INE GENERAL INFORMATION SECTION 6 ENGINE CONTENTS General Information Section 6 — Engine Electrical . Rape Coalinga “648 Deiveablty and Emission Controls se ine Coo Engine Fuel ~ GB Exhaust Systems.. & ENGINE GENERAL INFORMATION CONTENTS - SECTION 6 General Informatior 64 Engine Performance Diag 64 Engine Mechanical Diagnosis 64 Compression Test 67 All new General Motors vehicles are certified by the United States Environment Protection Agency as conforming to the requirements of the regulations for the control of pollution from new motor vehicles. This certification is contingent on certain adjustments being set to factory standards. In most cases, these adjustment points been ermanently sealed and/or made inaccessible to prevent indiscriminate or routine adjustment fi'the field. For this reason, the factory procedure for temporal moving plugs, caps, etc., for purposes of servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design.6:2_ ENGINE GENERAL INFORMATION suapevrwe sur «+ o> TENSIONER SECTION 6a” JO) vearen a tS pay ramon cou uoone4 Seat FUEL PUMP & FUEL TANK SECTION 6C EXHAUST sySTEM———> ‘SECTION 6F SE . nave os Ff er LS ae yey OWL FILTER ADAPTER CRANKSHAFT BALANCER ‘& FRONT COVER, SECTION 6A “CRANKSHAFT SENSOR ‘SECTION GE Figure 1 Drivetrain Locater ViewENGINE GENERAL INFORMATION 6.3 FUEL INJECTORS, EGR VALVE TMROTTLE BODY & ADAPTER E01 2 D)/ valve COVER & CYLINDER HEAC ‘SECTION 64, au. PAN SECTION 68 naosasgcn Figure 2 Drivetrain Locator View6-4 ENGINE GENERAL INFORMATION GENERAL INFORMATION CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on 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 Whenever valve train components are removed for service. they shoutd be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. GENERAL INFORMATION ON ENGINE SERVICE Important THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE = AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE. ‘When raising or supporting the engine for any reason, do not use a jack under the oil pan, Due to the small clearance between the oil pan and the oil pump sereen, jacking against the oll pan may cause ito be ‘bent against the pump sereen resulting in.a damaged oil pick-up unit. ‘When working on the engine, remember that the 12.volt electrical system is capable of causing short circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. IN THE MECHANICAL PROCEDURES DESCRIBED IN THIS SECTION, GENERALLY NO REFERENCES WILL BE MADE TO THE REMOVAL OF OPTIONAL EQUIPMENT SUCH AS POWER STEERING. PUMP, AIR CONDITIONING COMPRESSOR, ETC. SHOULD IT BECOME NECESSARY TO REMOVE ANY SUCH ITEM TO PERFORM OTHER SERVICE, REFER TO THE APPROPRIATE SECTION OF THIS SERVICE MANUAL FOR SPECIFIC INFORMATION. ENGINE PERFORMANCE DIAGNOSIS Engine performance diagnosis procedures are covered in Section 6E and should be consulted for diagnosis of any driveability, emissions, or “Service Engine Soon” tight complaint. Refer to: © Section 6E ~ Driveability and Emissions ENGINE MECHANICAL DIAGNOSIS The following diagnostic information covers common problems and possible causes. When the proper diagnosi replacement as required. is made, the problem should be corrected by adjustment, repair or part jefer to the appropriate section of the manual for these procedures. EXCESSIVE OIL LOSS Eacessive oil consumption (Not due 10 leaks) is the use of 1 9L (2 gts.) or more of engine oil within 2, 000 miles or 3,200 kilometers. © External oil leaks. Tighten bolts and/or replace gaskets and seals as necessary. © Improper reading of oil level indicator (dipstick). Check oil with car on a level surface and allow adequate drain-down time. © Improper oil viscosity. Use recommended S.A.E. viscosity for prevailing temperatures. See Section OB for proper specifications. ‘© Continuous high speed driving, and/or severe usage such as trailer hauling, will normally cause decreased oil mileage ‘© Crankcase ventilation system malfunctioning, '® Valve guides and/or valve stem seals worn, oF seals omitted. Ream guides and install oversize service valves and/or new valve stem seals. Piston rings broken, improperly installed, worn, ‘or not seated. Allow adequate time for rings to seat. Replace broken or worn rings as necessary. Piston improperly installed or misfitted.ENGINE GENERAL INFORMATION 6:5 OIL LEAK DIAGNOSIS Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedure may help in locating and repairing most leaks, FINDING THE LEAK 1 Identify the fluid, determine whether it is engine cil, automatic transmission fluid, power steering fluid, ete. At what point is the fluid leaking from? After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. After a few minutes, you should be able to find the approximate location of the leak by the drippings on the paper. Visually check around the suspected component, Check ‘around all gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach, If the leak still cannot be found, it may be necessary io clean the suspected area with ¢ degreaser, steam or spray solvent. Clean the area well, then dry the area. Operate the vehicle for several miles at normal operating temperature and varying speeds. After operating the vehicle, visually check the suspected component. If you still cannot locate the leak, try using the powder ‘or black light and dye method. Powder Method Clean the suspected area, Apply an aerosol-type powder (such as. foot powder) to the suspected area, Operate the car normal conditions Visually inspect the suspected component, You should be able to trace the leak path over the white powder surface to the source. under operating Black Light and Dye Method A dye and light kit is available for finding leaks. Refer to the manufacturer's directions when using the ki Pour specified amount of dye into leaking component. Operate the car under normal conditions as directed sm the kit. Direct the light toward the suspected area. The ‘dyed fluid will appear as a yellow path leading to ‘the source, operating Repairing the Leak back Once the leak has been pinpointed and traced to its source, the cause of the leak must be determined in order for it to be repaired properly. Ha gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also, Before attempting to tepait a Teak, check to be sure that the following conditions are correct as they may cause a leak. Gaskets: 6. cn & Seals ol inspect Fiuid Jevel/pressure is too high Crankcase ventilation system malfunctioning, Improperly tightened fasteners or dirty/damaged threads Warped flanges or sealing surface Scratches, burrs or other damage to the sealing surface Damaged or worn gasket Cracking or porosity of the component Improper sealant used (where applicable) inspect Fluid level/pressure is too high Crankcase ventilation system malfunctioning Damaged seal bore (scratched, burred or nicked) Damaged or worn seal Improper installation Cracks in component Shaft surface scratched, nicked or damaged Loose or worn bearing causing excess seal wear LOW OIL PRESSURE Low oi level, Fill to full mark on oil level indicator. Slow idle speed. Incorrect or malfunctioning oil pressure switch Incorrect or malfunctioning oil pressure gage, Replace with proper gage. Improper oil viscosity or diluted oil. Install oil of Proper viscosity for expected temperature, or we eeee install new oil if diluted with moisture or ‘unburned fuel mixtures. Oil pump worn or dirty. Plugged oil filter. Oil pickup screen loose or plugged, Hole in oil pickup tube. Excessive bearing clearance. Replace if necessary.6-6 ENGINE GENERAL INFORMATION Cracked, porous or plugged oil galleys. Repair or Galley plugs missing or misinstalled. Install plugs replace block. oo repair as necessary, VALVE TRAIN NOISE Low oil pressure. Repair as necessary. (See @ Sticking valves diagnosis above for low oil pressure.) © Lifters worn, dirty, or defective. Clean, inspect, Loase rocker arm attachments. Inspect and test and replace as necessary repair as necessary. © Camshaft worn, or poor machining. Replace Worn rocker arm, pivot, and/or pushrod. camshaft, Broken valve spring, © Worn valve guides. ENGINE KNOCK DIAGNOSIS Noises in engines are sometimes characteristic of the design. Compare the sounds in other engines to make sure you are not (rying to correct a normal condition, KNOCKS COLD AND CONTINUES FOR TWO TO THREE MINUTES INCREASES WITH TORQUE Flywheel contacting splash shield. Reposition Cold engine piston knock usually splash shield, disappears when the cylinder is grounded Loose or broken balancer or drive pulleys. out. Cold engine piston knock which Tighten or replace as necessary. disappears in 1.5 minutes should be Excessive piston to bore clearance. Replace considered acceptable. piston. © Bent connecting rod. HEAVY KNOCK HOT WITH TORQUE APPLIED Broken balancer or pulley hub. Replace parts as Flywheel cracked necessary. © Excessive main