PSI 8.8L Service

PSI 8.
8L PROPANE ENGINE SERVICE MANUAL
REVISION B
01/04/2016
This publication may not be reproduced without the written permission
of Power Solutions International (PSI).
At date of publication, all information included in this manual is
accurate to the best of our knowledge. PSI cannot be held responsible
for information that has changed after publication date.
Power Solutions International, Inc (PSI)

201 Mittel Drive
Wood Dale, IL 60191
USA
630-350-9400
Warning Summary
Never loosen fittings or vent propane. Escaping propane can cause frostbite and freezer
burns. Wear insulated PVC rubber gloves resistant to liquid propane, proper eye protection,
and thermal protected clothing when handling liquid propane systems.
DO NOT remove any valves, bulkheads or fittings from propane tank unless the propane tank
has been drained completely. Pressure inside a propane tank may push a bulkhead or valve
out with enough force to cause injury or death.
Keep all sources of ignition away from propane vehicles while fuel system is being serviced.
Even if the propane tank and system has been drained there may be still be flammable
vapors near the vehicle.
DO NOT disconnect any propane hoses unless they have been properly and completely
drained.
DO NOT vent or release propane indoors or near sewers, pits, or low lying areas. Propane
can accumulate in low spots, creating a fire hazard. Propane may also displace oxygen,
creating a suffocation hazard.
Always disconnect the battery before servicing the propane fuel system.
Before working on the fuel system, evacuate/drain/release the propane fuel pressure from the
LPEFI fuel lines. The fuel system contains liquid propane under pressure.
Propane is highly flammable. Purge LPG system outdoors and away from buildings. Failure
to comply may result in death or injury to personnel and damage to equipment.
Wear protective gloves and goggles to avoid freeze burns from liquid propane.
Valve springs are under tension. Always wear eye protection when removing and installing
valve springs. Failure to comply may result in injury to personnel.
Wear proper eye protection during disassembly and assembly. Failure to comply may result
in injury to personnel.
Wear approved safety glasses or face shield when cleaning components.
Failure to comply may result in injury to personnel.
Wear rubber gloves and protective clothing when cleaning components. Failure to comply
may result in injury to personnel.
Wear approved safety glasses or face shield when using compressed air.
Failure to comply may result in injury to personnel.
Wear approved safety glasses or face shield when using a wire carbon brush to clean
cylinder head ports. Failure to comply may result in injury to personnel.
Always wear protective clothing and proper eye protection when cleaning components.
Always wear proper eye protection when using compressed air.
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REVISION CONTROL INFORMATION
Revision Level Release Date Change Description (s)

A 10/30/2015 Initial release
Section 04 (Mech. Diagnosis) - Updated compression test procedure step 2
Section 07 (Fuel System) - Added image for #2 fuel injector position
Section 10 (Exhaust Manifold) - Added language to indicate technician should NOT
B 1/4/2016 reuse exhaust manifolds once removed
Section 36 (Starter) - Added Starter R&R
Section 38 (Winterization Kit)- Block heater is not reusable
Section 42 (Fuel Tank) Section Added
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TABLE OF CONTENTS
PREFACE ...........................................................................................................
WARNING SUMMARY........................................................................................................1
REVISION CONTROL INFORMATION ..............................................................................2
TABLE OF CONTENTS ......................................................................................................3
01 THEORY OF OPERATION AND ENGINE COMPONENTS ..............................

THEORY OF OPERATION ...............................................................................................09
ENGINE COMPONENTS VIEWS .....................................................................................11
02 ENGINE LUBRICATION ....................................................................................
LUBRICATION...................................................................................................................17
03 SPECIAL INSTRUCTIONS................................................................................
SAFETY INFORMATION ..................................................................................................20
DISASSEMBLY, CLEANING, AND MARKING .................................................................22
SEPARATING COMPONENTS.........................................................................................22
ENGINE GASKETS...........................................................................................................22
CLEANING GASKET SURFACES ....................................................................................23
SEALANT TYPES AND USES ..........................................................................................23
AEROBIC SEALANT RTV.................................................................................................23
ANAEROBIC GASKET SEALANT ....................................................................................24
ANAEROBIC THREADLOCK SEALANT ..........................................................................24
ANAEROBIC PIPE SEALANT...........................................................................................24
04 MECHANICAL DIAGNOSTIC PROCEDURES ..................................................

GENERAL INFORMATION ...............................................................................................26
STRATEGY BASED DIAGNOSTICS ................................................................................26
ENGINE COMPRESSION TEST.......................................................................................26
CYLINDER LEAKAGE TEST ............................................................................................27
OIL CONSUMPTION DIAGNOSIS....................................................................................28
OIL PRESSURE TEST AND DIAGNOSIS ........................................................................28
ENGINE FLUID LEAK DIAGNOSIS ..................................................................................29
CRANKCASE VENTILATION SYSTEM............................................................................29
DRIVE BELT NOISE DIAGNOSIS ....................................................................................30
05 FRONT ENGINE ACCESSORY DRIVE (FEAD)................................................

ENGINE BELT ROUTING .................................................................................................32
RIGHT-HAND PULLEY SYSTEM .....................................................................................33
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AIR COMPRESSOR PULLEYS ........................................................................................34
LEFT-HAND PULLEY SYSTEM........................................................................................35
06 ENGINE MOUNTS.............................................................................................
INSPECTION.....................................................................................................................37
FRONT ENGINE MOUNT REMOVAL ..............................................................................37
FRONT ENGINE MOUNT INSTALLATION ......................................................................38
REAR ENGINE MOUNT REMOVAL .................................................................................39
REAR ENGINE MOUNT INSTALLATION.........................................................................39
07 LPG FUEL SYSTEM SERVICE .........................................................................

FUEL RAIL REMOVAL .....................................................................................................41
FUEL INJECTOR REMOVAL............................................................................................43
FUEL INJECTOR INSTALLATION....................................................................................43
FUEL RAIL INSTALLATION..............................................................................................44
FUEL LINE FILL PROCEDURE ........................................................................................46
08 INTAKE MANIFOLD ..........................................................................................

PCV HOSE REMOVAL .....................................................................................................49
INTAKE MANIFOLD REMOVAL .......................................................................................50
MAP SENSOR REMOVAL ................................................................................................51
THROTTLE BODY REMOVAL..........................................................................................51
INTAKE MANIFOLD INSTALLATION ...............................................................................52
PCV HOSE INSTALLATION .............................................................................................54
THROTTLE BODY INSTALLATION..................................................................................55
MAP SENSOR INSTALLATION ........................................................................................56
09 VALVE COVERS ...............................................................................................

VALVE COVER REMOVAL...............................................................................................58
VALVE COVER INSTALLATION.......................................................................................58
10 EXHAUST MANIFOLD ......................................................................................

EXHAUST MANIFOLD REMOVAL ...................................................................................60
EXHAUST MANIFOLD INSTALLATION ...........................................................................60
11 OIL LEVEL INDICATOR TUBE..........................................................................

OIL LEVEL INDICATOR TUBE REMOVAL ......................................................................62
OIL LEVEL INDICATOR TUBE INSTALLATION ..............................................................62
12 VALVE TRAIN....................................................................................................
VALVE TRAIN REMOVAL.................................................................................................64
VALVE TRAIN INSTALLATION.........................................................................................64
13 VALVE LIFTERS................................................................................................
VALVE LIFTER REMOVAL ...............................................................................................66
VALVE LIFTER INSTALLATION.......................................................................................66
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14 CYLINDER HEADS ..........................................................................................
CYLINDER HEAD DISASSEMBLY ...................................................................................68
CYLINDER HEAD ASSEMBLY .........................................................................................70
15 CYLINDER HEAD INSPECTION .......................................................................

CLEANING ........................................................................................................................75
FLATNESS MEASUREMENT ...........................................................................................76
VALVE INSPECTION ........................................................................................................77
VALVE SPRING INSPECTION .........................................................................................78
VALVE GUIDE INSPECTION............................................................................................78
16 CRANKSHAFT BALANCER AND FRONT SEAL ..............................................

CRANKSHAFT BALANCER REMOVAL ...........................................................................80
CRANKSHAFT BALANCER INSTALLATION ...................................................................80
17 TIMING COVER, TIMING CHAIN, AND SPROCKETS .....................................

REMOVAL .........................................................................................................................84
INSTALLATION .................................................................................................................84
18 OIL PUMP DRIVE..............................................................................................

OIL PUMP DRIVE REMOVAL...........................................................................................87
OIL PUMP DRIVE INSTALLATION...................................................................................87
19 CAMSHAFT REMOVAL, CLEANING AND INSPECTION,

AND INSTALLATION........................................................................................
CAMSHAFT REMOVAL ....................................................................................................89
CAMSHAFT CLEANING AND INSPECTION....................................................................89
CAMSHAFT INSTALLATION ............................................................................................90
20 CAMSHAFT BEARING REPLACEMANT ..........................................................

CAMSHAFT BEARING REMOVAL ...................................................................................93
CAMSHAFT BEARING INSTALLATION...........................................................................94
21 OIL FILTER ADAPTER AND BYPASS VALVES ..............................................

OIL FILTER ADAPTOR AND BYPASS VALVES REMOVAL ...........................................96
OIL FILTER ADAPTOR AND BYPASS VALVES INSTALLATION ...................................96
22 OIL PAN.............................................................................................................
OIL PAN REMOVAL..........................................................................................................98
OIL PAN INSTALLATION..................................................................................................98
23 OIL PUMP..........................................................................................................
OIL PUMP REMOVAL.....................................................................................................100
OIL PUMP ASSEMBLY ...................................................................................................101
OIL PUMP INSTALLATION.............................................................................................102
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24 FLYWHEEL, TRANSMISSION ADAPTER AND REAR OIL SEAL ....................
REMOVAL .......................................................................................................................104
INSTALLATION ...............................................................................................................104
25 ENGINE OIL FILTER AND OIL REPLACEMENT ..............................................

OIL FILTER REMOVAL...................................................................................................108
OIL FILTER INSTALLATION...........................................................................................108
26 WATER PUMP...................................................................................................
WATER PUMP REMOVAL..............................................................................................111
WATER PUMP INSTALLATION......................................................................................111
27 WATER CROSSOVER AND THERMOSTAT ....................................................

WATER CROSSOVER AND THERMOSTAT REMOVAL ..............................................113
WATER CROSSOVER AND THERMOSTAT INSTALLATION ......................................114
28 CRANKSHAFT AND CRANKSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION ......................................................................
CRANKSHAFT POSITION SENSOR REMOVAL ...........................................................116
CRANKSHAFT REMOVAL..............................................................................................117
CRANKSHAFT INSTALLATION......................................................................................118
CRANKSHAFT POSITION SENSOR INSTALLATION ...................................................121
29 CRANKSHAFT CLEANING AND INSPECTION ................................................

CRANKSHAFT CLEANING.............................................................................................123
CRANKSHAFT INSPECTION .........................................................................................124
CHECKING MAIN BEARING CLEARANCE ...................................................................124
30 CYLINDER BLOCK CLEANING AND INSPECTION .........................................

BLOCK PLUG REMOVAL ...............................................................................................128
CYLINDER BLOCK CLEANING......................................................................................130
CYLINDER BLOCK INSPECTION ..................................................................................131
CYLINDER HONING .......................................................................................................132
BLOCK PLUG INSTALLATION .......................................................................................133
31 PISTON REMOVAL, CLEANING, INSPECTION, AND INSTALLATION ...........

PISTON AND CONNECTING ROD REMOVAL..............................................................137
PISTON AND CONNECTING ROD CLEANING.............................................................138
PISTON AND CONNECTING ROD INSPECTION .........................................................139
PISTON AND CONNECTING ROD ASSEMBLY............................................................142
PISTON AND CONNECTING ROD INSTALLATION......................................................144
32 AIR COMPRESSOR AND BRACKET................................................................

REMOVAL .......................................................................................................................148
INSTALLATION ...............................................................................................................148
HOSE AND FITTING INSTALLATION ............................................................................149
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33 POWER STEERING PUMP AND BRACKET ....................................................
REMOVAL .......................................................................................................................152
INSTALLATION ...............................................................................................................152
34 ALTERNATOR BRACKET .................................................................................

REMOVAL .......................................................................................................................154
INSTALLATION ...............................................................................................................154
35 OIL COOLER AND OIL COOLER HOSES ........................................................

OIL COOLER HOSE REMOVAL.....................................................................................156
OIL COOLER REMOVAL ................................................................................................156
OIL COOLER BRACKET REMOVAL ..............................................................................157
OIL COOLER BRACKET INSTALLATION......................................................................157
OIL COOLER INSTALLATION ........................................................................................158
OIL COOLER HOSE INSTALLATION.............................................................................158
36 STARTER MOTOR............................................................................................
REMOVAL .......................................................................................................................162
INSTALLATION ...............................................................................................................165
37 OIL PRESSURE SWITCH/SENSOR .................................................................

REMOVAL .......................................................................................................................169
INSTALLATION ...............................................................................................................169
38 WINTERIZATION KIT ........................................................................................

OIL HEATER REMOVAL.................................................................................................171
OIL HEATER INSTALLATION.........................................................................................171
BLOCK HEATER REMOVAL ..........................................................................................172
BLOCK HEATER INSTALLATION ..................................................................................172
39 TORQUE SPECIFICATIONS....................................................................... 174
40 MECHANICAL SPECIFICATIONS............................................................... 179
41 SPECIAL TOOLS LIST ................................................................................ 183
42 FUEL TANK AND FUEL FILL FILTER ......................................................... 188
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01 THEORY OF OPERATION AND ENGINE COMPONENTS
ENGINE COMPONENTS
CYLINDER BLOCK
The engine block is made of cast iron and it has eight cylinders arranged in a 90 degree V shape
with four cylinders in each bank. The engine block is a one piece casting with the cylinders
encircled by coolant jackets. The engine has four bolt main bearing caps. The engine is
equipped with one cooling jet per cylinder.
CRANKSHAFT
The 8.8L engine uses a forged crankshaft. The rear of the crankshaft has a 58x reluctor wheel pressed
on for crankshaft location sensing.
PISTONS AND CONNECTING RODS

The pistons are forged aluminum that use two compression rings and three piece oil control ring
assembly. The piston pins are a floating fit in the pistons and connecting rod. The pins are retained
by circlips on both sides of the piston. The connecting rods are forged steel.
CYLINDER HEADS
The cylinder heads are made of cast iron and have parent metal intake & exhaust valves. The intake
and exhaust seats are powdered metal. The water crossover pipe attaches to the front of each cylinder
head. The cylinder heads are ported to accepted fuel injectors.
CAMSHAFT
The camshaft is supported by five bearings pressed into the engine block. A camshaft sprocket is
mounted to the front of the camshaft and is driven by the crankshaft sprocket through a timing chain.
When camshaft is rotated, the valves are opened and closed by action of the camshaft lobes raising and
lowering hydraulic roller valve lifters. The roller valve lifters then raise valve push rods, and activate
truninon mounted rocker arms, which press the valves open. A spiral gear machined into the
camshaft near the rear journal drives a shaft assembly which operates the oil pump driveshaft
assembly.
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VALVE TRAIN
The valve train consists of valves, rocker arms, pushrods, and roller lifters. Valve train opening/closing
and duration, the lobe design of the camshaft controls the amount of air and fuel entering the combustion
chamber at any given point in time.
INTAKE MANIFOLD
The intake manifold a cast aluminum component. The throttle body is attached to the front of the intake
manifold. The fuel rails are retained on the intake manifold by two studs on each fuel rail. A Manifold
Absolute Pressure (MAP) sensor is mounted on top of the intake manifold and sealed by O-ring seal.
The MAP sensor is held in place with a retainer bolt. The positive crankcase ventilation (PCV) system
plugs into the top front portion of the manifold.
EXHAUST MANIFOLD
The two exhaust manifolds are installed per engine. The exhaust manifolds direct exhaust gases from the
combustion chambers to the downstream exhaust system.
BREATHER SYSTEM
The breather system is internally mounted under valley cover. Consists of fresh air make up and main
separators. There is no PCV valve with the PSI 8.8L propane engine, it is a fixed orifice in the valley
cover.
PROPANE FUEL SYSTEM

The propane fuel system consists of eight propane fuel injectors and two fuel rails. Four injectors are
installed on each fuel rail. A separate LPG fuel hose is connected to each fuel rail to supply liquid
propane to the injectors. The fuel supply hoses consist of an inner return hose and an outer liquid supply
hose.
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FIGURE 1. FRONT VIEW

1. Engine Control Module (ECM Chassis Mounted)
2. Throttle Body
3. Power Steering Pump
4. Air Compressor
5. Cam Position Sensor (CMP)
6. Oil Heater
7. Crankshaft Damper
8. Water Pump
9. Oil Dipstick and Tube
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FIGURE 2. REAR VIEW

1. Air Compressor
2. Left-Rear Lifting Eye
3. Manifold Absolute Pressure Sensor (MAP)
4. Right-Rear Lifting Eye
6. Engine Control Module (ECM Chassis Mounted)
7. Oil Cooler
8. Right Side Knock Sensor
9. Oil Heater
10. Flywheel
11. Left Side Knock Sensor
12. Crankshaft Position Sensor
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FIGURE 3. TOP VIEW
1. Fuel Rail
2. Oil Fill Cap
3. Right-Rear Engine Mount
5. Oil Cooler
6. Left-Rear Engine Mount
7. Fuel Rail
8. Ignition Coils
9. Air Compressor
11. Throttle Body
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FIGURE 4. LEFT VIEW
1. Air Compressor
2. Ignition Coils
3. Oil Cooler
5. Exhaust Manifold
6. Oil Pressure Sensor
7. Oil Filter
8. Cylinder Block Heater
9. Front Engine Mount
10. Water Pump
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FIGURE 5. RIGHT VIEW

