5.0 & 5.7 LITER

SERVICEMANUAL

Manual Part No. 0E7738

GMGAS

ENGINE

FOREWORDThis manual has been published by GENERAC POWER SYSTEMS,

INC. to aid our dealers mechanics, company service personnel andgeneral consumers when servicing the products described herein.

It is assumed that these personnel are familiar with the servicingprocedures for these products, or like or similar products, manufac-tured and marketed by GENERAC POWER SYSTEMS, INC. It is alsoassumed that they have been trained in the recommended servicingprocedures for these products, which includes the use of mechanicshand tools and any special tools that might be required.

Proper service and repair is important to the safe, economical andreliable operation of the products described herein. The trou-bleshooting, testing, service and repair procedures recommended byGENERAC POWER SYSTEMS, INC. and described in this manual areeffective methods of performing such operations. Some of theseoperations or procedures may require the use of specialized equip-ment. Such equipment should be used when and as recommended.

We could not possibly know of and advise the service trade of allconceivable procedures or methods by which a service might be per-formed, nor of any possible hazards and/or results of each proce-dure or method. We have not undertaken any such wide evaluation.Therefore, anyone who uses a procedure or method not recom-mended by the manufacturer must first satisfy himself that neitherhis safety, nor the products safety, will be endangered by the serv-ice or operating procedure selected.

All information, illustrations and specifications contained in thismanual are based on the latest product information available at thetime of publication. However, GENERAC POWER SYSTEMS, INC.reserves the right to change, alter or otherwise improve the productat any time without prior notice.

Some components or assemblies of the product described in thismanual may not be considered repairable. Disassembly, repair andreassembly of such components may not be included in this manual.

The engines described herein may be used to power a wide varietyof products. Service and repair instructions relating to any suchproducts are not covered in this manual. For information pertainingto use of these engines with other products, refer to any owners orservice manuals pertaining to said products.

The 5.0/5.7 Liter Gas Engine has been engineeredfor use in Generac Power Systems products. Thecontents of this manual have been reprinted from theoriginal manufacturers service and repair manual.

SERVICE RECOMMENDATIONS ................................................................................................................ A_2TORQUE SPECIFICATIONS .......................................................................................................... 6-1 THRU 6-3ENGINE MECHANICAL SPECIFICATIONS .................................................................................. 6-3 THRU 6-7COMPONENT LOCATOR ............................................................................................................ 6-9 THRU 6-15ENGINE IDENTIFICATION .......................................................................................................................... 6-16REPAIR INSTRUCTIONS ........................................................................................................ 6-17 THRU 6-139DESCRIPTION AND OPERATION ........................................................................................ 6-140 THRU 6-141LUBRICATION............................................................................................................................6-142 THRU 6-143CLEANLINESS AND CARE............................................................................................................................6-143REPLACING ENGINE GASKETS ..................................................................................................................6-143USE OF RTV AND ANAEROBIC SEALER....................................................................................................6-144SPECIAL TOOLS AND EQUIPMENT .................................................................................... 6-146 THRU 6-148

5.0/5.7 Liter Gas Engine Table of Contents

5.0/5.7 Liter Gas Engine Service Recommendations

ENGINE OIL RECOMMENDATIONSThe unit has been filled with break in engine oil at the factory. Use a high-quality detergent oil classi-fied For Service CC, SD, SE or SF. Detergent oilskeep the engine cleaner and reduce carbon deposits.Use oil having the following SAE viscosity rating,based on the ambient temperature range anticipatedbefore the next oil change:Engine Lubrication System:Type of Oil Pump .......................................................................... GearOil Filter ................................................................ Full Flow, CartridgeCrankcase Oil Capacity ...................................... 4.75 L (5.0 U.S. qts.)

COOLANT

Use a mixture of half low silicate, ethylene glycol baseantifreeze and half soft water. Use only soft water andonly low silicate antifreeze. If desired, you may add ahigh quality rust inhibitor to the recommendedcoolant mixture. When adding coolant, always add therecommended 50-50 mixture.Cooling System:Type .................................................... Pressurized, Closed RecoveryCoolant Capacity

System ................................................................ 19 L (5 U.S. gals.)

Do not remove the radiator pressure cap whilethe engine is hot or serious burns from boilingliquid or steam could result.

Ethylene glycol base antifreeze is poisonous. Donot use your mouth to siphon coolant from theradiator, recovery bottle or any container. Washyour hands thoroughly after handling. Neverstore used antifreeze in an open containerbecause animals are attracted to the smell andtaste of antifreeze even though it is poisonousto them.

Do not use any chromate base rust inhibitor withethylene glycol base antifreeze, or chromiumhydroxide (green slime) will form and causeoverheating. Engines that have been operatedwith a chromate base rust inhibitor must bechemically cleaned before adding ethylene glycolbase antifreeze. Using any high silicate antifreezeboosters or additives also will cause overheating.We also recommend that you DO NOT use anysoluble oil inhibitor for this equipment.

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DANGER

Temperature Oil Grade (Recommended)Above 75 F (24 C) SAE 30W

40 to 75 F (4.4 to 24 C) SAE 20W or 15W-4010 to 40 F (-12 to 4.4 C) SAE 10W or 15W-40

Below 10 F (-12 C) SAE 5W or 5W-20

A_2

5.0/5.7 Liter Gas Engine Service Recommendations

PERIODIC MAINTENANCE SCHEDULE:

SERVICE SCHEDULEAUTHORIZED OPERATOR MAINTENANCEFUNCTIONS

Every Month or 100 Hours(whichever comes first)

Test standby generator system. Inspect battery and cables. Check engine oil level. Check gearbox oil level (if so equipped). Check engine coolant level. Check generator ground connections. Test/inspect starting aids.

Every Three Months or Every 120 Hours(whichever comes first)

Inspect and test fuel system and connections. Inspect exhaust system. Inspect/test fuel supply system.

AUTHORIZED SERVICE TECHNICIANMAINTENANCE FUNCTIONS

After First 30 Hours of Operation Inspect wiring. Change engine crankcase oil and oil filter. Inspect engine fan belts. Inspect battery and cables.

Every Six Months or Every 100 Hours(whichever comes first)

Change engine oil and filter. Lubricate engine controls. Service engine air cleaner. Service engine fuel filter. Inspect AC generator. Test engine safety controls. Inspect fan belts. Check engine coolant level. Inspect engine cooling system hoses. Check optional starting aids. Check battery. Check engine compression. Check electrical connections. Check/test annunciator panel. Perform operational test.

Annually or Every 600 Hours(whichever comes first)

Check engine valve clearance. Test fuel injection nozzles. Test injection timing. Inspect all wiring. Test engine starter operation. Drain water from fuel tank. Retorque fan bolts. Drain and refill gearbox (if so equipped)

Every Two Years Replace all rubber hoses. Replace engine fan belts. Inspect the Standby Generator System. Drain, flush, refill cooling system.

Every 1,000 Operating Hours Inspect engine DC alternator. Inspect engine starter. Retorque engine mounting brackets. Remove/test fuel injection pump. Remove/test cooling system thermostat.

As Required Bleed engine fuel system.

A_3

Notes

Engine Mechanical - 5.0L and 5.7LSpecificationsSIE-ID = 784227

Fastener Tightening Specifications

ApplicationSpecification

Metric EnglishAccelerator Control Cable Bracket Bolt and Nut 12 Nm 106 lb inBelt Idler Pulley Bolt 50 Nm 37 lb ftCamshaft Retainer Bolt 2129 Nm 1521 lb ftCamshaft Sprocket Bolt 3040 Nm 2230 lb ftConnecting Rod Nut

First Pass 27 Nm 20 lb ftFinal Pass 70 degrees

Crankshaft Balancer Bolt 95 Nm 70 lb ftCrankshaft Bearing Cap Bolt and Stud Preferred Method

First Pass Two Bolt Type Bearing Cap 20 Nm 15 lb ftFinal Pass Two Bolt Type Bearing Cap 73 degreesFirst Pass Four Bolt Type Bearing Cap 20 Nm 15 lb ftFinal Pass Outboard Bolt Four Bolt Type Bearing Cap 43 degreesFinal Pass Inboard Bolt and Stud Four Bolt Type Bearing Cap 73 degrees

Crankshaft Bearing Cap Bolt and Stud Optional StrategyTwo Bolt Type Bearing Cap 105 Nm 77 lb ftInboard Bolt and Stud Four Bolt Type Bearing Cap 105 Nm 77 lb ftOutboard Bolt Four Bolt Type Bearing Cap 90 Nm 66 lb ft

Crankshaft Oil Deflector Nut 40 Nm 30 lb ftCrankshaft Position Sensor Bolt 9 Nm 80 lb inCrankshaft Pulley Bolt 58 Nm 43 lb ftCrankshaft Rear Oil Seal Housing Nut and Bolt 12 Nm 106 lb inCrankshaft Rear Oil Seal Housing Retainer Stud 6 Nm 53 lb inCylinder Head Bolt Preferred Method

All Bolts First Pass in Sequence 30 Nm 22 lb ftLong Bolt Final Pass in Sequence 75 degreesMedium Bolt Final Pass in Sequence 65 degreesShort Bolt Final Pass in Sequence 55 degrees

Cylinder Head Bolt Optional On-Vehicle StrategyFirst Pass in Sequence 35 Nm 26 lb ftSecond Pass in Sequence 60 Nm 44 lb ftFinal Pass in Sequence 90 Nm 66 lb ft

Cylinder Head Core Hole Plug 20 Nm 15 lb ftDistributor Cap Bolt 2.4 Nm 21 lb inDistributor Clamp Bolt 25 Nm 18 lb ftDrive Belt Tensioner Bolt 50 Nm 37 lb ftEGR Valve Bolt

First Pass 10 Nm 89 lb inFinal Pass 30 Nm 22 lb ft

EGR Valve Pipe Nut at Intake Manifold 25 Nm 18 lb ftEGR Valve Pipe Nut at Exhaust Manifold 30 Nm 22 lb ftEGR Valve Pipe Clamp Bracket Bolt 25 Nm 18 lb ft

Engine Engine Mechanical - 5.0L and 5.7L 6-1

2002 - Unit Repair (May 25, 2001)

Fastener Tightening Specifications (contd)

ApplicationSpecification

Metric EnglishEngine Block Coolant Drain Hole Plug 20 Nm 15 lb ftEngine Block Oil Gallery Plug 20 Nm 15 lb ftEngine Coolant Temperature (ECT) Gage Sensor 20 Nm 15 lb ftEngine Flywheel Bolt 100 Nm 74 lb ftEngine Front Cover Bolt 12 Nm 106 lb inEngine Lift Front Bracket Stud 35 Nm 26 lb ftEngine Mount Bolt to Engine Mount Bracket Through-bolt 95 Nm 70 lb ftEngine Mount Bolt to Engine Mount Frame Bracket 58 Nm 43 lb ftEngine Mount Bracket Bolt to Engine 54 Nm 40 lb ftEngine Mount Bracket Bolt to Frame 45 Nm 33 lb ftEngine Mount Heat Shield to Engine Mount Bracket 6 Nm 53 lb inEngine Mount Nut Through-bolt 68 Nm 50 lb ftEngine Oil Pressure Gage Sensor 30 Nm 22 lb ftEngine Oil Pressure Gage Sensor Fitting Plus Required Angle 15 Nm 11 lb ftEngine Wiring Harness Bracket Nut 12 Nm 106 lb inEvaporative Emission (EVAP) Canister Purge Solenoid Valve Stud 10 Nm 89 lb inExhaust Manifold Bolt