bearing clearance. Replace as Loose torque converter bolts. necessary, Accessory belts too tight or nicked. Replace and/ or tension to specsifications as necesSary. Exhaust system grounded. Reposition as necessary. @ Excessive rod bearing clearance, Replace as necessary. LIGHT KNOCK HOT Detonation or spark knock, Check operation of | @ Exhaust leak at manifold. Tighten bolts and/or EST or ESC (See Section 6E). Check fuel quality. replace gasket. Loose torque converter bolts @ Excessive rod bearing clearance. Replace bearings as necessary. KNOCKS ON INITIAL START-UP BUT ONLY LASTS A FEW SECONDS Improper oil viscosity. Install proper oil viscosity — An engine that is operated for only short for expected temperatures. See Section OB. periods between start-ups may have lifter Hydraulic lifter bleed down, Clean, test and noise that lasts for a few minutes. This is a replace as necessary normal condition, - When the engines stopped. some valves @ Excessive crankshaft end clearance, Replace wi pressure against lifters in will tend to bleed lifter down. Attempts to crankshaft thrust bearing. repair should be made only if the problem @-_Excessive front main bearing clearance. Replace is consistent worn parts.ENGINE GENERAL INFORMATION 6-7 KNOCKS AT IDLE HOT © Worn drive belt. Check tension and/or replace as necessary, © A/C Compressor or generator bearing. Replace or repair as necessary. ‘© Valve train. Replace parts as necessary. ‘© Improper oil viscosity. Install proper viscosity oil for expected temperature. See Section OB. ‘© Excessive piston pin clearance. Replace piston and pin. @ Connecting rod alignment, Check and replace rods as necessary. © Insufficient piston to bore clearance. Hone bore and fit new piston. © Loose crankshaft balancer. Torque and/or replace worn parts. © Piston pin offset to wrong side. Install correct piston. ENGINE COMPRESSION TEST COMPRESSION TEST Important Disconnect multi-pin connector from the C'l module to disable the ignition and fuel injection system. ‘To determine if the valves or pistons are at fault, a test should be made to determine the cylinder compression pressure. When checking cylinder ‘compression, the throttle and choke should be open, all spark plugs removed, and the battery at or near full Charge: The lowest reading cylinder should not be less than. 709% of the highest and no cylinder reading should be less than 689 kPa (100 psi). This should be done with four “puffs” per cylinder. Normal - Compression builds up quickly and evenly to specified compression on each cylinder. Piston Rings - Compression low on first stroke tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. Valves - Low on first stroke does not tend to build up on following strokes. Does not improve much with addition of oi. Use approximately three squirts from a plunger type oiler,3800 ENGINE VIN C_6A8-1 SECTION 6A8 3800 ENGINE VIN C RPO LN3 NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. Ifa fastener needs to be replaced, use the comect part number fastener for that application. Hf the correct part number fastener is not available. a fastener of equal size and strength {or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out, The correct torque Value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result CONTENTS GENERAL DESCRIPTION . Engine Identification Engine Construction. Lubrication System ON CAR SERVICE tine Belt ena Engine Assembly Engine Mount. Intake Manifold or Gasket Exhaust Manifold... Valve Cover soon Rocker Arm Assembly... SOARS Valve Stem Oil Seals A819 Valve Lifter Diagnosis 6AB-10 Valve Lifters SARI Cylinder Head Removal 6ASIL Cylinder Head Off-Car Service . OASIS ‘Valves, Springs and Retainers « 6A8-14 Valve Stem Height ... os 648-17 Valve Spring Installed Height A817 Crankshatt Balancer... SO 6ARI7 Front Cover ews een BABB Front Crankshaft Oil Seal 6A8-19 Oi Filter Adapter and Pressure Valve .. 6ARI9 Testing Oil Pressure ... 6A8-19 Oil Pump. 6A8-20 Timing Chain an 6A8-21 Balance Shaft 6A8-22 ‘Camshatt.. A822 Camshaft Bearings 6A8-24 OF PaM eee 6A8-24 68-26, A827 6AB-2T Rear Main Seal Repair... Rear Main Oil Seal Replacement .. Oil Pump Pipe and Screen Assembly .. Piston and Connecting Rod. Piston Fitting Piston Pin & Rings. Crankshaft... Connecting Rod and Main Bearings Bearing Clearance. se 6A8-33 Cylinder Block .. ens 6A8-35 Automatic Transaxle Flywheel .. on GAB34 Thread Repair. enn 6837 FASTENER TIGHTENING SPECIFICATIONS. 1 6A8-38, ENGINE SPECIFICA’ 648-39 SPECIAL TOOLS.. -6A8-39 Figure 1 3800 Engine6AB-2_3800 ENGINE VIN C GENERAL DESCRIPTION ENGINE IDENTIFICATION ‘The 3800 engine may be identified from the vehicle identification number. The code letter in the eighth digit location identifies the type and cubic inch displacement of the engine: Refer to Section 0A for additional information on identification of engine es. ENGINE CONSTRUCTION Starting at the front of the engine, cylinders in the left bank are numbered 1-3-5 and cylinders in the right bank are numbered 2-4-6. The crankshaft is supported in the crankcase by four bearings which are all specific. The crankshaft is counterbalanced by the flywheel, crankshaft balancer, and weights cast into the crankshaft. Additional counterbalancing is obtained from the balance shaft which rides in the block above the camshaft and is driven by the camshaft, ‘All V-6 engines are even-firing, in that the cylinders fire at equal 120° intervals of crankshaft rotation. The location of the crankpins has been offset by 30° in order to fire the cylinders at equal 120° intervals of crankshaft rotation. ‘The firing order of the V-6 is 1-6-5-4-3-2. The camshaft lobes and timing also reflect 120° spacing. Thus, the even-firing crankshaft provides an equal interval of 120° between ignition of each of the cylinders throughout the firing order. The aluminum alloy pistons have slipper skirts and are cam turned. Two transverse slots in the ol sing grooves extend through the piston wall and permit drain back of oil collected by the oil ring. ‘The camshaft is supported in the crankcase by four sieel-backed babbitt-lined bearings. It is driven from the crankshaft by sprockets and chain. ‘The cylinder heads are cast iron and incorporate integral valve stem guides. Right and left cylinder hheads are identical and interchangeable, although in service itis good practice to reinstall the cylinder heads on the side from which they are removed. The intake manifold is bolted to the inner faces of both cylinder heads so that it connects with all inlet ports. Each exhaust and intake valve has a valve spring of ample capacity to insure positive seating throughout the operating speed range. ‘The valve rocker arms for each bank of cylinders pivot on pedestals which bolt to the cylinder head. The pushrods are guided by a stamped steel guide plate. Hyéraulic roller valve lifters and tubular push rods are used to operate overhcad rocker arms and valves of both banks of cylinders from a single camshaft. This system requires no lash adjustment at time of assembly or in service. Operation of hydraulic valve lifters is described below. In addition to its normal function of a cam follower, each hydraulic valve lifter also serves as an ‘automatic adjuster which maintains zero lash in the valve train under all operating conditions. By eliminating all lash in the valve train and also providing & cushion of oil to absorb operating shocks, the hydraulic valve lifter promotes quiet valve operation, It also. eliminates the need for periodic valve adjustment to compensate for wear of parts. Oil is supplied to the lifter through a hole in the side of the lifter body which indexes with a groove and hole in the lifter plunger. Oil is then metered past the oit metering valve in the lifter, through the push-rods to the rocker arms, cox pa acide mat eloteo, Figure 2 Valve Lifter Operation When the lifter begins to move up the cam lobe, the ball check is held against its seat in the plunger by the ball check spring which traps the oil in the base of the lifter body below the plunger. The plunger and lifter body then raise as a unit, pushing up the push-rod to open the valve. The force of the valve spring which is exerted on the plunger through the rocker arm and push-rod causes a slight amount of leakage between the plunger and lifter body. This "leak-down” allows a slow escape of trapped oil in the base of the lifter body. 4s the lifter rolls down the other side of the cam lobe and reaches the base circle or “valve closed” position, the plunger spring quickly moves the plunger back (up) to its original position. This movement causes the ball check to open against the ball spring and oil from within the plunger is drawn into the base of the lifter. This restores the lifter to zero lash LUBRICATION SYSTEM The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the