GM CHEVY 5.7L V8 Marine & INDUSTRIAL Engine Workshop Manual

Engine Mechanical Service Manual 5.7L

This Page Was Intentionally Left Blank

Engine Engine Mechanical - 5.7L 6-1 2001 Marine/Industrial Engine Mechanical - 5.7L Specifications Fastener Tightening Specifications Specification Application Metric English Accelerator Control Cable Bracket Bolt and Nut 12 N•m 106 lb in Belt Idler Pulley Bolt 50 N•m 37 lb ft Camshaft Retainer Bolt 12 N•m 106 lb in Camshaft Sprocket Bolt 25 N•m 18 lb ft Connecting Rod Nut First Pass 27 N•m 20 lb ft Final Pass 55 degrees Crankshaft Balancer Bolt 95 N•m 70 lb ft Crankshaft Bearing Cap Bolt and Stud (Preferred Method) First Pass (Two Bolt Type Bearing Cap) 20 N•m 15 lb ft Final Pass (Two Bolt Type Bearing Cap) 73 degrees First Pass (Four Bolt Type Bearing Cap) 20 N•m 15 lb ft Final Pass Outboard Bolt (Four Bolt Type Bearing Cap) 43 degrees Final Pass Inboard Bolt and Stud (Four Bolt Type Bearing Cap) 73 degrees Crankshaft Bearing Cap Bolt and Stud (Optional Strategy) Two Bolt Type Bearing Cap 105 N•m 77 lb ft Inboard Bolt and Stud (Four Bolt Type Bearing Cap) 105 N•m 77 lb ft Outboard Bolt (Four Bolt Type Bearing Cap) 90 N•m 66 lb ft Crankshaft Oil Deflector Nut 40 N•m 30 lb ft Crankshaft Position Sensor Bolt 9 N . m 80 lb in Crankshaft Pulley Bolt 58 N . m 43 lb ft Crankshaft Rear Oil Seal Housing Nut and Bolt 12 N . m 106 lb ft Crankshaft Rear Oil Seal Housing Retainer Stud 6 N•m 53 lb in Cylinder Head Bolt (Preferred Method) All Bolts First Pass in Sequence 30 N•m 22 lb ft Long Bolts Final Pass in Sequence 75 degrees Medium Bolts Final Pass in Sequence 65 degrees Short Bolts Final Pass in Sequence 55 degrees Cylinder Head Bolt (Optional On-Vehicle Stategy) First Pass in Sequence 35 N . m 26 lb ft Second Pass in Sequence 60 N . m 44 lb ft Final Pass in Sequence 90 N . m 66 lb ft Cylinder Head Core Hole Plug 20 N•m 15 lb ft Distributor Cap Bolt 2.4 N•m 21 lb in Distributor Clamp Bolt 25 N•m 18 lb ft Drive Belt Tensioner Bolt 50 N•m 37 lb ft EGR Valve Bolt First Pass 10 N•m 89 lb in Final Pass 30 N•m 22 lb ft