First Pass 15 Nm 11 lb ftFinal Pass 30 Nm 22 lb ft

Fan and Water Pump Pulley Bolt 25 Nm 18 lb ftFuel Pipe Bracket Bolt 6 Nm 53 lb inFuel Pipe Retainer Nut 3 Nm 27 lb inGenerator and Drive Belt Tensioner Bracket Bolt and Nut to Engine 41 Nm 30 lb ftGenerator and Drive Belt Tensioner Bracket Stud to Engine 20 Nm 15 lb ftIgnition Coil Stud 12 Nm 106 lb inKnock Sensor 20 Nm 15 lb ftLower Intake Manifold Bolt

First Pass in Sequence 3 Nm 27 lb inSecond Pass in Sequence 12 Nm 106 lb inFinal Pass in Sequence 15 Nm 11 lb ft

Oil Filter Adapter Bolt 25 Nm 18 lb ftOil Filter Fitting 35 Nm 26 lb ftOil Level Indicator Tube Bolt 25 Nm 18 lb ftOil Pan Drain Plug 25 Nm 18 lb ftOil Pan Stud 6 Nm 53 lb inOil Pan Stud Nut 25 Nm 18 lb ftOil Pan Bolt or Stud 12 Nm 106 lb inOil Pump Bolt to Rear Crankshaft Bearing Cap

First Pass 20 Nm 15 lb ftFinal Pass 65 degrees

Oil Pump Cover Bolt 12 Nm 106 lb inPower Steering Pump Bolt 50 Nm 37 lb ftPower Steering Pump Bracket Bolt to Engine 41 Nm 30 lb ftPower Steering Pump Bracket Stud to Engine 20 Nm 15 lb ftPower Steering Pump Bracket Stud Nut 41 Nm 30 lb ftPower Steering Pump Nut to Engine 41 Nm 30 lb ftPower Steering Pump Rear Bracket Nut 50 Nm 37 lb ft

6-2 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Fastener Tightening Specifications (contd)

ApplicationSpecification

Metric EnglishSpark Plug

Initial Installation NEW Cylinder Head 30 Nm 22 lb ftAll Subsequent Installations 15 Nm 11 lb ft

Spark Plug Wire Support Bolt 12 Nm 106 lb inSquare Socket Plug Engine Block Oil Gallery 20 Nm 15 lb ftThrottle Body Stud 9 Nm 80 lb inTransmission Cover Bolt 12 Nm 106 lb inUpper Intake Manifold Stud

First Pass 5 Nm 44 lb inFinal Pass 10 Nm 89 lb in

Valve Lifter Guide Retainer Bolt 25 Nm 18 lb ftValve Rocker Arm Cover Bolt 12 Nm 106 lb inWater Outlet Stud 25 Nm 18 lb ftWater Pump Bolt 45 Nm 33 lb ft

SIE-ID = 784228

Engine Mechanical Specifications (5.0 L)

ApplicationSpecification

Metric EnglishGeneral Data

Engine Type V8Displacement 5.0 L 305 CIDRPO VIN Code L30 (M)Bore 94.89 mm 3.737 inStroke 88.39 mm 3.480 inCompression Ratio 9.4:1Firing Order 18436572Spark Plug Gap 1.52 mm 0.060 in

Oil Pressure Minimum at Normal Operating Temperature42 kPa at 1,000 RPM125 kPa at 2,000 RPM166 kPa at 4,000 RPM

6 psig at 1,000 RPM18 psig at 2,000 RPM24 psig at 4,000 RPM

CamshaftEnd Play 0.050.30 mm 0.0020.012 inJournal Diameter 47.44047.490 mm 1.86771.8697 inJournal Diameter Out-of-Round 0.025 mm 0.0010 inLobe Lift Exhaust 7.207.30 mm 0.2830.287 inLobe Lift Intake 6.977.07 mm 0.2740.278 inRunout 0.065 mm Maximum 0.0026 in Maximum

Connecting RodConnecting Rod Bearing Clearance Production 0.0330.078 mm 0.00130.0031 inConnecting Rod Bearing Clearance Service 0.0250.063 mm 0.00100.0025 inConnecting Rod Journal Diameter 56.50556.533 mm 2.22462.2257 inConnecting Rod Journal Out-of-Round Production 0.007 mm Maximum 0.0003 in MaximumConnecting Rod Journal Out-of-Round Service 0.025 mm Maximum 0.0010 in MaximumConnecting Rod Journal Taper Production 0.007 mm Maximum 0.0003 in MaximumConnecting Rod Journal Taper Service 0.025 mm Maximum 0.0010 in MaximumConnecting Rod Side Clearance 0.150.61 mm 0.0060.024 in

Engine Engine Mechanical - 5.0L and 5.7L 6-3

2002 - Unit Repair (May 25, 2001)

Engine Mechanical Specifications (5.0 L) (contd)

ApplicationSpecification

Metric EnglishCrankshaft

Crankshaft Bearing Clearance Journal #1 Production 0.0180.053 mm 0.00070.0021 inCrankshaft Bearing Clearance Journal #2, #3, and #4 Production 0.0300.068 mm 0.00120.0027 inCrankshaft Bearing Clearance Journal #5 Production 0.0200.060 mm 0.00080.0024 inCrankshaft Bearing Clearance Journal #1 Service 0.0250.051 mm 0.00100.0020 inCrankshaft Bearing Clearance Journal #2, #3, and #4 Service 0.0250.064 mm 0.00100.0025 inCrankshaft Bearing Clearance Journal #5 Service 0.0380.063 mm 0.00150.0025 inCrankshaft End Play 0.050.20 mm 0.0020.008 inCrankshaft Journal Diameter Journal #1 62.18962.212 mm 2.44842.4493 inCrankshaft Journal Diameter Journal #2, #3, and #4 62.18162.207 mm 2.44812.4491 inCrankshaft Journal Diameter Journal #5 62.18562.207 mm 2.44822.4491 inCrankshaft Journal Out-of-Round Production 0.005 mm Maximum 0.0002 in MaximumCrankshaft Journal Out-of-Round Service 0.025 mm Maximum 0.0010 in MaximumCrankshaft Journal Taper Production 0.005 mm Maximum 0.0002 in MaximumCrankshaft Journal Taper Service 0.025 mm Maximum 0.0010 in MaximumCrankshaft Runout at Rear Flange 0.038 mm 0.0015 in

Cylinder BoreDiameter 94.89494.947 mm 3.73603.7381 inOut-of-Round Production 0.025 mm 0.0010 inOut-of-Round Service 0.05 mm 0.002 inTaper Production Relief Side 0.025 mm 0.0010 inTaper Production Thrust Side 0.012 mm 0.0005 inTaper Service Limit 0.025 mm 0.0010 in

Cylinder HeadSurface Flatness Engine Block Deck 0.10 mm 0.004 inSurface Flatness Exhaust Manifold Deck 0.05 mm 0.002 inSurface Flatness Intake Manifold Deck 0.10 mm 0.004 in

Exhaust ManifoldSurface Flatness Flange to Flange 0.25 mm 0.010 inSurface Flatness Individual Flange 0.05 mm 0.002 in

PistonPiston Bore Clearance Production 0.0180.061 mm 0.00070.0024 inPiston Bore Clearance Service 0.0180.068 mm 0.00070.0026 in

Piston PinClearance in Piston Production 0.0100.020 mm 0.00040.0008 inClearance in Piston Service 0.0130.025 mm 0.00050.0010 inDiameter 23.54523.548 mm 0.92700.9271 inInterference Fit in Connecting Rod 0.0120.050 mm 0.00040.0019 in

Piston Rings End Gap Measured in Cylinder BorePiston Compression Ring Gap Production Top Groove 0.250.51 mm 0.0100.020 inPiston Compression Ring Gap Production 2nd Groove 0.460.66 mm 0.0180.026 inPiston Compression Ring Gap Service Top Groove 0.250.65 mm 0.0100.025 inPiston Compression Ring Gap Service 2nd Groove 0.460.90 mm 0.0180.035 inPiston Compression Ring Groove Clearance Production TopGroove 0.0300.070 mm 0.00120.0027 in

Piston Compression Ring Groove Clearance Production 2nd Groove 0.0300.074 mm 0.00120.003 in

6-4 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Engine Mechanical Specifications (5.0 L) (contd)

ApplicationSpecification

Metric EnglishPiston Compression Ring Groove Clearance Service Limit TopGroove 0.0300.090 mm 0.00120.0035 in

Piston Compression Ring Groove Clearance Service Limit 2nd Groove 0.0300.090 mm 0.00120.0040 in

Piston Oil Ring Gap Production 0.250.76 mm 0.0100.030 inPiston Oil Ring Gap Service 0.250.89 mm 0.0100.035 inPiston Oil Ring Groove Clearance Production 0.0510.203 mm 0.0020.008 inPiston Oil Ring Groove Clearance Service 0.0510.22 mm 0.0020.009 in

Valve SystemValve Face Angle 45 degreesValve Head Edge Margin 0.79 mm Minimum 0.031 in Minimum

Valve Lash Rotate the Valve Rocker Arm Nut Clockwise360 degrees from Zero LashValve Lifter Hydraulic RollerValve Rocker Arm Ratio 1.5:1Valve Seat Angle 46 degreesValve Seat Runout 0.05 mm Maximum 0.002 in MaximumValve Seat Width Exhaust 1.652.49 mm 0.0650.098 inValve Seat Width Intake 1.141.78 mm 0.0450.070 inValve Spring Free Length 51.3 mm 2.02 inValve Spring Installed Height Exhaust 42.9243.43 mm 1.671.70 inValve Spring Installed Height Intake 42.9243.43 mm 1.671.70 inValve Spring Pressure Closed 338374 N at 43.2 mm 7684 lb at 1.70 inValve Spring Pressure Open 832903 N at 32.3 mm 187203 lb at 1.27 inValve Stem Clearance Exhaust Production 0.0250.069 mm 0.00100.0027 inValve Stem Clearance Intake Production 0.0250.069 mm 0.00100.0027 inValve Stem Clearance Exhaust Service 0.0250.094 mm 0.00100.0037 inValve Stem Clearance Intake Service 0.0250.094 mm 0.00100.0037 inValve Stem Diameter 8.6618.679 mm 0.34100.3416 inValve Stem Oil Seal Installed Height Measured from the Top of theLarge Diameter Valve Guide Bevel to the Bottom of the Valve StemOil Seal