crankshaft, connecting rods, camshaft bearings, valve lifters, and a controlled volume is supplied to the rocker arms and push rods. All other moving parts are lubricated by gravity flow or splash, ‘The supply of oil is carried in the lower crankcase (il pan) which is filled through a filler opening in the rocker arm cover. A removable oil level indicator (dip stick) rod on the left side of the crankcase is provided to check oil level. ‘The oil pump is located in the front cover and is driven by the crankshaft, It is a “gerotor” style pumpwhich is a combination of gear and rotor pumps. It is connected by a passage in the cylinder crankcase to an oil screen housing and pipe assembly. The screen is submerged in the oil supply and has ample volume for all operating conditions. If the screen should become clogged for any reason, oil may be drawn into the system through the relief valve in the soreen, Oil is drawn into the pump through the screen and pipe assembly and a passage in the crankease which connects to passages in the front cover. All oil is discharged from the pump to the oil pump filter adapter assembly which consists of an oil filter bypass valve and nipple for installation of an oil filter. The spring loaded oil pressure relief valve located in the timing chain cover, limits the oil pressure. The oil filter by-pass valve opens when the filter has become restricted, to the extent that approximately 68.95 kPa (10 psi) pressure difference exists between the filter inlet and discharge, to by-pass the oil filter and channel unfiltered oil directly to the main oil galleries of the engine. A full flow oil filter is externally mounted to the oil filter adapter on the lower right front side of the engine. Normally, all engine oil passes through the filter clement, however, if the element becomes restricted, a spring loaded by-pass valve opens as mentioned above. ‘The main oil galleries run the full length of the crankcase and cut into the valve fifter guide holes 10 supply oil at full pressure to the lifters. Holes drilled from the crankshaft bearings to the main gallery intersect the cam bearing bores to supply oil to the cam bearings. Roles drilled in the crankshaft carry. oil from the crankshaft bearings to the connecting rod bearings. Pistons and cylinder walls are lubricated by oil thrown off the crankshaft and by connecting rod splash. Piston pins are lubricated by splash. Each rocker arm and valve is supplied with oil through the tubular push rod. This oil comes from the inside of the lifter, passing around the metering vaive and through a hole in the lifter push rod seat. Oi from the push rod passes through a hole in the rocker arm push rod seat, and emerges on top of the push rod seat boss. ON CAR SERVICE CAUTION: To minimize the chances of unwanted fuel spray and underhood fire, always depressurize the fuel lines before performing service that requires removing or onnecting of any portion of the fuel system. The fuet lines should be depressurized as follows: @ Raise the car and disconnect the fuel tank electrical connection. This will disable the fuel pump. Run the engine until it stops. 3800 ENGINE VIN C 6A8.3 Figure 3 Engine Lubrication ACCESSORY DAIVE BELT (Figures 4 thru 6} A single (serpentine) belt is used to drive all engine mounted accessories. All driven accessories are rigidly mounted to the engine. Drive belt tension is maintained by a spring loaded belt tensioner. ‘A belt squeak when the engine is started or stopped is normal and has no effect on belt durability. The drive belt tensioner can control belt tension cover a broad range of belt lengths; however, there are limits to the tensioner’s ability to compensate. Using, the tensioner outside of its operating range can result in poor tension control and/or damage 10 the tensioner. Drive Belt Tension Check Tool Required: BT-7825 or J 23600-B Belt Tension Gage J, Inspect tensioner markings to see if the belt is, within operating lengths. Replace belt if the belt is excessively worn or is outside of the tensioner's ‘operating range 2, Run engine with no accessories on until the engine is warmed up. Shut the engine off and read belt tension with toot BT-7825 or J 23600-B placed halfway between the generator and the ‘A/C compressor. For non-A/C applications read tension between the P/S pump and crankshaft pulley. Remove tool, 3. Start the engine (with accessories off) and allow the system to stabilize for 15 seconds. Turn theGA84 3800 ENGINE VIN C engine off. Using an 18 mm box end wrench, apply clockwise force (tighten) 10 the tensioner pulley bolt. Release the force and immediately take a tension reading without disturbing belt tensioner position. 4. Using the same wrench, apply a counterclockwise force to the tensioner pulley bolt and raise the pulley to the fully raised position, Slowly lower the pulley to engage the belt, Take a tension reading without disturbing the belt tensioner position, 5. Average the three readings. If the average of the three readings is lower than 298 N-m (67 Ibs.) and the belt is within the tensioner’s operating range, replace the belt tensioner. Power STEERING belt replacement. ft tensioner pulley witha TMM nox ena vwrenen on pulley ra. CRANKSHAFT BALANCER: sonmauna TENSIO® BELT TENSION INDICATOR MAXIMUM TENSION: BELT TENSIONER PULLEY. —__ts0000 Figure 4 Accessory Drive Belt Service 1. ppive seut TENSIONER, 2 50N“m G7 Ua. Fr se 98787 Gagan Figure 5 Balt Tensioner Removal [Joour tenencs42 es.) [2] water eumpruiey Figure 6 Water Pump Pulley ENGINE ASSEMBLY (Figures 8 & 9) [F}] Remove or Disconnect 1. Raise hood and cover fenders, 2. Depressarize and disconnect fuel fines from fue rail, See Caution on page 6A8-3 for proper fuel line depressurization procedure. 3. Negative battery cable. 4, Air intake duct. 5. Throttle cable bracket and cables from throttle ody. 6, Engine coolant, 7, Raise car and suitably support. See Section OA. 8, Exhaust pipe from rear exhaust manifold, 9. Engine mount bolts 10. Starter wiring and starter. HL. A/C compressor and set aside. 12. Power steering hoses at steering gear. 13. Lower transaxle to engine bolts. [2] important © One bolt is located between the transaxle case and engine block and is installed in the opposite direction. 4. Flywheel dust cover. 15. Flywheel to torque converter bolts, © Use a scribe to mark flywheel to torque converter relationship to assure proper reassembly 16. Engine support bracket at transaxle. 17. Lower car 18. Radiator hoses. 19. Heater hoses at engine. 20. Vacuum modulator and canister purge lines, 21, Engine wiring harness. 22. Remaining transaxle to engine bolts.3800 ENGINE VINC 688.5 (] our 22 hen 117185. FT) (2) waster [a] NUT 57 Nm a2 ues. Fr (a) tonaue steuT sour TORQUE STRUT ENGINE BRACKET NUTS 27 Nem (20 LBS. FT} (a) Bout 20 Nem 115.185. FT) [3] ToRaue staur encing COMPARTMENT BRACKET BOLT 23 Nem (17 LBS. FT) sso1sgoasne Figure 7 Engine Torque Strut 23. Engine Assembly. PA install or Connect @ Tocomplete engine installation, observe the following assembly tips and reverse the removal procedures. Assembly Tips @ One transaxle to engine bolt is tooated between the transaxle case and engine block and is installed in the opposite direction. ‘@ Besuretoline up the flywheel to torque converter marks made at disassembly Tighten torque converter to flywheel bolts twice to 63 N-m (46 Ibs. ft.) Check oil level Check fluid levels ‘Check fluid leaks Cheok for proper completion of repairs EE] nurar nem raouss er) [] mount asseway [a] wasnen [5] surat mem cao ues. Frs [B] eotr soneaie6.s.F7 BOLT 26 WAM 188. Figure @ Engine Front Mount ENGINE MOUNT (Figures 7, 8 & 9) ‘Tool required: J 28467 Support Fixture Remove or Disconnect Support engine using Tool J 28467. Raise car and suitably support. See Section 0A. Mount to engine mount bracket nuts. Raise engine slightly. “Mount to frame nuts Movnt L 2, 3 4. 5 6 Install or Connect 1. Mount to engine mount bracket nuts and torque to specification, Lower engine, Mount to frame nuts and torque to specification. Remove frame support and lower car. Remove engine support fixture, Inspect © For proper completion of repair © For mount alignment608-6 3800 ENGINE VIN C CE] TOROUE. 