Manual Taller Blazer Ingles

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INDICE

Diagramas Elctricos 2

Motor 15

Tren Delantero 733

Consola Central, Panel de Instrumentos 782

Puertas, accesorios, espejos 825

SIR (Airbags) 855

Tabla de Conversin de Medidas 871

Transmisin Automtica 900

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DIAGRAMAS ELECTRICOS

Electrical Center Identification Views

Document ID: 353473

Underhood Bussed Electrical Center (UBEC) Details (Base Pickup)

Click here for full size

No.

Fuse/Circuit

Breaker Rating Description

Maxi Fuses

1 INT BATT 50A HDLP SW, MIR/LKS, AUX PWR, RDO BATT,

CIGAR LTR, CTSY LP, and PWR LKS Fuses

2 ABS 60A Electronic Brake Control Module (EBCM) Assembly

3-4 Not Used

5 IGN B 50A Ignition Switch

6 RAP 50A Retained Accessory Power Relay

7 IGN A 40A Starter Relay and Ignition Switch

8 STUD #2 30A Not Used

Mini Fuses

9-

11 Not Used

12 VEH B/U 15A Backup Lamps, Right and Left


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13 RT TURN 10A Turn Signal Assembly, Right Front

14 LT TURN 10A Turn Signal Assembly, Left Front

15 LT TRN 10A Tail Lamp Assembly, Left Rear

16 RT TRN 10A Tail Lamp Assembly, Right Rear

17 RR PRK 10A License Lamp, Marker Lamp Assembly, and Tail Lamp

Assembly (All Right Side)

18 FR PRK 10A Turn Signal Lamp Assembly and Tail Lamp Assembly

(All Right Side)

19 Not Used

20 LT HDLP 10A Headlamp Low Beam, Left Side, and Daytime Running

Lamp (DRL) Relay

21 RT HDLP 10A Headlamp Low Beam and Headlamp High Beam (All

Right Side)

22 ENG 1 10A

Evaporative Emission Canister Purge Solenoid,

Evaporative Emission Canister Vent Solenoid, Mass Air

Flow Sensor (4.3L), and Camshaft Position Sensor

(4.3L)

23 ECM B 20A

Fuel Pump Relay, Powertrain Control Module (PCM)

(2.2L), Vehicle Control Module (4.3L), and Fuel Pump

and Engine Oil Pressure Gauge Sensor

24 HORN 15A Horn, Left and Right Side

25 ECM 1 15A

Electronic Ignition Control Module, Powertrain Control

Module/Vehicle Control Module, Crankshaft Position

Sensor, Fuel Injectors 1-6, and Ignition Coil

26 BTSI 10A Stop Lamp Switch Assembly and Transfer Case Control

Module

27 B/U LP 25A Backup Lamps Switch/Transmission Range Switch

28 Not Used

29 IGN E 10A A/C Compressor Clutch Relay

30 FOG LP 15A Fog Lamp Relay and Headlamp Ground Relay

31 OXYSEN 20A

Heated Oxygen Sensor, Post-Converter (2.2L), Heated

Oxygen Sensor, Left Front, Heated Oxygen Sensor,

Post-Converter, Heated Oxygen Sensor, Right Front, and

Heated Oxygen Sensor, Pre-Converter

32 LR PRK 10A Tail Lamp Assembly, Left Side, Marker Lamp

Assembly, Left Rear, and License Lamp, Left Side

33 IGN C 20A Ignition Switch

34 Not Used

35 PARK LP 20A Park Lamp Relay and Headlamp Switch Assembly

36 Not Used

37 Not Used

38 HVAC 30A Blower Motor Relay

39-

40 Not Used

41 CRANK 10A Transfer Case Control Module, Manual Transmission


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Clutch Start Switch, and Transmission Range Switch

(Automatic)

42 HAZ LP 20A Hazard Switch

43 VECHMSL 10A Dome and High Mounted Stop Lamp and Cruise Control

Module

44 Not Used

45 STOP LP 20A High Mounted Stop Lamp Relay and Stop Lamp Switch

46 TBC 10A Truck Body Control Module (TBC) and RFA Module

Assembly (Remote Keyless Entry)

Micro Relays

47 HDLP PWR Power Supply to the Headlamps

48 DRL Power Supply to the Daytime Running Lamps (DRL)

49 F/Pump Power Supply to the Fuel Pump

50 Horn Power Supply to the Horns

51 Not Used

52 HDLP GRD Ground Supply to the Headlamps

53 Not Used

54 CHMSL Power Supply to the Rear Brake Lamps

Mini Relays

55 Starter Power Supply to the Starter

56 Not Used

Diode

57 DRL Prevent Feedback from the DRL Relay

Underhood Bussed Electrical Center (UBEC) Details (Uplevel Pickup)


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No.

Fuse/Circuit


Maxi Fuses




3-4 Not Used




8 STUD#2 30A Not Used

Mini Fuses

9-

11 Not Used









(All Right Side)

19 Not Used


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20 LT HDLP 10A

Headlamp Low Beam Left, Headlamp High BeamLeft

(ZR2 w/ Service Harness), and Daytime Running Lamp

(DRL) Relay

21 RT HDLP 10A Right Headlamps

22 ENG 1 10A




(4.3L)

23 ECM B 20A





25 ECM 1 15A





Module


28 A/C 10A A/C Compressor Clutch Relay



31 OXYSEN 20A



Post-Converter, Heated Oxygen Sensor, Right Front, and





34 Not Used


36 ATC 20A Transfer Case Control Module

37 Not Used


39-

40 Not Used

41 CRANK 10A

Transfer Case Control Module, Manual Transmission


(Automatic)



Module

44 Not Used





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Micro Relays





51 A/C A/C Compressor Relay


53 FOG LP Power Supply to the Fog Lamps

54 CHMSL Power Supply to the Rear Brake Lamps

Mini Relays


56 Not Used

Diode


Underhood Bussed Electrical Center (UBEC) Details (Uplevel Utility)


No.

Fuse/Circuit


Maxi Fuses





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3-4 Not Used




8 STUD#2 30A AUX PWR Stud, UBEC

Mini Fuses

9 TRL TRN 10A Turn Signal, Left Side Trailer

10 TRR TRN 10A Turn Signal, Right Side Trailer

11 TRL B/U 10A Backup Lamp, Trailer






17 RR PRK 10A Tail Lamp Assembly, Right Side

18 FR PRK 10A Front Turn Signal Lamp Assembly, RH, LH

19 TRL PRK 10A Tail Lamp, Trailer, LH, RH, Vehicle Lisense Plate

Lamps


Lamp (DRL) Relay


Right Side)

22 ENG 1 10A




(4.3L)

23 ECM B 20A





25 ECM 1 15A




26 BTSI 10A Stop Lamp Switch Assembly/BTSI Solenoid and

Transfer Case Control Module





31 OXYSEN 20A



Post-Converter, Heated Oxygen Sensor, Right Front




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34 HTD SEAT 20A Heated Seat Assembly



37 RRDEFOG 30A Rear Window Defogger

38 HVAC 30A Blower Motor Relay/Blower Motor

39 TRCHMSL 10A Trailer Wiring Provision

40 RR W/W 15A Rear Window Wiper

41 CRANK 10A



(Automatic)


43 VECHMSL 10A Dome and Mounted Stop Lamp and Cruise Control

Module

44 HTDMIR 10A Heated Mirrors

45 STOP LP 20A Stop Lamp Switch, High Mounted Stop Lamp Relay



Micro Relays








54 Not Used

Mini Relays


56 RR DEFOG Power Supply to the Rear Defog

Diode


Underhood Bussed Electrical Center (UBEC) Details (Envoy)


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No.