12 mm 0.039370.07874 in

SIE-ID = 784231

Engine Mechanical Specifications (5.7 L)

ApplicationSpecification

Metric EnglishGeneral Data

Engine Type V8Displacement 5.7 L 350 CIDRPO VIN Code L31 (R)Bore 101.63 mm 4.0012 inStroke 88.39 mm 3.480 inCompression Ratio 9.4:1Firing Order 18436572Spark Plug Gap 1.52 mm 0.060 in

Oil Pressure Minimum at Normal Operating Temperature42 kPa at 1,000 RPM125 kPa at 2,000 RPM166 kPa at 4,000 RPM

6 psig at 1,000 RPM18 psig at 2,000 RPM24 psig at 4,000 RPM

Engine Engine Mechanical - 5.0L and 5.7L 6-5

2002 - Unit Repair (May 25, 2001)

Engine Mechanical Specifications (5.7 L) (contd)

ApplicationSpecification

Metric EnglishCamshaft

End Play 0.050.30 mm 0.0020.012 inJournal Diameter 47.44047.490 mm 1.86771.8697 inJournal Diameter Out-of-Round 0.025 mm Maximum 0.0010 in MaximumLobe Lift Exhaust 7.207.30 mm 0.2830.287 inLobe Lift Intake 6.977.07 mm 0.2740.278 inRunout 0.065 mm Maximum 0.0026 in Maximum

Connecting RodConnecting Rod Bearing Clearance Production 0.0330.078 mm 0.00130.0031 inConnecting Rod Bearing Clearance Service 0.0250.063 mm 0.00100.0025 inConnecting Rod Journal Diameter 56.50556.533 mm 2.22462.2257 inConnecting Rod Journal Out-of-Round Production 0.007 mm Maximum 0.0003 in MaximumConnecting Rod Journal Out-of-Round Service 0.025 mm Maximum 0.0010 in MaximumConnecting Rod Journal Taper Production 0.007 mm Maximum 0.0003 in MaximumConnecting Rod Journal Taper Service 0.025 mm Maximum 0.0010 in MaximumConnecting Rod Side Clearance 0.150.61 mm 0.0060.024 in

CrankshaftCrankshaft Bearing Clearance Journal #1 Production 0.0180.053 mm 0.00070.0021 inCrankshaft Bearing Clearance Journal #2, #3, and #4 Production 0.0300.068 mm 0.00120.0027 inCrankshaft Bearing Clearance Journal #5 Production 0.0200.060 mm 0.00080.0024 inCrankshaft Bearing Clearance Journal #1 Service 0.0250.051 mm 0.00100.0020 inCrankshaft Bearing Clearance Journal #2, #3, and #4 Service 0.0250.064 mm 0.00100.0025 inCrankshaft Bearing Clearance Service Journal #5 Service 0.0380.063 mm 0.00150.0025 inCrankshaft End Play 0.050.20 mm 0.0020.008 inCrankshaft Journal Diameter Journal #1 62.18962.212 mm 2.44842.4493 inCrankshaft Journal Diameter Journal #2, #3, and #4 62.18162.207 mm 2.44812.4491 inCrankshaft Journal Diameter Journal #5 62.18562.207 mm 2.44822.4491 inCrankshaft Journal Out-of-Round Production 0.005 mm Maximum 0.0002 in MaximumCrankshaft Journal Out-of-Round Service 0.025 mm Maximum 0.0010 in MaximumCrankshaft Journal Taper Production 0.005 mm Maximum 0.0002 in MaximumCrankshaft Journal Taper Service 0.025 mm Maximum 0.0010 in MaximumCrankshaft Runout at Rear Flange 0.038 mm 0.0015 in

Cylinder BoreDiameter 101.618101.643 mm 4.00074.0017 inOut-of-Round Production 0.025 mm 0.0010 inOut-of-Round Service 0.05 mm 0.002 inTaper Production Relief Side 0.025 mm 0.0010 inTaper Production Thrust Side 0.012 mm 0.0005 inTaper Service Limit 0.025 mm 0.0010 in

Cylinder HeadSurface Flatness Engine Block Deck 0.10 mm 0.004 inSurface Flatness Exhaust Manifold Deck 0.05 mm 0.002 inSurface Flatness Intake Manifold Deck 0.10 mm 0.004 in

Exhaust ManifoldSurface Flatness Flange to Flange 0.25 mm 0.010 inSurface Flatness Individual Flange 0.05 mm 0.002 in

Piston

6-6 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Engine Mechanical Specifications (5.7 L) (contd)

ApplicationSpecification

Metric EnglishPiston Bore Clearance Production 0.0180.053 mm 0.00070.002 inPiston Bore Clearance Service 0.0180.061 mm 0.00070.0024 in

Piston PinClearance in Piston Production 0.0130.023 mm 0.00050.0009 inClearance in Piston Service 0.0130.025 mm 0.00050.0010 inDiameter 23.54523.548 mm 0.92700.9271 inInterference Fit in Connecting Rod 0.0120.050 mm 0.00040.0019 in

Piston Rings End Gap Measured in Cylinder BorePiston Compression Ring Gap Production Top Groove 0.250.40 mm 0.0980.015 inPiston Compression Ring Gap Production 2nd Groove 0.0380.058 mm 0.00150.003 inPiston Compression Ring Gap Service Top Groove 0.250.50 mm 0.0090.019 inPiston Compression Ring Gap Service 2nd Groove 0.460.80 mm 0.0180.031 inPiston Compression Ring Groove Clearance Production TopGroove 0.0300.070 mm 0.00120.0027 in

Piston Compression Ring Groove Clearance Production 2nd Groove 0.0380.080 mm 0.00150.003 in

Piston Compression Ring Groove Clearance Service Limit TopGroove 0.0300.090 mm 0.00120.0035 in

Piston Compression Ring Groove Clearance Service Limit 2nd Groove 0.0400.100 mm 0.00150.0040 in

Piston Oil Ring Gap Production 0.250.76 mm 0.0090.029 inPiston Oil Ring Gap Service 0.250.90 mm 0.0090.035 inPiston Oil Ring Groove Clearance Production 0.0460.196 mm 0.00180.0077 inPiston Oil Ring Groove Clearance Service 0.0460.200 mm 0.00180.0079 in

Valve SystemValve Face Angle 45 degreesValve Head Edge Margin 0.79 mm Minimum 0.031 in Minimum

Valve Lash Rotate the Valve Rocker Arm Nut Clockwise360 degrees from Zero LashValve Lifter Hydraulic RollerValve Rocker Arm Ratio 1.5:1Valve Seat Angle 46 degreesValve Seat Runout 0.05 mm Maximum 0.002 in MaximumValve Seat Width Exhaust Heavy Duty 1.502.56 mm 0.0590.101 inValve Seat Width Exhaust Light Duty 1.652.49 mm 0.0650.098 inValve Seat Width Intake 1.021.65 mm 0.0400.065 inValve Spring Free Length 51.3 mm 2.02 inValve Spring Installed Height Exhaust 42.9243.43 mm 1.671.70 inValve Spring Installed Height Intake 42.9243.43 mm 1.671.70 inValve Spring Pressure Closed 338374 N at 43.2 mm 7684 lb at 1.70 inValve Spring Pressure Open 832903 N at 32.3 mm 187203 lb at 1.27 inValve Stem Clearance Exhaust Production 0.0250.069 mm 0.00100.0027 inValve Stem Clearance Intake Production 0.0250.069 mm 0.00100.0027 inValve Stem Clearance Exhaust Service 0.0250.094 mm 0.00100.0037 inValve Stem Clearance Intake Service 0.0250.094 mm 0.00100.0037 inValve Stem Diameter 8.6618.679 mm 0.34100.3416 inValve Stem Oil Seal Installed Height Measured from the Top of theLarge Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal 12 mm 0.039370.07874 in

SIE-ID = 378556

Engine Engine Mechanical - 5.0L and 5.7L 6-7

2002 - Unit Repair (May 25, 2001)

Sealers, Adhesives, and Lubricants

Application Type of MaterialGM Part Number

United States CanadaCamshaft Retainer Bolt Threadlock 12345382 10953489Crankshaft Balancer Keyway Adhesive 12346141 10953433Cylinder Head Bolt Sealant 12346004 10953480Engine Block Core Hole Plug Threadlock 12345382 10953489Engine Block Coolant Drain Hole Plug Sealant 12346004 10953480Engine Block to the Crankshaft Rear Oil Seal HousingJunction at the Oil Pan Sealing Surfaces Adhesive 12346141 10953433

Engine Block to the Engine Front Cover Junction at the OilPan Sealing Surfaces Adhesive 12346141 10953433

Engine Block at the Lower Intake Manifold SealingSurfaces Adhesive 12346141 10953433

Engine Block Oil Gallery Plug Sealant 12346004 10953480Engine Coolant Sensor Sealant 12346004 10953480Engine Coolant Temperature (ECT) Gage Sensor Sealant 12346004 10953480Engine Oil SAE 5W-30 Oil 12345610 993193Engine Oil Pressure Gage Sensor Sealant 12346004 10953480Engine Oil Pressure Gage Sensor Fitting Sealant 12346004 10953480Engine Oil Supplement Lubricant 1052367 992367Evaporative Emission (EVAP) Canister Purge SolenoidValve Stud Threadlock 12345382 10953489

Exhaust Manifold Bolt Threadlock 12345493 10953488Expansion Cup Plug Camshaft Rear Bearing Hole Sealant 12346004 10953480Expansion Cup Plug Engine Block Core Hole Sealant 12346004 10953480Fuel Meter Body Bracket Bolt Threadlock 12345382 10953489Fuel Pipe Bolt Threadlock 12345382 10953489Knock Sensor Sealant 12346004 10953480Lower Intake Manifold Bolt Threadlock 12345382 10953489Oil Level Indicator Tube Sealant 12346004 10953480Oil Pump Screen Tube Sealant 12346004 10953480Throttle Body Stud Threadlock 12345382 10953489Upper Intake Manifold Stud Threadlock 12345382 10953489Valve Rocker Arm Ball Stud Lubricant 1052271 10950849Valve Train Component Prelube Lubricant 12345501 992704Water Pump Bolt Sealant 12346004 10953480

6-8 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Component Locator

Disassembled ViewsSIE-ID = 348556

Legend(1) Fuel Pipe Retainer Bracket(2) Fuel Pipe Retainer Bracket Nuts(3) Fuel Pipe(4) Fuel Pipe Attachment Screw(5) Fuel Seal Retainer(6) Fuel Seal (Yellow O-ring)(7) Spacer Ring (Flat Washer)(8) Fuel Seal (Black O-ring)(9) Upper Intake Manifold

(10) Upper Intake Manifold to Lower IntakeGasket

(11) Fuel Meter Body Seal(12) Fuel Meter Body(13) Distributor Assembly(14) Hex Bolt (Distributor Clamp)(15) Distributor Clamp(16) Lower Intake Manifold(17) Lower Intake Manifold Gasket(18) EGR Valve Gasket(19) EGR Valve(20) EGR Valve Bolt(21) Engine Coolant Sensor