6-2 Engine Mechanical - 5.7L Engine 2001 Marine/Industrial Fastener Tightening Specifications (cont’d) Specification Application Metric English EGR Valve Pipe Nut at Intake Manifold 25 N•m 18 lb ft EGR Valve Pipe Nut at Exhaust Manifold 30 N•m 22 lb ft EGR Valve Pipe Clamp Bracket Bolt 25 N•m 18 lb ft Engine Block Coolant Drain Hole Plug 20 N•m 15 lb ft Engine Block Oil Gallery Plug 20 N•m 15 lb ft Engine Coolant Temperature (ECT) Sensor 20 N•m 15 lb ft Engine Flywheel Bolt 100 N•m 74 lb ft Engine Front Cover Bolt 12 N•m 106 lb in Engine Lift Bracket Bolt (Special Tool J 41427) 15 N•m 11 lb ft Engine Lift Front Bracket Stud 35 N•m 26 lb ft Engine Mount Bolt (Through-bolt) to Engine Mount Bracket 95 N•m 7 0 lb ft Engine Mount Bolt to Engine Mount Frame Bracket 58 N•m 43 lb ft Engine Mount Bracket Bolt to Engine 54 N•m 40 lb ft Engine Mount Bracket Bolt to Frame 45 N•m 33 lb ft Engine Mount Heat Shield to Engine Mount Bracket 6 N•m 53 lb in Engine Mount Nut (Through-Bolt) 68 N•m 50 lb ft Engine Oil Pressure Gauge Sensor 30 N•m 22 lb ft Engine Oil Pressure Gauge Sensor Fitting (Plus Required Angle) 15 N•m 11 lb ft Engine Wiring Harness Bracket Nut 12 N•m 106 lb in Evaporitive Emission (EVAP) Canister Purge Solenoid Valve Stud 10 N•m 89 lb in Exhaust Manifold Bolt First Pass 15 N•m 11 lb ft Final Pass 30 N•m 22 lb ft Fan and Water Pump Pulley Bolt 25 N•m 18 lb ft Fuel Pipe Bracket Bolt 6 N•m 53 lb in Fuel Pipe Retainer Nut 3 N•m 27 lb in Generator and Drive Belt Tensioner Bracket Bolt and Nut to Engine 41 N•m 30 lb ft Generator and Drive Belt Tensioner Bracket Stud to Engine 20 N•m 15 lb ft Ignition Coil Stud 12 N•m 106 lb in Knock Sensor 20 N•m 15 lb ft Lower Intake Manifold Bolt First Pass in Sequence 3 N•m 27 lb in Second Pass in Sequence 12 N•m 106 lb in Final Pass in Sequence 15 N•m 11 lb ft Oil Filter Adapter Bolt 25 N•m 18 lb ft Oil Filter Fitting 35 N•m 26 lb ft Oil Level Indicator Tube Bolt 25 N•m 18 lb ft Oil Pan Drain Plug 25 N•m 18 lb ft Oil Pan Stud (Front) 6 N•m 53 lb in Oil Pan Stud Nut 25 N•m 18 lb ft Oil Pan Bolt or Stud 12 N•m 106 lb in Oil Pump Bolt to Rear Crankshaft Bearing Cap

Engine Engine Mechanical - 5.7L 6-3 2001 Marine/Industrial Fastener Tightening Specifications (cont’d) Specification Application Metric English First Pass 20 N•m 15 lb ft Final Pass 65 degrees Oil Pump Cover Bolt 12 N•m 106 lb in Power Steering Pump Bracket Bolt to Engine 41 N•m 30 lb ft Power Steering Pump Bracket Bolt to Engine 20 N•m 15 lb in Power Steering Pump Bracket Stud Nut 41 N•m 30 lb ft Power Steering Pump Bolt 50 N•m 37 lb ft Power Steering Pump Nut to Engine (Rear Bracket to Engine) 41 N•m 30 lb ft Power Steering Pump Rear Bracket Nut 50 N•m 37 lb ft Spark Plug Initial Installation (NEW Cylinder Head) 30 N•m 22 lb ft All Subsequent Installations 15 N•m 11 lb ft Spark Plug Wire Support Bolt 12 N•m 106 lb in Square Socket Plug (Engine Block Oil Gallery) 20 N•m 15 lb ft Throttle Body Stud 9 N•m 80 lb in Transmission Cover Bolt 12 N•m 106 lb in Upper Intake Manifold Stud First Pass 5 N•m 44 lb in Final Pass 10 N•m 89 lb in Valve Lifter Pushrod Guide Bolt 16 N•m 12 lb ft Valve Rocker Arm Cover Bolt 12 N•m 106 lb in Water Outlet Stud 25 N•m 18 lb ft Water Pump Bolt 45 N•m 33 lb ft