Fuse/Circuit


Maxi Fuses

1 INT BATT 60A HDLP SW, MIR/LKS, AUX PWR, RDO BATT, CIGAR

LTR, CTSY LP, and PWR LKS Fuses


3-4 Not Used




8 STUD 30A Not Used

Mini Fuses

9 TRL TRN 10A Turn Signal, Left Side Trailer

10 TRR TRN 10A Turn Signal, Right Side Trailer

11 TRL B/U 10A Backup Lamp, Trailer










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(All Right Side)

19 TRL PRK 10A Tail Lamp, Trailer


Lamp (DRL) Relay


Right Side)

22 ENG 1 10A



Flow Sensor (4.3L), and Camshaft Position Sensor (4.3L)

23 ECM B 20A




24 LT HI 15A Left Hi Beam

25 RT HI 15A Right Hi Beam


27 ECM 1 15A




28 DRL 15A Daytime Running Lamps


Module





34 OXYGEN 20A


Oxygen Sensor, Left Front, Heated Oxygen Sensor, Post-

Converter, Heated Oxygen Sensor, Right Front, and





37 HTD SEAT 20A Heated Seat Assembly



40 RRDEFOG 30A Rear Window Defogger


42 TRCHMSL 10A Blunt Cut Wire

43 RR W/W 15A Rear Window Wiper

44 CRANK 10A



(Automatic)

45 LD LEV 25A Load Leveling

46 HI BEAM 20A HID Headlamps


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Module

49 HTDMIR 10A Heated Mirrors




Micro Relays






Mini Relays

57 LOW BEAM Power Supply to the Low Beam Headlamps

58 STARTER Power Supply to the Starter

59 RR DEFOG Power Supply to the Rear Defog

IP Fuse Block Details


Fuse

No.

Fuse/Circuit


Power

Windows/Circuit 30A

Door Lock and Side Window Switch Assembly,

Left and Right Side


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Breaker A

1 HDLP SW 10A Headlamp Switch

2 CIGAR LTR 15A Cigar Lighter and Data Link Connector

3 CRUISE 10A Truck Body Control Module (TBC), Cruise

Control Module and Cruise Control Switch

4 GAUGES 10A Truck Body Control Module (TBC) and

Instrument Cluster

5 ILLUM 10A

Radio, Heater Controller (Non-A/C), Heater and

A/C Controller (w/ A/C), Fog Lamp Switch, IP

Module Switch, Truck Body Control Module

(TBC), Transfer Case Select Switch, and

Instrument Cluster

6 Not Used

7 MIR/LKS 5A

Outside Rear View Mirror Switch and Door

Lock and Side Window Switch Assembly, Left

and Right Side

8 CTSY LP 10A

Console Courtesy Lamp, Left and Right Side,

Transfer Case Control Module and Inadvertent

Power Lamp Relay

9 HVAC 20A Heater Controller (Non-A/C) and Heater and

A/C Controller (w/ A/C)

10 TURN 20A Hazard Lamp Switch and Turn Signal Switch

11 CLSTR 10A

Instrument Cluster, Powertrain Control Module

(2.2L), Vehicle Control Module (4.3L), and

Automatic Transmission

12 PARK LPS 10A

IP Ashtray Lamp, Truck Body Control Module

(TBC), Outside Rear View Mirror Switch, and

Door Lock and Side Window Switch Assembly,

Left and Right Side

13 AUX PWR 20A Auxiliary Power Outlet, Left and Right Side

14 PWR LKS 15A Door Lock Relay, Door Unlock Relay, and

Driver Door Lock Relay

15 4WD 10A

Vehicle Control Module, Transfer Case Select

Switch, Transfer Case Control Module, and

Front Axle Switch

16 SIR 15A IP Module Switch and Supplemental Restraint

Sensing and Diagnostic Module

17 FRT WPR 25A Windshield Wiper Motor and Windshield

Wiper/Washer Control Switch

18 Not Used

19 RDO BATT 15A Radio and Instrument Cluster

20 AMP F (Envoy

Only) 25A Amplifier

21 HVAC1 10A Air Temperature Valve and Air Temperature

Valve Electric Actuator

22 ABS 10A Stop Lamp Switch and Electronic Brake Control


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Module Assembly

23 RR WPR 15A Rear Wiper Switch, Rear Window Washer Motor

24 RDO IGN 10A Radio


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MOTOR

Key and Lock Cylinder Coding

Document ID: 102500

Key Identification and Usage

The lock cylinder keyway is designed so that other model keys will not enter a current

model lock cylinder. A single key is used for all locks on the vehicle.

The key identification is obtained from the five-character key code stamped on the

knockout portion of the key head. Knock the plugs out of the key head after code

numbers have been recorded. The code list, available to owners of key cutting

equipment from equipment suppliers, determines the lock combinations from the code

numbers.

Cutting Keys

After the code has been determined from the code list or the key code diagram, perform

the following steps:

1. Cut a blank key to the proper level of each of the tumbler positions.

2. Inspect the key operation in the lock cylinder.

Replacement Lock Cylinders

New lock cylinders except ignition lock cylinders are available from the service parts

warehouse with new lock cylinder locking bars. The tumblers are also available and

must be assembled into the cylinder as recommended. For additional information, refer

to the following.

Lock Cylinder Tumbler Operation

All lock tumblers are shaped alike with the exception of the notched position on one

side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct

height so that notches on each tumbler are at the same level. When the notches on all six

tumblers line up, two small springs push the side bar into the notches, allowing the

cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock

combinations, and each is coded and stamped with a number between 1 and 5.

Assembling and Coding Ignition Lock Cylinders

Tools Required

J 41340 Ignition Lock Holding Fixture


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1. Determine the tumbler numbers/arrangement:

1. Place the tip of the key directly over the tip of the illustrated key.

2. Inspect that the diagram outlines the key.

3. Starting with position 1 (open end of cylinder), find and record the

lowest level (tumbler number) that is visible.

4. Repeat the previous step for positions 210.


2. Starting with position 1, insert the tumblers (4) into their corresponding slots in

the coded order.

3. Using your fingers, pull out the side bar (3) until the tumblers fall completely

into place.

4. Insert one tumbler spring (2) above each tumbler (4).

5. Lubricate the tumblers using Superlube GM P/N 12346241 or equivalent.

6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder.


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7. Press down the retainer (1) until fully seated in the depression.


8. Inspect for proper tumbler installation:

1. Hold the spring retainer (2) in position.

2. Insert the key (1) into the cylinder.

3. The side bar (3) should drop down flush with the cylinder diameter if

properly installed.

4. Disassemble and assemble properly as needed.

9. Remove the key.


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10. Secure the cylinder in the J 41340 .

1. Inspect that the spring retainer is facing up and positioned directly under

the punch slots.

2. Push the cylinder into the J 41340 until butted with the cylinder bezel.

3. Tighten the holding screw.


11. Stake the bezel end of the retainer in place:

1. Hold the flat side of the punch, part of J 41340 , squarely against the face

of the cylinder bezel.