1. Oil Cooler
3. Ignition Coils
4. Air Compressor
6. Starter Motor
7. Exhaust Manifold
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BLANK
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02 ENGINE LUBRICATION
LUBRICATION
Figure 1. Oil Flow
1. Oil Pump Drive

2. Oil Pressure Port
3. Oil Cooler Bypass Valve
4. Oil Filter Bypass Valve
5. Oil Flow to Oil Cooler
6. Oil Flow to Engine
7. Oil Flow to Oil Pump
A gear-type oil pump is driven by an extension driveshaft and an oil pump drive which is gear driven from
camshaft. Oil is drawn from oil pan through a pickup screen and tube, into oil pump (7). Pressurized oil
flows through oil filter, into oil cooler (5), back to engine (6), up to oil pressure port (2) and rear crankshaft
bearing, and is then distributed to upper oil galleries. Oil must flow around oil pump drive (1) in order to
reach right side valve lifters properly. Oil is delivered through internal passages to lubricate camshaft,
crankshaft bearings, and to provide lash control in hydraulic valve lifters. Oil is metered from valve lifters
through the valve push rods to lubricate valve rocker arms and ball pivots. Oil returning to oil pan from
cylinder heads and front camshaft bearing, lubricates camshaft timing chain, crankshaft, and camshaft
sprockets. There are two bypass valves located in cylinder block above oil filter. An oil filter bypass valve
(4) and an oil cooler bypass valve (3).
Figure 2. Oil Filter Bypass Valve
If oil filter becomes plugged, pressurized oil is diverted around top of oil filter. Oil filter bypass valve (1)
is forced open, allowing oil to continue on to oil cooler and engine oil passages. No oil filtration occurs
because oil is not allowed into the oil filter.
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Figure 3. Oil Cooler Bypass Valve
If oil cooler flow becomes blocked, either from a plugged oil cooler or a blocked or kinked oil cooler
line, then oil cooler bypass valve (1) is forced open, allowing oil to flow directly into engine oil
passages. Oil does not flow into or out of engine oil cooler.
Figure 4. Plugged Oil Cooler and Oil Filter

If both oil filter and oil cooler are plugged, pressurized oil is routed around top of the oil filter, through oil
filter bypass valve (2), through oil cooler bypass valve (1) and directly into engine oil passages. Lubrication
still occurs, but oil is not filtered or directed through oil cooler.
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BLANK
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03 SPECIAL INSTRUCTIONS
SAFETY INFORMATION
This manual provides general and specific maintenance procedures essential for reliable engine
operation and your safety. Since many variations in procedures, tools, and service parts are involved,
advice for all possible safety conditions and hazards cannot be stated.
Read safety instructions before performing any service and test procedures for the engine. See related
manuals for more information.
Obey Safety Instructions, WARNINGS, CAUTIONS, and NOTES in this manual. Failure to comply may
result in personal injury or death or damage to components or vehicle.
Safety Terminology
WARNING: A warning describes actions necessary to prevent or eliminate conditions, hazards,

and unsafe practices that may cause personal injury or death.
CAUTION: A caution describes actions necessary to prevent or eliminate conditions that may
cause damage to the engine or vehicle.
NOTE: A note describes actions necessary for correct and efficient engine operation.
Safety Instructions
Work Areas
Keep work area clean, dry, and organized.
Keep tools and parts off floor.
Ensure work area is well ventilated and well lit.
Ensure a First Aid Kit is available.
Safety Equipment
Use correct lifting devices.
Use safety blocks and jacks.
Protective Measures
Wear protective equipment such as shoes and eye protection.
Wear proper hearing protection.
Wear cotton work clothing.
Wear sleeved heat protective gloves.
DO NOT wear rings, watches, or other jewelry.
Restrain long hair.
Vehicle
Shift transmission to PARK or NEUTRAL, set parking brake, and block wheels before
performing diagnostic or service procedures.
Clear work area before starting engine.
Engine
Only a qualified individual should operate or service the engines.
Provide necessary ventilation when operating engine in enclosed areas.
Keep combustible material away from engine exhaust manifolds.
Install all shields and access covers before operating engine.
If an engine is not safe to operate, tag the engine and ignition key.
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Fire Prevention
Ensure proper rated and charged fire extinguishers are available in the work area.
Batteries
Always disconnect negative battery cable first.

Always connect negative battery cable last.
Avoid leaning over batteries.
Wear proper eye protection.
DO NOT expose batteries to spark or open flames.
DO NOT smoke near batteries.
Compressed Air
Use an OSHA approved blow gun. Limit blow gun air pressure to 30 psi (207 kPa).
Wear approve eye protection.
Wear approved hearing protection.
Use shielding to protect others in work area.
DO NOT direct compressed air at body or clothing.
Tools
Ensure all tools are in good condition.

Ensure all standard electrical tools are grounded.
Check power tools for frayed cords or damaged connectors.
Fluids Under Pressure
Use caution when working on systems under pressure.

Only follow approved procedures.
Removal of Tools, Parts, and Equipment
Ensure all tools, parts, and service equipment have been removed after servicing has
been completed
Reinstall all shields, safety guards, and cover after servicing has been completed
Propane Safety Instructions

WARNING
Never loosen fittings or vent propane. Escaping propane can cause frostbite and freezer
burns. Wear insulated PVC rubber gloves resistant to liquid propane, proper eye
protection, and thermal protected clothing when handling liquid propane systems.
DO NOT remove any valves, bulkheads or fittings from propane tank unless the propane
tank has been drained completely. Pressure inside a propane tank may push a bulkhead
or valve out with enough force to cause injury or death.
Keep all sources of ignition away from propane vehicles while fuel system is being
serviced. Even if the propane tank and system has been drained there may be still be
flammable vapors near the vehicle.
DO NOT disconnect any propane hoses unless they have been properly and completely
drained.
DO NOT vent or release propane indoors or near sewers, pits, or low lying areas.
Propane can accumulate in low spots, creating a fire hazard. Propane may also displace
oxygen, creating a suffocation hazard.
Always disconnect the battery before servicing the propane fuel system.
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DISASSEMBLY, CLEANING, AND MARKING

Throughout this section, it should be understood that proper cleaning and protection of machined
surfaces and friction areas is part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
When any internal engine parts are serviced, care and cleanliness is important.
When components are removed for service, they should be marked, organized or
retained in a specific order for reassembly.
At the time of installation, components should be installed in the same location and
with the same mating surface as when removed.
An automobile engine is a combination of many machined, honed, polished and
lapped surfaces with tolerances that are measured in millimeters or thousandths of an
inch. These surfaces should be covered or protected to avoid component damage.
A liberal coating of clean engine oil should be applied to friction areas during assembly.
Proper lubrication will protect and lubricate friction surfaces during initial operation.
SEPARATING COMPONENTS
Important: During use, many internal engine components will develop specific wear patterns on their
friction surfaces.
When disassembling the engine internal components MUST be separated, marked or

organized in a way to ensure reinstallation to original position.
Separate, mark, or organize the following components:
Piston to cylinder block bore

Piston rings to the piston
Connecting rod bearing caps to connecting rods
Crankshaft bearing caps to cylinder block
Roller valve lifters
Pushrods, pivot supports and rocker arms
Valve position to cylinder head
Valve spring and shim to the cylinder head location
ENGINE GASKETS
Use a rubber mallet in order to separate the components.
Bump the part sideways in order to loosen the components.
Bumping of the component should be done at bends or reinforced areas of the
component to prevent distortion of the components.
DO NOT reuse any gasket unless specified.
Gaskets that can be reused will be identified in the service procedure.
DO NOT apply sealant to any gasket or sealing surface unless specified in the service
procedure.
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CLEANING GASKET SURFACES
CAUTION
DO NOT use abrasive pads, sand paper, or power tools to clean the gasket surfaces.
These methods of cleaning can cause damage to the component sealing surfaces.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil.
This fine grit is an abrasive and can cause internal engine damage.
Use caution to avoid gouging or scraping the sealing surfaces. Use a plastic or wood scraper in order to
remove all the sealant from the components.
DO NOT use any other method or technique to remove the sealant or the gasket material from a part.
SEALANT TYPES AND USES
CAUTION
DO NOT apply sealant to any gasket or sealing surface unless specified in the service
procedure. Failure to comply may result in damage to components and engine leaks.
DO NOT interchange the sealants. Use only the sealant (or equivalent) as specified in the
service procedure.
The correct sealant and amount of sealant must be used in the proper location to
prevent oil leaks, coolant leaks, or the loosening of the fasteners.
The following two types of sealant are used on this engine:
Aerobic sealant cures when exposed to air and is called Room Temperature Vulcanizing
(RTV)
Anaerobic sealant cures in the absence of air and include the following types:
o Gasket eliminator
o Pipe
o Threadlock
AEROBIC SEALANT RTV
CAUTION
DO NOT use RTV sealant in areas where extreme temperatures are expected such as
exhaust manifolds and cylinder heads.
Always follow all the safety recommendations and the directions that are on the RTV
sealant container.
DO NOT allow the RTV sealant to enter any blind threaded holes, as it may prevent the
fasteners from clamping properly or cause damage when the fastener is tightened.
The surfaces to be sealed must be clean and dry.

Use a RTV sealant bead size as specified in the service procedure.
Apply the RTV sealant bead to the inside of any bolt holes areas.
Assemble the components while the RTV sealant is still wet to the touch
(within 3 minutes). DO NOT wait for the RTV sealant to skin over.
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ANAEROBIC GASKET SEALANT

CAUTION
Always follow all the safety recommendations and directions that are on the anaerobic
sealant container.
DO NOT allow the anaerobic sealant to enter any blind threaded holes, as it may prevent
the fasteners from clamping properly or cause damage when the fastener is tightened.
DO NOT use pipe sealant in areas where extreme temperatures are expected.
Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used
where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled
and no sealant or gasket is readily noticeable, then the 2 parts were probably assembled using an
anaerobic type gasket eliminator sealant.
Apply a continuous bead of gasket eliminator sealant to one flange.
Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket
eliminator sealant on the sealing surface.
Tighten the fasteners in sequence (if specified) and to the proper torque specifications.
DO NOT overtighten the fasteners.
After properly tightening the fasteners, remove the excess gasket eliminator sealant from
the outside of the joint.
ANAEROBIC THREADLOCK SEALANT

Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for
threadlocking and sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when confined
between 2 close fitting metal surfaces.
Always follow all safety recommendations and directions that are on the threadlock
sealant container.
All threaded surfaces to be sealed must be clean and dry.
Apply the threadlock sealant as specified on the thread lock sealant container.
ANAEROBIC PIPE SEALANT

Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type
of sealant is used where 2 parts are assembled together and require a leak proof joint.
Always follow all the safety recommendations and the directions that are on the pipe
sealant container.
Use a pipe sealant bead of the size or quantity as specified in the service procedure.
Apply a continuous bead of pipe sealant to 1 sealing surface.
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BLANK
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04 MECHANICAL DIAGNOSTIC PROCEDURES
GENERAL INFORMATION
Begin mechanical diagnosis by reviewing Theory of Operation and Engine Description.
This information will help you understand the engine operation. Refer STRATEGY BASED
DIAGNOSTICS to aid with identification correct procedures for diagnosing system
malfunctions.
STRATEGY BASED DIAGNOSTICS

All diagnostics of a vehicle should follow a logical process. Strategy Based Diagnostics is a
uniform approach for diagnosing and repairing engine system complaints. Diagnostic flow is
the place to start when a customer has come to you with a complaint.
The first step in Strategy Based Diagnosis is to verify the concern and perform a
visual/physical check;
Verify exact operating conditions under which customer concern exists. Note factors
such as engine RPM, ambient temperature, engine temperature, amount of engine
warm-up time, and other specifics that the customer reported.
Check for correct oil level, proper oil viscosity, and correct filter application.
Compare engine sounds, if applicable, to a known good engine and ensure you are
not trying to correct a normal condition.
Inspect easily accessible or visible system components for obvious damage or
conditions which could cause the symptom.
Use information acquired during checks above to determine area of engine or accessories
requiring further diagnostics.
ENGINE COMPRESSION TEST

1. Charge battery if not fully charged.
2. Disconnect ignition coil wire harness connector at each ignition coil.
3. Disconnect fuel injector electrical harness connectors at each fuel injector
4. Remove all eight spark plugs.
5. Block throttle plate wide open.
6. Install compression tester OTC5606 in first spark plug hole. Reference tool instruction document
4328343R1.
7. With compression gauge set to zero, crank engine four compression strokes and record gauge
reading.
8. Complete test on remaining cylinders. Be sure to record readings for each cylinder compression
test.
No cylinder should read less than 690 kPa (100 psi). Minimum compression in any one cylinder should not
be less than 70 percent of highest cylinder. For example, if highest pressure in a cylinder is
1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi).
(1035 x 70% = 725) (150 x 70% = 105).
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If any cylinders have readings less than 690 kPa (100 psi), add a tablespoon of oil to those cylinders
through spark plug hole and test compression again.
Normal Compression builds up quickly and evenly to the specified compression for each
cylinder.
Piston Rings Leaking Compression is low on the first stroke. Then compression builds up with
the following strokes but does not reach normal. Compression improves considerably when you
add oil.
Valves Leaking Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not
increase the compression, the cause may be a head gasket leaking between the two cylinders.
CYLINDER LEAKAGE TEST

Cylinder Leakdown Tester
1. Disconnect battery ground cable.

2. Remove all spark plugs.
3. Rotate crankshaft to place piston at Top Dead Center (TDC) for the cylinder being tested.
4. Install cylinder leakdown tester OTC5609. Reference tool instruction document 4328338R1.
5. Connect shop air pressure to leakdown tester and adjust pressure according to
manufacturers instructions.
6. Perform leak test and record readings.
Cylinder leakage exceeding 25% is considered excessive and may require component service.
In excessive leakage situations, inspect for the following conditions:
Air leakage sounds at throttle body or air inlet hose may indicate leaking intake valve.
Air leakage sounds at exhaust may indicate leaking exhaust valve.
Air leakage sounds at crankcase, oil level indicator tube, or oil fill tube may indicate worn piston
rings, damaged piston or scuffed cylinder walls.
Air bubbles in the cooling system may indicate damaged head gasket or cracked cylinder heads.
NOTE
Hold crankshaft balancer bolt to prevent crankshaft from rotating during test.
A cylinder leakage test may be performed to measure combustion chamber leakage. High combustion
chamber leakage may indicate one or more of the following:
Worn or burnt valves

Weak or broken valve springs
Stuck valve lifters
Worn or damaged pistons
Worn piston rings
Worn or scored cylinder bores
Damaged cylinder head gasket
Cracked or damaged cylinder head
Cracked or damaged cylinder block
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OIL CONSUMPTION DIAGNOSIS
Excessive oil consumption, not due to leaks, is defined as using more than 0.95 liter (1 quart) of engine
oil within 379 liters (100 gallons) of fuel used. However, during initial engine break-in periods,
5 0006 500 kilometers (3,0004,000 miles), oil consumption may exceed 1.9 liters (2 quarts) or more
per 379 liters (100 gallons) of fuel used.
The causes of excessive oil consumption include the following conditions:
1. Incorrect oil level or improper reading of oil level indicator. With vehicle on a level surface, allow
adequate drain down time and check for correct oil level.
2. Improper oil viscosity. Use only recommended API rated 5W30 oil.
3. Continuous operation in severe conditions.
4. Crankcase ventilation system restrictions. Perform CYLINDER LEAKAGE TEST.
5. Valve guides and/or valve stem oil seals worn, or seals omitted. Perform
CYLINDER LEAKAGE TEST.
6. Piston rings broken, improperly installed, worn, or not seated properly. Allow adequate time for
rings to seat. Perform CYLINDER LEAKAGE TEST.
7. Piston improperly installed or piston size incorrect. Perform CYLINDER LEAKAGE TEST.
OIL PRESSURE TEST AND DIAGNOSIS

With vehicle on level surface and engine shut off; allow adequate drain down time (23 minutes).
Measure engine oil level. If engine oil level is high, it may cause engine oil aeration.
If engine oil level is low, Fill crankcase to full mark with DEXOS rated 5W30 engine oil.
1. Operate engine and verify low or no oil pressure on gauge panel oil pressure gauge or oil
indicator light. Listen for a noisy valve train or knocking noise.
2. Remove oil pressure gauge sensor.
3. Install oil pressure test fitting 12-889-05, oil pressure manual gauge and measure engine oil
pressure.
OIL PRESSURE TABLE

1000 RPM 2000 RPM
Minimum Oil Pressure (Hot)
34.47 kPa (5 psi) 103.42 kPa (15 psi)
If engine oil pressure is below specifications, inspect engine for one or more of the following:
Oil pump worn or dirty
Plugged oil filter
Malfunctioning oil pump pressure relief valve
Oil pump screen loose, plugged, or damaged
Excessive bearing clearance or worn bearings
Cracked, porous or restricted oil galleries
Cylinder block oil gallery plugs incorrectly installed
Broken valve lifters
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ENGINE FLUID LEAK DIAGNOSIS
NOTE
You can repair most fluid leaks by first visually locating the fluid leak, repairing or
replacing components, or by resealing gasket surfaces. Identified and determine cause
of fluid leak. Repair cause of fluid leak as well as fluid leak itself.
ENGINE FLUID LEAK DIAGNOSTIC TABLE