6-4 Engine Mechanical - 5.7L Engine 2001 Marine/Industrial Engine Mechanical Specifications Specification Application Metric English General Data Engine Type V8 Displacement 5.7L 350 CID RPO (VIN Code) L31 (R) Bore 101.63 mm 4.0012 in Stroke 88.39 mm 3.480 in Compression Ratio 9.4:1 Firing Order 1-8-4-3-6-5-7-2 Spark Plug Gap 1.52 mm 0.060 in 42 kPa at 6.0 psig at 1,000 engine rpm 1,000 engine rpm Oil Pressure (Minimum) at Normal Operating Temperature 125 kPa at 18.0 psig at 2,000 engine rpm 2,000 engine rpm 166 kPa at 24.0 psig at 4,000 engine rpm 4,000 engine rpm Camshaft End Play 0.05-0.30 mm 0.002-0.012 in Journal Diameter 47.440-47.490 mm 1.8677-1.8696 in Journal Diameter Out-of-Round 0.025 mm (Maximum) 0.0010 in (Maximum) Lobe Lift (Exhaust) 7.20-7.30 mm 0.283-0.287 in Lobe Lift (Intake) 6.97-7.07 mm 0.274-0.278 in Runout 0.065 mm (Maximum) 0.0026 in (Maximum) Connecting Rod Connecting Rod Bearing Clearance (Production) 0.033-0.078 mm 0.0013-0.0031 in Connecting Rod Bearing Clearance (Service) 0.025-0.063 mm 0.0010-0.0025 in Connecting Rod Side Clearance 0.15-0.68 mm 0.006-0.027 in Connecting Rod Journal Diameter 53.304-53.334 mm 2.0986-2.0998 in Connecting Rod Journal Taper (Production) 0.007 mm (Maximum) 0.0003 in (Maximum) Connecting Rod Journal Taper (Service) 0.025 mm (Maximum) 0.0010 in (Maximum) Connecting Rod Journal Out-of-Round (Production) 0.007 mm (Maximum) 0.0003 in (Maximum) Connecting Rod Journal Out-of-Round (Service) 0.025 mm (Maximum) 0.0010 in (Maximum) Crankshaft Crankshaft Bearing Clearance (Journal #1-Production) 0.018-0.053 mm 0.0007-0.0021 in Crankshaft Bearing Clearance (Journal #2, #3 and #4-Production) 0.030-0.068mm 0.0012-0.0027 in Crankshaft Bearing Clearance (Journal #5-Production) 0.020-0.060 mm 0.0008-0.0024 in Crankshaft Bearing Clearance (Journal #1-Service) 0.025-0.051 mm 0.0010-0.0020 in Crankshaft Bearing Clearance (Journal #2, #3 and #4-Service) 0.025-0.064 mm 0.0010-0.025 in Crankshaft Bearing Clearance (Journal #5-Service) 0.038-0.063 mm 0.0015-0.0025 in Crankshaft End Play 0.050-0.20 mm 0.002-0.008 in Crankshaft Journal Diameter (Journal #1) 62.189-62.212 mm 2.4484-2.4493 in Crankshaft Journal Diameter (Journal #2 and #3) 62.181-62.207 mm 2.4481-2.4491 in Crankshaft Journal Diameter (Journal #5) 62.185-62.207 mm 2.4482-2.4491 in Crankshaft Journal Out-of-Round (Production) 0.005 mm (Maximum) 0.0002 in (Maximum) Crankshaft Journal Out-of-Round (Service) 0.025 mm (Maximum) 0.0010 in (Maximum) Crankshaft Journal Taper (Production) 0.005 mm (Maximum) 0.0002 in (Maximum) Crankshaft Journal Taper (Service) 0.025 mm (Maximum) 0.0010 in (Maximum) Crankshaft Runout at Rear Flange 0.038mm (Maximum) 0.0015 in (Maximum) Cylinder Bore Diameter 101.618-101.643 mm 4.0007-4.0017 in Out-of-Round (Production) 0.025 mm (Maximum) 0.0010 in (Maximum) Out-of-Round (Service) 0.05 mm (Maximum) 0.002 in (Maximum) Taper (Production-Relief Side) 0.025 mm (Maximum) 0.0010 in (Maximum)

