season

Step 1. Condition Fuel System:

Add DuraPlus TM Marine Fuel Stabilizer to fuel system. Follow instruc-

load at a high enough throttle setting to circulate conditioner through

Engine/eng Safety Related 1-13

• Engine should first be operated under load until oil is thor-

• With vertical drive in full down position, run engine at a

Step 4. Fog Engine:

Carbureted Models Only:

• Warm up engine to ensure fuel conditioner is throughout

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Prepare an engine “storage mixture” in an outboard V6 six gallon fuel

• Disconnect boat fuel line at engine fuel pump. Run engine

Step 5. Drain Cooling System:

When draining engine, raise or lower bow of boat to position engine in a

4.3 Gi Models Only

4.3 GL, GS and Gi Models

4 Port And Starboard

5.0 Gi and 5.7 GSi Models Only