STEP ACTION YES NO
1. Completely clean entire engine and surrounding components.
2. Operate vehicle for several kilometers (miles) at normal operating
temperature and at varying speeds.
1 3. Park vehicle on level surface, with engine over a large sheet of paper
or other clean surface and shut engine OFF.
4. Wait 15 minutes and check for drips under engine. Go to System
Can you find any drips or fluid leaks? Step 2 OK
1. Visually inspect suspected area. Use proper lighting and mirror as
necessary.
2. Check for leaks at the following locations;
Gaskets
2 Sealing surfaces
Hoses and fittings
Cracked or damaged components Go to Go to
Can you identify type of fluid and location of leak? Step 5 Step 3
Use a generic fluid leak detection kit for leaking fluid systems to identify and
3 pinpoint area of leakage. Refer to manufacturers instructions when using tool. Go to Go to
Have you located fluid leak? Step 5 Step 4
Inspect engine for mechanical damage. Special attention should be shown to
the following areas:
Plugged or malfunctioning crankcase ventilation system
Damaged or worn gaskets or seals
4 Damaged or worn sealing surfaces
Improper sealant or gasket installation
Damaged or porous components
Improperly tightened or damaged fasteners Go to Go to
Have you located fluid leak? Step 5 Step 1
Repair or replace all damaged or modified components. Refer to Engine
5 Repair Manual. Go to System
Does engine still leak fluids? Step 1 OK
CRANKCASE VENTILATION SYSTEM

A plugged positive crankcase ventilation (PCV) pipe/passage way may cause:
Rough idle
Slow idle speed and/or stalling
Oil leaks
Sludge build up in engine
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DRIVE BELT NOISE DIAGNOSIS
NOTE
Replacing drive belt(s) when they are not damaged or there is not excessive pilling will
only be a temporary repair.
A loose or improper installation of a body or suspension component or other items on the
vehicle may also cause noises which may be interpreted as drive belt noise.
Drive belt noise may be intermittent due to moisture on drive belts or drive pulleys. In order to duplicate
customers concerns, it may be necessary to spray a small amount of water onto drive belt(s). If spraying
water onto the drive belt(s) duplicates the symptom, cleaning accessory drive pulley(s) may be a
probable solution.
CAUTION
Running engine with drive belts removed may cause overheating. Do not run engine for
more than one minute with drive belts removed. Failure to comply may result in damage
to engine.
Diagnostic Trouble Codes (DTCs) may set while running engine with drive belts
removed. Clear codes after repairing belt noise.
Remove drive belts and run engine for a few seconds. If noise remains, then noise is most likely engine
related. If drive belt noise disappears, then noise is most likely coming from drive belts system
components. While drive belts are removed inspect the following:
1. Inspect drive belts for signs of pilling. Pilling are small balls, pills or strings in drive belt grooves
caused from accumulation of rubber dust. Clean pulley grooves with wire brush if grooves are
found to be contaminated.
2. Check for loose engine brackets, accessories, and fasteners for other sources of possible noise.
Repair engine brackets and accessories as necessary and tighten fasteners.
3. Inspect for damaged or bent pulleys. Repair or replace damaged pulleys.
4. Inspect air compressor, generator, power steering pump and air conditioner compressor for
proper operation. Repair or replace defective components.
5. Inspect belt tensioners including tensioner bearings and pulleys for proper tension, bearing
operation including seized bearings. A worn tensioner will allow drive belt to be loose. Repair or
replace defective parts.
6. Misalignment of drive belt pulley(s) may be caused by improper mounting or incorrect installation
of components. Test for misaligned pulley using a straight edge across grooves of two or three
pulleys. Repair or replace damaged or misaligned pulleys.
7. Inspect engine cooling fan for bent, twisted, loose, or cracked blades. Inspect fan clutch for
smooth operation. Inspect for a bent fan shaft or bent mounting flange. Repair or replace
components as necessary.
8. Inspect water pump drive shaft for being bent. Also inspect water pump bearings for smooth
operation and excessive play. Repair or replace components as necessary.
Clear any DTCs and run engine to verify repairs after inspection and repair of components.
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BLANK
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05 FRONT ENGINE ACCESSORY DRIVE (FEAD)
ENGINE BELT ROUTING
Figure 1. Right-Hand Belt Routing.
Right-hand belt runs over Alternator Pulley, under Idler Pulley, over Power Steering Pump, over Idler
Pulley, around Water Pump, around Crankshaft Pulley, over Tensioner Pulley and around Air Conditioner
(if equipped, if system has no A/C then Idler Pulley is used) then back to Alternator Pulley.
Figure 2. Left-Hand Belt Routing.
Left-hand belt runs over Air Compressor Pulley, behind Idler Pulley, over next Idler Pulley, around
Crankshaft Pulley, around Tensioner Pulley and back to Air Compressor Pulley.
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NOTE
For removal of crankshaft balancer, refer to 16 Crankshaft Balancer and Front Seal.
RIGHT-HAND PULLEY SYSTEM
Figure 3. Right-Hand
Pulley System
1. Alternator Bracket
2. 75mm Idler Pulley
3. Bolt, M10x1.25x60
4. Water Pump Pulley
5. Bolt, M8x1.25x16
6. Water Pump
7. Bolt, M10x1.25x55
8. Belt Tensioner
9. Washer
10. Bolt M10x1.5x60
11. 90mm Pulley
12. Bolt, M8x1.25x25
13. Bracket
DISASSEMBLY
1. Remove bolt (3) and 75mm idler pulley (2) from alternator bracket (1).
2. Remove four bolts (5) and water pump pulley (4) from water pump (6).
3. Remove bolt (7) and belt tensioner (8) from alternator bracket (1).
4. Remove bolt (10), washer (9), and 90mm pulley (11) from bracket (13).
5. Remove three bolts (12) and bracket (13) from alternator bracket (1)
ASSEMBLY
1. Apply blue Loctite to threads of three M8x1.25x25mm bolts (12).
2. Install bracket (13) on alternator bracket (1) with three M8x1.25x25mm bolts (12). Tighten
bolts (12) to 27 ft-lbs (37 Nm).
3. Apply blue Loctite to threads of M10x1.5x60mm bolt (10).
4. Install 90mm pulley (11) on bracket (13) with washer (9) and M10x1.5x60mm bolt (10). Tighten
bolt (10) to 53 ft-lbs (72 Nm).
6. Install belt tensioner (8) on alternator bracket (1) with M10x1.5x60mm bolt (7). Tighten bolt (7)
to 53 ft-lbs (72 Nm).
7. Install water pump pulley (4) on water pump (6) with four M8x1.25x16mm bolts (5) Tighten
bolts (5) to 18 ft-lbs (24 Nm).
8. Apply blue Loctite to threads of M10x1.25x60 bolt (3).
9. Install 75mm idler pulley (2) on alternator bracket (1) with M10x1.25x60 bolt (3). Tighten bolt (3)
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AIR COMPRESSOR PULLEYS
Figure 4. Air Compressor

Pulleys
1. Nut
2. Air Compressor Pulley
3. Air Compressor
4. Bracket
5. Pulley
6. Bolt, M10x1.5x70mm
7. Belt Tensioner
10. Washer
11. Pulley
12. Washer
DISASSEMBLY
1. Remove nut (1) and air compressor pulley (2) from air compressor (3).
2. Remove bolt (6) and idler pulley (5) from bracket (4).
3. Remove bolt (8) and belt tensioner (7) from bracket (4).
4. Remove bolt (9), washer (10), pulley (11), and washer (12) from bracket (4).
ASSEMBLY
1. Install washer (12), pulley (11), and washer (10) on bracket (4) with M10x1.5x70mm bolt (9).
Tighten bolt (9) to 53 ft-lbs (72 Nm).
2. Install belt tensioner (7) on bracket (4) with M10x1.5x60mm bolt (8). Tighten bolt (8) to
32 ft-lbs (43 Nm).
3. Install idler pulley (5) on bracket (4) with M10x1.5x70mm bolt (6). Tighten bolt (6) to
32 ft-lbs (43 Nm).
4. Install air compressor pulley (2) on air compressor (3) with nut (1). Tighten nut (1)
to 150 ft-lbs (200 Nm) plus torque to align pin, not to exceed 155 ft-lbs (210 Nm).
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LEFT-HAND PULLEY SYSTEM
Figure 5. Left-Hand Pulley System
1. Flange Nut, 1/2-20

2. Pulley, Power Steering, 90mm
4. Power Steering Pump Bracket
5. Pulley, 75mm
6. Bolt, M10x1.5x55
DISASSEMBLY
1. Using proper size wrench, hold 90mm power steering pulley (2) from rotating, and remove flange
nut (1) from power steering pump (3).
2. Remove power steering pulley (2) from power steering pump (3).
3. Remove bolt (6) and idler pulley (5) from power steering pump bracket (4)
ASSEMBLY
1. Apply blue Loctite to threads of M10x1.5x55 bolt (6).
2. Install 75mm idler pulley (5) on power steering pump bracket (4) with M10x1.5x55 bolt (6).
Tighten bolt (6)
3. Install 90mm power steering pump pulley (2) on power steering pump (3)
with 1/2-20 flange nut (1).
4. Using proper size wrench, hold power steering pulley (2) from rotating, and tighten flange nut (1)
For installation of crankshaft balancer, refer to 16 Crankshaft Balancer and Front Seal.
Install drive belts as necessary.
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BLANK
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06 ENGINE MOUNTS
INSPECTION
CAUTION
Broken or deteriorated engine mounts can cause misalignment and damage to
components. When an engine mount breaks, remaining mounts are subjected to
abnormally high stresses.
When raising or supporting engine, DO NOT raise or support engine under oil pan,
sheet metal, or crankshaft balancer. Failure to comply may cause damage to
components.
1. Measure engine movement between engine and engine mount to check or damaged or
weak rubber insulators.
a. Apply park brake

b. Open engine hood
c. Start engine
d. Firmly apply and hold primary brakes
e. Have an assistant stand to side of engine to observe engine movement
f. Place engine in DRIVE position and slightly load the engine. Place engine in REVERSE
position and slightly load engine.
g. Movement of engine more than 0.945 in. (24 mm) from at rest position indicates weak or
damaged engine mounts.
h. Check for damaged engine mounts and loose bolts
2. If engine mount bolt torque is within specifications, check rubber insulators for the following
conditions:
a. Split rubber insulators
b. Heat check cracks on rubber insulators
c. Separation of rubber insulators from motor mount brackets
3. Replace any motor mount that does not meet specifications or visual inspection.
FRONT ENGINE MOUNT REMOVAL
Figure 1. Battery Ground Cable
1. Battery
2. Battery Ground Cable
1. Disconnect battery ground cable (2) from battery (1).
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06 ENGINE MOUNTS
Figure 2. Front Engine Mount
1. Engine
2. Bolt, M12x1.75x50
CAUTION
sheet metal, or crankshaft balancer. Failure to comply may cause damage to
components.
2. Using suitable equipment, raise and support engine (1).

3. Remove four bolts (2) and front engine mount (3) from engine (1).
FRONT ENGINE MOUNT INSTALLATION

1. Install front engine mount (3) on engine (1) with four M12x1.75x50mm bolts (2).
2. Tighten bolts (2) to 70 ft-lbs (95 Nm).
1. Battery
3. Connect battery ground cable (2) to battery (1).
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06 ENGINE MOUNTS
REAR ENGINE MOUNT REMOVAL
1. Battery

CAUTION
sheet metal, or crankshaft balancer. Failure to comply may result in damage to
components.
2. Using suitable equipment, raise and support engine.
Figure 5. Rear Engine Mounts
1. Bracket
2. Bolt, M12x1.75x45
3. Left Engine Mount
4. Engine
5. Bolt, M12x1.75x45
6. Right Engine Mount
3. Left Engine Mount - Remove four bolts (2), bracket (1), and left engine mount (3)
from engine (4).
4. Right Engine Mount Remove four bolts (5) and right engine mount (6) from engine (4).
REAR ENGINE MOUNT INSTALLATION

1. Right Engine Mount Install right engine mount (6) on engine (4) with four M12x1.75x45mm
bolts (5).
3. Left Engine Mount Install left engine mount (3) and bracket (1) on engine (4) with four
M12x1.75x45mm bolts (2).
5. Connect battery ground cable (2) to battery (1).
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06 ENGINE MOUNTS
BLANK
40 of 195
07 LPG FUEL SYSTEM SERVICE
FUEL RAIL REMOVAL
WARNING
Before working on the fuel system, evacuate/drain/release the propane fuel pressure
from the LPG fuel lines. The fuel system contains liquid propane under pressure.
Propane is highly flammable. Purge LPG system outdoors and away from buildings.
Failure to comply may result in death or injury to personnel and damage to equipment.
Wear protective gloves and goggles to avoid freeze burns from liquid propane.
CAUTION
Use compressed air and blow gun, clear dirt and debris from around all eight injectors.
Failure to comply may result in damage to engine
NOTE
This procedure covers left and right fuel rail removal and injector service.
1. Battery

2. Remove dog house, if necessary.
15-127-02 Fuel Pressure

Gauge Testing Kit
Figure 2. Fuel Tank Schrader Valve
3. Schrader Valve
41 of 195
1. Remove cap from Schrader valve (3) located on the LPDM.

2. Using 15-127-02 Fuel Pressure Gauge Testing Kit, attach hose to Schrader valve (3) located on
the LPDM.
3. Purge LPG fuel system outdoors in a safe area away from buildings.
4. Remove P-clamp from fuel hose.
Figure 3. Fuel Rail Connection
1. Fuel Rail
2. Fuel Line Fitting
3. Fuel Hose
CAUTION
Fuel line O-rings are bonded to fuel lines. DO NOT attempt O-ring removal. Failure to
comply may result in damage to O-rings.
5. Disconnect fuel line fitting (2) from fuel rail (1) and remove fuel hose (3) from fuel rail (1).
Figure 4. Fuel Rail Removal
1. Fuel Injector
2. Nylon Locknut, M6x1.0
3. Fuel Rail
6. Disconnect fuel injector harness connectors from four fuel injectors (1).
7. Remove two nylon locknuts (2) and fuel rail (3) with four injectors (1) from cylinder head.
If necessary to remove remaining fuel rail, remove two nylon locknuts and remaining fuel rail.
NOTE
TO AID IN REMOVAL OF THE FUEL RAIL (3) TECHNICIAN SHOULD WIGGLE THE
COMPONENT BACK AND FORTH DURING REMOVAL.
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Figure 5. Fuel Injector
1. O-ring
2. Washer
3. Plastic Retaining Clip
4. O-ring
5. Washer
6. Fuel Injector
7. Fuel Rail
8. O-ring
LPG FUEL INJECTOR REMOVAL

NOTE
Injector O-rings are re-useable. However, they need a close visual inspection. Inspect for cuts,
damage, excessive wear, etc. If any issues are found with an O-ring then it must be replaced.
8. Remove plastic retaining clip (3), fuel injector (6), O-ring (2), washer (1), O-ring (4), and washer
(5) from fuel rail (7). O-rings (2 and 4). O-ring (8).
LPG FUEL INJECTOR INSTALLATION
NOTES
Apply clean motor to O-rings (2, 4, and 8) prior to installation.
CYLINDER #2 FUEL INJECTOR requires the electrical connector to face the Intake
Manifold. All other fuel injector electrical connectors are facing the valve cover. See
image below.
1. Install O-ring (8) on fuel injector (6).

2. Install washer (1) and O-ring (2) in fuel rail (7).
3. Install washer (5) and O-ring (4) on fuel injector (6).
4. Install fuel injector (6) in fuel rail (7) and secure with plastic retaining clip (3).
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FUEL RAIL TO FUEL LINE CONNECTION
1. Fuel Rail
3. Fuel Hose
NOTE
Lubricate fuel line O-rings with Parker Super O Lube or clean motor oil prior to
connection of fuel lines.
Connect fuel line to fuel rail by turning the fuel rail onto the line prior to installing
fuel rail onto the engine.
1. Connect fuel line (3) to fuel rail (1) by turning the fuel rail (1) onto the fuel line fitting (2).
LPG FUEL RAIL INSTALLATION

CAUTION
Ensure fuel injector ports on intake manifold are clean and free of debris. Failure to
comply may result in dirt and debris entering intake manifold ports.
2. Align four fuel injectors (1) with fuel injector ports and install fuel rail (3) with fuel injectors (1) in
fuel injector ports.
3. Align fuel rail mounting tabs on intake manifold studs and secure with two M6x1.0 nylon
locknuts (2). Tighten M6x1.0 nylon locknuts (2) to 85 in-lbs (10 Nm).
Figure 7. Fuel Rail Installation
1. Fuel Injector
2. Nylon Locknut, M6x1.0
3. Fuel Rail
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1. Fuel Rail
3. Fuel Hose
CAUTION
Ensure crows foot is at right angle to torque wrench to ensure accurate tightening torque.
Failure to comply may result in damage to equipment.
4. With crows foot at right angles to in-lbs torque wrench, tighten fuel line fitting (2)
to 66 in-lbs (7 Nm).
5. Install P-clamp on fuel hose (3).
6. Connect fuel injector harness to fuel injectors.
7. Install dog house, if removed.
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LPG FUEL LINE FILL PROCEDURE

15-127-02 Fuel Pressure
Gauge Testing Kit
1. Battery
8. Connect battery ground cable (2) to battery (1)
NOTE
Monitor fuel pressure gauge. When fuel line pressure stabilizes, the LPG fuel lines
should be filled.
For LPG fuel line fill, use the following procedure:
9. KEY ON 10 SECONDS, KEY OFF 10 SECONDS. It may take ten to twenty key cycles
to fill the LPG fuel line from empty.
Monitor fuel pressure gauge during this process. When the pressure on the gauge stabilizes
it indicates the fuel lines are filled.
When performing a key on cycle, you will notice the gauge pressure increase 55-65psi, this is
called boost pressure created by the booster pump.
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Figure 10. Fuel Tank Schrader Valve
3. Schrader Valve
10. Disconnect 15-127-02 Fuel Pressure Tester Gauge Kit hose from schrader valve (3).
11. Install cap on schrader valve (3).
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BLANK
48 of 195
08 INTAKE MANIFOLD
Figure 1. Front PCV Hose
1. PCV Hose
2. Clamp
3. Vent Pipe
4. Vent Pipe (REMOVABLE
ORFICE INTERNALLY)
5. Clamp
PCV HOSE REMOVAL

1. Loosen clamps (2 and 5) on PCV hose (1).
2. Remove PCV hose (1) from vent pipes (3 and 4).
Figure 2. Rear PCV Hose

1. PCV Hose
2. Bolt, M6x1.0x15
3. P-Clamp
4. Bracket
5. Vent Pipe
6. PCV Quick-Disconnect
3. Loosen quick-disconnect fitting (6) and remove PCV hose (3) from vent pipe (5).
4. Remove bolt (2), P-clamp (3), and PCV hose (1) from bracket (4).
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08 INTAKE MANIFOLD
Figure 3. Intake Manifold Removal
1. Intake Manifold
3. Vent Pipe
4. Cylinder Block
5. Cylinder Head
6. Intake Manifold Gasket
7. Orifice
8. Bolt, M6x1.0x16
9. Valley Cover
INTAKE MANIFOLD REMOVAL

1. Remove ten bolts (2) and intake manifold (1) from engine (5).
2. Remove fourteen bolts (8) and valley cover (9) from two cylinder heads (5) and
cylinder block (4).
3. Remove two intake manifold gaskets (6) from cylinder heads (5). Discard intake manifold
gaskets (6).
NOTE: LOWER PANEL (1) ON INTAKE IS NOT SERVICABLE.