Engine Engine Mechanical - 5.7L 6-5 2001 Marine/Industrial Taper (Production-Thrust Side) 0.012 mm (Maximum) 0.0005 in (Maximum) Taper (Service Limit) 0.025 mm (Maximum) 0.0010 in (Maximum) Cylinder Head Surface Flatness (Engine Block Deck) 0.10 mm (Maximum) 0.004 in (Maximum) Surface Flatness (Exhaust Manifold Deck) 0.05 mm (Maximum) 0.002 in (Maximum) Surface Flatness (Intake Manifold Deck) 0.10 mm (Maximum) 0.004 in (Maximum) Exhaust Manifold Surface Flatness (Flange to Flange) 0.25 mm (Maximum) 0.010 in (Maximum) Surface Flatness (Individual Flange) 0.05 mm (Maximum) 0.002 in (Maximum) Piston Piston Bore Clearance (Production) 0.018-0.053 mm 0.0007-0.002 in Piston Bore Clearance (Service) 0.018-0.053 mm 0.0007-0.002 in Piston Pin Clearance in Piston (Production) 0.013-0.023 mm 0.0005-0.0009 in Clearance in Piston (Service) 0.013-0.025 mm 0.0005-0.0010 in Diameter 23.545-23.548 mm 0.9270-0.9271 in Fit in Connecting Rod 0.021-0.040 mm 0.0008-0.0016 in (Interference) (Interference) Piston Rings (End Gap Measured in Cylinder Bore) Piston Compression Ring Gap (Production-Top Groove) 0.25-0.40 mm 0.098-0.015 in Piston Compression Ring Gap (Production- 2nd Groove) 0.46-0.66 mm 0.018-0.025 in Piston Compression Ring Gap (Service -Top Groove) 0.25-0.50 mm 0.009-0.019 in Piston Compression Ring Gap (Service - 2nd Groove) 0.46-0.80 mm 0.018-0.031 in Piston Compression Ring Groove Clearance (Production-Top Groove) 0.030-0.070 mm 0.0012-0.0027 in Piston Compression Ring Groove Clearance (Production- 2nd Groove) 0.040-0.080 mm 0.0015-0.003 in Piston Compression Ring Groove Clearance (Service-Top Groove) 0.030-0.090 mm 0.0012-0.0035 in Piston Compression Ring Groove Clearance (Service-2nd Groove) 0.040-0.100 mm 0.0015-0.0040 in Piston Oil Ring Gap (Production) 0.25-0.76 mm 0.009-0.029 in Piston Oil Ring Gap (Service) 0.25-0.90 mm 0.009-0.035 in Piston Oil Ring Groove Clearance (Production) 0.046-0.096 mm 0.0018-0.0037 in Piston Oil Ring Groove Clearance (Service) 0.046-0.100 mm 0.0018-0.0039 in Valve System Valve Face Angle 45 Degrees Valve Head Edge Margin 0.79 mm (Minimum) 0.031 in (Minimum) Valve Lash Rotate the Valve Rocker Arm Nut Clockwise 360 degrees (1 Turn) from Zero Lash Valve Lifter Hydraulic Roller Valve Rocker Arm Ratio 1.5:1 Valve Seat Angle 46 Degrees Valve Seat Runout 0.05 mm (Maximum) 0.002 in (Maximum) Valve Seat Width (Exhaust-Heavy Duty) 1.50-2.56 mm 0.059-0.101 in Valve Seat Width (Exhaust-Light Duty) 1.65-2.49 mm 0.065-0.098 in Valve Seat Width (Intake) 1.02-1.65 mm 0.040-0.065 in Valve Spring Free Length 51.3 mm 2.02 in Valve Spring Installed Height (Exhaust) 42.92-43.43 mm 1.67-1.70 in Valve Spring Installed Height (Intake) 42.92-43.43 mm 1.67-1.70 in Valve Spring Pressure (Closed) 338-374 N at 43.2 mm 76-84 lb at 1.70 in Valve Spring Pressure (Open) 832-903 N at 32.3 mm 187-203 lb at 1.27 in Valve Stem Clearance (Exhaust-Production) 0.025-0.069 mm 0.0010-0.0027 in Valve Stem Clearance (Intake-Production) 0.025-0.069 mm 0.0010-0.0027 in Valve Stem Clearance (Exhaust-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Clearance (Intake-Service) 0.025-0.094 mm 0.0010-0.0037 in Valve Stem Diameter 8.661-8.679 mm 0.3410-0.3416 in Valve Stem Oil Seal Installed Height (Measured from the Top of the 1-2 mm 0.03937-0.07874 in Large Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal) Engine Mechanical Specifications (cont’d)