2. Stake the lock cylinder metal over the retainer corners.


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12. Stake the other end of the retainer:

1. Remove the punch, part of J 41340 .

2. Rotate the punch, part of J 41340 , 180 degrees.

3. Hold the punch, part of J 41340 , squarely against the end of the punch

slot on J 41340 .

4. Stake the metal over the other end of the retainer.


13. Loosen the holding screw.

14. Remove the cylinder from the J 41340 .

15. Inspect that the retainer is properly staked. Restake as needed.

16. Lubricate the cylinder retainer slot.

17. Insert the following parts into the cylinder retainer slot:

o The retainer spring (2)

o The retainer (3)


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Important: Use a paste type grease, not a spray, for the following step.

18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed:

o The detent pins (1)

o The cylinder retainer (3)

Fastener Tightening Specifications

Document ID: 450026

Specification

Application Metric English

Accelerator Control Cable Bracket Nut 12 N-m 106 lb in

Accelerator Control Cable and Cruise Control Cable Bracket Nut 9 N-m 80 lb in

Accelerator Control Cable Bracket Stud to Intake Manifold 6 N-m 53 lb in

Accelerator Control Cable Bracket Stud to Throttle Body 12 N-m 106 lb in

Air Cleaner Adapter Stud 8 N-m 71 lb in

Air Conditioning (A/C) Compressor Mounting Bolt 50 N-m 37 lb ft

Balance Shaft Driven Gear Bolt

First Pass 20 N-m 15 lb ft

Final Pass 35 degrees

Balance Shaft Retainer Bolt 12 N-m 106 lb in

Battery Negative Cable Bolt to Engine 35 N-m 26 lb ft

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



Crankshaft Balancer Bolt 95 N-m 70 lb ft

Crankshaft Bearing Cap Bolt (Preferred Method)



Crankshaft Bearing Cap Bolt (Optional Strategy) 105 N-

m 77 lb ft


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Crankshaft Position Sensor Bolt 9 N-m 80 lb in

Crankshaft Pulley Bolt 58 N-m 43 lb ft

Crankshaft Rear Oil Seal Housing Bolt and Nut 12 N-m 106 lb in

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 Bolt Final Pass in Sequence 75 degrees

Medium Bolt Final Pass in Sequence 65 degrees

Short Bolt Final Pass in Sequence 55 degrees

Cylinder Head Bolt (Optional On-Vehicle Strategy)

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 7 N-m 62 lb in

Final Pass 30 N-m 22 lb ft

EGR Valve Inlet Pipe Clamp Bolt 25 N-m 18 lb ft

EGR Valve Inlet Pipe Nut at Intake Manifold 25 N-m 18 lb ft

EGR Valve Inlet Pipe Nut at Exhaust Manifold 30 N-m 22 lb ft

Engine Block Left Side Oil Gallery Plug 20 N-m 15 lb ft

Engine Block Left Rear Oil Gallery Plug 30 N-m 22 lb ft

Engine Block Right Rear Oil Gallery Plug 20 N-m 15 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 Heater Bolt/Screw 2 N-m 18 lb in

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


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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) 74 N-m 55 lb ft

Engine Mount Bolt to Engine 54 N-m 40 lb ft

Engine Mount (Rear) Bolt to Transmission 50 N-m 37 lb ft

Engine Mount (Rear) Nut to Crossmember 45 N-m 33 lb ft

Engine Mount Bracket Bolt to Frame 45 N-m 33 lb ft

Engine Mount Nut (Through-bolt) 63 N-m 46 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 to Intake Manifold 12 N-m 106 lb in

Engine Wiring Harness Bracket Bolt to Rear of Cylinder Head 35 N-m 26 lb ft

Engine Wiring Harness Bracket Bolt to Generator and Drive Belt

Tensioner Bracket

25 N-m 18 lb ft

Evaporative Emission (EVAP) Canister Purge Solenoid Valve

Stud to Intake Manifold 10 N-m 88 lb in

Exhaust Manifold Bolt/Stud


Final Pass 30 N-m 22 lb ft

Fan and Water Pump Pulley Bolt 25 N-m 18 lb ft

Fuel Meter Body Bracket Bolt 10 N-m 88 lb in

Fuel Pipe Bracket Bolt 6 N-m 53 lb in

Fuel Pipe Bracket Bolt to Rear of Cylinder Head 30 N-m 22 lb ft

Fuel Pipe Retainer Nut 3 N-m 27 lb in

Fuel Supply Pipe Nut (Fuel Tank Side) 30 N-m 22 lb ft

Generator and Drive Belt Tensioner Bracket Bolt to Engine 41 N-m 30 lb ft

Generator and Drive Belt Tensioner Bracket Stud to Engine 20 N-m 15 lb ft

Generator and Drive Belt Tensioner Bracket Stud Nut 41 N-m 30 lb ft

Generator Mounting Bolt 50 N-m 37 lb ft

Ground Wire Bolt to Rear of Cylinder Head 35 N-m 26 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 21 N-m 15 lb ft

Oil Filter Fitting 35 N-m 26 lb ft


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Oil Level Indicator Tube Bolt 12 N-m 106 lb in

Oil Pan Baffle Bolt 12 N-m 106 lb in

Oil Pan Bolt and Nut in Sequence 25 N-m 18 lb ft

Oil Pan Drain Plug 25 N-m 18 lb ft

Oil Pump Bolt to Rear Crankshaft Bearing Cap 90 N-m 66 lb ft

Oil Pump Cover Bolt 12 N-m 106 lb in

Power Steering Fluid Reservoir Filler Neck Bolt to Power

Steering Pump Bracket

20 N-m 15 lb ft

Power Steering Pump Bracket Bolt to Engine 41 N-m 30 lb ft

Power Steering Pump Bracket Stud to Engine 20 N-m 15 lb ft

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 41 N-m 30 lb ft

Power Steering Pump Rear Bracket Nut to Power Steering Pump 50 N-m 37 lb ft

Radiator Inlet Hose Support Bracket Nut to Exhaust Manifold

Stud

36 N-m 27 lb ft

Remote Oil Filter Adapter Mounting Bracket Bolt 30 N-m 22 lb ft

Remote Oil Filter Adapter Nut 25 N-m 18 lb ft

Remote Oil Filter Inlet and Outlet Hose Clip Bolt 10 N-m 88 lb in

Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter

Adapter Bolt 35 N-m 26 lb ft

Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter Pipe

Adapter Bolt 35 N-m 26 lb ft

Secondary Air Injection (AIR) Check Valve Pipe Bracket Bolt to

Exhaust Manifold 10 N-m 88 lb in

Secondary Air Injection (AIR) Check Valve Pipe Stud Nut 25 N-m 18 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

Starter Motor Bolt 40 N-m 29 lb ft

Starter Motor Wiring Harness/Transmission Cooler Pipe Bracket

Bolt to Oil Pan 12 N-m 106 lb in

Throttle Body Stud 9 N-m 80 lb in

Transmission Bolt to Oil Pan 47 N-m 35 lb ft

Transmission Cover Bolt 12 N-m 106 lb in

Upper Intake Manifold Stud

First Pass 5 N-m 44 lb in

Final Pass 9 N-m 80 lb in


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Valve Lifter Pushrod Guide Bolt 16 N-m 12 lb ft