Intake Manifolds and Components SIO-ID = 67224

66997

Engine Engine Mechanical - 5.0L and 5.7L 6-9

2002 - Unit Repair (May 25, 2001)

(22) Engine Coolant Thermostat(23) Water Outlet(24) Water Outlet Stud(25) Upper Intake Manifold Stud

(26) Throttle Body Gasket(27) Throttle Body(28) Throttle Body Attaching Stud

6-10 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Legend(1) Engine Front Cover(2) Camshaft Timing Chain(3) Camshaft Sprocket(4) Camshaft Sprocket Bolt(5) Valve Lifter Guide Retainer Bolt(6) Valve Lifter Guide Retainer(7) Valve Lifter Guide(8) Valve Lifter(9) Engine Block

(10) Engine Camshaft(11) Camshaft Sprocket Locator Pin(12) Camshaft Retainer(13) Camshaft Retainer Bolt(14) Water Pump Gasket

(15) Water Pump(16) Water Pump Bolt(17) Water Pump Inlet Hose Clamp(18) Water Pump Inlet Hose(19) Engine Block Oil Gallery Plug(20) Camshaft Bearings(21) Crankshaft Position Sensor(22) Crankshaft Position Sensor Bolt(23) Front Groove Pin (Crankshaft Balancer)(24) Crankshaft Balancer Bolt(25) Crankshaft Balancer Bolt Washer(26) Crankshaft Balancer(27) Crankshaft Front Oil Seal

Front of Engine SIO-ID = 197523

182828

Engine Engine Mechanical - 5.0L and 5.7L 6-11

2002 - Unit Repair (May 25, 2001)

Legend(1) Valve Rocker Arm Cover Bolt(2) Valve Rocker Arm Cover Bolt Washer(3) Valve Rocker Arm Cover(4) Valve Rocker Arm Cover Gasket(5) Valve Stem Keys(6) Valve Spring Cap(7) Valve Spring(8) Valve Stem Oil Seal(9) Valve

(10) Cylinder Head Bolt (Long)(11) EGR Valve Pipe(12) EGR Valve Pipe Clamp(13) EGR Valve Pipe Clamp Bracket Bolt(14) Cylinder Head Bolt (Medium)(15) Cylinder Head Bolt (Short)

(16) Spark Plug Wire Support Bracket(17) Spark Plug Wire Support Bracket Bolt(18) EGR Valve Pipe Fitting(19) Exhaust Manifold Bolts(20) Engine Coolant Temperature (ECT) Gauge

Sensor(21) Spark Plug Wire Shields(22) Exhaust Manifold(23) Exhaust Manifold Gasket(24) Cylinder Head Gasket(25) Valve Pushrod(26) Valve Rocker Arm(27) Valve Rocker Arm Ball(28) Valve Rocker Arm Nut

Cylinder Head and Exhaust Manifold Area SIO-ID = 197712

182825

6-12 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Legend(1) Piston Ring Kit(2) Piston(3) Connecting Rod(4) Connecting Rod Bolt(5) Connecting Rod Bearings(6) Connecting Rod Cap(7) Hex Nut (Connecting Rod)(8) Engine Oil Pressure Gauge Sensor Fitting(9) Engine Oil Pressure Gauge Sensor

(10) Engine Block(11) Expansion Cup Plug (Camshaft Rear

Bearing Hole)(12) Dowel Straight Pin (Transmission Locator)(13) Engine Block Coolant Drain Hole Plug(14) Engine Block Core Hole Plug(15) Crankshaft Rear Oil Seal Housing Bolt

(16) Crankshaft Rear Oil Seal(17) Engine Flywheel (Automatic Transmission)(18) Flywheel Bolt(19) Engine Flywheel (Manual Transmission)(20) Crankshaft Rear Oil Seal Housing Nut(21) Crankshaft Rear Oil Seal Housing Stud(22) Crankshaft Rear Oil Seal Housing(23) Crankshaft Rear Oil Seal Housing Gasket(24) Crankshaft Rear Oil Seal Housing Stud(25) Crankshaft(26) Crankshaft Bearing (Rear Thrust Bearing)(27) Crankshaft Bearing Cap (Rear)(28) Crankshaft Bearing Cap(29) Crankshaft Bearing Cap Stud(30) Crankshaft Bearing Cap Bolt(31) Crankshaft Bearings

Cylinder Block and Components SIO-ID = 348439

317429

Engine Engine Mechanical - 5.0L and 5.7L 6-13

2002 - Unit Repair (May 25, 2001)

(32) Crankshaft Sprocket(33) Crankshaft Position Sensor Reluctor Ring(34) Woodruff Keys (Crankshaft Balancer)(35) Crankshaft Bearing(36) Crankshaft Bearing (Rear Thrust Bearing)(37) Spring Type S Pin (Flywheel Locator)

(38) Spring Type S Pin (Crankshaft Rear Oil SealHousing Locator)

(39) Oil Level Indicator Tube(40) Oil Level Indicator Tube Bolt(41) Oil Level Indicator(42) Piston Pin

6-14 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Legend(1) Engine Block(2) Oil Pump Driveshaft(3) Oil Pump Driveshaft Retainer(4) Pin (Oil Pump Locator)(5) Oil Pump(6) Oil Pan Gasket(7) Oil Pan(8) Oil Pan Drain Plug Seal (O-ring)

(9) Oil Pan Drain Plug(10) Oil Pan Nut(11) Oil Pan Bolt(12) Oil Pan Reinforcement(13) Crankshaft Oil Deflector Bolt(14) Crankshaft Oil Deflector Nut(15) Crankshaft Oil Deflector

Bottom of Engine SIO-ID = 197524

182829

Engine Engine Mechanical - 5.0L and 5.7L 6-15

2002 - Unit Repair (May 25, 2001)

Engine IdentificationSIE-ID = 650058

The Vehicle Identification Number (VIN) is located onthe left side rear of the engine block, near thetransmission bellhousing, and typically is a 9 digitnumber stamped onto the engine at the vehicleassembly plant.

The first digit identifies the division. The second digit identifies the model year. The third digit identifies the assembly plant. The fourth through ninth digits are the last 6 digits

of the Vehicle Identification Number (VIN).

6-16 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Repair Instructions

Draining Fluids and Oil Filter RemovalSIE-ID = 194572

1. Remove the oil pan drain plug and allow theengine oil to drain into a suitable container.

2. Remove the oil filter and discard.

182850

316766

Engine Engine Mechanical - 5.0L and 5.7L 6-17

2002 - Unit Repair (May 25, 2001)

3. Remove the engine block coolant drain hole plugand allow the coolant to drain into a suitablecontainer.

4. Remove the knock sensor and allow the coolantto drain into a suitable container.

Engine Flywheel RemovalSIE-ID = 527623

1. Remove the engine flywheel bolts.2. Remove the engine flywheel.

316798

182837

522146

6-18 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Exhaust Manifold Removal - LeftSIE-ID = 650059

Notice: SIO-ID = 2878 Twist the spark plug bootone-half turn in order to release the boot. Pull on thespark plug boot only. Do not pull on the spark plugwire or the wire could be damaged.1. Remove the spark plug wires from the

spark plugs.1.1. Rotate the spark plug wire boot

one half turn.1.2. Pull outward on the spark plug wire boot to

release from the spark plug.2. Remove the bolts and the spark plug wire

supports.

3. Remove the exhaust manifold bolts.4. Remove the spark plug wire shields.5. Remove the exhaust manifold.6. Remove and discard the exhaust manifold gasket.

Exhaust Manifold Removal - RightSIE-ID = 650060

Notice: SIO-ID = 2878 Twist the spark plug bootone-half turn in order to release the boot. Pull on thespark plug boot only. Do not pull on the spark plugwire or the wire could be damaged.1. Remove the spark plug wires from the

spark plugs.1.1. Rotate the spark plug wire boot

one half turn.1.2. Pull outward on the spark plug wire boot to

release from the spark plug.2. Remove the bolts and the spark plug wire

supports.

317185

64925

317179

Engine Engine Mechanical - 5.0L and 5.7L 6-19

2002 - Unit Repair (May 25, 2001)

3. Remove the exhaust manifold bolts.4. Remove the spark plug wire shields.5. Remove the exhaust manifold.6. Remove and discard the exhaust manifold gasket.

Oil Level Indicator and Tube RemovalSIE-ID = 518523

1. Remove the oil level indicator tube bolt.2. Remove the oil level indicator tube from the

engine block.

Water Pump RemovalSIE-ID = 69041

Tools RequiredJ 41240 Fan Clutch Remover and Installer1. Remove the bolts and the fan and water pump

pulley using the J 41240.

69032

500691

317191

6-20 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

2. Remove the clamps and the water pumpinlet hose.

3. Remove the water pump bolts.4. Remove the water pump.5. Remove the water pump gaskets.6. Discard the water pump gaskets.

Crankshaft Balancer RemovalSIE-ID = 66682

Tools RequiredJ 23523-F Balancer Remover and Installer1. Remove the crankshaft balancer bolt and washer.

182853

69011

173172

Engine Engine Mechanical - 5.0L and 5.7L 6-21

2002 - Unit Repair (May 25, 2001)

2. Remove the bolts and the crankshaft pulley.

Notice: Refer to Fastener Notice in Cautions andNotices.

3. Use the J 23523-F in order to remove thecrankshaft balancer.

3.1. Install the J 23523-F plate and bolts ontothe crankshaft balancer.TightenTighten the bolts to 25 Nm (18 lb ft).

3.2. Install the J 23523-F forcing screw intothe plate.

3.3. Rotate the J 23523-F forcing screwclockwise in order to remove the crankshaftbalancer.

4. Remove the J 23523-F from the crankshaftbalancer.

5. Note the position and length of any front groovecrankshaft balancer weight pins, if applicable.

188055

66878

182849

6-22 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Valve Rocker Arm Cover Removal - LeftSIE-ID = 650061

1. Remove the valve rocker arm cover bolts andwashers.

2. Remove the valve rocker arm cover.3. Remove the valve rocker arm cover gasket.4. Discard the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - RightSIE-ID = 650062

1. Remove the valve rocker arm cover bolts andwashers.

2. Remove the valve rocker arm cover.3. Remove the valve rocker arm cover gasket.4. Discard the valve rocker arm cover gasket.

Distributor RemovalSIE-ID = 69504

1. Remove the ignition coil wire harness from theignition coil and distributor cap.

39119

182833

341359

Engine Engine Mechanical - 5.0L and 5.7L 6-23

2002 - Unit Repair (May 25, 2001)

2. Remove the distributor clamp bolt.3. Remove the distributor and the distributor clamp.

4. Remove the distributor gasket and discard.

Intake Manifold RemovalSIE-ID = 66685

1. Remove the evaporative emission canister purgesolenoid valve harness.

1.1. Push the quick disconnect clip and holdin place.

1.2. Pull outward on the harness elbow.

69303

523516

317211

6-24 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

2. Remove the lower intake manifold bolts.Important: The intake manifold may be removed asan assembly. Do not remove the specific intakemanifold components unless component service isrequired.Do not allow dirt or debris to enter the fuel system.Ensure that the ends of the fuel system are properlysealed.Do not disassemble the Central Sequential FuelInjection (SFI) unit, unless service is required.3. Remove the intake manifold assembly.4. Remove and discard the lower intake manifold

gaskets.