75 Wm (6 tbs.) “wis bots orn (2 in al @ others are 45mm i, in.) No bot in the poston Tighten bots ee in edhuenee 1082 Nm (46 bs.) our Memos as. nr Tease. {3} rmorn Boor [a] rmornecaste bracxe® Fig Figure 8 Engine to Waraavle INTAKE MANIFOLD (Pigues 10 thr 16) [65] Remove or Disconnect racket to Throttle Body Raise hood and cover fenders Depressurize and disconnect fuel lines from fuel rail. See Caution on page 6A8-3 for proper fuel ine depressurization procedure. Negative battery cable Drain coolant Drive belt Generator and brace Power steering pump braces Coolant bypass hose Heater pipe Upper radiator hose Air inlet duct Throttle cable bracket from throttle body ‘Vacuum hoses from intake manifold Electrical connections EGR pipe EGR valve and adapter from throttle body adapter Throttle body coolant pipe from intake manifold Throttle body adapter and throttle body from imtake manifold Rear spark plug wires3800 ENGINE VIN C _GA8-7 morte sor rm [Enmore Gl ngomesoor [sno Calovvenzouas rr, [El oasxer INTAKE MANIFOLD woososnse ire 11 Throttle Body & Adapter to Intake Manifold 20. Intake manifold bolts and intake manifold -) Q) [[ijrewmon wooue [2] ceneraron support T]ovo; ene 18185--7 [B]aocr: 25 wemcrotasi Qevwsr ee [ZJsrancucnanness Frown Figure 14 0% Unit to Engine snoqeosase Figure 12 Spark Plug Wiring Harness (Front) Install or Connect © To complete installation, observe the following assembly tips and reverse the removal procedures. Assembly Tips © Clean the cylinder block, heads and intake manifold sealing surface of ALL oil with a suitable solvent, © Apply sealer P/N 12345336 or equivalent to the tends of the manifold seals ¢ Clean the intake manifold bolts and bolt holes of adhesive compound. Apply thread lock compound P/N12345493 to the intake manifold bolt threads before assembly. © Tighten the intake manifold bolts TWICE to 10 7] enorective CONDUIT + in). ch Figui Elwane voom ue (88 Ibs. in). Follow the sequence in (Figure seooe1 0458 ‘© Lubricate throttle body coolant and heater pipe Figure 14 Spark Plug Wiring Harness (Rear) ‘O-ring seals with antifreeze before assembly."GAGS 3800 ENGINE VIN [Heovr soweneo usin SRSTEN TINGE RGVENSEQUENCE. APPLY PK TEM TO HOLS FORE ASSEMELY 7] wiraKe MAMFOLD [By miraxe manro.o caster [a] wiraxe wavaroun seat [B] cuEawsuneace wir surasce SOLVENT AND APaLY Bnvagsceaae TO te ENDS OF IRTAKE MaANFOLD BEALS Figure 16 Intake Manifold & Gaskets Figure 16 Intake Manifold Bolt Tightening Sequence EXHAUST MANIFOLD (Figures 17, 18 & 19) Left Side (Front) {<>} Remove or Disconnect 1, Negative battery cable 2, Two bolts attaching exhaust crossover pipe to manifold 3. Spark plug wires from spark plugs 4, Manifold bolts 5. Gil level indicator tube and indicator 6. Manifold Right Side (Rear) Remove or Disconnect Negative battery cable Spark plug wires from spark plugs Oxygen sensor lead EGR Pipe Two bolts attaching exhaust crossover pipe to manifold Manifold bolts Transaxle oil level indicator tube Raise car and suitably support, see Section OA. Exhaust pipe to manifold bolts 10. Manifold tnstal or Connect, © To complete 1 2 3. 4 5. installation, reverse the removal procedure [72] AIGHT (REAR) EXHAUST MANIFOLD (2) stun senewia1 ves. Ft Figure 17 Fight Exhaust Manifold VALVE COVERS AND/OR GASKET Left Front) (Figure 20) [>] Remove or Disconnect 1. Negative battery cable Drive belt Generator to brace bolt Generator brace Spark plug wire hamess 6. Valve cover bolts and cover © Apply P/N12345493 to bolt threads @ Tighten to 10 N-m (88 Ibs. in.)(] stu ssnom ier ves. Fr (21) vert nonn) exnausr MANIFOLD Figure 18 LeR Exhaust Manifold BOLT 27 Nim (20 LBS. FT.) (2) EGR ire ASseMeLy Brn (16 CBS. FCS T] ExHausr maNiFoLo [a] Gasket TZ] cor ro nem iestss.ny [APPLY PIN 17345493 10 BOLTS BEFORE ASSEMBLY. Figure 20 Valve Cover and Gasket 3800 ENGINE VIN C_6A8-9 Right (Rear) [5] Remove or Disconnect 1. Negative battery cable 2. Drive belt 3. Loosen power steering pump bolts and slide pump forward 4. Power steering pump braces 5. EGR pipe 6. EGR valve and adapter from throttle body adapter Spark plug wires Valve cover bolts and cover BA Insta or Connect © To complete installation, observe the following assembly tips and reverse the removal procedure Assembly Tips, © Clean the valve cover bolts of all thread Tocking adhesive © Apply P/N12345493 to bolt threads © Tighten to 10 N-m (88 Ibs. in} © Fluid leaks ROCKER ARM ASSEMBLY (Figures 20 and 22) [59] Remove or Disconnect 1, Valve cover 2, Rocker arm pedestal retaining bolts 3._ Pedestal and rocker arm assembly [i inpocane ‘© Place assemblies on a clean surface. © Store components in order so they can be reassembled in the same location and with the same mating surfaces as when removed. BF instal or Connect @ To complete installation, observe the following assembly tips and reverse. the removal procedure Assembly Tips @ Clean the rocker arms and pedestal bolts in a suitable solution and inspect for wear © Clean the rocker arm pedestal bolts of all thread adhesive © Apply P/N12345493 to bolt threads before assembly © Tighten to 38 N-m (28 Ibs.ft.) © Inspect for proper completion of repairs © Listen for valve train noiseGAB-10 3800 ENGINE VIN C VALVE STEM OIL SEAL (Figure 21) ‘Tools required: 3 26513-A Valve Spring Compressor 3.23590 Spark Plug Port Adapter [6] Remove or Disconnect 1. Negative battery cable 2. Valve cover 3. Rocker arm assemblies 4. Spark plug 5. Install J 23590 into cylinder head ‘© Charge the eylinder with compressed air to hold the valves closed. 6. Compress valve spring using J 26513-A 7. Valve keys 8. Valve spring and retainer 9. Valve stem seal © The color of the replacement seal may not bbe the same color as the original seal. ‘© Install seals in their correct location based ‘on P/N and package description VALVE STEM KEY VALVE SPRING CAP VALVE SPRING [z]vanve stemsean vase Sea RMLY ONTOVALVE GUIDE | CYLINDER HEAD CASTING VALVE Figure 21 Valve Stem Seal Bie] Assombie 10. Valve stem seal ‘© Be sure seal is fully seated on valve guide 11. Valve spring and retainer 12. Valve keys 13, Release tension on spring ‘© Repeat Steps 6 thru 13 on the remaining valve for this cylinder, Install or Connect Spark plug Rocker arm assemblies Valve cover Negative battery cable VALVE LIFTER DIAGNOSIS 1 Momentarily Noisy When Car is Started: This condition is normal. Oil drains from the lifters which are holding the valves open when the engine is not running. It will take a few seconds for the lifter to fill after the engine is started. Intermittently Noisy On Idle Only, Disappearing When Engine Speed is Increased: Intermittent clicking may be an indication of a pitted check valve ball, or it may be caused by dirt. Correction: replace lifter. Noisy At Slow Idle Or With Hot Oil, Quiet With Cold Oil Or As Engine Speed Is Increased: High leak down rate. Replace suspect lifter. Noisy At High Car Speeds And Quiet At Low Speeds: a, High oil level - Oil level above the "Full” ‘mark allows crankshaft counterweights to churn the oil into foam. When foam is pumped into the lifters, they will become noisy since a solid column of oil is required for proper operation. Correction: Drain oil until proper level is, oblained. See Section 0A. b. Low oil level - Oil level below the "Add” ‘mark allows the pump to pump air at high ‘speeds which results in noisy lifters. Correction: Fill until proper oil level is obtained. See Section OA. Gil pan bent on bottom or pump screen cocked or loose, replace or repair as necessary. ‘Noisy At Idle Becoming Louder As Engine Speed Is Increased To 1500 rpm: This noise is not connected with lifter ‘malfunction. It becomes most noticeable in the ‘car at 10 to 15 mph "1" (Low) range, or 30 t0 35 ‘mph "D" (Drive) range and is best described as a hashy sound. At slow idle, it may be entirely gone of appear as a light ticking noise in one or more valves. It is caused by one or more of the following: a. Badly worn or scuffed valve tip and rocker arm pad b. Excessive valve stem to guide clearance. ec. Excessive valve seat runout. 4d. OM square valve spring.e. Excessive valve face runout. £ Valve spring damper clicking on rotator. To check valve spring and guide clearance, remove the valve covers. a. Occasionally this noise can be eliminated by rotating the valve spring and valve. Crank engine until noisy valves off its seat. Rotate spring. This will also rotate valve. Repeat until valve becomes quiet. IF correction is obtained, check for an off square valve spring, It spring is off square more than 1/ 16” in free position, replace spring, b. Check for excessive valve stem to guide clearance. If necessary, correct as required. Valves Noisy Regardless Of Engine Speed: This condition can be caused by foreign particles cr excessive valve lash. Check for valve lash by turning engine so the piston in that eylinder is on top dead center of firing stroke. If valve lash is present, the push-rod can be freely moved up and down a certain amount with rocker arm held against valve. If OK, replace suspected valve lifters. Valve lash indicates one of the following: a. Wom push-rod. b. Wor rocker arm, Lifter plunger stuck in down position due to dirt or carbon. 4. Faulty lifter. Checking of the above four items: Look at the upper end of push-rod. Excessive ‘wear of the spherical surface indicates one of the following conditions, a. Improper hardness of the push-rod ball ‘The push-rod and rocker arm must be replaced. ~ b. Improper lubrication of the push-rod, The push-rod and rocker arm must be replaced. ‘The oiling system to the push-rod should be checked. If push-rod appears in good condition and has been properly lubricated, replace rocker arm and recheck valve lash. If vaive lash cxists and push-rod and rocker arm are ok, trouble is in the lifter. Lifter should be replaced. VALVE LIFTERS (Figure 22) 1 2. 