DO NOT REMOVE THE PANEL ON THE LOWER PORTION OF
THE PANEL
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08 INTAKE MANIFOLD
Figure 5. MAP Sensor Removal
1. Bolt, M6x1.0x16
2. Washer
3. MAP Sensor
4. Intake Manifold
MAP SENSOR REMOVAL

Remove bolt (1), washer (2), and MAP sensor (4) from intake manifold (4).
Figure 6. Throttle Body Removal
1. Throttle Body
2. Throttle Body Gasket
3. Intake Manifold
4. Washer
5. Bolt, M6x1.0x45
THROTTLE BODY REMOVAL

Remove four bolts (5), washers (4), throttle body (1), and gasket (2) from intake manifold (3).
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08 INTAKE MANIFOLD
Figure 7. Valley Cover Installation
1. Intake Manifold
3. Vent Pipe
4. Cylinder Block
5. Cylinder Head
7. Orifice
8. Bolt, M6x1.0x16
9. Valley Cover
INTAKE MANIFOLD INSTALLATION

1. Install orifice (7) in vent tube of valley cover (9).
2. Apply a silicone gasket sealant such as Permatex Ultra Grey RTV silicone or equivalent across
ends of cylinder block (4) from cylinder head-to-
cylinder head (5).
3. Install two new intake manifold gaskets (6) on cylinder heads (5) over dowel pins.
4. Apply Permatex sealant to lower corners of intake manifold gaskets (6) where they contact the
cylinder block (4).
5. Install valley cover (9) on two cylinder heads (5) and cylinder block (4).
6. Apply blue Loctite to threads of fourteen M6x1.0x16mm bolts (8)
7. Secure valley cover (9) to cylinder heads (5) and cylinder block (4) with fourteen M6x1.0x16mm
bolts (8). Finger-tighten bolts (8).
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08 INTAKE MANIFOLD
Figure 8. Valley Cover Torque Sequence
8. Following torque sequence above, Tighten fourteen bolts (10) in two stages:
Stage 1. 54 in-lbs (6.1 Nm)
Stage 2. 106 in-lbs (12 Nm)
Figure 9. Intake Manifold Installation
1. Intake Manifold
3. Vent Pipe
4. Cylinder Block
5. Cylinder Head
7. Orifice
8. Bolt, M6x1.0x16
9. Valley Cover
9. Apply blue Loctite to threads of ten M6x1.0x75mm bolts (2).

10. Install intake manifold (1) on cylinder heads (6) with ten M6x1.0x75mm
bolts (2). Finger-tighten bolts (2).
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08 INTAKE MANIFOLD
Figure 10. Intake Manifold Torque Sequence
11. Following torque sequence above, tighten ten bolts (2) by steps:
a. Step 1, 40 in-lbs (4.5 Nm)
b. Step 2, 80 in-lbs (9 Nm)
c. Step 3, 120 in-lbs (13.5 Nm)
d. Step 4, 153 in-lbs (17 Nm) - - REPEAT THIS STEP FOUR TIMES
Figure 11. Front PCV Hose
1. PCV Hose
2. Clamp
3. Vent Pipe
4. Vent Pipe
5. Clamp
PCV HOSES INSTALLATION

12. Install PCV hose (1) on two vent pipes (3 and 4) with two clamps (2 and 5).
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08 INTAKE MANIFOLD
Figure 12. Rear PCV Hose

1. PCV Hose
2. Bolt, M6x1.0x15
3. P-Clamp
4. Bracket
5. Vent Pipe
6. PCV Quick-Disconnect
13. Install PCV hose (1) on vent pipe (5), ensure quick disconnect fitting (6) is fully seated.
14. Install PCV hose (1) on bracket (4) with P-clamp (3) and M6x1.0x15 bolt (2).
Figure 13. Throttle Body Installation
1. Throttle Body
2. Throttle Body Gasket
3. Intake Manifold
4. Washer
5. Bolt, M6x1.0x45
THROTTLE BODY INSTALLATION

Install new gasket (2) and throttle body (1) on intake manifold (3) with four washers (4) and
M6x1.0x45mm bolts (5). Tighten bolts (5) to 106 in-lbs (12 Nm).
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08 INTAKE MANIFOLD
Figure 14. MAP Sensor Removal
1. Bolt, M6x1.0x16
2. Washer
3. MAP Sensor
4. Intake Manifold
MAP SENSOR INSTALLATION

Install MAP sensor (3) on intake manifold (4) with washer (2), and M6x1.0x16mm bolt (1).
Tighten bolt (1) to 106 in-lbs (12 Nm).
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08 INTAKE MANIFOLD
BLANK
57 of 195
09 VALVE COVERS
Figure 1. Valve Cover
1. Bolt, M6x1.0x25
2. Ignition Coil
3. Grommet
4. Bolt, M6x1.0x24
5. Valve Cover
6. Valve Cover Gasket
7. Cylinder Head
NOTE
This procedure describes left valve cover removal. Right valve cover
removal is similar.
Perform Step 1, if necessary to remove ignition coils.
VALVE COVER REMOVAL

1. Remove four bolts (1) and two ignition coils (2) from valve cover (5).
2. Remove seven bolts (4), grommets (3) and valve cover (5) from cylinder head (7).
3. Remove gasket (6) from valve cover (5). Discard gasket (6) and grommets (3).
VALVE COVER INSTALLATION

1. Install new gasket (6) on valve cover (5).
2. Install seven new grommets (3) on valve cover (5).
3. Install valve cover (5) on cylinder head (7) with seven M6x1.0x24mm bolts (4). Tighten
bolts (4) to 106 in-lbs (12 Nm).
NOTE
Valve cover with oil fill opening installs on right side of engine.
Valve cover without oil fill opening installs on left side of engine.
Perform Step 3, if ignition coils have been removed.
4. Install two ignition coils (2) on valve cover (5) with four M6x1.0x25mm bolts (1). Tighten bolts (4)
to 106 in-lbs (12 Nm).
NOTE: THE MANUFACTURE OF RECORD (MOR) LABEL IS SELF DESTRUCTIVE AND WILL REQUIRE REPLACEMENT IF
THE VALVE COVER IS REPLACED. CONTACT YOUR PARTS PERSONAL FOR INSTRUCTIONS ON ORDERING A
REPLACEMENT MOR LABEL
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09 VALVE COVERS
BLANK
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10 EXHAUST MANIFOLDS
Figure 1, Exhaust Manifold
1. Cylinder Head
2. Exhaust Manifold Gasket
3. Exhaust Manifold
4. Washer
5. Bolt, M8x1.25
NOTE
DO NOT ATTEMPT TO REUSE EXHAUST MANIFOLD
Due to distortion during heat cycling the exhaust manifold should be replaced
with a new exhaust manifold after it is removed from the cylinder head
This procedure describes left exhaust manifold, for right side see Dipstick Service
Procedure.
EXHAUST MANIFOLD REMOVAL

1. Remove eight bolts (5), washers (4), exhaust manifold (3) and exhaust gasket (2) from
cylinder head (1). Discard gasket (2).
EXHAUST MANIFOLD INSTALLATION

NOTE
While viewing exhaust gasket from left-to-right, with port 1 at your left, bend
tab on exhaust gasket between 3rd and 4th exhaust ports prior to assembly.
1. Install new exhaust gasket (2) (bend tab as described in NOTE above) and NEW
exhaust manifold (3) on cylinder head (1) using eight washers (4) and M8x1.25 bolts (5).
2. Install two bolts (5) a few threads, leaving manifold adjustable.
3. Line up and install the remaining bolts (5).
4. Torque all bolts to 22 ft.-lbs (30 Nm).
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10 EXHAUST MANIFOLDS
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11 ENGINE OIL DIPSTICK TUBE
Figure 1. Engine Oil Dipstick Tube
1. Exhaust Manifold
2. Bolt, M10x1.5x15
3. Bracket
4. Engine Oil Dipstick Tube
5. Engine Oil Dipstick
6. Grommet
ENGINE OIL DIPSTICK TUBE REMOVAL

1. Remove engine oil dipstick (5) from engine oil dipstick tube (4).
2. Remove bolt (2) from bracket (3).
3. Loosen manifold bolts enough to allow removal of indicator tube (4) from behind exhaust
manifold (1)
NOTE: Do not remove manifold bolts completely
4. Remove grommet (6) from oil pan. Discard grommet (6).
ENGINE OIL DIPSTICK TUBE INSTALLATION

1. Apply 5W30 motor oil to new grommet (6) and install grommet (6) on oil dipstick tube (4).
2. Install engine oil dipstick tube (4) through center space of exhaust manifold (1).
3. Torque exhaust manifold bolts. 22 ft-lbs (30 Nm)
4. Install oil dipstick tube (4) into the oil pan, line up bracket (3) on cylinder head, install
M10x1.5x15mm bolt (2). Torque bolts (2) to 30 ft-lbs (41 Nm).
5. Install engine oil dipstick (5) in engine oil dipstick tube (4).
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11 ENGINE OIL DIPSTICK TUBE
BLANK
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12 VALVE TRAIN
Figure 1. Valve Train
1. Cylinder Head
2. Intake Push Rod
3. Rocker Arm
4. Bolt,
5. Bolt,
6. Exhaust Push Rod
7. Rocker Arm
NOTE
Remove valve cover. Refer to 09 Valve Covers.
Remove intake manifold. Refer to 08 Intake Manifold.
Intake and Exhaust push rods are different sizes.
Mark and organize push rods and rocker arms so they may
be installed in their original positions.
VALVE TRAIN REMOVAL

1. Remove eight rocker arm bolts (4 and 5) and eight rocker arms (3 and 7) from cylinder head (1).
2. Remove four intake pushrods (2) and four exhaust push rods (6) from cylinder head (1).
VALVE TRAIN INSTALLATION

1. Apply 5W30 motor oil to the ends of four intake push rods (2) and four exhaust push rods (6).
2. Install four intake push rods (2) and four exhaust push rods (6) in their original positions, through
cylinder head (1) and on valve lifters.
3. Apply 5W30 motor oil to eight rocker arms (3 and 7) and on threads of eight rocker arm
bolts (4 and 5).
4. Install eight rocker arms (3 and 7) on cylinder head (1) and push rods (2 and 6) with eight rocker
arm bolts (4 and 5). Tighten bolts (4 and 5) to 22 ft-lbs (30 Nm).
Install intake manifold. Refer to 08 Intake Manifold.

Install valve cover. Refer to 09 Valve Covers.
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12 VALVE TRAIN
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13 VALVE LIFTERS
Figure 1. Valve Lifters
1. Lifter Retainer
2. Bolt, M8x1.25x16
3. Lifter retainer Tab
4. Valve Lifter Guide
5. Valve Lifter
6. Cylinder Block
NOTE
Remove valve train. Refer to 12 Valve Train.
Mark and organize valve lifters so they may be installed in
their original positions.
VALVE LIFTER REMOVAL

1. Remove four bolts (2) and lifter retainer (1) from cylinder block (5).
2. Remove eight lifter guides (4) and sixteen valve lifters (5) from cylinder block (6).
VALVE LIFTER INSTALLATION

CAUTION
Oil port on valve lifters must face front of engine. Failure to comply
may result in damage to engine.
Apply clean 5W30 motor oil to each lifter prior to assembly.
1. Install sixteen valve lifters (5) into their original positions in cylinder block (6). Ensure oil ports
face front of engine block (6).
2. Install eight lifter guides (4) on sixteen lifters (5).
3. Apply blue Loctite to threads of four M8x1.25x16mm bolts (2).
4. Install lifter retainer (1) on cylinder block (6) with four M8x1.25x16mm bolts (2). Finger tighten
bolts (4).
5. Ensure tabs (3) of lifter retainer (1) are centered on eight lifter guides (4). Tighten
M8x1.25x16mm bolts (2) to 22 in-lbs (2.5 Nm).
NOTE
Install valve train. Refer to 12 Valve Train.
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13 VALVE LIFTERS
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14 CYLINDER HEADS
Figure 1, Cylinder Head Bolts
1. Cylinder Head
2. Bolt, M10-1.5x86
3. Bolt, M10-1.5x103
4. Bolt, M10-1.5x52
NOTE
Remove exhaust manifold. Refer to 10 Exhaust Manifold.
Remove valve train. Refer to 12 Valve Train.
Mark and organize valve lifters so they may be installed in
their original positions.
CYLINDER HEAD DISASSEMBLY

1. Remove twelve M10-1.5x103 bolts (3), two M10-1.5x86 bolts (2) and four M10-1.5x52 bolts (4)
from cylinder head (1). Discard bolts (2, 3, and 4).
Figure 2. Cylinder Head Removal
1. Cylinder Head
2. Cylinder Head Gasket
3. Cylinder Block
2. Using suitable lifting device, remove cylinder head (1) and cylinder head gasket (2) from
cylinder block (3). Discard cylinder head gasket (2).
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14 CYLINDER HEADS
Figure 3. Valve Removal
1. Cylinder Head
2. Valve Stem Seal
3. Spacer
4. Valve Spring
5. Keeper
6. Cap
WARNING
Valve springs are under tension. Always wear eye protection
when removing and installing valve springs. Failure to comply may result in injury to
personnel.
Wear proper eye protection during disassembly and assembly. Failure to comply may
result in injury to personnel.
NOTE
Place valves in a rack to ensure valves are replaced in original
location during assembly.
3. Using valve spring compressor, compress valve spring (4) and remove two keepers (5).
4. Slowly release tension on valve spring compressor and remove cap (6) and valve spring (4) from
cylinder head (1).
5. Remove valve (7), valve stem seal (2), and spacer (3) from cylinder head (1). Discard valve
stem seal (2).
6. Repeat steps 3 through 5 for remaining valves.
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14 CYLINDER HEADS
Figure 4. Valve Installation
1. Cylinder Head
2. Valve Stem Seal
3. Spacer
4. Valve Spring
5. Keeper
6. Cap
7. Valve
CYLINDER HEAD ASSEMBLY
WARNING
Valve springs are under tension. Always wear eye protection when removing and installing
valve springs. Failure to comply may result in injury to personnel.
Wear proper eye protection during disassembly and assembly. Failure to comply may result
in injury to personnel.
NOTE
Coat eight valve stem seals with 5W30 motor oil prior to assembly.
Install valves in same locations as noted during disassembly
1. Install spacer (3) on cylinder head (1).

2. Using valve stem seal installer, install new valve stem seal (2) on cylinder head (1).
3. Apply 5W30 motor oil to stem of valve (7) and install valve (7) in cylinder head (1).
4. Install valve spring (4) and cap (6) over valve (7).
5. Using valve spring compressor on valve spring (4) and compress valve spring until groove on
valve (4) is clear of cap (6).
6. Install two valve keepers (5) in groove of valve (7).
7. Slowly release valve spring compressor while ensuring valve keepers (5) are seated in groove of
valve (7).
8. Perform steps 1 through 7 for remaining valve assemblies.
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14 CYLINDER HEADS
Figure 5. Core Plug Installation
1. Core Plug
2. Core Plug Bore
9. Apply Loctite 540 retaining compound on new cylinder head core plug and cylinder head core
plug bore.
NOTE
Ensure there is no debris that could impair sealing on the cylinder head plug bore.
10. Install new cylinder core plug into the cylinder head.
Figure 6. Cylinder Head

Installation
1. Cylinder Head
2. Cylinder Head Gasket
3. Cylinder Block
NOTE
Refer to, 15 Cylinder Head Inspection, for cleaning and inspection information.
Clean gasket surfaces of cylinder head and cylinder block, then wipe dry with alcohol.
11. Align head gasket locating marks to face up position.