Valve Rocker Arm Ball Stud 47 N-m 35 lb ft

Valve Rocker Arm Cover Bolt 12 N-m 106 lb in

Valve Rocker Arm Nut 25 N-m 18 lb ft

Water Outlet Stud 25 N-m 18 lb ft

Water Pump Bolt 45 N-m 33 lb ft

Engine Mechanical Specifications

Document ID: 104659

Specification

Application Metric English

General Data

Engine Type V6

Regular Production Option (RPO) Code LF6 VIN Code X, and RPO Code

L35 VIN Code W

Displacement 4.3L 262 CID

Bore 101.60 mm 4.012 in

Stroke 88.39 mm 3.480 in

Compression Ratio 9.2:1

Firing Order 165432

Spark Plug Gap 1.52 mm 0.060 in

Oil Pressure (Minimum) at Normal

Operating Temperature

42 kPa at

1,000 RPM

125 kPa at

2,000 RPM

166 kPa at

4,000 RPM

6 psig at

1,000 RPM

18 psig at

2,000 RPM

24 psig at

4,000 RPM

Balance Shaft

Rear Bearing Journal Clearance 0.0500.088 mm

0.0020

0.0035 in

Rear Bearing Journal Diameter 38.085

38.100 mm 1.49941.500 in


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Camshaft

End Play 0.0254

0.2286 mm

0.0010

0.0090 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) (L35) 7.207.30 mm 0.2830.287 in

Lobe Lift (Exhaust) (LF6) 6.546.64 mm 0.2570.261 in

Lobe Lift (Intake) (L35) 6.977.07 mm 0.2740.278 in

Lobe Lift (Intake) (LF6) 6.766.86 mm 0.2660.270 in

Runout 0.065 mm 0.0026 in

Connecting Rod

Connecting Rod Bearing Clearance

(Production) 0.0380.078 mm 0.0015

0.0031 in

Connecting Rod Bearing Clearance

(Service) 0.0250.076 mm 0.0010

0.0030 in

Connecting Rod Side Clearance 0.150.44 mm 0.0060.017 in

Connecting Rod Journal Diameter 57.116

57.148 mm

2.2487

2.2497 in

Connecting Rod Journal Taper

(Production) 0.00508 mm

(Maximum)

0.00030 in

(Maximum)

Connecting Rod Journal Taper (Service) 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Connecting Rod Journal Out-of-Round


(Maximum)

0.0002 in

(Maximum)

Connecting Rod Journal Out-of-Round

(Service) 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Crankshaft

Crankshaft Bearing Clearance (Journal

#1Production) 0.020.508 mm 0.0008

0.0020 in


#2, #3, and #4Production) 0.0280.058 mm 0.0011

0.0023 in


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#1Service) 0.02540.05 mm 0.0010

0.0020 in


#2, #3, and #4Service) 0.0250.063 mm 0.0010

0.0250 in

Crankshaft End Play 0.0500.20 mm 0.0020.008 in

Crankshaft Journal Diameter (Journal

#1) 62.199

62.217 mm

2.4488

2.4495 in


#2 and #3) 62.191

62.215 mm

2.4485

2.4494 in


#4) 62.179

62.203 mm

2.4480

2.4489 in

Crankshaft Journal Out-of-Round


(Maximum)

0.0002 in

(Maximum)

Crankshaft Journal Out-of-Round

(Service) 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Crankshaft Journal Taper (Production) 0.007 mm

(Maximum)

0.0003 in

(Maximum)

Crankshaft Runout 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Cylinder Bore

Diameter 101.618

101.643 mm

4.0007

4.0017 in

Out-of-Round (Production) 0.0127 mm

(Maximum)

0.00050 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)

Taper (Production Thrust Side) 0.012 mm

(Maximum)

0.0005 in

(Maximum)

Taper (Service) 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Cylinder Head

Surface Flatness 0.10 mm

(Maximum)

0.004 in

(Maximum)

Exhaust Manifold


(Maximum)

0.002 in

(Maximum)


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Intake Manifold


(Maximum)

0.004 in

(Maximum)

Oil Pan

Oil Pan Alignment at Rear of Engine

Block 0.3 mm

(Maximum)

0.011 in

(Maximum)

Piston

Piston Bore Clearance (Production) 0.0180.061 mm

0.0007

0.0024 in

Piston Bore Clearance (Service) 0.075 mm

(Maximum)

0.0029 mm

(Maximum)

Piston Pin

Clearance in Piston (Production) 0.0130.023 mm

0.0005

0.0009 in

Clearance in Piston (Service) 0.025 mm

(Maximum)

0.0010 in

(Maximum)

Diameter 23.545

23.548 mm

0.9270

0.9270 in

Fit in Connecting Rod 0.0210.040 mm

(Interference)

0.0008

0.0016 in

(Interference)

Piston Rings (End Gap Measured in Cylinder Bore)

Piston Compression Ring Gap

(ProductionTop Groove) 0.250.40 mm 0.0100.016 in

Piston Compression Ring Gap

(Production2nd Groove) 0.460.66 mm

(Maximum)

0.0180.026 in

(Maximum)

Piston Compression Ring Gap (Service

Top Groove) 0.5 mm

(Maximum)

0.19 in

(Maximum)

Piston Compression Ring Gap (Service

2nd Groove) 0.8 mm

(Maximum)

0.31 in

(Maximum)

Piston Compression Ring Groove

Clearance (ProductionTop Groove) 0.0300.070 mm 0.0012

0.0027 in


Clearance (Production2nd Groove) 0.0400.080 mm 0.0015

0.0031 in


Clearance (Service) 0.085 mm

(Maximum)

0.0033 in

(Maximum)

Piston Oil Ring Gap (Production) 0.250.76 mm 0.0100.029 in


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Piston Oil Ring Gap (Service) 0.90 mm

(Maximum)

0.035 in

(Maximum)

Piston Oil Ring Groove Clearance

(Production) 0.0460.096 mm 0.0018

0.0037 in

Piston Oil Ring Groove Clearance

(Service) 0.10 mm

(Maximum)

0.0039 in

(Maximum)

Valve System

Valve Face Angle 45 degrees

Valve Head Edge Margin 0.79 mm

(Minimum)

0.031 in

(Minimum)

Valve Lash Net LashNo Adjustment

Valve Lift (Exhaust) (L35) 10.879 mm 0.4280 in

Valve Lift (Exhaust) (LF6) 9.887 mm 0.3890 in

Valve Lift (Intake) (L35) 10.527 mm 0.4140 in

Valve Lift (Intake) (LF6) 10.215 mm 0.4020 in

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) 1.5752.362 mm 0.0650.098 in

Valve Seat Width (Intake) 0.891.52 mm 0.0350.060 in

Valve Spring Free Length 51.3 mm 2.02 in

Valve Spring Installed Height (Exhaust) 42.9243.43 mm 1.6701.700 in

Valve Spring Installed Height (Intake) 42.9243.43 mm 1.6701.700 in

Valve Spring Pressure (Closed) 338374 N at

43.2 mm

7684 lb at

1.70 in

Valve Spring Pressure (Open) 832903 N at

32.3 mm

187203 lb at

1.27 in


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Valve Stem Clearance (Exhaust

Production) 0.0250.069 mm 0.0010

0.0027 in

Valve Stem Clearance (Exhaust

Service) 0.0250.094 mm 0.0010

0.0037 in

Valve Stem Clearance (Intake

Production) 0.0250.069 mm 0.0010

0.0027 in

Valve Stem Clearance (IntakeService) 0.0250.094 mm

0.0010

0.0037 in

Valve Stem Oil Seal Installed Height

(Measured from the Top of the Large

Diameter Valve Guide Bevel to the

Bottom of the Valve Stem Oil Seal)

12 mm 0.03937

0.07874 in

Oil Pressure Diagnosis and Testing

Document ID: 23360

1. With the vehicle on a level surface, allow adequate drain down time, 2

3 minutes, and measure for a low engine oil level.