Valve Rocker Arm and Push Rod RemovalSIE-ID = 66690

Important: Mark, sort, and organize the componentsso that the components can be reinstalled to theoriginal location.1. Remove the following components from the

cylinder head:1.1. The valve rocker arm nuts (1)1.2. The valve rocker arm balls (2)1.3. The valve rocker arms (3)

2. Remove the valve pushrods.

66456

182835

22766

Engine Engine Mechanical - 5.0L and 5.7L 6-25

2002 - Unit Repair (May 25, 2001)

Cylinder Head Removal - LeftSIE-ID = 650064

1. Remove the engine coolant temperature gagesensor.

2. Remove and discard the spark plugs.

3. Remove the cylinder head bolts.

521828

317307

317217

6-26 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Notice: SIO-ID = 13838 After removal, place thecylinder head on two wood blocks to prevent damage.

4. Remove the cylinder head.

5. Remove and discard the cylinder head gasket.

6. Remove the cylinder head locator dowel pin, ifrequired.

317227

317233

182846

Engine Engine Mechanical - 5.0L and 5.7L 6-27

2002 - Unit Repair (May 25, 2001)

Cylinder Head Removal - RightSIE-ID = 650065

1. Remove and discard the spark plugs.

2. Remove the cylinder head bolts.

Notice: SIO-ID = 13838 After removal, place thecylinder head on two wood blocks to prevent damage.

3. Remove the cylinder head.

317307

317239

317246

6-28 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

4. Remove and discard the cylinder head gasket.

5. Remove the cylinder head locator dowel pin, ifrequired.

Valve Lifter RemovalSIE-ID = 24119

Tools RequiredJ 3049-A Valve Lifter Remover1. Remove the bolts and valve lifter guide retainer.

317255

182846

11508

Engine Engine Mechanical - 5.0L and 5.7L 6-29

2002 - Unit Repair (May 25, 2001)

Important: Place the valve lifters in the rack in theupright position in order to maintain the oil inside thevalve lifter.

2. Remove the valve lifter guides and valve lifters.3. Place the components in a rack so that the

components can be reinstalled to the originallocation.

Important: Some valve lifters may be stuck in thevalve lifter bores because of gum or varnish deposits.

4. Use the J 3049-A in order to remove the stuckvalve lifters.

Oil Filter Adapter RemovalSIE-ID = 69505

1. Remove the oil filter adapter bolts and washers, ifapplicable.

2. Remove the oil filter adapter.3. Remove the oil filter adapter seal, O-ring, and the

oil filter adapter gasket, if applicable.4. Discard the oil filter adapter seal, O-ring, and the

oil filter adapter gasket, if applicable.

11509

31350

39122

6-30 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Oil Pan RemovalSIE-ID = 66836

1. Remove the oil pan bolts and nuts.2. Remove the oil pan reinforcements.3. Remove the oil pan.4. Remove and discard the oil pan gasket.

5. Remove the oil pan studs.

182851

521817

Engine Engine Mechanical - 5.0L and 5.7L 6-31

2002 - Unit Repair (May 25, 2001)

Oil Pump, Pump Screen and DeflectorRemovalSIE-ID = 195387

1. Remove the nuts (6) and the crankshaft oildeflector (2).

2. Remove the oil pump bolt (1).3. Remove the oil pump (3), the oil pump

driveshaft (5), and the oil pump driveshaftretainer (4).

4. Separate the oil pump (3), the oil pumpdriveshaft (5), and the oil pump driveshaftretainer (4).

Important: Always install a NEW oil pump driveshaftretainer during assembly.5. Discard the oil pump driveshaft retainer.

6. Inspect the oil pump locator pins for damage.Replace the pins if required.

Engine Front Cover RemovalSIE-ID = 195381

1. Remove the crankshaft position sensor bolt.2. Remove the crankshaft position sensor.

11438

182852

11485

6-32 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Important: Always install a NEW crankshaft positionsensor seal, O-ring, during assembly.

3. Remove the crankshaft position sensor seal,O-ring.

4. Discard the crankshaft position sensor seal,O-ring.

5. Remove the engine front cover bolts.6. Remove the engine front cover and gasket.

Important: DO NOT reuse the composite engine frontcover and gasket. Always install a NEW enginefront cover.7. Discard the engine front cover and gasket.

Timing Chain and Sprockets RemovalSIE-ID = 66838

Tools RequiredJ 5825-A Crankshaft Gear Remover1. Remove the crankshaft position sensor

reluctor ring.

387759

69010

69450

Engine Engine Mechanical - 5.0L and 5.7L 6-33

2002 - Unit Repair (May 25, 2001)

2. Check the camshaft timing chain free play.If the camshaft timing chain can be moved inexcess of 11 mm (0.43 in), replacement ofthe camshaft timing chain and the sprockets isrecommended during assembly.

2.1. Rotate the camshaft sprocket (1)counterclockwise until all slack is removedfrom the camshaft timing chain (2).

2.2. Measure the free play on the slack side (3)of the camshaft timing chain.

3. Remove the camshaft sprocket bolts.4. Remove the camshaft sprocket.5. Remove the camshaft timing chain.

6. Remove the crankshaft sprocket using theJ 5825-A.

341357

500645

11506

6-34 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

7. Remove the crankshaft balancer woodruff keys, ifrequired.

Camshaft RemovalSIE-ID = 69031

1. Remove the bolts and the camshaft retainer.

Notice: SIO-ID = 13833 All camshaft journals are thesame diameter, so care must be used in removing orinstalling the camshaft to avoid damage to thecamshaft bearings.

2. Remove the engine camshaft.2.1. Install the three 5/1618 x 4.0 inch bolts in

the engine camshaft front bolt holes.2.2. Using the bolts as a handle, carefully rotate

and pull the engine camshaft out of thecamshaft bearings.

2.3. Remove the bolts from the front of theengine camshaft.

182847

182836

69013

Engine Engine Mechanical - 5.0L and 5.7L 6-35

2002 - Unit Repair (May 25, 2001)

Piston, Connecting Rod, and BearingRemovalSIE-ID = 24200

Tools Required J 5239 Connecting Rod Bolt Guide Set J 24270 Cylinder Bore Ridge Reamer

Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Remove the ring ridge.

1.1. Turn the crankshaft until the piston is at thebottom of the stroke.

1.2. Place a cloth on the top of the piston.1.3. Use the J 24270 in order to remove cylinder

ring ridge.1.4. Turn the crankshaft so the piston is at the

top of the stroke.1.5. Remove the cloth.1.6. Remove the cutting debris.

Important: Place matchmarks or numbers on theconnecting rods and the connecting rod caps.2. Remove the connecting rod nuts.3. Remove the connecting rod cap.

11497

480549

6-36 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

4. Use the J 5239 in order to protect the crankshaftjournals and remove the connecting rod and thepiston out of the top of the engine block.

Important: Always assemble the connecting rod capsto the matching connecting rods.

5. Remove the connecting rod bearings. Keep the connecting rod bearings with the

original connecting rod and connecting rod cap. Wipe the oil from the connecting bearings. Wipe the oil from the crankpins.

Crankshaft Rear Oil Seal and HousingRemovalSIE-ID = 24222

1. Remove the crankshaft rear oil seal from thecrankshaft rear oil seal housing.Insert a suitable tool into the access notches andthen carefully pry the crankshaft rear oil sealfrom the crankshaft rear oil seal housing.

2. Discard the crankshaft rear oil seal.

31373

188017

31379

Engine Engine Mechanical - 5.0L and 5.7L 6-37

2002 - Unit Repair (May 25, 2001)

3. Remove the crankshaft rear oil seal housing nutand bolts.

4. Remove the crankshaft rear oil seal housing.5. Remove the crankshaft rear oil seal housing

gasket.6. Discard the crankshaft rear oil seal housing

gasket.7. Remove the rear oil seal housing retainer stud

from the engine block.

Crankshaft and Bearings RemovalSIE-ID = 69426

1. Mark or identify the crankshaft bearing caplocations and positions for assembly.

2. Remove the crankshaft bearing cap boltsand studs.

3. Remove the crankshaft bearing caps.

4. Remove the crankshaft.

11479

317268

317351

6-38 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

5. Remove the crankshaft bearings from thecrankshaft bearing caps.

6. Remove the crankshaft bearings from theengine block.

Engine Block Plug RemovalSIE-ID = 348910

Tools RequiredJ 41712 Oil Pressure Switch SocketCaution: Refer to Safety Glasses Caution inCautions and Notices.1. Remove the transmission locator pins, if required.

317295

317292

182855

Engine Engine Mechanical - 5.0L and 5.7L 6-39

2002 - Unit Repair (May 25, 2001)

2. Remove the S type pin, and the crankshaft rearoil seal housing, if required.

3. Remove the expansion cup plug from thecamshaft rear bearing hole.

4. Remove the engine oil pressure gage sensorusing the J 41712.

521820

182854

333649

6-40 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

5. Remove the engine oil pressure sensor gagesensor fitting.

6. Remove the engine block oil gallery plugs fromthe rear of the engine block and discard.

7. Remove the left side rear and left rear top engineblock oil gallery plugs.

333652

69847

182841

Engine Engine Mechanical - 5.0L and 5.7L 6-41

2002 - Unit Repair (May 25, 2001)

8. Remove the engine block oil gallery plugs fromthe front of the engine block and discard.Insert a 3/8 x 26 inch rod into the rear oil galleryholes in order to drive out the front engine block oilgallery plugs.

9. Remove the engine block core hole plugs.9.1. Use a suitable tool in order to drive the

engine block core hole plug into thecoolant jacket.

9.2. Use a suitable tool in order to pull theengine block core hole plug from thecoolant jacket.

9.3. Discard the engine block core hole plug.

182838

500648

6-42 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Engine Block Cleaning and InspectionSIE-ID = 784233

Tools RequiredJ 8087 Cylinder Bore GageCaution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean all the remaining sealing or gasket material

from the sealing surfaces.2. Clean the engine block in cleaning solvent.3. Flush the engine block with clean water or steam.4. Clean the cylinder bores.5. Clean the oil galleries and the oil passages.6. Clean the scale and the deposits from the coolant

passages.7. After cleaning the engine block, spray or wipe the

cylinder bores and the machined surfaces withclean engine oil.