12. Install new head gasket (2) over locating studs and on cylinder block (3)
13. Install cylinder head (1) on cylinder block (3).
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14 CYLINDER HEADS
Figure 7, Cylinder Head Bolts
1. Cylinder Head
2. Bolt, M10-1.5x86
3. Bolt, M10-1.5x103
4. Bolt, M10-1.5x52
CAUTION
Do not reuse cylinder head bolts. The cylinder head bolts are torque-to-yield bolts and cannot be reused
once the initial torque is applied. A stretched cylinder head bolt may break stretch or break during use.
Failure to comply may result in damage to engine or components.
14. Apply white Permatex thread sealant to threads and undercap of head bolts (2, 3, and 4).
15. Secure cylinder head (1) to cylinder block with twelve M10-1.5x103 bolts (3),
two M10-1.5x86 bolts (2) and four M10-1.5x52 bolts (4). Finger -tighten bolts.
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14 CYLINDER HEADS
Figure 8. Cylinder Head Bolt Torque Sequence
NOTE
The twelve long bolts (M10x1.5x103mm) are used in locations 1, 2, 3, 6, 7, 8, 9,
10, 11, 14, 16, and 17.
The two medium length bolts (M10x1.5x86) are used in locations 15 and 18.
The four short bolts (M10x1.5x52 are used in locations 4, 5, 12, and 13.
16. Following torque sequence shown above, tighten all cylinder head bolts to 22 ft.-lbs (30 Nm).
17. Using 108407 Torque Angle Meter and following torque sequence in above, tighten all cylinder
head bolts +120 degrees.
18. Using 108407 Torque Angle Meter and following torque sequence shown above:
Tighten four M10x1.5x52mm bolts +30 degrees
Tighten two M10x1.5x86mm bolts +45 degrees
Tighten twelve M10x1.5x103mm bolts +60 degrees
NOTE
Install valve train. Refer to 12 Valve Train.
Install exhaust manifold. Refer to 10 Exhaust Manifolds.
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14 CYLINDER HEADS
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15 CYLINDER HEAD INSPECTION
Figure 1. Valve Inspection
1. Keepers
2. Retainer
3. Valve Spring
4. Spring Seat Washer
5. Valve Groove
6. Valve Stem
7. Valve Head
CLEANING
WARNING
Wear approved safety glasses or face shield when cleaning components.
Failure to comply may result in personal injury.
Wear rubber gloves and protective clothing when cleaning components. Failure to
comply may result in personal injury.
NOTE
Mark, sort, or organize parts for return to their original positions.
1. Clean valve stems (6) and valve heads (7) free of debris. Ensure valve groove is
clean of debris.
2. Clean the following components in solvent:
a. Keepers
b. Retainers
c. Valve springs
d. Spring seat washers
e. Valves
f. Cylinder heads
WARNING
Wear approved safety glasses or face shield when using compressed air.
Failure to comply may result in personal injury.
3. Dry components with compressed air.
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CLEANING (CONTINUED)
WARNING
Wear approved safety glasses or face shield when using a wire carbon brush to clean
cylinder head ports. Failure to comply may result in injury to personnel.
CAUTION
Use care not to damage valve chambers and valve seats when cleaning cylinder
head ports.
Figure 2. Carbon Brush Cleaning Figure 3. Cylinder Head Warpage Check
Using a wire carbon brush, clean carbon from cylinder head ports.
Inspect cylinder head for the following conditions:

a. Damaged gasket surfaces
b. Damage to threaded bolts holes
c. Burnt or eroded areas in the combustion chambers
d. Cracks in the intake and exhaust ports and combustion chambers
e. External cracks in the water chambers
f. Restrictions in the intake and exhaust passages
g. Restrictions in the cooling system passages
FLATNESS MEASURMENT
1. Measure cylinder head surface for warping using a straight edge and feeler gauge.
Measure cylinder head block deck warp and record measurement. Warpage in excess
of 0.002 in. (0.050 mm) within a 6 in. (150 mm) area must be repaired or replaced.
Measure cylinder head exhaust deck warp and record measurement. Warpage in
excess of 0.004 in. (0.102 mm) must be repaired or replaced.
Measure cylinder head intake deck warpage and record measurement. Warpage in
excess of 0.012 in. (0.305 mm) must be repaired or replaced.
2. Cylinder head block decks may be resurfaced to a maximum removal
of 0.012 in. (0.305 mm).
CAUTION
Excessive cylinder head resurfacing will affect compression ratio and emission control.
3. A cylinder head that requires excessive resurfacing must be replaced.
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Figure 4. Valve Inspection
1. Burnt Valve Head

2. Undersize Valve Head
3. Bent Stem
4. Scoring or Damaged Stem
5. Worn Key Groove
Worn Stem Tip
VALVE INSPECTION
NOTE
Minor imperfections of valves may be corrected during reconditioning. Valves with
excessive damage must be replaced.
1. Inspect valves for the following conditions:

a. Burnt or damaged areas
b. Undersized valve margin
c. Bent stem
d. Scoring or other damage to stem
e. Worn key groove
f. Worn stem tip
Figure 5. Valve Face
1. Undersized Margin
2. Pitted Surface
3. Burnt or Eroded areas
4. Acceptable Edge, Margin
2. Inspect valve contact area for the following conditions:

a. Undersized margin
b. Pitted surface
c. Burnt or eroded areas
d. Acceptable edge, margin
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VALVE SPRING INSPECTION
Figure 6. Valve Spring Resistance Tool
1. Inspect valve springs for broken coils or broken coil ends.

2. Use a spring compressor and measure coil resistance. Refer to 39 Mechanical Specifications.
NOTE
Add a maximum of one shim up to 0.030 in. (0726 mm) thick to increase spring tension.
3. If spring tension is low, use a shim to increase tension.

4. Recheck valve spring tension. A valve spring that does not meet specifications must be
replaced.
VALVE GUIDE INSPECTION
CAUTION
Excessive valve stem-to-guide clearance may cause excessive oil consumption and
may also cause valve breakage.
Insufficient clearance will result in noisy and sticky functioning of the valve and will
disturb engine smoothness.
Figure 7. Valve Stem Clearance
1. Valve Guide
2. Valve Stem
3. Dial Indicator
1. Using a dial indicator (3), measure valve stem (2) to valve guide (1) clearance.
a. Install dial indicator with indicator stem against valve stem (2).
b. Drop valve head about 0.064 in. (1.6 mm) off valve seat.
c. Pull valve stem (2) towards dial indicator (3) and zero the dial indicator.
d. Gently move the valve stem (2) away from dial indicator and note reading and refer
to 40 Mechanical Specifications.
2. If the valve guide (1) has excessive clearance the cylinder head must be replaced.
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BLANK
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16 CRANKSHAFT BALANCER AND FRONT SEAL
Figure 1. Crankshaft Balancer Removal
1. Bolt
2. Washer
3. Crankshaft Balancer
4. Crankshaft
5. Timing Cover
6. Front Seal
NOTE
Remove drive belts. Refer to 05 Front Engine Accessory Drive (FEAD).
CRANKSHAFT BALANCER REMOVAL

1. Remove bolt (1) and washer (2).
2. Install crankshaft protector tool 12-075-01 and apply dab of grease to exposed end of tool.
3. Use OTC4531 Harmonic Balancer Puller to remove
crankshaft balancer (3) from crankshaft (5).
4. Remove front seal (7) from timing cover (6). Discard front Seal (7).
NOTE
Apply 5W30 motor oil to surface of crankshaft and on machined surfaces of crankshaft
balancer prior to assembly.
Apply 5W30 motor oil to surface of seal.
Seal surface faces away from engine.
CRANKSHAFT BALANCER INSTALLATION

5. Using 12-174-01 Front Cover Seal Installer, install new front seal (7) on timing cover (6).
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Figure 2. Crankshaft Balancer Installation
1. Installation Rod
2. Crankshaft
4. Aluminum Spacer
5. Washer
6. Nut, 1.0 in. x 10
NOTE
Make sure all components are clean and free of defects/debris.
Using OTC4531 Harmonic Balancer Installer, install crankshaft balancer:

1. Lubricate threads of installation rod (1) and 1 in. x10nut (6) with 5W30 engine oil.
2. Thread installation rod (1) into nose of crankshaft (2) and snug it with a 3/4 in. wrench.
3. Align crankshaft balancer (3) keyway with crankshaft key and slide crankshaft balancer (3) over
installation rod (1) onto crankshaft (2).
4. Slide aluminum spacer (4) over installation rod (1).
5. Lubricate thrust bearing (6) with 5W30 motor oil and install thrust bearing (6) over
installation rod (1).
6. Install 1 in. x10 nut (7) onto installation rod (1) and hand-tighten 1 in.x10 nut (7).
CAUTION
DO NOT use power tools when tightening nut. Failure to comply may cause
damage to equipment.
DO NOT over tighten nut. Failure to comply may cause damage to equipment.
7. Using a large wrench, tighten 1 in.x10 nut (6) to push crankshaft balancer (3) into final position on
crankshaft (2).
8. Once crankshaft balancer (3) is fully seated, back off 1.0 in.x10 nut (6) a few turns to take
pressure off installation rod (1).
9. Using a 3/4 in. wrench, loosen installation rod (1) from the nose of crankshaft (2) and remove
entire tool as one piece.
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Figure 3. Secure Crankshaft Balancer
1. Bolt, 1 in. x10

2. Washer
10. Apply blue Loctite to threads of 1 in. x10 bolt (1).

11. Secure crankshaft balancer (3) on crankshaft with washer (2) and 1 in. x10 bolt (1). Tighten
bolt (1) to 90 ft.-lbs (122 Nm).
Install drive belts. Refer to 05 Front Engine Accessory Drive (FEAD).
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17 TIMING COVER, TIMING CHAIN, AND SPROCKETS
Figure 1. Timing Cover Removal
1. Bolt, M8x1.25x25 7. Crankshaft Sprocket

2. Timing Cover 8. Bolt, M8x1.25x25
3. Cylinder Block 9. Timing Chain
4. Camshaft 10. Timing Cover Gasket
5. Crankshaft 11. Bolt, M6x1.0x15
6. Camshaft Sprocket 12. Camshaft Sensor
NOTE
Remove drive belts. Refer to 05 Front Engine Accessory Drive (FEAD).
Remove crankshaft balancer. Refer to 16 Crankshaft Balancer and Front Seal.
Remove oil pan. Refer to 22 Oil Pan removal section
REMOVAL
1. Remove bolt (11) and cam sensor (12) from timing cover (2).
2. Remover six bolts (1), timing cover (2), and gasket (10) from engine (3). Discard gasket (10).
3. Remove three bolts (8), camshaft sprocket (6), and timing chain (9) from camshaft (4).
4. Remove crankshaft sprocket (7) from crankshaft (5).
NOTE
Apply 5W30 motor oil to machined surface of crankshaft.
Apply 5W30 motor oil on timing chain.
INSTALLATION
1. Align groove of crankshaft sprocket (7) with key on crankshaft (5) and install crankshaft
sprocket (7) on crankshaft (5).
2. Rotate camshaft (4) until timing mark on camshaft sprocket (6) is at 6 oclock position.
3. Rotate crankshaft (5) until timing mark on crankshaft sprocket (7) is at 12 oclock position.
4. Apply Clevite Bearing Guard lubricant to back of camshaft sprocket (6).
5. Apply blue Loctite to threads of three M8x1.25x25mm bolts (8).
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Figure 2. Timing Cover Installation
1. Bolt, M8x1.25x25
2. Timing Cover
3. Cylinder Block
4. Camshaft
5. Crankshaft
6. Camshaft Sprocket
7. Crankshaft Sprocket
8. Bolt, M8x1.25x25
9. Timing Chain
10. Timing Cover Gasket
11. Bolt, M6x1.0x15
12. Camshaft Sensor
CAUTION
Timing marks MUST be in alignment as shown in the image above
6. Install timing chain (9) on crankshaft sprocket (7) and on the camshaft sprocket (6), align timing
marks as shown above and install timing chain.
7. While ensuring timing marks remain in alignment, install camshaft sprocket (6) on camshaft (4)
with three M8x1.25x25mm bolts (8). Tighten bolts (8) to 22 ft.-lbs (30 Nm).
8. Install new gasket (10) in groove of timing cover (2).
9. Apply RTV sealant along left and right sides of timing cover (2) where it meets engine block (3).
10. Apply blue Loctite to threads of six M6x1.0x25mm bolts (1).
11. Align timing cover (2) on dowel pins and install timing cover (2) on engine (3) with six
M8x1.25x25mm bolts (1). Hand-tighten bolts (6).
12. Install cam sensor (12) on timing cover (2) with M6x1.0x15mm bolt (11).
13. Tighten bolts (1 and 11) to 106 in-lbs (12 Nm).
Install oil pan. Refer to 22 Oil Pan

Install crankshaft balancer. Refer to 16 Crankshaft Balancer and Front Seal.
Install drive belts. Refer to 05 Front Engine Accessory Drive (FEAD).
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18 OIL PUMP DRIVE
Figure 1. Oil Pump Drive
1. Oil Pump Drive

2. Bolt, M8-1.25x25
3. Cylinder Block
OIL PUMP DRIVE REMOVAL

1. Remove bolt (2) and oil pump drive (1) from cylinder block (3).
OIL PUMP DRIVE INSTALLATION

NOTE
Apply Clevite Bearing Guard lubricant to the oil pump drive gear.
1. Apply blue Loctite to threads of bolt (2).

2. Install oil pump drive (1) in cylinder block (3) with M8-1.25x25 bolt (2). Tighten bolt (2) to 22 ft-lbs
(30 Nm).
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18 OIL PUMP DRIVE
BLANK
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AND INSTALLATION
Figure 1. Camshaft Removal
1. Cam Retainer
2. Camshaft
3. Cylinder Block
4. Bolt, M6-1.0x20
NOTE
Remove timing cover and timing chain.
Remove intake manifold, rocker arm covers, and lifters.
Remove valley cover
Remove oil pan
Remove oil pump drive
CAMSHAFT REMOVAL
1. Remove two bolts (4) and cam retainer (1) from cylinder block (3).
2. Using three, M6x1.0x100mm bolts threaded into camshaft (2), carefully remove camshaft (2)
from cylinder block (3).
NOTE
Apply 5W30 motor oil to surface of camshaft journals and lobes.
Apply 5W30 motor oil to cam retainer.
Figure 2. Camshaft Inspection
1. Camshaft Bearing Journal

2. Camshaft Lobe
3. Oil Pump Drive Gear
4. Camshaft Sprocket Bolt Holes
CAMSHAFT CLEANING AND INSPECTION
WARNING
Always wear proper eye protection when using compressed air.
1. Clean camshaft with solvent.

2. Dry camshaft with compressed air
3. Inspect camshaft retainer plate for damage
4. Inspect camshaft bearing journals for:
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AND INSTALLATION
a. Wear, scoring, or other damage
b. Worn lobes
c. Stripped or damaged threads
d. Worn or damaged drive gear
Figure 3. Camshaft Journal Diameter Inspection
5. Measure camshaft journals with a micrometer to verify the journals are the correct diameter.
Refer to 39 Mechanical Specifications.
Figure 4. Camshaft Installation
1. Cam Retainer
2. Camshaft
3. Cylinder Block
4. Bolt, M6-1.0x20
CAMSHAFT INSTALLATION
1. Using three, M6x1.0x100mm bolts threaded into camshaft (2), carefully install camshaft (2) in
cylinder block (3).
2. Apply blue Loctite to threads of two M6x1.0 bolts (4).
3. Secure camshaft in engine (3) with cam retainer (1) and two M6-1.0x20mm bolts (4). Tighten
bolts (4) to 106 in-lbs (12 Nm).
NOTE
Install timing cover and timing chain Refer to module 017
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AND INSTALLATION
Install intake manifold, rocker arm covers, and lifters. Refer to module 08, 09, 13
Install valley cover Refer to module 12
Install oil pan Refer to module 22
Install oil pump drive Refer to module 18
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AND INSTALLATION
BLANK
92 of 195
20 CAMSHAFT BEARING REPLACEMENT
Figure 1. Camshaft Bearing Position
1. Cam Bearing 1
2. Cam Bearing 2
3. Cam Bearing 3
4. Cam Bearing 4
5. Cam Bearing 5
CAMSHAFT BEARING REMOVAL

CAUTION
A loose camshaft bearing may be caused by an enlarged, out-of-round, or damaged
cylinder block bearing bore.
1. Prior to bearing removal, inspect camshaft bearings for loose fit in cylinder block bearing bores
2. Remove rear camshaft plug if not previously removed by inserting a long bar through front of
cylinder block and drive plug out of rear of cylinder block.
Figure 2. Camshaft Bearing Tool Alignment
NOTE
Remove inner cam bearings (2, 3, and 4) first. The outer cam bearings (1 and 5) serve
as a guide for the cam bearing remover.
3. Using camshaft bearing remover/installer, drive out three inner bearings in positions (2, 3, and 4)
from their cylinder block bores.
4. Using camshaft bearing remover/installer, drive out two outer bearings (1 and 5) from their
cylinder block bores.
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Figure 3. Cam Bearing Tool
CAMSHAFT BEARING INSTALLATION
CAUTION
The outer camshaft bearings positions (1 and 5) must be installed first. These bearings
serve as guide for the tool and help center the inner bearings during the installation
process.
Ensure correct camshaft bearing fits into the proper bore. The camshaft bearing bores
vary in size
Ensure that camshaft bearing lubrication hole or holes align with the oil gallery hole or
holes in cylinder block. On some engines, oil holes may be difficult to see. Verify that
holes are aligned.
DO NOT shim, scrape, or file bearing inserts.
DO NOT touch bearing surface with bare fingers. Skin oil and acids may etch bearing
surfaces.
An improperly aligned camshaft bearing oil gallery hole will restrict oil flow to bearings
and camshaft journals and cause premature wear.
Figure 4. Camshaft Bearing Position
1. Cam Bearing 1
2. Cam Bearing 2
3. Cam Bearing 3
4. Cam Bearing 4
5. Cam Bearing 5
1. Using camshaft bearing remover/installer, align oil hole in bearings with oil passages in cylinder
block and install outer bearings (1 and 5) in their proper cylinder block bores.
2. Using camshaft bearing remover/installer, align oil hole in bearings with oil passages in cylinder
block and install inner bearings (2, 3, and 4) in their proper cylinder block bores.
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BLANK
95 of 195
21 OIL FILTER ADAPTOR AND BYPASS VALVES
Figure 1. Adapter and Bypass Valves
1. Cylinder Block
3. Oil Filter Adapter
OIL FILTER ADAPTOR AND BYPASS VALVES REMOVAL