3. 4 Remove or Disconnect Negative battery cable Valve covers Intake manifold Rocker arms and pedestals ‘© Be sure to keep all valve train parts in order so they may be reinstalled in their original locations and with the same mating surfaces ‘as when removed. 2, 3 4, 5 6 1, & ‘3800 ENGINE VIN C 648-11 Pushrods Guide retainer bolts & retainer Lifter guides Valve lifters FBR clean © All gasket surfaces with degreaser. © Valve train parts Inspect © Valve train parts © Lifters for wear ¢ Cam lobes for wear Install or Connect Lifters © Before installation, dip the bottoms of the lifters in GM E.OS. P/N 12345493 or equivalent. Lifter guides Guide retainer Pushrods Rocker arms, pedestals, and bolts, © Apply P/N 1052624 to bolt threads before assembly. © Tighten to 38 N-m (28 Ibs. ft.) Intake manifold and gaskets Valve covers and gaskets Refill coolant CYLINDER HEAD REMOVAL (Figures 20 and 22) Tools required: 3 36660 Torque Angle Meter 7/16-14 Tap Remove or Disconnect Negative battery cable Intake manifold Exhaust manifold Valve cover Front (Left) Cylinder Head: © C'Land spark plug wires © Generator bracket © One A/C compressor bracket bolt Rear (Right) Cylinder Head: © Power steering pump @ Belt tensioner assembly © Fuel line heat shield Rogker arm assemblies, puide plate and pushrods Cylinder head bolts and cylinder headGAB-12_3800 ENGINE VIN C [TJeotra7newi27tes.er+ (Blurter cue revamen [3] puso [E]urtencuoe [E]rusinoo cue {B] aocxe ana ocktn ARMPWOT [pjeou st wemia7ias. et [a] exo casxer x0 60" owe. Ph [tal vasve veren swoossease | Figure 22 Gylinder Head and Valve Train lean 2, © All gusket mating surfaces ; @ Cylinder head bolt holes in block 5. inspect 6 @ Inspect the cylinder head, see CYLINDER 7. HEAD OFF CAR SERVICE. 8 NOTICE: This engine uses special torque to yield head bolts, This design bolt requires a special 9, tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage. 10. ne ie 1. Clean threads in the block using a 7/1614 tap. 13, ‘Clean bolt threads using a wire brush Cylinder head gasket on block Apply P/N 1052080 sealant on bolt threads Cylinder head bolts Tighten cylinder head bolts to 47 N-m (35 Ibs. ft.) in the sequence shown in Figure 23. Rotate each bolt 130° in sequence using J 36660 Rotate the center four bolts an additional 30° in sequence using J 36660 Pushrods, guide plate and rocker arm assemblies ‘© Apply P/N12345493to rocker arm pedestal bolts before assembly © Tighten rocker arm pedestal bolts t0 38 Nem (28 lbs. ft) Intake manifold Valve cover Exhaust manifold Front (Left) Cylinder Head © A/C compressor bracket bolt to 70. N-m (52 Tbs. ft.) © Generator support bracket to cylinder head © Generator © CL and spark plug wires Rear (Right) Cylinder Head ‘© Belt tensioner assembly © Power stecring pump © Fuel line heat shield Negative battery cableCYLINDER HEAD OFF CAR SERVICE (Figures 24, 25 & 26) Important © During disassembly, be sure that the valve train components are kept together and identified so that they can be re-installed in their original locations and with the same mating surfaces as when removed. © Before removing the cylinder head(s) from the engine and before disassembling the valve mechanism, perform a compression test and record the results. [2] disassemble 1. Valve train 2. Water jacket plugs ¢ Obtain a suitable self-threading screw. Drill a hole in the plug, © Install the self-threading screw. © Pry out plug. Spark plugs Inspect © Cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, determine the cause: = Improper installation = Loose or warped cylinder head = Missing dowel pins Cl © Cylinder head bolts © Cylinder head. Remove all varnish, soot and carbon to the bare metal. DO NOT use a motorized wire brush on any gasket sealing surface. © Valve guides using J 8101 © Threaded holes ‘Remains of sealer from plug holes CAUTION: Safety glasses must be worn when using a power wire brush to avoid injury to the eyes. Inspect Cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools. Important ‘© Any bolts that are suspected of damage ‘aust be replaced. 2. Cylinder head for cracks, especially between valve seats, and in the exhaust ports 3. Cylinder head deck for corrosion, sand inclusions and blow holes. 3800 ENGINE VIN C_6A813 © Do not attempt to weld the cylinder head, replace it. Cylinder head deck, intake and exhaust manifold mating surfaces for flatness, ‘These surfaces may be re-conditioned by parallel grinding. If more than 25 mm (.010") must be removed, replace the head. To determine if the cylinder head has sufficient deck surface thickness for resurfacing, measure the height from the deck surface to the cast pads as shown in (Figure 26). New cylinder heads will measure from 1.372mm (.054") to 1.676mm (. 066"). The minimum dimension allowed after resurfacing is 1.118mm (,044"), If the cylinder head does not mect the minimum thickness after resurfacing, replace the cylinder head. Figure 24 Checking Cylinder Head Flatness Ail threaded holes for damage. Repair as needed Seating surfaces @ Water jacket plugs ‘Clean and inspect valve guides for wear. Valve seats for excessive wear and burned spots © Valve seats may be re-conditioned by grinding. An oscillating type valve seat grinder is preferred. Follow the grinder manufacturer's instructions. If, "after erinding, the new seat is t00 wide, it may be arrowed by using a 20° or 70° stone. The 20" stone will lower the seat and the 70° stone will raise the seat. If the seats are re~ conditioned, the valves also must be re- conditioned or replaced. Refer to VALVES SPRINGS AND RETAINERS.6A8-14_ 3800 ENGINE VIN C ssogot ans, Figure 25 Checking Cylinder Head Resurfacing Dimension [+] Assemble 1. Cooting jacket plugs. Coat plugs with GM 1080026 sealer or equivalent. 2. Valve and spring mechanism. VALVES, SPRINGS AND RETAINERS (Figures 27 thru 33) Tools Required: J 5830-4 Valve Guide Reamer .254mm ( 010")}0S J 8101 Valve Guide Cleaner NOTICE: Avoid breaking the valve guide. If the valve stem bas mushroomed due to rocker arm wear or there ate burrs at the keeper grove, remove burrs by chamafering the valve stem with an oil stone or file, Do not remove the valve from the guide using « hammer and drift punch ia 026 (638) 1,935-1.975 149.15 60.17) g in] o015- oose z two | _“taae’ ons ~ 45° », [was al 000-080 g mm) 12.03 - 1.53), & Rout inf 002 ¥ ‘wa (880) 3 Face Angle = nieuw | 0a mag” men | 838 cen ve] 3938-1978 ge ima | aaieosath 8 Ten in| 0018-0002 = Clearance trom 1,038 -.081) E = . e070 Fa hae ee a 7,030,750 g 403. eas) & [toe ten| _7081e1.780 Somes wen | (o0B-a7 SEAS. [eee Wem | tae m@n| 200-22001.918 open wer | tes0-a7oes9.4 Figure 26 Valve and Spring SpeciO00 ENGINE VIN C BASIS © Valve face for grooving. If the groove is so deep that re-facing would result in 2 knife edge (estroying the margin), the valve must be replaced. © Measure valve margin after grinding valves. if the ‘margin is less than the minimum recommended margin, replace the valve. Figure 27 Cleaning Valve Guide [disassemble 1. Clean valves of carbon, oil and varnish. Carbon can be removed with a wire brush, varnish by soaking in carburetor cleaning fluid CAUTION: Safety glasses must be worn when using a power wire brush. Avoid inhaling of fumes and exposure of skin to carburetor cleaning fluid, as bodily injury may result. ‘© Donot scratch the valve stem with the wire ‘brush 2._ Clean valve guides using J 8101 [S| sect ‘@ Valve stem tip for wear The valve stem tip may be reconditioned by grinding. ‘© Follow the grinder manufacturer's instructions ‘Make sure the new surface is perpendicular to the valve stem. © Valve lock (keeper) for chipped or worn lands. Reptace the valve if chipped or worn or severely burned at the keeper groove © Valve face for burning or cracking. If pieces are broken off, inspect the corresponding piston and cylinder head area for damage. ‘© Valve stem for burrs and seratehes. Burrs and minor scratches may be removed with an oil stone. @ Valve stem for straightness and valve head for bending or distortion. Use “V" blocks. Bent 07 distorted valves must be replaced. NEW VALVE WORN VALVE, 4-STEM-MOST WORN ‘SECTION 5-FACE 6-MARGIN 1-VALVE TIP. 2-KEEPER GROOVE -STEM-LEAST WORN SECTION Figure 26 Valve Wear Measure ‘There are (wo acceptable ways of measuring valve to guide clearance, Method "A" is preferred. Method A Insert the valve into its guide. Lift it 2mm (1/8") off the seat and move it side to side, measuring the amount of movement with a dial indicator, or Method B With a hole gage, measure the valve guide ID. and measure