6-6 Engine Mechanical - 5.7L Engine 2001 Marine/Industrial GM SPO Group Numbers Application GM SPO Group Number Accelerator Control Cable Bracket 3.454 Belt Idler Pulley (Grooved) 1.062 Belt Idler Pulley (Smooth) 1.062 Camshaft Bearing 0.539 Camshaft Retainer 0.529 Camshaft Sprocket 0.736 Camshaft Sprocket Locator Pin 0.738 Camshaft Timing Chain 0.724 Clutch Pilot Bearing 0.649 Connecting Rod 0.603 Connecting Rod Bearing Kit 0.616 Crankshaft Balancer 0.659 Crankshaft Bearing Kit 0.096 Crankshaft Front Oil Seal 0.213 Crankshaft Oil Deflector 1.430 Crankshaft Rear Oil Seal 0.137 Crankshaft Rear Oil Seal Housing 0.137 Crankshaft Rear Oil Seal Housing Retainer Stud 0.137 Crankshaft Rear Oil Seal Housing Gasket 0.137 Crankshaft Rear Oil Seal Retainer Stud 0.137 Crankshaft Position Sensor 2.383 Crankshaft Position Sensor Reluctor Ring 2.383 Crankshaft Position Sensor Seal (O-ring) 2.383 Crankshaft Pulley 0.659 Crankshaft Sprocket 0.728 Cylinder Head 0.269 Cylinder Head Gasket 0.289 Distributor 2.361 Distributor Cap 2.367 Distributor Clamp 2.363 Distributor Gasket 2.363 Dowel Pin (Cylinder Head Locator) 8.939 Dowel Straight Pin (Transmission Locator) 8.939 Drive Belt Tensioner 1.060 EGR Valve 3.670 EGR Valve Gasket 3.680 EGR Valve Pipe 3.675 EGR Valve Pipe Fitting 3.680 Evaporative Emission Canister Purge Solenoid Valve 3.130 Evaporative Emission Canister Purge Solenoid Valve Harness 3.145 Engine Block N.S. Engine Block Core Hole Plug 0.034 Engine Block Oil Gallery Plug 1.531 Engine Camshaft 0.519 Engine Coolant Heater 1.152 Engine Coolant Temperature Sensor 1.150 Engine Coolant Temperature Gauge Sensor 1.150 Engine Coolant Thermostat 1.246 Engine Coolant Thermostat Seal (O-ring) 1.252 Engine Crankshaft 0.646 Engine Flywheel 0.666 Engine Front Cover 0.206 Engine Mount 0.029