1. Using proper size hex wrench, remove oil filter adapter (3) from cylinder block (1).
2. Remove oil filter bypass valve (2) (if required). Un-stake the tangs on the oil filter
bypass valve (2) and remove with long nose pliers.
3. Remove oil cooler bypass valve (4) (if required). Un-stake the tangs on the oil cooler
bypass valves (4) and remove with long nose pliers.
4. Discard oil bypass valves (2 and 4), if removed.
OIL FILTER ADAPTOR AND BYPASS VALVES INSTALLATION

1. Install oil filter bypass valve (2), if removed.
2. Install oil cooler bypass valve (4), if removed.
3. Stake tangs on both oil bypass valves (2 and 4).
4. Install oil filter adapter (3) on cylinder block (1). Tighten oil filter adapter (3) to 49 ft-lbs (66 Nm).
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21 OIL FILTER ADAPTOR AND BYPASS VALVES
BLANK
97 of 195
22 OIL PAN
Figure 1. Oil Pan
1. Cylinder Block
2. Oil Pan Gasket
3. Bolt, M8-1.25x25
4. Oil Pan
5. Washer
6. Drain Plug
NOTE 7. Bolt, M12-1.75x40
Ensure all engine oil has been drained from oil pan.
OIL PAN REMOVAL

1. Remove all the clamps attached to the oil pan (4).
2. Remove starter assembly and oil filter. see Starter Motor Service Procedure
3. Remove both dust shields.
4. Remove drain plug (6) and washer (5) from oil pan (4).
5. Remove twelve bolts (3), two bolts (7) and oil pan (4) from cylinder block (1).
6. Remove oil pan gasket (2) from oil pan (4). Discard gasket (2).
OIL PAN INSTALLATION

1. Install new oil pan gasket (2) on oil pan (4).
2. Apply blue Loctite to threads of twelve M8-1.25x25mm bolts (3).
3. Tighten the M8-1.25x25 bolts (3) a few threads, leaving oil pan adjustable.
4. Torque the twelve M12-1.75x40 bolts (7) connecting the flywheel housing to the oil pan (4) to
17 ft-lbs.
5. Torque the two M8-1.25x25 bolts (3) to 22 ft-lbs.
6. Torque the twelve M12-1.75x40 bolts (7) connecting the flywheel housing to the oil pan (4) to
70 ft-lbs.
NOTE
Flywheel housing bolts will pull the oil pan into the correct position.
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22 OIL PAN
Figure 2. Oil Pan Bolt Sequence
7. Install oil pan (4) on cylinder block (1) with twelve M8-1.25x25mm bolts (3). Following torque
sequence, tighten bolts (3) to 22 ft-lbs (30 Nm).
8. Install washer (5) and drain plug (6) in oil pan (4). Tighten drain plug (6) to 22 ft-lbs (30 Nm).
9. Install both dust shields
10. Install starter assembly and oil filter assembly. See Starter Motor Service Procedure
11. Reinstall all clamps and hose lines
BLANK
99 of 195
23 OIL PUMP
Figure 1. Oil Pump Removal
1. Cylinder Block
2. Drive Shaft
3. Plastic Coupler
4. Oil Pump
5. Bolt, M10x1.5x50
6. Oil Pump Shaft
OIL PUMP REMOVAL

1. Remove bolt (5) from oil pump (4).
2. Remove oil pump (4) and drive shaft (2) from cylinder block (1).
3. Remove drive shaft (2) and plastic coupler (3) from oil pump shaft (6). Discard
plastic coupler (3).
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23 OIL PUMP
Figure 2. Oil Pump Shaft
1. Oil Pump
2. Oil Pump Shaft
3. Plastic Coupler
4. Drive Shaft
OIL PUMP ASSEMBLY

1. Apply 5W30 motor oil to oil pump shaft (4).
2. Install plastic coupler (2) on oil pump shaft (4) and use a dead-blow to hammer fully to
seat the plastic coupler.
3. Apply 5W30 motor oil to tanged end of drive shaft (3).
4. Line up tanged end of drive shaft (3) with slotted end of oil pump shaft (4) and install drive shaft
(3) in plastic coupler.
5. Use a dead-blow hammer to fully seat drive shaft (3) in plastic coupler and in slot of oil pump
drive shaft (4).
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23 OIL PUMP
Figure 3. Oil Pump Installation
1. Cylinder Block
2. Oil Pump
3. Plastic Coupler
4. Oil Pump
5. Bolt, M10-1.5x50
6. Oil Pump Shaft
OIL PUMP INSTALLATION

1. Apply red Loctite to threads of M10-1.5x50mm bolt (3).
2. Install oil pump (2) on cylinder block (1) rear main bearing cap (4) with M10-1.5x50mm bolt (3).
Tighten bolt (3) to 60 ft-lbs (91 Nm).
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23 OIL PUMP
BLANK
103 of 195
24 FLYWHEEL, TRANSMISSION ADAPTER,
AND REAR OIL SEAL
Figure 1. Flywheel and Seal Removal
1. Bolt
2. Transmission Adapter
3. Bolt
4. Adapter Plate
5. Spacer
6. Flywheel
7. Rear Oil Seal
8. Crankshaft
9. Engine Block
REMOVAL
1. Remove six bolts (3), adapter plate (4), spacer (5), and flywheel (6) from crankshaft (8).
NOTE
There are three different length bolts securing the transmission adapter to
the engine block. Note locations of bolts during removal to aid installation.
2. Remove nine bolts (1) and transmission adapter (2) from cylinder block (9).
3. Using 12-183-02 Rear Seal Puller, remove rear oil seal (7) from cylinder block (9). Discard
rear oil seal (7).
INSTALLATION
NOTE
Apply a light coat of 5W30 motor oil onto the crankshaft sealing surface.
Do not apply oil to the sealing surface of the engine block.
1. Ensure lip of new rear oil seal (7) is facing engine block (9).
2. Using 12-183-03 Rear Seal Installer, install rear oil seal (7) on crankshaft (8) and
engine block (9).
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AND REAR OIL SEAL
Figure 2. Bolt Locations
1. Bolt, M10-1.5x35
2. Bolt, M10-1.5x65
3. Bolt, M12-1.75x40
NOTE
There are three different length bolts securing the transmission adapter
to the cylinder block. Install bolts as shown in above figure.
3. Apply blue Loctite to threads of two MM10x1.50x65mm bolts (2), five M10x1.5x35mm bolts
(1) and two M12x 175x40mm bolts (3).
4. Install transmission adapter (4) on dowels of cylinder block with two MM10-1.50x65mm bolts
(2), five M10-1.5x35mm bolts (1) and two M12-1.75x40mm bolts (3).
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AND REAR OIL SEAL
Figure 1. Flywheel and Seal Removal
1. Bolt, all
3. Bolt, 7/16-20x3.25 in.
4. Adapter Plate
5. Spacer
6. Flywheel
7. Rear Oil Seal
8. Crankshaft
9. Cylinder Block
5. Tighten bolts (1) to 70 ft.-lbs (95 Nm).

6. Apply 5W30 motor oil to threads of six 7/16-20x3.25 in. bolts (3).
7. Install flywheel (6), spacer (5), and adapter plate (4), on crankshaft (8) with
six 7/16-20x3.25 in. bolts (3). Tighten bolts (3) to 60 ft.-lbs (81 Nm).
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AND REAR OIL SEAL
BLANK
107 of 195
25 ENGINE OIL FILTER AND OIL REPLACEMENT
Figure 1. Oil Filter and Oil Replacement
1. Cylinder Block
2. Oil Filter Adapter
3. Oil Filter
4. Oil Pan
5. Washer
6. Drain Plug
NOTES
CHECK THE OIL LEVEL WITHIN 10 MINUTES OF ENGINE SHUTDOWN
DRAIN PLUG MUST NOT BE OUT OF ENGINE LONGER THAN 60 MINUTES AFTER ENGNE SHUTDOWN
OIL FILTER REMOVAL & OIL DRAIN

1. Raise vehicle and using suitably rated safety stands support vehicle.
2. Clean the oil pan surface near the drain plug.
3. Using suitable drain pan under oil pan (4) remove drain plug (6) and washer (5) from oil pan (4)
and allow engine oil to drain completely.
4. Remove oil filter (3) from oil filter adapter (2) and allow engine oil to drain completely from
cylinder block (1).
OIL FILTER INSTALLATION & OIL FILL

1. Clean oil filter surface and threads (2).
2. Clean drain plug area on oil pan (4), drain plug (6) and washer (5).
3. Install washer (5) and drain plug (6) on oil pan (4). Tighten drain plug (6) to 21 ft.-lbs (28 Nm).
4. Install new oil filter (3) on engine block (1). Tighten oil filter (3) per the oil filter manufacturers
instructions printed on the oil filter box.
5. Remove safety stands and lower vehicle.
6. Fill engine with 7.5 qts (7.09L) of new Dexos1 rated 5W30 engine oil.
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CAUTION
The PSI 8.8L Propane engine requires the use of synthetic blend oil that meets Dexos1
standards.
This requirement will provide a reduction in volatility and oil consumption, significant wear
protection, and improved fuel efficiency while providing better oxidation properties.
All oil used in the PSI 8.8L LP engine must meet the Dexos1 specification and display the
green Dexos1 logo.
Oil Recommendation
SAE Oil Viscosity Grades

It is required that the Dexos1 oil meet SAE 5W-30 viscosity standards. This oil weight will be used
regardless of ambient temperature.
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BLANK
110 of 195
26 WATER PUMP
Figure 1. Water Pump
1. Water Pump
2. Gasket
3. Cylinder Block
4. Bolt, M10x1.5x65
NOTE
Perform the following prior to water pump removal:
Drain coolant into suitable container.
Remove drive belts, cooling fan and fan pulley. Refer to 05 Front Engine Accessory
Drive (FEAD).
Disconnect lower radiator hose from water pump.
Disconnect water crossover hose from water pump.
Remove alternator bracket. Refer to 34 Alternator Bracket.
Remove power steering bracket. Refer to 33 Power Steering Pump and Bracket.
WATER PUMP REMOVAL

1. Remove four bolts (4), water pump (1) and two gaskets (2) from cylinder block (3).
Discard gaskets (2).
WATER PUMP INSTALLATION

1. Install two new gaskets (2) and water pump (1) on cylinder block (3) with four M10x1.5x65mm
bolts (4). Tighten bolts (4) to 40 ft-lbs (54 Nm).
Install alternator bracket. Refer to 34 Alternator Bracket.

Install power steering bracket. Refer to 33 Power Steering Pump and Bracket.
Connect water crossover pipe to water pump.
Connect lower radiator hose to water pump.
Install fan pulley, cooling fan, and drive belts. Refer to 05 Front Engine Accessory Drive
(FEAD).
Fill cooling system.
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26 WATER PUMP
BLANK
112 of 195
27 WATER CROSSOVER AND THERMOSTAT
Figure 1. Water Crossover and Thermostat
1. Water Crossover
2. O-ring
3. Thermostat
4. Thermostat Housing
5. Bolt, M8x1.25x25
6. Cylinder Head
7. Gasket
8. Bolt, M10x1.5x30
9. Bypass Hose
NOTE
Perform the following prior to water pump removal:
Drain coolant into suitable container.
Remove drive belts, cooling fan and fan pulley. Refer to 05 Front Engine Accessory
Drive (FEAD).
Disconnect upper radiator hose from thermostat housing.
Remove power steering bracket. Refer to 33 Power Steering Pump and Bracket.
Remove alternator bracket. Refer to 34 Alternator Bracket.
WATER CROSSOVER AND THERMOSTAT REMOVAL

1. Remove two bolts (5) and thermostat housing (4) from water crossover (1).
2. Remove thermostat (3) and O-ring (2) from water crossover (1).
3. Disconnect water crossover hose (9) from water crossover (1).
4. Remove four bolts (8), water crossover (1), and two gaskets (7) from two cylinder heads (6).
Discard gaskets (7).
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Figure 2. Water Crossover and Thermostat
1. Water Crossover
2. O-ring
3. Thermostat
4. Thermostat Housing
5. Bolt, M8x1.25x25
6. Cylinder Head
7. Gasket
8. Bolt, M10x1.5x30
9. Bypass Hose
WATER CROSSOVER AND THERMOSTAT INSTALLATION

1. Install two new gaskets (2) and water crossover (1) on two cylinder heads (6) with four
M10x1.5x30mm bolts (8). Finger-tighten bolts (8).
2. Install bypass hose (9) on water crossover (1).
3. Tighten four bolts (8) to 40 ft-lbs (54 Nm).
4. Install new thermostat (3) with O-Ring (2) in water crossover (1).
5. Install thermostat housing (4) on water crossover (1) with two M8x1.25x25mm bolts (5).
Tighten bolts (5) to 18 ft-lbs (24 Nm).
Install alternator bracket. Refer to 34 Alternator Bracket.

Install power steering bracket. Refer to 33 Power Steering Pump and Bracket.
Install upper radiator hose on thermostat housing.
Install fan pulley, cooling fan, and drive belts. Refer to 05 Front Engine Accessory
Drive (FEAD).
Fill cooling system.
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BLANK
115 of 195
REMOVAL AND INSTALLATION
Figure 1. Crankshaft Position Sensor

2. Bolt, M6x1.0x15
3. Cylinder Block
CRANKSHAFT POSITION SENSOR REMOVAL

1. Remove bolt (2) from cylinder block (3).
2. Remove crankshaft sensor (1) from cylinder block (3).
3. Inspect O-Ring for damage, replace as needed.
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Figure 2. Crankshaft Removal
1. Bolt, Outer,
2. Bolt, Inner,
3. Main Bearing Cap
4. Rear Main Bearing Cap
5. Rear Main Bearing, Lower
6. Main Bearing, Lower
7. Crankshaft
8. Rear Main Bearing, Upper
9. Main Bearing, Upper
10. Cylinder Block
REMOVE FRONT COVER, DAMPER, OIL PAN, FLYWHEEL AND HOUSING, TIMING CHAIN, OIL
PUMP, OIL PUMP SHAFT/DRIVE PRIOR TO BELOW OPERATION
CRANKSHAFT REMOVAL
CAUTION
Main bearing caps must be assembled to their original cylinder block journals. Match
mark main bearing caps to cylinder block journals to aid assembly.
1. Remove ten outer main bearing cap bolts (1) from four main bearing caps (3) and rear main
bearing cap (4).
2. Remove ten inner main bearing cap bolts (2) from four main bearing caps (3) and rear main
bearing cap (4).
3. Remove four main bearing caps (3) and rear main bearing cap (4) from cylinder block (10).
4. Remove four lower main bearings (6) from four main bearing caps (3),
Discard main bearings (6).
5. Remove lower rear main bearing (5) from main bearing cap (4).
Discard lower rear main bearing (5).
CAUTION
In order to prevent damage to crankshaft position sensor reluctor wheel/ring, care
must be taken when removing or installing crankshaft.
6. Remove crankshaft (7) from cylinder block (10).

7. Remove four upper main bearings (9) from cylinder block (10). Discard upper main bearings (9).
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8. Remove lower rear main bearing (8) from cylinder block (10).
Discard lower rear main bearing (8).
Figure 3. Crankshaft Bearings
1. Bolt, Outer,
2. Bolt, Inner,
3. Main Bearing Cap
7. Crankshaft
10. Cylinder Block
CRANKSHAFT INSTALLATION
CAUTION
Main bearing caps and the backs of main bearing surfaces must be free of oil and dirt.
DO NOT lubricate the backside of any main bearings.
NOTE
If oversized/undersized bearings are used, ensure that bearings are fitted to proper journals.
1. Install four upper bearings (9) and upper rear main bearing (8) on cylinder block (10).
2. Apply 5W30 engine oil to surface of upper main bearings (8 and 9).
3. Install four lower main bearings (6) on main bearing caps (3).
4. Install lower rear main bearing (5) on rear main bearing cap (4).
5. Apply 5W30 engine oil on surface of upper main bearings (5 and 6).
CAUTION
In order to prevent damage to crankshaft position sensor reluctor wheel/ring, care
must be used when removing or installing this component.
6. Carefully install crankshaft (7) on cylinder block (10).
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Figure 4. Crankshaft Installation
1. Bolt, Outer, 1/2-13x2.75 in.