the valve stem with a micrometer and compare the clearance. © The valve guides may be reamed to accept an oversized valve NOTICE: Clean the valve guide before reaming. ‘To avoid breaking reamer flutes do not push down ‘on the zeamer. Clean and lubricate the reamer often during use. [BE inspect @ Valve springsGA8-16 3800 ENGINE VIN C [i].2001 oc novcaTor [a] vaive SMOVESTEMN QUE AND NOTE CLEARANCE wT VALVE (OFF OF VALVE SEAT Expanded height Spring ends. If they are not parallel, the spring is bent and must be replaced. Spring load. If below specification, replace. © Valve spring seating surface of the spring retainers for wear or gouging. Replace as requived, Ee] Assomble 1. Valves Figure 32 Checking Valve Spring Load Valve Run-out. Lift the valve offits seat and apply a dab of prussian blue on the valve face. Seat the valve and carefully rotate it. The prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. Clean all traces of prussian blue. Apply a dab of prussian blue on the valve seat and repeat the check, The traces of prussian blue transferred to the valve face indicates valve run-out. Re-condition valve seat/face or replace valves as required. Be sure to measure valve margin after refacing any valve, Replace any valve that is less than the specified minimum. Valve stem oil seals Important Push the valve stem seals down as far as they will go. Intake and exhaust valve stem seals are different and should be installed inthe correct position based on part number and package description. 3. Complete assembly of the valve mechanism VALVE STEM HEIGHT 1. Place the valve in its guide and hold it in the ‘closed position. 2, With a steel machinists rule, measure from the machined spring seat to the valve tip. 3. The measurement should be 49.15 mm to 50. 17mm (1.935" to 1.975") VALVE SPRING INSTALLED HEIGHT ‘© Valve spring installed height. Excessive valve spring installed height is caused by the lowering ‘of the valve seat by wear and grinding and valve face grinding during re-conditioning. To correct the valve spring installed height, add shims under the valve spring. Place the valve in the guide Install valve spring retainer and keepers Pull up on the valve spring retainer to seat it. With a steel machnists rule or other suitable measuring device, measure the distance from the machined spring seat to the spring-side of the retainer. 5. The measurement should be 42.15mm to 44. 48mm (1,690" to 1.750") .030). Tf not within specifications, add shims under the valve spring as required. (CRANKSHAFT BALANCER: (Figures 34 & 35) Tool Required: 337096 Flywheel Holding Tool Remove or Disconnect pees Negative battery cable Serpentine belt Raise car and suitably support, see Section OA. Right front wheel and tire assembly Inner fender splash shield (right side) Torque converter cover Hold flywheel with J 37096 Balancer bolt Crankshaft balancer Important ‘e The balancer is serviced as an assembly. Do not attempt 10 separate pulley from balancer bub. Install or Connect 1. Crankshaft balancer 1 2 3 4. 5 6 2 8 9. 3600 ENGINE VIN C 688-17 [i] maconasr's aunt DETERMINE INSTALLED HEIGHT BY MEASURING FROM SPRING POCKET TO RETAINER SURFACE Figure 33 Measuring Valve Spring Installed Height 220U8s. Fr [Elcranmsnart SoU Rsseneur ‘© Lubricate seal surface with engine oil 2. Balancer bolt © Hold flywheel with J 37096 @ Balancer bolt to 297 N-m (219 Sbs. ft.) ‘Inner fender splash shield 44, Right front wheel and tire assembly “Torque converter cover Lower car. ‘Serpentine belt. (Figures 3 and 4) Negative battery cable eaeBAR \8-18 3800 ENGINE VIN C FRONT COVER (Figures 34 thes 37 [55] Remove or Disconnect EB ees av aene 12, Tool Required: 3.37087 Crankshaft Sensor Adjuster 3.37096 Flywheel Holding Tool 1. OSEAL 2. CAM BUTTON 3. CAM BUTTON SPRING gift Figure 36 Front Cover Negative battery cable Engine coolant Drive belt ‘Heater pipes Lower radiator hose from cover ‘Coolant bypass hose from cover Raise car and suitably support. See Section OA. Right front wheel and tire Inner fender splash shield Balancer bolt and balancer Electrical connections at © Camshaft sensor © Crankshaft sensor © Oil Pressure sender Oil pan to front cover bolts Front cover attaching bolts and cover Inspect ‘Timing chain for overall "in and out” movement. Should not exceed 25.4mm (one inch). Sprockets for wear FER clean L 2 3 4 3. 6 7 8 9. 10. ul 12, 13 14, 15, Gasket mating surfaces at timing chain cover, and cylinder block. Ifoil pan gasket is excessively swollen, the oil pan ‘must be removed and the gasket replaced Figure 37 Crankshaft Sensor Adjustment Bee] instat or Connect Gasket at cylinder block Front cover and attaching bolts © Apply P/N 1052080 or equivalent to bolt threads © Tighten bolts to 30 Nem (22 Ibs. ft.) Oil pan to front cover bolts ‘© Tighten to 10 Nv (88 Ibs. in.) Electrical connections Adjust crankshaft sensor using J 37087 Balancer and bolt @ Tighten to 297 N-m (219 Ibs. ft.) Inner fender splash shield Right front wheel and tire Lower car Coolant bypass hose Lower radiator hose Heater pipes Drive belt Fill cooling system. See Section 6B. Negative battery cableFRONT COVER OIL SEAL ‘Figure 38) Tool Required: 1 35354 Seal Installer Remove or Disconnect 1. Crankshaft balancer and bolt 2. Pry out old seal with a screwdriver © Usecare to avoid damage to seal bore or seal contact surfaces. FRONT CRANKSHAFT SEAL 935954 SEAL INSTALLER BALANCER BOLT Figure 38 Installing Oil Seal Using J 35354 Pe insta or Connect 1. Oil seal using J 35354 seal installer Use the crankshaft balancer ‘bolt with the to ‘@. Tighten the bolt until the seal is’ seated in the cover 2. Remove J 35354 2. Coat outside seal surface of crankshaft balancer with GM 1050169 lubricant or equivalent 3. Crankshaft balancer and bolt © Tighten bolt to 297 N-m (219 Ibs. ft.) OIL FILTER ADAPTER & PRESSURE VALVE (Figure 39) [A] Remove ot Disconnect 1. Four bolis holding oil filter adapter to front cover 2. Oil filter adapter, gasket, oil pressure valve and spring Rr Clean @ Ports in suitable solvent & dry ‘© Inspect oil pressure valve and the valve bore for burrs Gasket surfaces Spring for loss of tension (replace if in doubt) 3800 ENGINE VINC 6AB19 [ee] Instat or Connect 1. Spring into front cover 2. Oil pressure valve into front cover 3. Oil filter adapter and a new gasket 4 Bolts ten 10 41 Nem (30 bs. ft) VALVESIL PRESSURE 39Nem (24 18S. FTI —_1seooraas.crt Figure 49 Oif Filter Adapter & Oil Pressure Vaive TESTING OIL PRESSURE Tool required: 25087 Oil Pressure Test Kit ‘© If low oil pressure is suspected, the pressure can be checked on the car. 1. Cheek oil level. . Raise car and remove oil filter. 3. Assemble plunger valve in the large hole of the tester base and the hose in the small hole of the tester base. Connect gage to the end of the hose. 4, Insert the flat side of the rubber plug, for ease of installation, in the by-pass valve without depressing the by-pass valve itself. 5. Install the tester on filter mounting pad. 6. Start engine to check overall pressure, sender switch, or noisy lifters. Engine should be at ‘operating temperature before checking oil pressure. Pressure should be about 275 kPa (40 psi) @ 1850 rpm using 5W-30 engine oil 7. If adequate oil pressure is indicated, check pressure sending switch 8. Ifa low reading is indicated, depress the valve on tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time would indicate a good pump and the previous low pressure was due to worn bearings etc. A low reading while depressing the valve would indicate a faulty pump.8A820_3800 ENGINE VIN C Olt PUMP {Figures 40 thru 44} Remove or Disconnect 1. Front cover from engine 2. Remove oil filter adapter, pressure regulator valve & spring 3. Remove oil pump cover attaching screws & cover 4. Remove gears risen anes.na ( oluPumP coven Fue oureR GEAR PUMP INNER GEAR, FRONT COVER Figure 40 Oil Pump and Housing FH ctean © All parts in a suitable solvent, Remove all varnish, sludge and dirt. ‘© Remove all traces of old gasket from front cover and engine block. inspect © Pump cover and front cover for: ~ eracks ~ scoring + porous or damaged casting ~ damaged threads ~ excessive wear ‘© Pressure regulator valve for: ~ scoring + sticking in bore + burrs © Pressure regulator spring for: = toss of tension ~ bent condition + if in doubt, replace the spring © Oil pump gears for: + chipping + galling - scoring ~ excessive wear © Oil pump gears for ~ inner gear tip clearance outer gear diameter clearance ~ Gear end clearance (gear drop in housing) © Pressure regulator valve for: ~ Valve to bore clearance omer Gear Tip Clerance ~ Figure 41 Measuring Geer Tip Clesrance Figure 43 Measuring Gear End Cl (Gear Drop in Housing )3800 ENGINE VIN C_6A8-21 END CLEARANGETGEAR ta] O01. O03 DRoPINHOUSING) "im | 1025-089 inven GEAR TIP 208 ClEanaNce toi | (821 OUTERGEAR DIAMETER in. | 008-015 | cteanance tmmi | 