8. Inspect the following areas: Cylinder bores (1) for scratches or gouging Valve lifter bores (2) for excessive scoring

or wear

Coolant jackets (3) for cracks Threaded holes (4) for damage Crankshaft bearing webs (5) for cracks Crankshaft bearing caps (6) and the crankshaft

bearing bores (7) for damage The crankshaft bearing bores should be

round and uniform when measuring theinside diameter (ID).

The surface where the crankshaft bearingscontact the crankshaft bearing bore shouldbe smooth.

If a crankshaft bearing cap is damaged andrequires replacement, replace the crankshaftbearing cap first. Then rebore the engineblock crankshaft bearing bores andcheck for the proper alignment. Finally,check the crankshaft bearings for the properclearances.

Expansion cup plug bores (8) for damage Engine block (9) for cracks or damage Engine mount bosses (10) for damage

317297

Engine Engine Mechanical - 5.0L and 5.7L 6-43

2002 - Unit Repair (May 25, 2001)

9. Measure the cylinder bores for taper andout-of-round.

9.1. Depress the plunger on the J 8087 7 mm(0.275 in) or until the J 8087 enters thecylinder bore.

9.2. Center the J 8087 in the cylinder bore andturn the indicator dial to 0.

9.3. Move the J 8087 up and down the cylinderbore to determine the taper. Refer toEngine Mechanical Specifications (5.0 L) orEngine Mechanical Specifications (5.7 L).

9.4. Turn the J 8087 to different points aroundthe cylinder bore to determine theout-of-round condition. Refer to EngineMechanical Specifications (5.0 L) or EngineMechanical Specifications (5.7 L).

Cylinder Boring and HoningSIE-ID = 784235

Honing ProcedureCaution: Refer to Safety Glasses Caution inCautions and Notices.1. When honing the cylinder bores, follow the

manufacturers recommendations for equipmentuse, cleaning, and lubrication. Use only clean sharp stones of the proper

grade for the amount of material to beremoved.

Dull, dirty stones cut unevenly and generateexcessive heat.

DO NOT hone to a final grade with a coarse ormedium-grade stone.

Leave sufficient metal so that all the stonemarks will be removed with the fine gradestones.

Perform the final honing with a fine-gradestone and hone the cylinder bore in across hatch pattern at 4565 degrees to obtainthe proper clearance.

2. During the honing operation, thoroughly check thecylinder bore. Repeatedly check the cylinder bore fit with the

selected piston. All measurements of the piston or cylinder

bore should be made with the componentsat normal room temperature.

3. When honing to eliminate taper in the cylinderbore, use full strokes the complete length of thecylinder bore.Repeatedly check the measurement at the top,the middle, and the bottom of the cylinder bore.

The finish marks should be clean butnot sharp.

4972

186747

6-44 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

The finish marks should be free from imbeddedparticles or torn or folded metal.

4. When finished, the reconditioned cylinder boresshould have less than or meet the specifiedout-of-round and taper requirements.

5. After the final honing and before the piston ischecked for fit, clean the cylinder bore with hotwater and detergent.

5.1. Scrub the cylinder bores with a stiffbristle brush.

5.2. Rinse the cylinder bores thoroughly withclean hot water.

5.3. Dry the cylinder bores with a clean rag.5.4. Do not allow any abrasive material to

remain in the cylinder bores. Abrasive material may cause premature

wear of the new piston rings and thecylinder bores.

Abrasive material will contaminate theengine oil and may cause prematurewear of the bearings.

6. Perform final measurements of the piston and thecylinder bore.

7. Permanently mark the top of the piston for thespecified cylinder to which it has been fitted.

8. Apply clean engine oil to each cylinder bore inorder to prevent rusting.

Boring ProcedureCaution: Refer to Safety Glasses Caution inCautions and Notices.1. Before starting the honing or reboring operation,

measure all the new pistons with the micrometercontacting at points exactly 90 degrees fromthe piston pin centerline.

2. File the top of the cylinder block in order toremove any dirt or burrs before using any type ofboring bar.

3. Follow the instructions furnished by themanufacturer regarding use of the boringequipment.

4. When reboring the cylinders, make sure all thecrankshaft bearing caps are installed in theoriginal position and direction.

5. Tighten the crankshaft bearing caps to the propertorque specifications in order to avoid distortion ofthe cylinder bores in the final assembly.

6. When making the final cut with the boring bar,leave 0.03 mm (0.001 in) on the cylinder borediameter for finish honing. This gives the requiredposition to the cylinder clearance specifications.Carefully perform the honing and boring operationin order to maintain the specified clearancesbetween the pistons, the piston rings, andthe cylinder bores.

Engine Engine Mechanical - 5.0L and 5.7L 6-45

2002 - Unit Repair (May 25, 2001)

Piston and Connecting Rod DisassembleSIE-ID = 195087

Tools RequiredJ 24086-C Piston Pin Remover/InstallerCaution: Refer to Safety Glasses Caution inCautions and Notices.1. Remove the piston rings from the pistons.

2. Press the piston pin from the connecting rodusing the J 24086-C.The piston pin has an interference fit into theconnecting rod, and is full floating in the piston.

3. Mark, separate, and organize the parts forassembly.

4967

4965

34671

6-46 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Piston, Connecting Rod, and BearingsCleaning and InspectionSIE-ID = 784237

Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: Measurement of all the componentsshould be taken with the components at roomtemperature.Do not use a wire brush in order to clean any part ofthe piston.1. Clean the piston and connecting rod in cleaning

solvent.2. Dry the components with compressed air.

3. Clean the piston ring grooves with a suitable ringgroove cleaning tool.

4. Clean the piston oil lubrication holes and slots.5. Inspect the piston for the following:

Eroded areas (1) on the top of the piston Scuffed or damaged skirt (2) Damage to the piston pin bore (3) Cracks in the piston ring lands, the piston skirt,

or the piston pin bosses Piston ring grooves for nicks, burrs, or other

warpage which may cause the piston ringto bind.

6. Inspect the piston pin for scoring, wear or otherdamage.

34671

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Engine Engine Mechanical - 5.0L and 5.7L 6-47

2002 - Unit Repair (May 25, 2001)

7. Measure the piston ring-to-piston ring groove sideclearance.

7.1. Insert the edge of the piston ring into thepiston ring groove.

7.2. Roll the piston ring completely around thepiston. If binding is caused by a distorted piston

ring groove, MINOR imperfections maybe removed with a fine file.

If binding is caused by a distorted pistonring, then replace the piston ring.

8. Measure the piston ring side clearance with afeeler gage. If the piston ring side clearance is too small,

try another piston ring set. If the proper piston ring-to-piston ring groove

clearance cannot be achieved, replace thepiston and pin assembly.

9. To determine the proper piston ring sideclearance, refer to Engine MechanicalSpecifications (5.0 L) or Engine MechanicalSpecifications (5.7 L).

10. Inspect the connecting rod for an out-of-roundbearing bore. Refer to Engine MechanicalSpecifications (5.0 L) or Engine MechanicalSpecifications (5.7 L).

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6-48 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

11. Inspect the connecting rod for twisting.12. Inspect the connecting rod for damage to the

connecting rod bolt threads.

13. Measure the piston compression ring end gap.Important: Fit each piston compression ring to thecylinder in which it will be used.

13.1. Place the piston compression ring into thecylinder bore.

13.2. Push the piston compression ring into thecylinder bore to approximately 6.5 mm(0.25 in) above the piston ring travel.

The piston ring must be square to thecylinder wall.

13.3. Use a feeler gage in order to measure thepiston ring end gap. Refer to EngineMechanical Specifications (5.0 L)or Engine Mechanical Specifications(5.7 L).

Select another size piston ring set if thepiston ring end gap exceeds specifications.

Piston and Connecting Rod AssembleSIE-ID = 195097

Tools RequiredJ 24086-C Piston Pin Remover/InstallerCaution: SIO-ID = 71607 Avoid contact with HOTcomponents. Wear safety glasses and protectivegloves to avoid personal injury.Notice: SIO-ID = 71608 Applying excessive heat to theconnecting rod may damage or distort the rod. Rodtemperature SHOULD NOT exceed 315C (600F). Atthis temperature the end of the connecting rod willturn a straw color upon visual inspection.Notice: SIO-ID = 38775 After the J 24086-C installerhub bottoms on the support assembly, DO NOTexceed 35,000 kPa (5,000 psi) or the tool may bedamaged.

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Engine Engine Mechanical - 5.0L and 5.7L 6-49

2002 - Unit Repair (May 25, 2001)

Important: When assembling the piston andconnecting rod, the mark on the top of the piston mustpoint to the front of the engine block. The left bankconnecting rods should have the flange face towardthe front of the engine block. The right bank connectingrods should have the flange face toward the rear ofthe engine block.The new piston pin has an interference fit into theconnecting rod and is full floating in the piston.1. Install the new piston pin and connecting rod

assembly.1.1. Lubricate the piston pin bores with clean

engine oil.1.2. Use a torch and apply MILD heat to the

piston pin end of the connecting rod.1.3. Use the J 24086-C in order to press the

new piston pin into the piston andconnecting rod assembly.

1.4. Inspect for the proper installation of thepiston and piston pin.The piston must move freely on the newpiston pin with no binding or interference.

Notice: SIO-ID = 16608 Use a piston ring expander toinstall the piston rings. The rings may be damaged ifexpanded more than necessary.2. Install the piston rings onto the piston.

2.1. Install the oil control piston ring spacer.2.2. Install the lower oil control piston ring.2.3. Install the upper oil control piston ring.2.4. Install the lower compression piston ring.

The mark on the side of the piston ringshould face the top of the piston.

2.5. Install the upper compression piston ring.The mark on the side of the piston ringshould face the top of the piston.

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6-50 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

3. Space the compression piston ring end gaps120 degrees apart.

4. Space the oil control piston ring end gaps aminimum of 90 degrees apart.

Crankshaft and Bearings Cleaning andInspectionSIE-ID = 69074

Tools Required J 7872 Magnetic Base Dial Indicator J 36660-A Torque Angle Meter J 43690 Rod Bearing Clearance Checking Tool

Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: Use care when handling the crankshaft.Avoid damage to the crankshaft bearing surfaces.1. Clean the crankshaft in cleaning solvent. Remove

all sludge or restrictions from the oil passages.2. Dry the crankshaft with compressed air.

3. Clean the crankshaft bearings in cleaning solvent.Wipe the crankshaft bearings clean with a softcloth. Do not scratch the crankshaft bearingsurfaces.

4. Dry the crankshaft and crankshaft bearings withcompressed air.

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Engine Engine Mechanical - 5.0L and 5.7L 6-51

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5. Inspect the crankshaft for the following: Crankshaft journals (1) should be smooth with

no evidence of scoring or damage. Deep grooves (2) Scratches or uneven wear (3) Pitted surfaces (4) Wear or damage to the thrust journal surfaces Scoring or damage to the rear seal surface Restrictions to the oil passages Damage to the threaded bolt holes

6. Inspect the crankshaft balancer woodruff keys (1),the keyway (2), and the threaded hole (3) fordamage.

7. Measure the crankpins for out-of-round and taper.Refer to Engine Mechanical Specifications (5.0 L)or Engine Mechanical Specifications (5.7 L).