2. Bolt, Inner, 1/2-13x3.75 in.
3. Main Bearing Cap
7. Crankshaft
10. Cylinder Block
CAUTION
Install each main bearing cap to previously marked locations on cylinder block. Failure to
comply may cause damage to components.
7. Apply anti-seize to threads of ten 1/2-13x2.75 in. outer bolts (1) and ten 1/2-13x3.75 in. bolts (2).
8. Install four main bearing caps (3) and rear main bearing cap (4) on previously marked positions of
cylinder block (10) with ten 1/2-13x2.75 in. outer bolts (1) and ten 1/2-13x3.75 in. inner bolts (2).
Finger-tighten bolts (1 and 2)
CAUTION
In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, tap
the main bearing caps into the cylinder block cavities using a plastic type hammer before
bolts are tightened. DO NOT use main bearing bolts to pull crankshaft bearing caps into
cylinder block locations. Failure to use this process may damage cylinder block or
bearing caps.
The crankshaft position sensor reluctor wheel/ring is not serviced separately. Do not
repair the crankshaft position sensor reluctor wheel/ring. If the crankshaft position sensor
reluctor ring is damaged, the crankshaft assembly must be replaced.
9. Using plastic type hammer seat main bearing caps (3 and 4) on cylinder block (10).
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Figure 5. Main Bearing Bolt Torque Sequence
10. Tighten main bearing cap bolts per torque sequence shown above in three stages:
a. Stage 1, 33 ft.-lbs (45 Nm)
b. Stage 2, 66 ft.-lbs (89 Nm)
c. Stage 3, 100 ft.-lbs (136 Nm)
11. Measure crankshaft endplay as follows:
a. Install dial indicator on cylinder block and align plunger with a crankshaft counterweight.
b. Firmly thrust crankshaft rearward then forward to line up thrust surfaces of rear main bearing.
c. With crankshaft pushed forward, zero the dial indicator. Push crankshaft rearward and read
dial indicator.
d. Crankshaft endplay specification is 0.005-0.014 in. (0.127-0.350 mm).
e. If correct endplay cannot be obtained, inspect for the following conditions:
1) Verify correct size crankshaft bearing has been installed.
2) Inspect crankshaft thrust wall surface or surfaces for wear or excessive runout.
Refer to 43 Mechanical Specifications.
12. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, loosen main
bearing cap bolts, one cap at a time, until the tight bearing has been located.
13. The following condition or conditions may cause a lack of clearance at the bearing:
a. Burrs on the main bearing cap
b. Foreign material between bearing and cylinder block
c. Foreign material between bearing and main bearing cap
d. Faulty main bearing
e. Improper size bearing
f. Cap installed in the wrong location on the engine block
g. Cap installed backwards
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Figure 6. Crankshaft Position Sensor

2. Bolt, M6x1.0x15
3. Cylinder Block
CRANKSHAFT POSITION SENSOR INSTALLATION
CAUTION
Ensure that the crankshaft position sensor is fully seated against the crankshaft reluctor
ring. The upper flange on the sensor may not always seat against the engine block.
The crankshaft position sensor bolt has thread sealant applied to threads. Thread sealant
may have come off during bolt removal. Ensure bolt hole is clean of any debris before
installing the crankshaft position sensor.
1. Verify condition of O-Ring is acceptable for use, if not replace.

2. Apply 5W30 engine oil to O-ring.
4. Install crankshaft position sensor (1) in cylinder block (3) with M6x1.0x15mm bolt (2).
Tighten bolt (2) to 106 in-lbs (12 Nm). Apply a small amount of force while tightening the M6 bolt
to ensure crankshaft position sensor is fully seated.
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BLANK
122 of 195
29 CRANKSHAFT CLEANING AND INSPECTION
Figure 1. Crankshaft
CRANKSHAFT CLEANING
CAUTION
Use care when handling crankshaft. Avoid damage to bearing journals and reluctor.
Always wear protective clothing and approve eye protection when cleaning components
Wear approved eye protection when using compressed air.
1. Clean crankshaft in solvent. Remove all sludge and restrictions from oil passages.
2. Dry crankshaft with compressed air.
Figure 2. Crankshaft Inspection
1. Rear Seal Surface

2. Reluctor Wheel
3. Rear Main Bearing Journal
4. Connecting Rod Journals
5. Main Bearing Journals
6. Thrust Bearing Surfaces
3. Inspect crankshaft for the following conditions:

a. Rear main bearing journal (3) and main bearing journals (5) for scoring, scratching, pitting,
discoloration, and other damage
b. Connecting rod journal (4) for scoring, scratching, pitting, discoloration and other damage.
c. Thrust bearing surfaces (6) for wear, scratching or other damage.
d. Rear seal surface (1) for scoring or damage.
e. Restricted oil passages.
f. Threaded bolt hole for stripped or damaged threads.
g. Inspect crankshaft reluctor wheel (2) for bends, cracks or other damage
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Figure 3. Crankshaft Journals
CRANKSHAFT INSPECTION
CAUTION
The crankshaft and connecting rod bearings are of the precision insert type and do not
use shims for adjustment.
Crankshafts with journals measuring less than minimum specifications must be
replaced.
4. Measure crankshaft main journal diameter with a micrometer in several places along the length
approximately 90 degrees apart, minimum of 4 places, and average the measurements.
5. Measure crankshaft rod journal diameter with a micrometer in several places along the length
approximately 90 degrees apart, minimum of 4 places, and average the measurements.
6. Determine the taper and the out-of-round. Refer to 39 Mechanical Specifications for wear limits.
Figure 4. Checking Runout
7. Using a suitable fixture, support crankshaft.

a. Using a dial indicator, measure crankshaft runout.
b. Crankshaft runout should not exceed 0.0026 in. (0.07 mm).
8. Inspect thrust surfaces at rear main crankshaft journal. Refer to 39 Mechanical Specifications for
wear limits.
CHECKING MAIN BEARING CLEARANCE
1. Measure crankshaft main journal diameter with a micrometer in several places along the length
approximately 90 degrees apart, minimum of 4 places, average the measurements and record
for later use.
2. Determine the taper and the out-of-round. Refer to 39 Mechanical Specifications.
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Figure 5. Crankshaft Removal
1. Bolt, Outer, 1/2-13x2.75 in.

2. Bolt, Inner, 1/2-13x3.75 in.
3. Main Bearing Cap
6. Main Bearings, Lower
7. Main Bearings, Upper
9. Cylinder Block
3. Install new upper main bearings (7 and 8) on cylinder block (9).

4. Install new lower main bearings (5 and 6) on main bearing caps (3 and 4).
5. Apply anti-seize to threads of ten 1/2-13x2.75 in. outer bolts (1) and ten 1/2-13x3.75 in inner
bolts (2).
6. Install four main bearing caps (3) and rear main bearing cap (4) on previously marked positions of
cylinder block (9) with ten 1/2-13x2.75 in. outer bolts (1) and ten 1/2-13x3.75 in. inner bolts (2).
Finger-tighten bolts (1 and 2)
CAUTION
In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the
main bearing caps are tapped into the cylinder block cavities using a brass, lead, or a
leather mallet before the attaching bolts are tightened. DO NOT use main bearing bolts to
pull the crankshaft bearing caps into seats. Failure to use this process may damage
cylinder block or bearing caps.
The crankshaft position sensor reluctor wheel/ring is not serviced separately. Do not
repair the crankshaft position sensor reluctor wheel/ring. If the crankshaft position sensor
reluctor ring is damaged, the crankshaft assembly must be replaced.
7. Using brass, lead, or leather hammer, seat main bearing caps (3 and 4) on cylinder block (10).
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Figure 6. Main Bearing Bolt Torque Sequence
8. Tighten main bearing cap bolts per torque sequence shown above in three stages:
a. Stage 1, 33 ft-lbs (45 Nm)
b. Stage 2, 66 ft-lbs (89 Nm)
c. Stage 3, 100 ft-lbs (136 Nm)
9. Measure crankshaft bearing inside diameter (ID) using an inside micrometer. Measure at a
minimum of four places and average the measurements.
10. In order to determine the crankshaft bearing clearance, subtract the crankshaft journal diameter
from the crankshaft bearing ID.
11. Compare crankshaft bearing clearance to specifications. Refer to 39 Mechanical Specifications.
12. If crankshaft bearing clearances exceeds specifications, install undersize crankshaft bearings to
achieve the correct clearance.
13. Perform steps 3 through 12.
14. Replace crankshaft if proper clearances cannot be obtained with standard bearings or
undersize bearings.
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BLANK
127 of 195
30 CYLINDER BLOCK CLEANING AND INSPECTION
BLOCK PLUG REMOVAL
Figure 1. Engine Plugs, Right
1. Cylinder Block
2. Freeze Plug
3. Oil Passage Plug, 1/4-18 NPT
1. Remove three freeze plugs (2) from cylinder block (1).

2. Remove oil passage plug (3) from cylinder block (3).
Figure 2. Engine Plugs, Left
1. Cylinder Block
2. Freeze Plug
3. Remove three freeze plugs (2) from cylinder block (1).

4. Remove oil passage plug (3) from cylinder block (1).
Figure 3. Engine Plugs, Front
1. Oil Passage Plug, 1/4-18 NPT with Orifice

3. Cylinder Block
CAUTION
Oil passage plug (1) has an oil orifice hole. Ensure the oil passage plug is marked for
assembly in upper left oil passage.
5. Remove three oil passage plugs (1 and 2) from cylinder block (3)
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Figure 4. Engine Plugs, Rear
1. Cylinder Block
6. Remove six oil passage plugs (2) from cylinder block (1).
1. Freeze Plug
2. Cylinder Block
7. Remove two freeze plugs (1) from cylinder block (2).
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Figure 6. Cylinder Block
CYLINDER BLOCK CLEANING
WARNING
1. Boil cylinder block in caustic solution

2. Flush cylinder block with water or steam.
3. Clean the following areas:
a. All gasket surfaces. Refer to Engine Gaskets in 03 Special Instructions.
b. Cylinder bores, remove excessive cylinder ridge as required.
c. Main bearing caps.
d. Oil galleries, remove all sludge and restrictions.
e. Scale deposits from coolant passages.
f. All dirt and debris from threaded holes.
WARNING
Always use proper eye protection when using compressed air.
4. Dry cylinder block with compressed air.

5. Lubricate cylinder bores with 5W30 motor oil to prevent rust.
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Figure 7. Cylinder Block, Top and Bottom
CYLINDER BLOCK INSPECTION

1. Inspect the cylinder block for the following conditions:
a. Gasket surfaces for deep gouges or other damage
b. Crankshaft bearing bores for wear
NOTE
The surfaces where crankshaft bearings contact crankshaft bearing bore must be
smooth.
All crankshaft bearing bores must be round and uniform on inside diameter (ID) at all
bearing supports
If a crankshaft bearing cap is damaged and requires replacement line boring of the main
bearing bore will be necessary.
c. Camshaft bearing bores for wear or damage
d. Valve lifter bores for wear or damage
e. Engine block for cracks or other damage
f. Coolant jackets for cracks
g. Crankshaft bearing webs for cracks
h. Engine mount bosses for damage
i. Oil passages for restrictions
Figure 8. Cylinder Block Flatness
2. Inspect cylinder head deck for flatness using a straight edge and feeler gauge. The surface must
be flat within 0.001 in. (0.030 Nm) measured between bolt holes.
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Figure 9. Cylinder Bore Measurement
3. Using a cylinder bore gauge, measure cylinder bore for taper, for out-of-round, and oversize.
Check the bore parallel and perpendicular to the centerline of the crankshaft at the top, center,
and bottom of the bore. Refer to 39 Mechanical Specifications for tolerances.
CYLINDER HONING
Figure 10. Cylinder Honing
CAUTION
Remove all bearings and components from engine block before cleaning, boring or
honing the engine block.
1. When honing cylinders, follow all manufacturers recommendation for equipment use, cleaning,
and lubrication.
a. Use only clean sharp stones of the proper grade for amount of material you are removing.
b. Dull, dirty stones cut unevenly and generate excessive heat.
c. DO NOT hone to a final grade with a coarse or medium-grade stone.
d. Leave sufficient metal so that all stone marks may be removed with fine grade stones.
e. The re-honed surface finish should be 1020 micro inches (0.250.50 micrometers).
f. Perform final honing with a fine-grade stone and hone the cylinder in a cross hatch pattern
at 20 to 30 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore.
a. Repeatedly check the cylinder bore for fit with the selected oversized piston.
b. All measurements of the cylinder bore should be made with the components at normal room
temperature.
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3. When finished, reconditioned cylinder bores should have less than or meet the specified out-of-
round or taper requirements.
CAUTION
Abrasive material remaining in cylinder bores may cause premature wear of new rings
and pistons.
Abrasive material will contaminate engine oil and cause premature wear of bearings.
4. After honing and before the piston is checked for fit, clean the bores with hot water and
detergent.
a. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water.
DO NOT allow any abrasive material to remain in the cylinder bores.
b. After washing cylinder bore, dry with a clean shop towel.
5. Perform final measurements of cylinder bores.
6. Permanently mark the piston for the specific cylinder to which it has been fitted
7. Apply clean engine oil to cylinder bores to prevent rusting.
BLOCK PLUG INSTALLATION
1. Freeze Plug
2. Cylinder Block
1. Apply Permatex Aviation Form-a-Gasket or equivalent to outside edge of two freeze plugs (1)
and to inside diameter of plug bores on cylinder block (2).
2. Using appropriate installation tool, install two freeze plugs (1) in plug bores on cylinder block (2).
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1. Cylinder Block
3. Apply Permatex thread sealant or equivalent to threads of six 1/4-18 NPT oil passage plugs
(2).
4. Install six 1/4-18 NPT oil passage plugs (2) in cylinder block (1). Tighten plugs (2) to
25 ft-lbs (34 Nm).
Figure 13. Engine Plugs, Front
1. Oil Passage Plug, 1/4-18 NPT with Orifice

3. Cylinder Block
CAUTION
Oil passage plug (1) has an oil orifice hole. Ensure the oil passage plug is installed
the upper left position.
5. Apply Permatex thread sealant or equivalent to threads of 1/4-18 NPT orifice oil passage plug
(1).
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6. Install 1/4-18 NPT orifice oil passage plug (1) in cylinder block (3). Tighten plug (1) to
25 ft-lbs (34 Nm).
7. Apply Permatex thread sealant or equivalent to threads of two 1/4-18 NPT oil passage plugs
(3). Tighten plugs (2) to 25 ft-lbs (34 Nm).
8. Install two 1/4-18 NPT orifice oil passage plugs (1) in cylinder block (3). Tighten plugs (2) to
25 ft-lbs (34 Nm).
Figure 14. Engine Plugs, Left
1. Cylinder Block
2. Freeze Plug
9. Apply Permatex Aviation Form-a-Gasket or equivalent to outside edge of three freeze plugs (2)
and to inside diameter of plug bores on cylinder block (1).
10. Using appropriate installation tool, install three freeze plugs (2) in plug bores on
cylinder block (1).
11. Apply Permatex thread sealant or equivalent to threads of 1/4-18 NPT oil passage plug (3).
12. Install 1/4-18 NPT oil passage plug (3) in cylinder block (1). Tighten oil passage plugs (2) to
25 ft-lbs (34 Nm).
Figure 15. Engine Plugs, Right
1. Cylinder Block
2. Freeze Plug
13. Apply Permatex Aviation Form-a-Gasket or equivalent to outside edge of three plugs (2) and to
inside diameter of plug bores on cylinder block (1).
14. Using appropriate installation tool, install three plugs (2) in plug bores on cylinder block (1).
15. Apply Permatex thread sealant or equivalent to threads of 1/4-18 NPT oil passage plug (3).
16. Install 1/4-18 NPT oil passage plug (3) in cylinder block (1). Tighten oil passage plug (2) to
25 ft-lbs (34 Nm).
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BLANK
136 of 195
31 PISTON REMOVAL, CLEANING, INSPECTION,
AND INSTALLATION
Figure 1. Piston Removal
1. Piston and Rod Assembly

2. Connecting Rod Bearing. Upper
3. Cylinder Block
4. Connecting Rod Bearing, Lower
5. Connecting Rod Cap
6. Bolt, 7/16-20x1.594 in.
PISTON AND CONNECTING ROD REMOVAL

CAUTION
Connecting rod caps must be assembled paired with connecting rods. Match mark
connecting rods to connecting rod caps to aid assembly.
1. Remove two bolts (6) and connecting rod cap (5) from piston connecting rod assembly (1).
CAUTION
Use care when removing piston and rod assembly to prevent connecting rod from
damaging crankshaft or cylinder bore.
Use a cylinder ridge reamer if excessive ridge is found at top of cylinder bore.
Mark pistons to cylinder block position to aid installation.
2. Remove piston connecting rod assembly (1) from cylinder block (3).
3. Perform steps 1 and 2 to remove remaining piston and rod assemblies.
4. Remove eight lower bearings (4) from eight connecting rod caps (2). Discard lower
bearings (3).
5. Remove eight upper bearings (2) from eight piston and connecting rod assemblies (1).
Discard upper bearings (2).
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AND INSTALLATION
Figure 2. Piston and Rod Disassembly
1. Compression Ring, Upper

2. Compression Ring,
3. Oil Control Rings
4. Piston
5. Connecting Rod
6. Connecting Rod Bearing Set
8. Connecting Rod Bolts, 7/16-20x1.594 in.
PISTON AND CONNECTING ROD CLEANING
1. Remove compression rings (1 and 2) from piston (4). Discard compression rings (1 and 2).
2. Remove oil control rings (3) from piston (4). Discard oil rings (3)
WARNING
Always use proper eye protection when using compressed air.
3. Clean pistons (4), connecting rods (5), rod caps (7), and bolts (8) in solvent.
4. Dry components with compressed air.
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AND INSTALLATION
Figure 3. Cleaning Piston Ring Grooves
5. Using a suitable ring groove cleaning tool, clean piston ring grooves.
6. Clean piston oil lubrication holes and slots.
PISTON AND CONNECTING ROD INSPECTION
Figure 4. Piston Inspection
1. Piston Erosion
2. Piston Skirt Damage
7. Inspect pistons for the following conditions:

a. Eroded areas (1) an top of piston
b. Scuffed or damaged skirt (2)
c. Cracks in the piston ring lands, piston skirt, and pin bosses
d. Piston ring grooves for nicks, burrs, or other damage
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AND INSTALLATION
Figure 5. Piston Ring Groove Binding Check
8. Measure piston ring-to-piston ring groove side clearance. Refer to 39 Mechanical Specifications.
a. Insert edge of new piston ring into piston ring groove.
b. Roll piston ring completely around piston to check for binding.
c. If binding is caused by distorted piston ring groove, minor imperfections may be removed
using a fine file.
Figure 6. Piston Ring Side Clearance
9. Measure piston ring side clearance with a feeler gauge.