203.81) 2 [onessunenecucaron in | 0016-008 Z| vatvero eons mm) | (038-076) & | cueanance [lor wesna7uss. er ean POCKET 489-4805 Ferman berrH cnn 78) [Beaman senocxer “GEAR POGKET 3s089.512 [a] camswarr cea Diamever 3108920) Slew [Bjoawren [aloo specu ro nem neues. F13 [a] seme el cranesnar spaocker sone Figure 44 O1 Pump Specifications Figure 48 Timing Chain and Sprockets = wewa oS, [ie] Assemble iO a i ALIGN Ser 1, Lubricate gears with petroleum jelly. ass 2. Assemble gears in housing, 0 3. Pack gear cavity with petroleum jelly. gro 6 4, Install oil pup cover and screws. LS 5, Tighten oil pump caver screws to specifications. oro 6. stall pressure ulate Install pr regulator spring & valve, aALnczziarr1o CRANKSHAFT 7. Insta ol filter adapter with a new gasket. NM SAMEHAPT © Tighten oil filter adapter bolts to 33 N-m (24 Ibs. ft.) 8. Install front cover on engine. TIMING CHAIN AND SPROCKETS (Figures 45 and 46) [e2 Remove or Disconnect 1. Front cover 2. Camshaft thrust button 3. Align timing marks on sprockets so that they are as close together as possible. (Figure 46) ‘Fiming chain damper ‘Camshaft sprocket bolts ‘Camshaft sprocket and chain (Crankshaft sprocket ers Figure 46 Timing Balance Shaft and Camshaft Marks Clean © Timing chain © Sprockets [EF] inspect ‘All components for wear and/or damage. fra inst or Connoct hl Important © If the pistons have not been moved in the engine, go to Step 3, otherwise Step 1. © If the balance shaft timing has been disturbed, refer to. "Balance Shaft” Assembly procedures 6 thru 11.GA8-22 3800 ENGINE VIN C 1. Turn crankshaft so that number one piston is at top dead center. 2. Turn camshaft. so, with sprocket temporarily installed, timing mark is straight down, 3. Assemble timing chain on sprockets with timing ‘marks in their closest together position (Figure 46, View B). 4, Timing chain and sprocket. 5. Camshaft sprocket bolts @ Tighten to 37 N-m (27 tbs. ft.) 6. Camshaft thrust button and spring. 7. ‘Fiming chain dampener, 8. Front cover, BALANCE SHAFT (Figure 47 thru 49) Tools Required: 8001 Dial Indicator 3 36995 Rearing Remover Installer ‘J 36996 Balance Shaft Installer J 6125-B Slide Hammer J 36660 Torque Angle Meter [>] Remove or Disconnect 1. Negative battery cable 2. Engine assembly 3. Flywheel Intake manifold Lifter guide retainer Front cover Balance shaft drive gear bott ‘Camshafi sprocket and timing chain Balance shaft retainer bolts, retainer and gear Balance shaft with J 6125-B Balance shaft rear plug Balance shaft rear bearing using J 36995-5 tmportant The balance shaft and both bearings are serviced 3 a complete package. ¢- Use only the correct tools for bearing and shaft installation, © Inspect the balance shaft drive gear and the camshaft drive gear for nicks and Burrs, Bee] instt oe Connect 1, Balance shaft rear bearing using J 36995-1 © Dip bearing in clean engine oil before installation © Install the bearing with the rolled edge facing into, the and the manufacturer's markings facing the flywheel side, * ° 2. Balance shaft into block using J 36996 10. Tt 12. 1B. 14, 15. 16. 17. 18, 19. 20. ‘© Dip the front balance shaft bearing into cclean engine oil before assembly ‘Temporarily install balance shaft bearing retainer and Balance shaft drive gear and bolt @ Apply P/N12345493 to bolt threads @ Tighten to 20 N-m (14 Ibs. ft) and rotate 35° using J 36660 Balance shaft rear plug Measure balance shaft end play © End play should be 0-.203mm (0-.008in.) Measure balance shaft radial play at both the front and rear © Front radial play should be 0-.028mm (0-. Oottin,) ‘© Rear radial play should be .0127-.119mm (. (0005-.0047in.) Tum the camshaft so, with the camshaft sprocket temporarily installed, timing mark is. straight down, With the camshaft sprocket and the camshaft gear removed, turn the balance shaft so that the timing mark on the gear points straight down Camshaft gear @ Align the marks on the balance shaft gear and the camshaft gear by turning the balance shaft (Pigure 46, View A). Turn the crankshaft so that number one piston is at top dead center. ‘Timing chain and camshaft sprocket Measure gear lash at four places, every 1/4 turn, Lash should be .050-.127mm (.002-.00Sin.) Balance shaft front bearing retainer and bolts. © Tighten to 35 N-m (26 Ibs f.) Front cover Lifter guide retainer Intake manifold Flywheel © Tighten bolt to 82 Nom (61 Ibs. ft.) Engine assembly Negative battery cable CAMSHAFT ‘Figures 60 thru 52) 1 2 3 4 5, 6 1 8 9. lemove or Disconnect Negative battery cable Engine Intake manifold Valve covers Rocker arms Push rods Valve lifters Crankshaft balancer Front cover3800 ENGINE VIN G 608-23 ] Remove or Disconnect Negative battery cable Raise car and suitably support. See Section OA. Engine oil Transaxle converter cover Starter motor Oil filter Oil pan retaining bolts Oil pan Old oil pan gasket and discard @ The formed rubber oil pan gasket cannot be rested Mclean @ Oil pan and cylinder block ‘mating surfaces Install or Connect New formed rubber oil pan gasket to oil pan flange 2. Oil pan and torque bolts to 14 N-m (124 Ibs. in.) © Do not over-tighten bolts or damage to the cil pan will occur, resulting in an oil leak. 3. Starter motor 4. Transaxle converter cover PA Rwbee De3800 ENGINE VIN 6A825 MEASURING FRONT RADIAL PLAY [3 J 2001 brat worcaTor ssoorecnsa, Figure 49 Measuring Balance Shaft Clearances sauna (ecanmis ano sans assemauy Figure 50 Comshal Lobe Lik Cilenennet 5. Lower ea {aJecanncs 6 Engine oil Fa] cur pus 7. Negative battery cable Figure 51 Camenatt6A8-26 3800 ENGINE VINC our in] 1.7880. 2.7260 Barat tmnt | e558. 46588 eowing in| 17885-17068 fee tmnt | eae ae 39 ore g 2 | emma im | 0008-0035 Soa tmmi | tonoso80" 5 | Gatos mae in 200 & Umm 16.43) g B len in 268 toon |e Figure 62 Gandhalt ond Bearing Specteatons 2}OU PAN ‘B) BOLTS 14.NoM (124 LBS. INP 0080 9a50-81 Figure 53 Oil Pan REAR MAIN OIL SEAL REPAIR (Figures 54, 55 & 66) Tool Required: J 21526 Seal Packing Tool [65] Remove or disconnect 1. Raise car and suitably support, See Section OA. 2, Engine oil 3. Oil pan 4. Rear niain bearing cap 5. Oil seal from bearing cap 1._ PACKING TOOL J-21526-2 aren Figure 84 Packing Seal into Block 1. SHORT PIECE OF ROPE SEAL 2, GUIDE TOOL J21576-1 INSTALLED Figure 65 Guide Tool installed 4. PACKING TOOL 2 GUIDE TOOL Figure 66 Packing pe & Cylinder BlockBA insta or connect 1. Insert packing tool J 21526-2 the seal in the cylinder block in until it i tight 2. Repeat Step 1 on the other side of the seal. 3. Measure the amount the seal was driven up into the block on one side and add approximately 2 mm (1/16°). With a single edge razor blade, cut this amount off of the old lower seal. The bearing cap can be used as a holding fixture. 4. Install packing guide J 21526-1 onto ¢; block. 5, Using the packing tool, work the short pieces of seal into the guide tool and pack into the cylinder block until the tool hits the built in stop. © A.small amount of oil on the pieces of seal may be helpful when packing into the eylinder bloc 6. Repeat Step 5 on the other side 7. Remove guide tool. 8. Install new rope seal in the bearing cap, 9. Main bearing cap and bolts © Tighten to 122 N-m (90 Ibs ft.) 10. Bearing cap side seals, 11, Oil pan and new gasket 12, Add oil © Proper oil Jevel REAR MAIN OiL SEAL REPLACEMENT {Figures 57 & 58) ainst one end of sk the old seal inder [ep] Remove or Disconnect 1. Engine from car 2, Oil pan 3. Crankshaft FRA clean ‘© Remains of sealer and adhesive from: + Upper and lower bearing groove = Mating surface of the bearing cap Bq instal or Connect 1 Rope seal 2. Apply GM 1052621 sealer or equivalent to the seal groove. 3. Within one (1} minute insert seal into groove. 4. Roll into place with a suitable tool until seal pigs above groove no more than 1.59 mam (1/ 5. Seat the seal with a suitable tool. 6 Cutexcess seal material with a sharp knife at the bearing cap parting line using the sea! installer to hold the seal in place. Apply 2 thin film of chassis grease to rope seal 8. Apply a thin film of GM 1052942 sealer, of equivalent on the bearing cap mating surface around the seal groove. 3800 ENGINE VIN C_6A8.27 NEOPRENE COMPOSITION SEAL cur Enos, OF FagRic SEAL SQUARE ‘ANG FLUSH FABRIC SEAL noo 164.08 Figure 57 installing Rear Main Boaring Oil Seal In Cap. NEOPRENE COMPOSITION SEAL APPLY SEALER To THESE WO AREAS Figure 68 Sealer Application on Rear Main ring Cap Important @ Use sealer sparingly. Keep sealer out of bolt threads. Soak sealing strips in light oil or kerosene for 5 minutes before installing. 