Add the recommended grade engine oil, and fill the crankcase until the oil level

measures FULL on the oil level indicator.

2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure

gage or the oil indicator light.

Listen for a noisy valve train or a knocking noise.

3. Inspect for the following:

o Engine oil diluted by moisture or unburned fuel mixtures

o Improper engine oil viscosity for the expected temperature

o Incorrect or faulty oil pressure gage sensor

o Incorrect or faulty oil pressure gage

o Plugged oil filter

o Malfunctioning oil filter bypass valve

4. Remove the oil pressure gage sensor or another engine block oil gallery plug.

5. Install an oil pressure gage.

6. Start the engine and then allow the engine to reach normal operation

temperature.

7. Measure the engine oil pressure at the following RPM:

Specification

1. 42 kPa (6 psig) minimum, at 1,000 RPM


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8. If the engine oil pressure is below minimum specifications, inspect the engine

for one or more of the following:

o Oil pump worn or dirty

o Malfunctioning oil pump pressure relief valve

o Oil pump screen loose, plugged, or damaged

o Excessive bearing clearance

o Cracked, porous or restricted oil galleries

o Engine block oil gallery plugs missing or incorrectly installed

o Broken valve lifters

Checks Action

Engine performance diagnosis procedures are covered in Engine Controls and

should be consulted for diagnosis of any Driveability, Emissions, or

Malfunctioning Indicator Lamp (MIL) concerns.

The following diagnosis covers common concerns and possible causes.

When the proper diagnosis is made, the concern should be corrected by adjustment,

repair or replacement as required.

Refer to the appropriate section of the service manual for each specific procedure.

This diagnostic table will assist in engine misfire diagnosis due to a mechanical

concern such as a faulty engine camshaft, worn or damaged bearings or bent valve

pushrod.

This table will not isolate a crossed fuel injector wire, faulty fuel injector or any

other driveability component failure that may cause a misfire.

The Powertrain On-Board Diagnostic System checks must be performed first.

When using this table to make a Base Engine Misfire diagnosis, begin with the

preliminary information below and then proceed to the specific category.

Preliminary 1. Perform DTC P0300 before proceeding with Base

Engine Misfire Diagnosis information.

DTC P0300 will assist in determining which cylinder or

cylinders are misfiring.

2. Perform a visual inspection of the following:

o A loose or improperly installed engine flywheel

or crankshaft balancer

o Worn, damaged or misaligned accessory drive

system components

3. Listen to the engine for any abnormal internal engine

noises.


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4. Inspect the engine for acceptable oil pressure.

5. Verify if the engine has excessive oil consumption.

6. Verify if the engine has excessive coolant consumption.

7. Perform a compression test on the engine.

Intake Manifold

Leaks

An intake manifold that has a vacuum leak may cause a

misfire.

Inspect for the following:

Improperly installed or damaged vacuum hoses

Faulty or improperly installed lower intake manifold

and/or gaskets

Cracked or damaged lower intake manifold

Improperly installed MAP sensor

The sealing grommet of the MAP sensor should not be

torn or damaged

Improperly installed throttle body or damaged gasket

Warped intake manifold

Warped or damaged cylinder head sealing surface

Coolant

Consumption

Coolant consumption may or may not cause the engine to

overheat.

Inspect for the following:

External coolant leaks

Faulty cylinder head gasket

Warped cylinder head

Cracked cylinder head

Damaged engine block

Oil Consumption Oil consumption may or may not cause the engine to misfire.

1. Remove the spark plugs and inspect for an oil fouled

spark plug.

2. Perform a cylinder compression test.

3. If the compression test indicates worn valves or valve

guides, inspect the following:

o Worn, brittle, or improperly installed valve stem

oil seals

o Worn valve guides

o Worn valve stems

o Worn or burnt valves or valve seats

4. If the compression test indicates worn or damaged

piston rings, inspect the following:

o Broken or improperly seated piston rings

o Excessive piston ring end gap


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o Excessive cylinder bore wear or taper

o Cylinder damage

o Piston damage

Abnormal Internal

Engine Noises

1. Start the engine and determine if the noise is timed to

the engine camshaft speed or the crankshaft speed.

2. Using a timing light, two knocks per flash is the

crankshaft speed and one knock per flash is the engine

camshaft speed.

3. If the noise is timed to the engine camshaft speed,

inspect the following:

o Missing or loose valve train components

o Worn or loose valve rocker arms

o Worn or bent valve pushrods

o Faulty valve springs

o Bent or burnt valves

o Worn engine camshaft lobes

o Worn or damaged camshaft timing chain and/or

sprockets

Important: A slight COLD knock or piston slapping

noise could be considered normal if not present after the

engine has reached normal operating temperatures.

4. If the knock is timed to the crankshaft speed, inspect the

following:

o Worn crankshaft or connecting rod bearings

o Piston or cylinder damage

o Worn piston or piston pin

o Faulty connecting rod

o Excessive carbon build-up on the top of the

piston

No Abnormal

Internal Engine

Noise

1. Inspect for a worn or improperly installed camshaft

timing chain and/or sprockets.

2. Remove the valve rocker arm cover on the side of the

engine with the cylinder that is misfiring.

3. Inspect for the following:

o Loose valve rocker arm studs

o Bent valve push rods

o Faulty valve springs

o Faulty valve lifters (bleeding down)

o Worn or improperly seated valves

o Worn engine camshaft lobes

Engine Compression Test

Document ID: 723193


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1. Ensure that the vehicle batteries are in good condition, and fully charged.

2. Operate the vehicle until the engine is at normal operating temperature.

3. Disconnect the positive ignition coil wire plug from the ignition coil.

4. Disconnect the fuel injector electrical connector.

5. Remove all of the spark plugs.

Notice: Do not insert objects into the throttle plate opening. Damage to the

throttle body can result, requiring replacement of the throttle body assembly.

6. Block the throttle linkage wide open.

7. Install the engine cylinder compression gage to the cylinder being tested.

8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression

strokes, or puffs, for the cylinder being tested. If the engine rotates for more than

4 compression strokes, test the cylinder again.

9. Record the compression reading.

10. Remove the engine cylinder compression gage from the cylinder being tested.

11. Repeat steps 811 for each additional cylinder. All cylinders must be tested to

obtain valid test results.

12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of

engine oil into the cylinder through the spark plug hole.

13. Repeat steps 811 for all low compression cylinders.

14. The minimum compression in any one cylinder should not be less than

70 percent of the highest cylinder. No cylinder should read less than 690 kpa

(100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa

(150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa

(105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x

70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the

lowest allowable pressure in any other cylinder.

o Normal

The compression builds up quickly and evenly to the specified

compression.

o Piston rings leaking

Compression is low on the first compression stroke. The compression

builds up on the following strokes, but does not reach normal.