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6-52 Engine Mechanical - 5.0L and 5.7L Engine

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8. Using wooden V-blocks, support the crankshaft onthe front and rear journals.

9. Use the J 7872 in order to measure crankshaftjournal runout.Refer to Engine Mechanical Specifications (5.0 L)or Engine Mechanical Specifications (5.7 L).

10. Measure the crankshaft end play.Important: In order to properly measure the crankshaftend play, the crankshaft, the crankshaft bearings,the crankshaft bearing caps, and the fasteners mustbe installed into the engine block, and the boltsand studs tightened finger tight.

10.1. Firmly thrust the end of the crankshaft,first rearward then forward. This will lineup the rear crankshaft bearing andthe crankshaft thrust surfaces. Tighten thecap bolts and studs. Refer to EngineMechanical Specifications (5.0 L)or Engine Mechanical Specifications(5.7 L).

10.2. With the crankshaft pushed forward, inserta feeler gage between the crankshaft andthe crankshaft bearing surface, thenmeasure the clearance. Refer to EngineMechanical Specifications (5.0 L) orEngine Mechanical Specifications (5.7 L).

10.3. Turn the crankshaft to check for binding. Ifthe crankshaft does not turn freely, loosenthe crankshaft bearing bolts and studs,one crankshaft bearing cap at a time, untilthe tight crankshaft bearing is located.

Burrs on the crankshaft bearing capor engine block, foreign matter between thecrankshaft bearing and the crankshaftbearing cap or the engine block, or a faultycrankshaft bearing could cause a lack ofclearance between the crankshaft andcrankshaft bearing.

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Engine Engine Mechanical - 5.0L and 5.7L 6-53

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11. Inspect the crankshaft bearings for craters orpockets. Flattened sections on the crankshaftbearing halves also indicate fatigue.

12. Inspect the crankshaft bearings for excessivescoring or discoloration.

13. Inspect the crankshaft bearings for dirt or debrisimbedded into the crankshaft bearing material.

14. Inspect the crankshaft bearings for improperseating indicated by bright, polished sections ofthe crankshaft bearings. If the lower half of the crankshaft bearing is

worn or damaged, both the upper andlower halves of the crankshaft bearing shouldbe replaced.

Generally, if the lower half of the crankshaftbearing is suitable for use, the upper halfof the crankshaft bearing should also besuitable for use.

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6-54 Engine Mechanical - 5.0L and 5.7L Engine

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Measuring Crankshaft Bearing ClearancesNotice: SIO-ID = 5016 Do not shim, scrape, or filebearing inserts. Do not touch the bearing surface of theinsert with bare fingers. Skin oil and acids will etchthe bearing surface.

The crankshaft bearings are precision insert typeand do not use shims for adjustment. If theclearances are excessive, then new upper andlower crankshaft bearings will be required.The service crankshaft bearings are available inthe standard size and an undersize.

The selective fitting of the crankshaft bearings arenecessary in production in order to obtain closetolerances. For this reason, in one journalbore you may use one-half of a standardcrankshaft bearing with one-half of an undersizecrankshaft bearing.

In order to determine the correct replacementbearing size, the bearing clearance must bemeasured accurately. When checking mainbearing clearances, either the micrometer orplastic gage method may be used. The micrometermethod gives more reliable results and ispreferred. When checking connecting rod bearingclearances, the plastic gage method will resultin unreliable measurements. The use of J 43690is preferred.

If the crankshaft bearing clearance is withinspecifications, the crankshaft bearing issatisfactory. If the clearance is not withinspecifications, replace the crankshaft bearing.Always replace both the upper and lowercrankshaft bearings as a unit.

A standard, or undersize crankshaft bearingcombination, may result in the proper clearance. Ifthe proper crankshaft bearing clearance cannotbe achieved using the standard or the undersizecrankshaft bearings, it may be necessary torepair or replace the crankshaft.

Measuring Crankshaft Bearing Clearances Micrometer Method1. Measure the crankshaft journal diameter with a

micrometer in several places, approximately90 degrees apart. Average the measurements.

2. Determine the taper and out-of-round of thejournal. Refer to Engine Mechanical Specifications(5.0 L) or Engine Mechanical Specifications(5.7 L).

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Engine Engine Mechanical - 5.0L and 5.7L 6-55

2002 - Unit Repair (May 25, 2001)

3. Install the bearings into the engine block.

Notice: Refer to Fastener Notice in Cautions andNotices.

4. Install the bearing cap bolts and tighten tospecifications. Refer to Fastener TighteningSpecifications.

5. Measure the bearing inside diameter (ID) at thetop and bottom.

6. In order to determine the bearing clearance,subtract the average journal diameter fromthe bearing inside diameter.

7. Compare the readings to specifications. Refer toEngine Mechanical Specifications (5.0 L) orEngine Mechanical Specifications (5.7 L).

8. Replace bearing halves as required to obtain theproper bearing clearances.

Measuring Connecting Rod BearingClearances J 43690 Method1. Remove the oil pan and other necessary

components to gain access to the connecting rods.Remove the oil pump, screen, and deflector,when applicable.

2. Rotate the crankshaft until the crankshaftjournal/connecting rod to be measured is in the10 oclock position.

Important: The crankshaft must be secure, with nomovement or rotation, in order to obtain an accuratereading. Remove an intermediate bearing cap, asrequired, in order to secure the crankshaft and allowmeasurement of connecting rod bearing clearances.3. Remove the bearing cap bolts (1), cap (2)

and bearing half.

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4. Insert a piece of paper card stock onto thecrankshaft journal. Install the bearing half, bearingcap, and bolts. Refer to Fastener TighteningSpecifications.

5. Install the foot (1) and bolt (2) to the pivot armassembly (3).

6. Tighten the bolt until snug.

7. Install the screw (1 or 3) to the pivot armassembly (2).

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Engine Engine Mechanical - 5.0L and 5.7L 6-57

2002 - Unit Repair (May 25, 2001)

8. Install the pivot arm assembly (1) onto theconnecting rod.

9. Position the foot of the pivot arm assembly overthe large end of the connecting rod bolt.

10. Position the screw (1) onto the small end of theconnecting rod bolt and tighten securely.

11. Install the base (1) and bolt (2) to the oil pan rail.

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6-58 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

12. Align the center of the base (1) with the screw (3)of the pivot arm assembly.

13. Tighten the bolt (2) until snug.

14. Align the link (1) of the pivot arm assembly on aplane (3) equal to that of the connecting rodbeam (2).

15. With the link of the pivot arm assembly aligned tothe beam of the connecting rod, position the pivotarm to the base and insert the pin (1).

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Engine Engine Mechanical - 5.0L and 5.7L 6-59

2002 - Unit Repair (May 25, 2001)

16. Insert the handle (1) to the pivot arm assembly.

17. Select the adapter (2), as required, and install tothe swivel base (1).

18. Tighten until snug.

Important: The clamp of the swivel base and theshaft of the indicator should be free of oil or otherdebris. A loose or improperly clamped indicator mayindicate incorrect readings.

19. Install the indicator (2) to the swivel base (1).20. Tighten the clamp of the base until snug.

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6-60 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

21. Install the swivel base (1) to the oil pan rail of theengine block.

22. Tighten until snug.

23. Adjust the swivel base as required, and positionthe indicator tip slightly above the connecting rodcap. Lock the swivel base in position by rotatingthe locking lever (1). Do not allow the tip ofthe indicator to contact the connecting rod atthis time.

24. The tip of the indicator should be positionedabove, and NOT in contact with the cap end ofthe connecting rod.

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Engine Engine Mechanical - 5.0L and 5.7L 6-61

2002 - Unit Repair (May 25, 2001)

25. Rotate the fine adjustment knobs, on the dialindicator end of the swivel base, to position the tipof the indicator in contact with the connecting rod.

26. Lightly actuate the handle of the pivot armassembly, multiple times in both directions, toensure the oil film is removed from the journal.

27. Load the handle in the forward position andzero the dial indicator. Load the handle multipletimes in both directions and record the reading.

Important: During this procedure, card stock mayenter the crankshaft journal oil galleries. Remove allcard stock from the bearing journal and oil galleriesprior to reassembly.28. Remove the bearing cap bolts, cap, and

paper stock.29. Replace bearing halves, as required, to obtain the

proper bearing clearances.30. Install the bearings, cap, and bolts. Refer to

Fastener Tightening Specifications.

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6-62 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

Measuring Crankshaft Bearing Clearances Plastic Gage Method1. Install the crankshaft bearings into the

engine block.

2. Install the crankshaft.

3. Install the gaging plastic the full width of thejournal.

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4. Install the crankshaft bearings into the crankshaftbearing caps.

5. Install the crankshaft bearing caps in the originalpositions, and the arrow on the crankshaft bearingcaps in the direction of the front of theengine block.

Notice: Refer to Fastener Notice in Cautions andNotices.6. Install the crankshaft bearing cap bolts and the

crankshaft bearing cap studs. Refer to FastenerTightening Specifications.

7. Remove the crankshaft bearing cap boltsand studs.

8. Remove the crankshaft bearing caps. The gagingplastic may adhere to either the crankshaftbearing journal or the crankshaft bearing surface.

9. Without removing the gaging plastic, measure thecompressed width at the widest point, using thegraduated scale on the edge of the gaging plasticenvelope.If the flattened gaging plastic tapers toward themiddle or the ends, there may be a differencein clearance indicating taper, low spot or otherirregularity of the crankshaft bearing or thecrankshaft bearing journal.

10. Remove the flattened gaging plastic.11. Measure the remaining crankshaft bearing

journals.

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6-64 Engine Mechanical - 5.0L and 5.7L Engine

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Measuring Connecting Rod Bearing SideClearance1. Insert a feeler gage between the connecting rod

caps and measure the connecting rod sideclearance. Refer to Engine MechanicalSpecifications (5.0 L) or Engine MechanicalSpecifications (5.7 L).

2. The connecting rod side clearances may also bemeasured with a dial indicator set.

Crankshaft Balancer Cleaning andInspectionSIE-ID = 194518

Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean the crankshaft balancer in cleaning solvent.2. Dry the crankshaft balancer with compressed air.3. Inspect the crankshaft balancer for the following:

Worn or damaged bolt hole threads (1) Worn, chunking, or deteriorated rubber (2)

between the hub and outer ring Loose or improperly installed balance

weights (3)A properly installed balance weight should beinstalled until flush or below flush with theface of the crankshaft balancer.

Worn or damaged keyway (4)Important: A crankshaft front oil sealing surface withexcessive scoring, grooves, rust, or other damagemust be replaced.

Worn, grooved, or damaged crankshaft frontoil sealing surfaceMinor imperfections on the crankshaft balancercrankshaft front oil seal surface may beremoved with a polishing compound or finegrade emery cloth.