9, Revinstall the rear main bearing cap. 10. Place composition strips into grooves along the sides of the main bearing cap. OIL PUMP PIPE AND SCREEN ASSEMBLY {Figure 69) fe] Remove or Disconnect 1 Oil pan 2. Oil pump pipe and screen assembly attaching bolts FEM cieon . Screen and housing with solvent and blow dry. © Gasket mating surfaces on pipe flange and eylinder block. Bee] instat or Connect 1. Oil pump pipe and screen with new gasket and tighten bolts to specification, 2. Oil panGAB-28 3800 ENGINE VIN C [es a > ENGINE LEFT ENGINE FRONT ENGINE RIGHT 2] 2}-— 1. CYLINDER aLock 2, OILPUMP PIPE AND SCREEN 3. GASKET, 4.10 Nom (7 LBS, FT) as7oscasaan 1-OIL'RING SPACER GAP (TANG IN HOLE OR SLOT WITH ARC) 2-OIL RING RAIL GAPS 3-2ND COMPRESSION RING GAP ‘4—TOP COMPRESSION RING GAP Figure 69 Oil Pump Pipe & Screen Assembly PISTON AND CONNECTING ROD ASSEMBLY (Figures 60, 61 & 62) Tool required: + 36660 Torque Angle Meter Piston Ring Compressor Remove or Disconnect Ridgets) coward ‘heat of engine Figure 60 Piston Installation Direction 1. Cylinder head 2 Oil pan Important ‘® To avoid damage to piston ring lands be sure to remove any carbon or ridge at the top of the cylinder bore. 3. Mark the connecting rod cap and rod for proper reassembly Connecting rod bolts Conneeting rod cap Piston and connecting rod assembly See PISTON FITTING, PISTON RINGS, BEARING CLEARANCE AND CYLINDER BLOCK in this section for proper measurement and replacement procedures ere Figure 61 Piston Ring Gap Locations [a] senrey pus piston INTO CYLINDER ‘BORE WITH A HAMMER HANDLE [Zancscompaesson —viorop ence, Figure 62 Installing o Piston Using Ring Compressor Install or Connect, Piston rings to piston © In order to provide an effective compression seal, the ring gaps must be staggered (Figure 61) Turn crankshaft to bottom dead center Lubricate cylinder with oil Connecting rod bearing Piston and connecting rod assembly using a ring compressor. Ridge(s) toward front of engine (see figure 60) NOTICE: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal. 6. Connecting rod cap and bolts 7. Tighten connecting rod bolts to 27 N-m (20 Ibs. fr. plus 50° rotation using J 36660 Torque Angle Meter 8. Oil pan 9. Cylinder Head 2. 3 4 5PISTON FITTING {Figure 63) [2] important . When fitting pistons, both piston and cylinder bore condition must be considered together. Production and service pistons have the same nominal weight and can be intermixed without affecting engine balance. If necessary, used pistons may be fitted selectively to any cylinder of the engine, providing they ate in good condition. © Do not cut oversize balance will be alfect jstons down or engine Measure Piston, If worn or damaged, replace with a standard or oversize piston. 2. Cylinder bore, refer to CYLINDER BLOCK. If worn beyond specifications, rebore and hone to size. Meosuve piston atcenterine: Of piston pinhole. raoorsee Figure 63 Measuring Piston 3. Select a piston 4. Hone the cylinder bore to recommended clearance. 5. Scrub the cylinder bore and the piston with soap and water and remove all foreign material. Dry and rub in clean engine oil. obtain the Measure Check piston to cylinder bore clearance as follows: a. Measure the cylinder bore diameter with telescope gage. Measure the piston diameter (Figure 63) ¢, Subtract piston diameter from cylinder bore diameter to determine _ piston-to-bore clearance. d. Compare piston-to-bore clearance obtained with specifications, Determine if piston-to-bore clearance is in ‘acceptable range. 2. Ifa used piston is not acceptable, check service piston sizes and determine if a new piston can be Selected. (Service pistons are available in standard and .254mm (010°) oversize. 3800 ENGINE VIN C 6A8.29 3. [feylinder bore must be reconditioned, measure new piston diameter then hone cylinder bore to obtain preferable clearance. 4. Select new piston and mark piston to identify the cylinder for which it was fitted. (On some cars oversize pistons may be found. These pistons will bbe 010" oversize.) lean © Scrub the cylinder bore and the piston with soap and water and remove all foreign material. Dry and rub in clean engine oil PISTON PIN & RINGS (Figures 64 thru 68) Fe disassemble Tool required 1.24086 Piston Pin Remover/Installer 1. Piston and connecting rod assembly CAUTION: Use care when handling the piston. Worn piston rings are sharp and may cause bodily injury. Piston rings. Use a suitable tool to expand the rings, Piston rings must not be re-used. 3. Place the piston and connecting rod assembly into Fixture J 24086 and press out the piston pin Figure 64 Removing Piston Pin Using Tool J 240866A8-30 3800 ENGINE VIN C Clean © Piston, piston pin and connecting rod - Sludge + Carbon ~ Tris essential that the piston ring grooves ‘are cleaned of carbon to the bare metal ‘© Use proper sing cleaning tools to avoid ‘damage to the piston ring lands. + Varnish from the piston pin by soaking in carburetor cleaning solution. CAUTION: Avoid inhaling fumes or posure of the skin to carburetor cleaning fluid, as bodily injury may result. - Do not scrape the piston skirt Inspect 1. Connecting rod for: © Bending or twisting = Install the connecting rod cap and torque to specifications, + Place the connecting rod assembly on a checking fixture and check for bending or twisting. -I¥_ the connecting rod is bent more than 127mm. {.005") measured over the entire length of the connecting rod, it must be replaced -If the connecting rod is twisted more than .2S4mm (010") measured over the entire length of the connecting rod, it must be replaced. @ Do not attempt to straighten any connecting rod. Always check “new connecting rods before using them. © Outside of the connecting rod bearing and the LD. of the connecting rod lower end for ‘wear indicating high spots in the connecting rod lower end. © Connecting rod bolts for stretching by comparing them with a new bolt © Upper end for scoring 2. Piston pin for: © Scoring ® Galling caused by improper installation © Fit in connecting rod and piston 3. Piston for: © Scoring of the skirt © Cracks, © Broken ring groove lands. © Wear [El Menae © Piston Rings © Select a set of new piston rings © Piston ring end gap + Place piston into the cylinder at the bottom of the ring travel. + Place a piston ring on top of the piston. ~ Back off the piston. - Measure the ring gap If the gap is below specification increase the gap by carefully filing off excess material. "TO MEASURE PISTON RINGEND GAP: * PLACE THE RING IN THE CYLINDERIN WHICH TWILL BE USED. + SQUARE THE RING IN THE BORE USING A, PISTON, + MEASURE THE END GAP USING & FEELER GAGE morsoancr Figure 65 Measuring Piston Ring Gap # Piston ring side clearance (compression rings) + Roll the piston ring around the groove in which it is to be installed and measure the side clearance. If the ring is too tight, check for nicks or burrs in groove or on ring. Burrs may be Femoved using emmery paper. If no cause can be found, determine if the ring is within specification and replace the ring or the piston as necessary. NOTICE: Do not attempt to cut the ring groove with a file or other rough edged tool. Ring groove straightness and smoothness is very important to ‘maintain good performance and durabilit FH Assembie ‘© Connecting rod and piston assembly Tool required: J 24086 Piston Pin Remover/Installer3800 ENGINE VINC BABY eterna ferrets 3800 LN3 VIN C Figure 65 Measuring Piston Ring Side Clearance LE] important © The pistons may be installed on the connecting rod in either direction. 1. Place piston and connecting rod into Fixture J 24086 2, Adjust plunger of the fixture to the appropriate setting 3. Coat the piston pin with clean engine oil 4. Press the piston pin into place ‘© Piston for freedom of movement BA Insta or Connect 1. Oil control ring assembly ~ Expander = Lower oil control ring Upper oil control ring, 2. Upper and lower compression ring. ‘Manufacturers mark facing up. NOTICE: Use a piston ring expander to install the rings. Avoid expanding the rings more than necessary, Which may cause ring damage. CRANKSHAFT [E>] Remove o Disconnect (Figure 69) 1, Engine 2. Front cover 3. Timing chain 4. Oil pan 5. Oil pump pipe and screen assembly & Conueeting. tod caps and push piston. and connecting rod assemblies 10 top of cylinder bores, 7. Secure connecting rods to outside of cylinder ‘block using rubber bands attached to oil pan rail bolts. 8. Main bearing cap attaching bolts 9. Main bearing caps ommereR we] a8 EA CYLINDER. in] 0004-0027 a i LEARANCE 200405 iAweveR in] 9055 953 smn| 22995 2200 | g [FR PRTON nf ne co 3 snn|_010: 0000 B) lavinnoo in] 0007-0097 Press m|_o18-083, TOP 73.178 EQMMPRESSION mm 4.909.4519, E[zno in] 773.178 ‘Si COMPRESSION 4389.451 ie fon. in] 165.171 [eontRoL azewane oF in| 010.026 [compression vm] 254.635 8 |ano in} 010-925 |CONPRESSION mm 254.835 Jou in] 015-055 [Cowrmo. som|_384-1 937 gy aitor inl 00130037 $) e\Coteenessiow aim oa-078 sigs|a in] 0013-0081 3)pz|commression 25.099 5) Bon, oy 008 EI 2 [Conmon 7b. 200 hor 581 0085 & |comnession Pave a7 3 [ano in| 58%. 0587 3 |Gomenession com) 13751497 Z Jou on 022 ne? eowrrot inm| 2080 3.902 igure 67 Cylinder and Piston Specific