Compression improves considerably when you add oil.

o Valves leaking

Compression is low on the first compression stroke. The compression

does not build up on the following strokes, and does not reach normal.

Compression does not improve much, if at all, when you add oil.

o Head gasket leaking

Compression is low on the first stroke. The compression does not build

up on the following strokes, and does not reach normal. Compression

does not improve much, if at all, when you add oil. Adjacent cylinders

have the same, or similar, low compression readings.


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15. If one or more cylinders fails to meet the minimum specified compression,

repair or replace all damaged or worn components and test the engine again.

Lower Engine View 2 4.3L L35/LF6 -

Document ID: 41408

Lower Engine View 2


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1. Crankshaft Rear Oil Seal Housing Bolt

2. Flywheel Locator Pin

3. Crankshaft Rear Oil Seal Housing Nut

4. Crankshaft Rear Oil Seal Housing

5. Crankshaft Rear Oil Seal Housing Retainer Stud

6. Crankshaft Rear Oil Seal Housing Gasket

7. Crankshaft

8. Oil Pump Drive Shaft

9. Oil Pump Locator Pin

10. Oil Pump Drive Shaft Retainer

11. Oil Pump


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12. Oil Pump Bolt

13. Oil Pan

14. Oil Pan Bolt

15. Oil Pan Gasket

16. Crankshaft Bearing Cap Bolt

17. Crankshaft Bearing Cap

18. Crankshaft Bearings (Lower)

19. Crankshaft Sprocket

20. Crankshaft Position Sensor Reluctor Ring

21. Engine Front Cover

22. Crankshaft Front Oil Seal

23. Crankshaft Balancer

24. Crankshaft Balancer Bolt

25. Crankshaft Balancer Key

26. Crankshaft Bearings (Upper)

Upper Engine View 2 4.3L L35/LF6 (ST, GMT150) -

Document ID: 41410

Upper Engine View 2


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1. Valve Rocker Arm Cover

2. Valve Rocker Arm Cover Gasket

3. Valve Rocker Arm Nut

4. Valve Rocker Arm Ball

5. Valve Rocker Arm

6. Spark Plug Wire Support

7. Spark Plug Wire Support Bolt

8. Exhaust Manifold Gasket

9. Exhaust Manifold

10. Exhaust Manifold Bolt

11. Spark Plug Wire Shields


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12. Exhaust Manifold Gasket

13. Valve Lifter

14. Valve Lifter Pushrod Guide

15. Valve Pushrod

16. Cylinder Head Gasket

17. Engine Lift Front Bracket

18. Cylinder Head Bolt

19. Cylinder Head

Upper and Lower Intake Manifold View 4.3L L35/LF6 -

Document ID: 356346

Upper and Lower Intake Manifold View


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1. Fuel Pipe Retainer Bracket Nut

2. Fuel Pipe Retainer

3. Fuel Pipe

4. Fuel Pipe Bolt

5. Fuel Seal Retainer

6. Upper Fuel Seal (Yellow O-ring)

7. Spacer Ring (Metal Flat Washer)

8. Lower Fuel Seal (Black O-ring)

9. Upper Manifold Attaching Stud

10. Upper Intake Manifold


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11. Upper Intake to Lower Intake Manifold Gasket

12. Fuel Meter Body Seal (O-ring)

13. Fuel Meter Body

14. Intake Manifold

15. Throttle Body to Upper Intake Manifold Gasket

16. Throttle Body

17. Throttle Body Attaching Stud

Intake Manifold Replacement -

Document ID: 193909

Removal Procedure


1. Disconnect the PCV tube from the air cleaner outlet duct.

2. Remove the air cleaner outlet duct from the throttle body.

3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement

in Engine Controls.


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4. Disconnect the following electrical connectors:

o The A/C pressure switch, if equipped

o The throttle position (TP) sensor

o The idle air control (IAC) motor

o The fuel meter body assembly connector

o The manifold absolute pressure (MAP) sensor

o The EVAP canister purge solenoid valve

5. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister

Purge Solenoid Valve Replacement in Engine Controls.


6. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.

7. Remove the vacuum brake booster hose.


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8. Remove the PCV valve hose assembly form the intake manifold and the valve

rocker arm cover.


9. Disconnect the accelerator control cable from the throttle shaft and the

accelerator cable bracket. Refer to Accelerator Control Cable Replacement in

Engine Controls.

10. Disconnect the cruise control cable, if equipped from the throttle shaft and the

accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise

Control.

11. Remove the accelerator cable bracket from the throttle body and the intake

manifold.


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12. Remove the accelerator and cruise control cable bracket from the throttle body.

Leave the accelerator and cruise control cables and the engine wiring harness on

the bracket.


13. Remove the bracket for the engine wiring harness from the intake stud.

14. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel

Hose/Pipes Replacement - Engine Compartment in Engine Controls.


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15. Remove the upper intake manifold. Refer to Intake Manifold Disassemble in

Engine Mechanical - 4.3L

16. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in

Engine Mechanical - 4.3L

Installation Procedure


1. Install the upper intake manifold. Refer to Intake Manifold Assemble in Engine

Mechanical - 4.3L

2. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes

Replacement - Engine Compartment in Engine Controls.


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3. Install the bracket for the engine wiring harness on the lower intake manifold

stud.

Notice: Use the correct fastener in the correct location. Replacement fasteners

must be the correct part number for that application. Fasteners requiring

replacement or fasteners requiring the use of thread locking compound or sealant

are identified in the service procedure. Do not use paints, lubricants, or corrosion

inhibitors on fasteners or fastener joint surfaces unless specified. These coatings

affect fastener torque and joint clamping force and may damage the fastener.

Use the correct tightening sequence and specifications when installing fasteners

in order to avoid damage to parts and systems.

4. Install the engine wiring harness bracket nut.

Tighten

Tighten the engine wiring harness bracket nut to 12 N-m (106 lb in).


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5. Install the accelerator and cruise control cable bracket to the throttle body.

6. Install the accelerator and cruise control cable bracket nuts.

Tighten

Tighten the accelerator and cruise control cable bracket nuts to 9 N-m (80 lb in).


7. Install the accelerator cable bracket to the throttle body and the intake manifold.

Tighten

Tighten the accelerator cable bracket studs and nuts to 12 N-m (106 lb in).


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8. Install the cruise control cable, if equipped to the throttle shaft and the bracket.

Refer to Cruise Control Cable Replacement in Cruise Controls.

9. Install the accelerator cable to the throttle shaft and the bracket. Refer to

Accelerator Control Cable Replacement in Engine Controls - 4.3L Engine

Controls.

10. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge

Solenoid Valve Replacement in Engine Controls.


11. Connect the PCV valve hose assembly to the intake manifold and the valve

rocker arm cover.


12. Connect the vacuum hose to the intake manifold, if equipped with A/C.

13. Install the vacuum brake booster hose to the intake manifold.


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14. Connect the following electrical connectors:

o The A/C pressure switch, if equipped



o The fuel meter body assembly connector

o The manifold absolute pressure (MAP) sensor



15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in

Engine Controls.