Engine Engine Mechanical - 5.7L 6-7 2001 Marine/Industrial GM SPO Group Numbers (cont’d) Application GM SPO Group Number Engine Mount Bracket 0.029 Engine Mount Bracket Spacer 0.029 Engine Oil Pressure Gauge Sensor 1.800 Engine Oil Pressure Gauge Sensor Fitting 1.800 Engine Piston Kit (Piston and Pin) 0.629 Engine Wiring Harness Bracket 2.559 Exhaust Manifold 3.601 Exhaust Manifold Gasket 3.270 Exhaust Valve 0.297 Expansion Cup Plug (Camshaft Rear Bearing Hole) 8.970 Fan & Water Pump & A/C Compressor & Generator & Power Steering Pump Belt 1.066 Fan & Water Pump & Generator & Power Steering Pump Belt 1.066 Fan & Water Pump Pulley 1.062 Flywheel Locator Pin 0.669 Front Groove Pin (Crankshaft Balancer Weight) 8.940 Fuel Pipe (Included in Fuel Injection Feed and Return Pipe Kit Only) 3.163 Fuel Pipe Retainer Bracket (Included in Fuel Injection Feed and Return Pipe Kit Only) 3.163 Fuel Injector (O-ring) Seal Kit 3.331 Fuel Meter Body 3.374 Generator & Drive Belt Tensioner Bracket 1.060 Ignition Coil 2.170 Ignition Coil Wire Harness 2.240 Intake Valve 0.296 Knock Sensor 2.383 Lower Intake Manifold (Included in Lower Intake Manifold Kit Only) 3.265 Lower Intake Manifold Gasket Kit 3.270 MAP Sensor 3.682 MAP Sensor Seal 3.682 Oil Fill Cap 1.758 Oil Filter 1.836 Oil Filter Adapter 1.840 Oil Filter Adapter Gasket 1.840 Oil Filter Adapter Seal (O-ring) 1.844 Oil Filter Bypass Valve 1.837 Oil Filter Fitting 1.855 Oil Level Indicator 1.516 Oil Level Indicator Tube 1.516 Oil Pan Drain Plug 1.453 Oil Pan Drain Plug Seal (O-ring) 1.456 Oil Pan Gasket 1.429 Oil Pan Kit with Gasket 1.426 Oil Pan Reinforcement 1.426 Oil Pump 1.652 Oil Pump Cover 1.723 Oil Pump Drive Shaft 1.639 Oil Pump Drive Shaft Retainer 1.639 Oil Pump Pressure Relief Valve 1.609 Oil Pump Pressure Relief Valve Spring 1.609 Oil Pump Pressure Relief Valve Spring Bore Plug 1.609 Oil Pump Pressure Relief Valve Spring Straight Pin 1.609 Oil Pump Screen 1.656 PCV Tube 1.762 PCV Valve 1.745

6-8 Engine Mechanical - 5.7L Engine 2001 Marine/Industrial Application GM SPO Group Number PCV Valve Cover 1.745 PCV Valve Elbow 1.762 PCV Valve Grommet 1.745 PCV Valve Hose 1.762 Pin (Oil Pump Locator) 1.723 Piston (with Pin) 0.629 Piston Ring Kit 0.643 Power Steering Pump Bracket 6.606 Secondary Air Injection (AIR) Check Valve 3.670 Secondary Air Injection (AIR) Check Valve Gasket 3.680 Secondary Air Injection (AIR) Check Valve (Crossover) Pipe 3.675 Secondary Air Injection (AIR) Pipe 3.675 Spark Plug 2.270 Spark Plug Wire 2.240 Spark Plug Wire Retainer 2.251 Spark Plug Wire Shield 2.251 Spark Plug Wire Support 2.251 Spring Type S Pin (Crankshaft Rear Oil Seal Housing Locator) 8.940 Square Socket Plug (Engine Block Oil Gallery) 8.971 Throttle Body 3.335 Throttle Body to Upper Manifold Gasket (Included in Service Kits Only) N.S. Upper Intake Manifold (Included in Upper Intake Manifold Kit Only) 3.625 Upper Intake Manifold to Lower Intake Manifold Gasket (Included in Intake Manifold Seal Kit) 3.270 Valve Lifter 0.459 Valve Lifter Guide 0.439 Valve Lifter Guide Retainer 0.439 Valve Pushrod 0.426 Valve Rocker Arm (Included in the Valve Rocker Arm Kit only) N.S. Valve Rocker Arm Ball (Included in the Valve Rocker Arm Kit only) N.S. Valve Rocker Arm Ball Stud 0.429 Valve Rocker Arm Cover 0.386 Valve Rocker Arm Cover Gasket 0.423 Valve Rocker Arm Kit (Includes the Valve Rocker Arm, the Valve Rocker Arm Ball and the Valve Rocker Arm Nut) 0.333 Valve Rocker Arm Nut 0.429 Valve Spring 0.303 Valve Spring Cap 0.309 Valve Stem Key 0.310 Valve Stem Oil Seals 0.308 Water Outlet 1.153 Water Pump Gasket 1.079 Water Pump Inlet Hose 1.097 Water Pump Kit (Includes the Water Pump Gaskets) 1.069 Woodruff Key (Crankshaft Balancer) 8.960 GM SPO Group Numbers (cont’d)

GM CHEVY 5.7L V8 Marine & INDUSTRIAL Engine Workshop Manual

You're Reading a Preview

Recently Viewed