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2002 - Unit Repair (May 25, 2001)

Engine Flywheel Cleaning and InspectionSIE-ID = 195065

Caution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean the engine flywheel (1 or 2) in cleaning

solvent.2. Dry the engine flywheel with compressed air.

3. Inspect the engine flywheel, automatictransmission, if equipped, for the following: Stress cracks around the engine

flywheel-to-torque converter bolt holelocations (1)

Missing balance weights Stress cracks around the engine

flywheel-to-crankshaft bolt holelocations (2 or 3)

Important: Do not attempt to repair the welded areasthat retain the ring gear to the engine flywheelplate. Always install a NEW engine flywheel.

Welded areas that retain the ring gear onto theengine flywheel for cracking (4)

Damaged ring gear teeth (5)

4. Inspect the engine flywheel, manual transmission,if equipped, for loose or improperly installedflywheel weights, if applicable.A properly installed flywheel weight should beinstalled until flush or below flush with the face ofthe engine flywheel.

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6-66 Engine Mechanical - 5.0L and 5.7L Engine

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5. Inspect the engine flywheel, manual transmission,if equipped, for the following: Pitted friction surface (1) Scoring or grooves (2) Rust or other surface damage (3) Damaged ring gear teeth (4) Loose or improperly positioned ring gear

The ring gear has an interference fit onto theengine flywheel and the ring gear shouldbe positioned completely flat against the flangeof the engine flywheel.

Camshaft and Bearings Cleaning andInspectionSIE-ID = 32312

Tools RequiredJ 7872 Magnetic Base Dial IndicatorCaution: Refer to Safety Glasses Caution inCautions and Notices.1. Clean the engine camshaft in cleaning solvent.2. Dry the engine camshaft with compressed air.3. Inspect the camshaft retainer plate for damage.

If the camshaft retainer plate is damaged, replaceas necessary.

4. Inspect the camshaft bearings for correct fit intothe engine block camshaft bearing bores.The camshaft bearings have an interference fit tothe engine block camshaft bearing bores andmust not be loose in the engine block camshaftbearing bores.

Important: If any camshaft bearing is excessivelyworn or scored, replace all the camshaft bearings.5. Inspect the camshaft bearings for excessive wear

or scoring.

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6. Inspect the engine camshaft for the following: Worn, scored, or damaged bearing journals (1) Worn engine camshaft lobes (2) Damaged bolt hole threads (3) Damaged camshaft sprocket locator pin (4)

7. Measure the engine camshaft journals with amicrometer.If the camshaft journals are more than 0.025 mm(0.0010 in) out-of-round, then replace theengine camshaft.

8. Measure for a bent engine camshaft or excessiveengine camshaft runout using the J 7872.

8.1. Mount the engine camshaft in a suitablestand between centers.

8.2. Use the J 7872 in order to check theintermediate engine camshaft journals.If the runout exceeds 0.065 mm (0.0026 in),the engine camshaft is bent and must bereplaced.

9. Measure the engine camshaft lobe lift using theJ 7872.

9.1. Place the engine camshaft on the V-blocks.9.2. Use the J 7872 in order to measure the

engine camshaft lobe lift.10. Replace the engine camshaft if the engine

camshaft lobe lift is not within specifications.

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2002 - Unit Repair (May 25, 2001)

Camshaft Bearing RemovalSIE-ID = 195130

Tools RequiredJ 33049 Camshaft Bearing Service Kit1. Select the cone (1), the handle (10), the

expanding driver (48), the washer (2 or 3), andthe expander assembly (15) from the J 33049.

2. Assemble the J 33049.

Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: A loose camshaft bearing may be causedby an enlarged, out-of-round, or damaged engineblock camshaft bearing bore.Important: Always remove the camshaft innerbearings #2, #3, and #4 first. The camshaft outerbearings #1 and #5 serve as a guide for the J 33049.

3. Remove the camshaft inner bearings #2, #3,and #4.

3.1. Insert the J 33049 through the front of theengine block and into the camshaft innerbearing #2.

3.2. Tighten the J 33049 expander assembly nutuntil snug.

3.3. Push the J 33049 guide cone into thecamshaft front bearing in order to alignthe J 33049.

3.4. Drive the camshaft inner bearing #2 fromthe camshaft inner bearing bore #2.

3.5. Loosen the J 33049 expander assembly nut.3.6. Remove the camshaft inner bearing #2

from the J 33049 expander assembly.3.7. Insert the J 33049 expander assembly into

the camshaft inner bearing #3.3.8. Tighten the J 33049 expander assembly nut

until snug.3.9. Push the J 33049 guide cone into the

camshaft front bearing in order to alignthe J 33049.

3.10. Drive the camshaft inner bearing #3 fromthe camshaft inner bearing bore #3.

3.11. Loosen the J 33049 expander assembly nut.3.12. Remove the camshaft inner bearing #3

from the J 33049 expander assembly.3.13. Insert the J 33049 expander assembly into

the camshaft inner bearing #4.

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3.14. Tighten the J 33049 expander assembly nutuntil snug.

3.15. Push the J 33049 guide cone into thecamshaft front bearing in order to alignthe J 33049.

3.16. Drive the camshaft inner bearing #4 fromthe camshaft inner bearing bore #4.

3.17. Loosen the J 33049 expander assembly nut.3.18. Remove the camshaft inner bearing #4

from the J 33049 expander assembly.4. Remove the J 33049 from the engine block.

5. Remove the camshaft outer bearings #1 and #5.5.1. Insert the J 33049 into the camshaft outer

bearing #1.5.2. Tighten the J 33049 expander assembly nut

until snug.5.3. Drive the camshaft outer bearing #1 from

the camshaft outer bearing bore #1.5.4. Loosen the J 33049 expander assembly nut.5.5. Remove the camshaft outer bearing #1

from the J 33049 expander assembly.5.6. Remove the J 33049 from the engine block.5.7. Insert the J 33049 into the camshaft

outer bearing #5.5.8. Tighten the J 33049 expander assembly nut

until snug.5.9. Drive the camshaft outer bearing #5 from

the camshaft outer bearing bore #5.5.10. Loosen the J 33049 expander assembly nut.5.11. Remove the camshaft outer bearing #5

from the J 33049 expander assembly.6. Remove the J 33049 from the engine block.7. Discard the camshaft bearings.

Camshaft Bearing InstallationSIE-ID = 195136

Tools RequiredJ 33049 Camshaft Bearing Service KitImportant: Always install the camshaft outer bearings#1 and #5 first. The camshaft outer bearings serveas a guide for the J 33049 and help center thecamshaft inner bearings during the installation process.Look to ensure that the camshaft bearing lubricationhole or holes align with the oil gallery hole or holes inthe engine block. On some engines, the oil galleryholes may be difficult to see. Verify that the camshaftbearing lubrication holes and the oil gallery holesare aligned.1. Assemble the J 33049 handle (10), the expanding

driver (48), the washer (2 or 3), and the expanderassembly (15).

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Caution: Refer to Safety Glasses Caution inCautions and Notices.Important: The camshaft bearing lubrication holesmust align with the oil gallery holes in the engine block.After installation of the camshaft bearings, alwaysinspect the camshaft bearing lubrication holesfor proper alignment with the oil gallery holes.An improperly aligned camshaft bearing lubricationhole and oil gallery hole will restrict oil flow tothe camshaft bearing and the camshaft journal.2. Install the NEW camshaft outer bearings #5

and #1.2.1. Install the NEW camshaft outer bearing #5

onto the J 33049 expander assembly.2.2. Tighten the J 33049 expander assembly nut

until snug.2.3. Align the camshaft outer bearing #5

lubrication hole with the oil gallery holein the camshaft outer bearing bore #5 at therear of the engine block.

2.4. Drive the camshaft outer bearing #5 into thecamshaft outer bearing bore #5 at the rearof the engine block.

2.5. Loosen the J 33049 expander assembly nut.2.6. Remove the J 33049 expander assembly

from the camshaft outer bearing #5.2.7. Install the NEW camshaft outer bearing #1

onto the J 33049 expander assembly.2.8. Tighten the J 33049 expander assembly nut

until snug.2.9. Align the camshaft outer bearing #1

lubrication hole with the oil gallery holein the camshaft outer bearing bore #1 at thefront of the engine block.

2.10. Drive the camshaft outer bearing #1 into thecamshaft outer bearing bore #1 at the frontof the engine block.

2.11. Loosen the J 33049 expander assembly nut.2.12. Carefully slide the J 33049 into the engine

block until the J 33049 expander assemblyis positioned between the camshaftinner bearing bores #3 and the camshaftinner bearing bore #4.

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Important: The camshaft bearing lubrication holesmust align with the oil gallery holes in the engine block.After installation of the camshaft bearings, alwaysinspect the camshaft bearing lubrication holesfor proper alignment with the oil gallery holes.An improperly aligned camshaft bearing lubricationhole and oil gallery hole will restrict oil flow tothe camshaft bearing and the camshaft journal.3. Install the NEW camshaft inner bearings #4, #3,

and #2.3.1. Install the NEW camshaft inner bearing #4

onto the J 33049 expander assembly.3.2. Tighten the J 33049 expander assembly nut

until snug.3.3. Align the camshaft inner bearing #4

lubrication hole with the oil gallery holein the camshaft inner bearing bore #4 of theengine block.

3.4. Push the J 33049 guide cone into thecamshaft front bearing bore #1 in orderto align the J 33049.

3.5. Drive the camshaft inner bearing #4 into thecamshaft inner bearing bore #4.

3.6. Loosen the J 33049 expander assembly nut.3.7. Carefully slide the J 33049 until the

J 33049 expander assembly is positionedbetween the camshaft inner bearing bore #3and the camshaft outer bearing bore #2.

3.8. Install the NEW camshaft inner bearing #3onto the J 33049 expander assembly.

3.9. Tighten the J 33049 expander assembly nutuntil snug.

3.10. Align the camshaft inner bearing #3lubrication hole with the oil gallery holein the camshaft inner bearing bore #3 of theengine block.

3.11. Push the J 33049 guide cone into thecamshaft front bearing bore #1 in orderto align the J 33049.

3.12. Drive the camshaft inner bearing #3 into thecamshaft inner bearing bore #3.

3.13. Loosen the J 33049 expander assembly nut.3.14. Carefully slide the J 33049 until the

J 33049 expander assembly is positionedbetween the camshaft inner bearing bore #2and the camshaft outer bearing bore #1.

3.15. Install the NEW camshaft inner bearing #2onto the J 33049 expander assembly.

3.16. Tighten the J 33049 expander assembly nutuntil snug.

3.17. Align the camshaft inner bearing #2lubrication hole with the oil gallery holein the camshaft inner bearing bore #2 of theengine block.

3.18. Push the J 33049 guide cone into thecamshaft front bearing bore #1 in orderto align the J 33049.

4985

6-72 Engine Mechanical - 5.0L and 5.7L Engine

2002 - Unit Repair (May 25, 2001)

3.19. Drive the camshaft inner bearing #2 into thecamshaft inner bearing bore #2.

3.20. Loosen the J 33049 exp