16. Install the air cleaner outlet duct to the throttle body assembly.

17. Connect the PCV tube to the air cleaner outlet duct.

Intake Manifold Replacement -


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Document ID: 193927

Removal Procedure


1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine

Electrical.




in Engine Controls.


5. Drain the cooling system. Refer to Cooling System Draining and Filling in

Engine Cooling.

6. Remove the radiator inlet hose at the water outlet.

7. Remove the heater hose from the intake manifold.

8. Remove the water pump inlet hose form the intake manifold.


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9. Disconnect the accelerator control cable from the throttle shaft and the

accelerator cable bracket. Refer to Accelerator Control Cable Replacement in

Engine Controls.

10. Disconnect the cruise control cable, if equipped from the throttle shaft and the

accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise

Control.

11. Remove the accelerator cable bracket from the throttle body and the intake

manifold.


12. Remove the accelerator and the cruise control cable bracket from the throttle

bracket.

Leave the accelerator and cruise control cables and the wiring harness on the

bracket.


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13. Remove the following electrical connectors:

o The fuel meter body assembly




o The A/C compressor high pressure switch, if equipped

o The A/C clutch switch, if equipped

o The exhaust gas recirculation (EGR) valve

o The engine coolant temperature (ECT) sensor

o The ignition coil

o The ignition control module (ICM)

14. Remove the engine wiring harness from the retainers.

15. Move the engine wiring harness aside.

16. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.



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17. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and

exhaust manifold.

18. Disconnect the fuel supply and return pipes at the rear of the intake manifold.

Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine

Controls.


19. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.

20. Disconnect the vacuum brake booster hose


21. Disconnect the PCV hose assembly from the intake manifold and the valve

rocker arm cover.




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23. Important: Do not discharge the refrigerant.

Perform the following in order to remove the left front bolt for the intake

manifold:

1. Remove the drive belt. Refer to Drive Belt Replacement .

2. Loosen the nut for the power steering pump rear bracket at the side of the

engine.

3. Remove the nut for the power steering pump rear bracket at the front of

the engine.

4. Remove the bolts and the nut for the power steering pump mounting

bracket.

5. Leave the A/C compressor, if equipped, and the power steering pump on

the power steering pump mounting bracket.

6. Slide the power steering pump bracket forward to access the bolt at the

front of the intake manifold.


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24. Remove the lower intake manifold. Refer to Intake Manifold Removal .

25. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in

Engine Mechanical - 4.3L .



1. Notice: Proper lower intake manifold fastener tightening sequence and torque is

critical. Always follow the tightening sequence, and torque the intake manifold

bolts using the 3 step method. Failing to do so may distort the crankshaft bearing

bore alignment and cause damage to the crankshaft bearings.

Install the lower intake manifold. Refer to Intake Manifold Installation .


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2. Position the power steering pump mounting bracket.

3. Loosely install the power steering pump mounting bracket bolts and nuts.









4. Install the nut for the power steering pump rear bracket at the front of the engine.

Tighten

Tighten the power steering pump mounting bracket bolts and the power steering

pump rear bracket nuts to 41 N-m (30 lb ft).

5. Install the drive belt. Refer to Drive Belt Replacement .




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7. Connect the vacuum brake booster hose.

8. Connect the vacuum hose to the intake manifold, if equipped with A/C.


9. Install the PCV hose assembly to the intake manifold and the valve rocker arm

cover.

10. Install the fuel supply and return pipes to the rear of the intake manifold. Refer

to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.


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11. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake

manifold and the exhaust manifold.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m

(18 lb ft).

2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m

(22 lb ft).

3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).


12. Important: In order to install the distributor for the correct engine timing,

position the engine to number one cylinder top dead center.


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Remove the spark plug for number one cylinder.

13. Rotate the crankshaft until number one cylinder is in the compression stroke.

14. Align the two reference marks on the crankshaft balancer (1) and (4) with the

two alignment marks (2) and (3) on the front cover.

15. Install the spark plug. Refer to Spark Plug Replacement in Engine Electrical.

16. Install the distributor. Refer to Distributor Replacement in Engine Electrical.


17. Position the engine wiring harness.

18. Install the engine wiring harness in the retainers.

19. Install the following electrical connectors:

o The fuel meter body assembly




o The A/C compressor high pressure switch, if equipped.

o The A/C compressor clutch switch, if equipped.

o The exhaust gas recirculation (EGR) valve

o The engine coolant temperature (ECT) sensor

o The ignition coil

o The ignition control module (ICM)


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20. Install the accelerator cable and cruise control bracket to the throttle body.

Tighten

Tighten the accelerator cable and cruise control bracket nuts to 9 N-m (80 lb in).


21. Install the accelerator cable bracket to the intake manifold and the throttle body.

Tighten

Tighten the accelerator cable bracket studs and nuts to 12 N-m (106 lb in).

22. Install the accelerator control cable to the bracket and the throttle shaft. Refer to

Accelerator Control Cable Replacement in Engine Controls.


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23. Install the cruise control cable, if equipped to the bracket and the throttle shaft.

Refer to Cruise Control Cable Replacement in Cruise Control.


24. Install the water pump inlet hose to the intake manifold.

25. Install the heater hose to the intake manifold.

26. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement

in Engine Cooling.

27. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine

Cooling.



Engine Controls.

29. Install the air cleaner outlet duct to the throttle body.


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30. Connect the PCV tube to the air cleaner outlet duct.

31. Connect the battery negative cable. Refer to Battery Replacement in Engine

Electrical.

Valve Rocker Arm Cover Replacement -

Document ID: 193937

Removal Procedure


1. Disconnect the PCV tube from the air cleaner outlet duct,



in Engine Controls.


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4. Remove the PCV valve hose assembly from the valve rocker arm cover.

5. Disconnect the engine coolant temperature (ECT) gauge sensor.

6. Partially drain the engine coolant. Refer to Cooling System Draining and Filling

in Engine Cooling.

7. Remove the radiator inlet hose from the water outlet. Refer to Engine Coolant

Thermostat Replacement in Engine Cooling.


8. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake

manifold and the exhaust manifold.


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9. Important: A/C compressor and bracket removal is not necessary.

Remove the bolts and the valve rocker arm cover.

10. Clean all sealing surfaces. Refer to Valve Rocker Arm Cover Cleaning and

Inspection in Engine Mechanical - 4.3L .



1. Install the valve rocker arm cover and bolts. Refer to Valve Rocker Arm Cover

Installation .


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2. Notice: Use the correct fastener in the correct location. Replacement fasteners








Install the exhaust gas recirculation (EGR) valve inlet pipe into the intake and

exhaust manifolds.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m

(18 lb ft).

2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m

(22 lb ft).

3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).


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3. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement

in Engine Cooling.

4. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine

Cooling.

5. Install the PCV valve hose assembly to the valve rocker arm cover.

6. Connect the ECT gauge sensor.



Engine Controls.

8. Install the air cleaner outlet duct to the throttle body.

9. Connect the PCV tube to the air cleaner outlet duct,


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Valve Rocker Arm Cover Replacement -

Document ID: 195305

Removal Procedure


1. Remove the PCV tube from the air cleaner outlet duct and the valve rocker arm

cover.

2. Disconnect the spark plug wires from the spark plugs for the right side of the

engine. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



4. Unfasten the heater hose retainer above the valve rocker arm cover.

5. Move and secure the heater hoses aside.



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6. Remove the bolt holding the engine wiring harness bracket to the generator.

7. Disconnect the crankcase position (CKP) sensor electrical connector.

8. Move and secure the engine wiring harness aside.


9. Remove the bolts and the right valve rocker arm cover.

10. Clean all sealing surfaces. Refer to Valve Rocker Arm Cover Cleaning and

Inspection in Engine Mechanical - 4.3L .



1. Install the right valve rocker arm cover and bolts. Refer to Valve Rocker Arm

Cover Installation .


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2. Position the engine wiring harness.

3. Connect the CKP sensor electrical connector.









4. Install the engine wiring harness and bolt to the generator mounting bracket.

Tighten

Tighten the engine wiring harness bolt to 25 N-m (18 lb ft),

5. Position the heater hoses.

6. Install the heater hoses in the retainer above the valve rocker arm cover.




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8. Connect the spark plug wires to the spark plugs for the right side of the engine.

Refer to Spark Plug Wire Harness Replacement in Engine Electrical.

9. Install the PCV tube to the air cleaner outlet duct and the valve rocker arm

cover.

Valve Rocker Arm and Push Rod Replacement

Document ID: 194238

Removal Procedure


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1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover

Replacement in Engine Mechanical - 4.3L .

2. Remove the valve rocker arm nut, valve rocker arm with the valve rocker arm

ball . Refer to Valve Rocker Arm and Push Rod Removal in Engine Mechanical

- 4.3L .

3. Remove the valve pushrods.

4. Clean and inspect the valve rocker arms, valve rocker arm nuts, valve rocker

arm ball and the valve pushrods. Refer to Valve Rocker Arm and Push Rod

Cleaning and Inspection in Engine Mechanical - 4.3L



1. Install the valve pushrods.

2. Install the valve rocker arm nut, valve rocker arm with the valve rocker arm ball.

Refer to Valve Rocker Arm and Push Rod Installation in Engine Mechanical -

4.3L .

3. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover


Valve Stem Oil Seal and Valve Spring Replacement

Document ID: 195683

Removal Procedure

Tools Required


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J 22794 Spark Plug Port Adapter

J 38606 Valve Spring Compressor

J 5892-D Valve Spring Compressor


1. Remove the valve rocker arms. Refer to Valve Rocker Arm and Push Rod


2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.


3. Install the J 22794 into the spark plug hole.

4. Apply compressed air in order to hold the valves in place.

5. Install a valve rocker arm nut.


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6. Use the J 5892-D in order to compress the valve spring.


7. Notice: When using J 38606 ensure that the jaws are completely engaged on the

valve spring. If the jaws are not completely engaged the jaws may slip off and

scratch the valve spring. Replace the valve spring if the valve spring becomes

scratch.

Use J 38606 when J 5892-D will not fit.


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8. Remove the valve stem keys (1).

Carefully release the valve spring tension.

9. Remove the J 5892-D or the J 38606 .

10. Remove the valve spring cap (2) and the valve spring (3).

11. Remove the valve stem oil seal (4).


Tools Required

J 22794 Spark Plug Port Adapter

J 38606 Valve Spring Compressor

J 42073 Valve Stem Seal Installer

J 5892-D Valve Spring Compressor


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1. Important: The exhaust valve oil seal has the letters EX (1) molded into the top

of the seal. The seal material is brown in color (2) with a white stripe (3) painted

on the outside diameter of the seal or the material may be off-white in color (2)

with no paint stripe. The intake valve seal is black in color. The exhaust and

intake valve seals are not interchangeable.

Select the proper valve stem oil seal for the specific valve guide.

2. Lubricate the valve stem oil seal and the outside diameter of the valve guide

with clean engine oil.

3. Assemble the valve stem oil seal onto the valve guide using the J 42073 and a

hammer.

4. Install the valve stem oil seal onto the valve guide until the installation tool

bottoms against the valve spring seat.



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5. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed

against the valve guide.

There should be a 1 2 mm (0.03937 0.07874 in) gap between the bottom edge

of the seal and the valve guide.


6. Install the valve spring (3).

7. Install the valve spring cap (2) on the valve stem.

8. Compress the valve spring (3) using the J 5892-D


9. Notice: When using J 38606 ensure that the jaws are completely engaged on the

valve spring. If the jaws are not completely engaged the jaws may slip off and

scratch the valve spring. Replace the valve spring if the valve spring becomes

scratch.


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Use the J 38606 if the clearance does not permit use of J 5892-D .

Notice: Make sure that the valve stem keys are properly seated in the valve

spring cap. Engine damage could occur if not properly installed.

10. Install the valve stem keys.

Use grease in order to hold the valve stem keys in place.


11. Carefully release the valve spring pressure, making sure the valve stem keys stay

in place.

12. Remove the J 5892-D or the J 38606 and the J 22794 .



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13. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.

14. Install the valve rocker arms to the cylinder head.

Refer to Valve Rocker Arm and Push Rod Replacement in Engine Mechanical -

4.3L .

Valve Lifter Replacement

Document ID: 195687

Removal Procedure

Tools Required

J 3049-A Valve Lifter Remover


1. Remove the lower intake manifold. Refer to Intake Manifold Replacement in

Engine Mechanical - 4.3L .

2. Remove the valve pushrods and the valve rocker arms. Refer to Valve Rocker

Arm and Push Rod Replacement in Engine Mechanical - 4.3L .


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3. Remove the valve lifter pushrod guide and the bolts.


4. Remove the valve lifters from the engine block. Refer to Valve Lifter Removal .


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5. Use the J 3049-A in order to remove stuck valve lifters.



1. Important: It is normal for NEW lifters to make a slight ticking noise when the

engine is first started. Increasing the engine RPMs slightly to raise oil pressure

should stop the noise.

Install the valve lifters to the engine block. Refer to Valve Lifter Installation .


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2. Install the valve lifter pushrod guide. Refer to Valve Lifter Installation .


3. Install the valve pushrods and valve rocker arms. Refer to Valve Rocker Arm

and Push Rod Replacement in Engine Mechanical - 4.3L .


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4. Install the intake manifold. Refer to Intake Manifold Replacement in Engine

Mechanical - 4.3L .

Exhaust Manifold Replacement -

Document ID: 194018

Removal Procedure





in Engine Controls.


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4. Disconnect the engine coolant temperature (ECT) gauge sensor electrical

connector.

5. Remove the intermittent steering shaft.

o Refer to Lower Intermediate Steering Shaft Replacement in Steering

Wheel and Column - Standard.

o Refer to Lower Intermediate Steering Shaft Replacement in Steering

Wheel and Column - Tilt.

6. Disconnect the exhaust gas recirculation (EGR) valve inlet pipe from the

exhaust manifold.


7. Remove the radiator inlet hose support bracket and nut.

8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General

Information.


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9. Disconnect the exhaust pipe from the exhaust manifold. Refer to Exhaust

Manifold Pipe Replacement in Engine Exhaust.

10. Lower the vehicle to the proper height.

11. Remove the front tire to gain access to the rear exhaust manifold bolts. Wheel

Removal in Tire and Wheels.


12. Remove the fender wheelhouse extension.

13. Disconnect the spark plug wires from the spark plugs. Refer to Spark P

Manual Taller Blazer Ingles

Documents

Transcript of Manual Taller Blazer Ingles