10. If side clearance is too small, try another piston ring set. Refer to 39 Mechanical Specifications.
11. If proper ring-to-piston ring groove clearance cannot be achieved, replace piston-rod assembly.
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AND INSTALLATION
Figure 7. Bearing Bore Out-of-Round Check
12. Inspect connecting rod bearing bore for out-of-round condition. Refer to 39 Mechanical
Specifications.
Figure 8. Connecting Rod Damage Check
13. Inspect the connecting rod for twisting.

14. Check connecting rod bolt holes for stripped or damaged threads.
Figure 9. Piston Ring End Gap Check
CAUTION
Fit each compression ring to the cylinder in which it will be used. Failure to comply may
result in damage to components.
15. Measure piston compression ring end gap;

a. Place compression ring in cylinder bore.
b. Push compression ring in cylinder bore approximately 1.00 in. (25.4 mm) down cylinder from
top of fire deck. Compression ring must be square to cylinder wall.
c. Use a feeler gauge to measure end gap. Refer to 39 Mechanical Specifications.
d. Select another ring set if end gap exceeds specifications.
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AND INSTALLATION
PISTON AND CONNECTING ROD ASSEMBLY
Figure 10. Oil Control Ring Spacer Installation
1. Install the oil control ring spacer on piston.
Figure 11. Lower Oil Control Ring Installation
2. Install the lower oil control ring on piston.
Figure 12. Upper Oil Control Ring Installation
3. Install upper oil control ring on piston.
Figure 13. Oil Control Ring Spacing
1. Upper Oil Control Ring Gap

2. Lower Control Ring Gap
3. Oil Control Ring Spacer Gap
4. Space the oil control ring end gaps (1, 2 and 3) 120 degrees apart.
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AND INSTALLATION
Figure 14. Lower Compression Ring
CAUTION
Use a piston ring expander to install compression piston rings. The rings may be
damaged if expanded more than necessary.
5. Using piston ring expander, install lower compression ring in second groove on piston.
Figure 15. Upper Compression Ring
6. Using piston ring expander, install upper compression ring in first groove on piston.
7. Space compression ring gaps 180 degrees apart.
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AND INSTALLATION
Figure 16. Piston Lubrication

3. Cylinder Block
6. Bolt, 7/16-20x1.594 in.
PISTON AND CONNECTING ROD INSTALLATION
1. Coat the following components with clean 5W30 motor oil:

a. Pistons
b. Piston rings
c. Cylinder block bore
d. Upper and lower connecting rod bearing surfaces
2. Install upper bearing (2) on piston and rod assembly (1).
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AND INSTALLATION
CAUTION
The mark on top of piston must face front of cylinder block on all cylinders.
Dimples in the connecting rod need to face the front of the cylinder block on the left bank.
Dimples in the connecting rod need to face the rear of the cylinder block on the right
bank.
Take precautions to preventing connecting rods from damaging cylinder walls and
crankshaft journals during installation.
3. Install the piston-rod assembly through top of cylinder block.

4. Use piston ring compressor to compress piston rings.
5. Firmly hold piston ring compressor and lightly tap top of piston with a wooden hammer handle
until all piston rings are have entered the cylinder bore.
6. Guide the connecting rod onto the crankshaft journal.
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AND INSTALLATION
Figure 18. Piston and Rod Installation

3. Cylinder Block
6. Bolt, 7/16-20x1.594 in.
7. Install lower bearing (4) on connecting rod cap (5).

8. Install connecting rod cap (5) on connecting rod with two 7/16-20x1.594 in. bolts (6), using ARP
thread lubricant or equivalent.
9. Tighten 7/16-20x1.594 in. bolts (6) 70 ft-lbs (95 Nm)
10. Repeat steps 1 through 9 for remaining pistons and rod assemblies.
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AND INSTALLATION
BLANK
147 of 195
32 AIR COMPRESSOR AND BRACKET
Figure 1. Air Compressor and Bracket
1. Air Compressor
2. Adapter, 37 degree flare 1/2 MPT
3. Air Compressor Bracket
4. Bolt:
a. M10x1.50x45
b. M10x1.50x110
c. M10x1.50x80
5. Stud
6. Nut, M10x1.5
NOTE
Remove drive belts and pulleys. Refer to 05 Front Engine Accessory Drive (FEAD).
Disconnect air compressor lines.
REMOVAL
1. Remove adapter (2) from air compressor bracket (3).
2. Remove four nuts (6) from studs (5).
3. Remove air compressor (1) from air compressor bracket (3).
4. Remove four bolts (4) and air compressor bracket (3) from engine block.
INSTALLATION
1. Install air compressor bracket (3) on engine block with one M10x1.50x45mm, one
M10x1.50x110mm, and two M10x1.50x80mm bolts (4). Tighten bolts (4) to
53 ft-lbs (72 Nm).
2. Install air compressor (1) on studs (5) of air compressor bracket (3) with four M10x1.5 nuts (6).
Tighten nuts (6) to 53 ft-lbs (72 Nm).
3. Install 37 degree flare 1/2 MPT adapter (2) on air compressor bracket (3). Tighten adapter (2)
to 1.5 3 turns past finger tight to face front of engine.
Connect air compressor lines.

Install pulleys and drive belts, Refer to 05 Front Engine Accessory Drive (FEAD).
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Hose and Fitting Installation Guidelines
Figure 2. Air Compressor Hose and Fittings
1. Fitting MPT x 5/8 Flare

2. Fitting 5/8 Flare x 5/8
3. Hardline Assembly Coolant Supply
4. Water Pump Fitting
5. Bolt M8-1.25 x 20
6. Nut M8-1.25
1. Install MPT x 5/8 Flare fitting (1) to air compressor with PTFE pipe sealant on threads. Tighten
1.5 to 3 turns past finger tight.
2. Insert Bolt M8-1.25 x 20 (5) through clamp and tighten to 18 ft-lbs
3. Install clamp on stud at air compressor bracket. Tighten Nut M8-1.25 (6) to 18 ft-lbs.
4. Install 5/8 Flare x 5/8 Fitting (2) on MPT x 5/8 Flare fitting (1). Tighten to 60 ft-lbs.
5. Install Hardline Assembly Coolant Supply (3) fitting to 5/8 Flare x 5/8 Fitting (2). Tighten to
60 ft-lbs.
6. Install Hardline Assembly Coolant Supply (3) fitting to Water Pump Fitting (4). Tighten to 60 ft-lbs.
NOTE: Hold Hardline Assembly Coolant Supply (3) with wrench to keep from twisting during torqueing.
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Figure 3. Air Compressor Hose and Fittings
1. Fitting NPT x HB90De

2. Hose Oil Drain Air Compressor
3. Adaptor 37 Deg Flare
4. Adapter, 37 degree flare 1/2 MPT
5. Fitting FNPT x FNPT
6. Nipple FNPT x 3 w/ Hex
7. Fitting MPT x HB
8. Clamp
9. Adaptor -2 MNPT 37 DF
10. Tube Air Compressor Oil Feed
11. Rubber Hose 3/4
12. Clamp
13. Fitting MPT x HB
1. Install NPT x HB90De (1) fitting to air compressor with PTFE Sealant on threads. Tighten
1.5 to 3 turns past finger tight. Orient fitting 30 degrees counter clockwise from vertical.
2. Install MPT x HB (13) fitting to air compressor with PTFE Sealant on threads. Tighten 1.5 to
3 turns past finger tight.
3. Install Nipple FNPT x 3 w/ Hex (6) to block with PTFE Sealant on threads. Tighten 1.5 to 3
turns past finger tight.
4. Install FNPT x FNPT (5) fitting to NPTF x 3 w/ Hex (6) nipple with PTFE Sealant on
threads. Tighten 1.5 to 3 turns past finger tight. Orient fitting vertical.
5. Install MPT x HB (7) fitting to FNPT x FNPT (5) fitting with PTFE Sealant on threads.
Tighten 1.5 to 3 turns past finger tight.
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6. Install Rubber Hose between MPT x HB (7) fitting and MPT x HB (13) fitting. Secure
with clamps (8 and 12). Ensure clamps face inward to the engine.
7. Install Oil Drain Air Compressor Hose (2) on 37 Degree Flange Adaptors (3 and 4). Torque each
fitting to 40 ft-lbs.
8. Insert Adaptor -2 MNPT 37 DF (9) to air compressor with PTFE sealant on threads. Torque 1.5 to
3 turns past finger tight.
9. Install Air Compressor Oil Feed Tube (10) to -2 MNPT 37 DF (9) Adaptor. Torque to 12 ft-lbs.
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33 POWER STEERING PUMP AND BRACKET
Figure 1. Power Steering Pump and Bracket
1. Bracket
3. Bolt, M10x1.5x35
4. Bolt:
a. M10x1.5x35
b. M10x1.5x120
5. Bracket
6. Engine
NOTE
Disconnect power steering pump hoses.
REMOVAL
1. Remove two bolts (3) and power steering pump (2) from bracket (1).
2. Remove four bolts (4) and bracket (5) from cylinder block (6).
INSTALLATION
1. Install bracket (5) on cylinder block (6) with one M10x1.5x35mm and
three M10x1.5x120mm bolts (4). Tighten bolts (4) to 53 ft-lbs (72 Nm).
2. Install power steering pump (2) on bracket (1) with two M10x1.5x35mm bolts (3).
Tighten nuts (6) to 53 ft-lbs (72 Nm).
Connect power steering pump hoses.

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33 POWER STEERING PUMP AND BRACKET
BLANK
153 of 195
34 ALTERNATOR BRACKET
Figure 1. Alternator Bracket
1. Alternator Bracket
2. Bolt:
a. M10-1.5x110
b. M10-1.5x60
NOTE
REMOVAL
Remove three M10x1.5x110mm and one M10x1.5x60mm bolts (2) and bracket (1) from cylinder
block.
INSTALLATION
Install bracket (1) on cylinder block with three M10-1.5x110mm and one M10-1.5x 60mm bolts (2).
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34 ALTERNATOR BRACKET
BLANK
155 of 195
35 OIL COOLER AND OIL COOLER HOSES
Figure 1. Oil Cooler Hoses
1. Oil Cooler
2. Oil Cooler Hose
3. Oil Cooler Hose
OIL COOLER HOSE REMOVAL

1. Remove oil cooler hoses (2 and 3) from oil cooler (1).
Figure 2. Oil Cooler Hose Adapter
1. Oil Cooler Hoses

2. O-ring
3. Adapter
4. Washer
5. Bolt, M10x1.5x60
6. Cylinder Block
2. Remove two oil cooler hoses (1) from adapter (3).

3. Remove bolt (5), washer (4) and adapter (3) from cylinder block (6).
4. Remove two O-rings (2) from adapter (3). Discard O-rings (2),
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Figure 3. Oil Cooler Removal
1. Oil Cooler Fitting

3. Oil Cooler
4. Oil Cooler Bracket
5. Bolt, M8x1.25x25
OIL COOLER REMOVAL

1. Disconnect coolant hoses from fittings (1 and 2).
2. Remove four bolts (5) from oil cooler (3).
3. Remove oil cooler (3) from oil cooler bracket (4).
Figure 4. Oil Cooler Bracket
1. Engine
3. Bolt, M8-1.25x25
OIL COOLER BRACKET REMOVAL

Remove three bolts (3) and oil cooler bracket (2) from two cylinder heads (1).
OIL COOLER BRACKET INSTALLATION

Install oil cooler bracket (2) on two cylinder heads (1) with three M10-1.5x25mm bolts (3).
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Figure 5. Oil Cooler Removal

3. Oil Cooler
5. Bolt, M8x1.25x25
OIL COOLER INSTALLATION

1. Install oil cooler (3) on bracket (4) with four M8x1.25x25mm bolts (5). Tighten bolts (5) to
14 ft-lbs (19 Nm).
2. Connect coolant hoses on fittings (1 and 2).
OIL COOLER HOSE INSTALLATION
Figure 6. Oil Cooler Hose Adapter
1. Oil Cooler Hoses

2. O-ring
3. Adapter
4. washer
5. Bolt, M10x1.5x60
6. Cylinder Block
1. Install two new O-rings (2) on adapter (3).

2. Install adapter (3) on cylinder block (6) with washer (4) and M10x1.5x60mm bolt (5).Tighten bolt
(3) to 50 ft-lbs (68 Nm).
3. Connect two oil cooler hoses (1) to adapter (3).
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Figure 1. Oil Cooler Hoses
1. Oil Cooler
2. Oil Cooler Hose
3. Oil Cooler Hose
4. Connect oil cooler hoses (2 and 3) to oil cooler (1).
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BLANK
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36 STARTER MOTOR
Figure 1. Starter Motor Assembly
1. Bolt, Starter M10-1.50x110

2. Bolt, Starter Extended Thru
3. Starter
4. Bracket
5. Nut, M5 x 0.8
6. Washer, Lock M5
7. Washer, Flat #10
8. Washer, Lock #10
9. Nut, 10-24
10. Bolt, M8 X 1.25 X 16,
11. Nut, M8x1.25 Copper Plated
12. Heat Shield
WARNING
To avoid accidental engine starting, disconnect the battery cable from the negative (-)
battery terminal. Completely tape all metal surfaces of the disconnected battery cable
end in order to prevent contact with other metal surfaces.
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36 STARTER MOTOR
STARTER MOTOR BRACKET REMOVAL
Figure 2. Starter Motor
1. Bolt, M8 X 1.25 X 16
2. Washer, Flat #10
3. Washer, Lock #10
4. Nut, 10-24
6. Bracket
1. Remove Nut (4), lock washer (3), flat washer (2), and bolt (5) from starter assembly.
2. Remove bolt (1) from engine
3. Remove bracket (6) from starter assembly
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36 STARTER MOTOR
HEAT SHIELD REMOVAL
1. Heat Shield
4. Remove heat shield (1) from starter motor assembly by prying gently on the edges of the heat
shield.
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36 STARTER MOTOR
WIRING AND STARTER MOTOR REMOVAL
1. Starter S Terminal
5. Remove Nut, M5 x 0.8 and Washer, Lock M5 from S Terminal (1) on starter solenoid.
6. Remove wire harness from S Terminal (1) on starter solenoid.
7. Remove Nut (2) from battery positive stud on starter solenoid, remove battery
positive cable from stud
8. Remove two Bolts (3) from starter assembly, remove starter from engine assembly.
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36 STARTER MOTOR
WIRING AND STARTER MOTOR INSTALLATION
1. Starter S Terminal
9. Install starter motor assembly onto engine by fastening two bolts (3) to engine block.
Torque two starter bolts (3) to 37 ft/lbs.
10. Install wire harness onto S Terminal (1) at starter solenoid with Nut, M5 x 0.8 and
Washer, Lock M5. Route wire harness the same as it was prior to removal. Torque
M5 nut to 30 in/lbs.
11. Install Battery positive cable onto starter solenoid battery positive terminal with nut
(2). Torque nut (2) to 7 ft/lbs.
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36 STARTER MOTOR
HEAT SHIELD INSTALLATION
1. Heat Shield
12. Line up tab on the heat shield(Point A) with the slot on starter solenoid(Point B)
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36 STARTER MOTOR
STARTER BRACKET INSTALLATION
1. Bolt, M8 X 1.25 X 16
2. Washer, Flat #10
3. Washer, Lock #10
4. Nut, 10-24
6. Bracket
13. Install bracket (6) onto engine block and starter assembly using bolt (1) to secure it to
the engine block. Torque bolt (1) to 18 ft/lbs.
14. Install hardware bolt (5) to secure bracket (3) to the starter. Torque bolt (5) to 40 in/lbs.
15. Install hardware flat washer (2), lock washer (3), and nut (4) to starter. Torque to 20 in/lbs.
16. Install Battery negative (-) cable on battery using the OEM recommended procedure.
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36 STARTER MOTOR
BLANK
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36 OIL PRESSURE SENSOR
Figure 1. Oil Pressure Sensor
1. Cylinder Block
2. Oil Pressure Sensor
REMOVAL
Remove oil pressure sensor (2) from cylinder block (1).
INSTALLATION
1. Apply White Permatex thread sealant to threads of oil pressure switch/sensor (2).
2. Install oil pressure sensor (2) in cylinder block (1). Tighten oil pressure
sensor (2) to 22 ft-lbs (30 Nm).
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36 OIL PRESSURE SENSOR
BLANK
170 of 195
37 WINTERIZATION KIT
Figure 1. Oil Heater
1. Oil Heater
2. Oil Pan
OIL HEATER REMOVAL

NOTE
Using suitable container, drain motor oil from oil pan.
Remove oil heater (1) from oil pan (2).
OIL HEATER INSTALLATION

1. Apply white Permatex thread sealant to threads of oil heater (1).
2. Install oil heater (1) in oil pan (2). Tighten oil heater (1) to 30 ft-lbs (41 Nm).
Fill engine with approved 5W30 engine oil.
171 of 195
Figure 2. Block Heater
1. Cylinder Block
2. Block Heater
BLOCK HEATER REMOVAL

NOTE
Block Heater is manufactured to be installed ONE TIME ONLY, DO NOT reuse the heater
Drain cooling system prior to block heater removal.
1. Remove block heater (2) from cylinder block (1).
2. Discard block heater (2).
BLOCK HEATER INSTALLATION

NOTE
Block heater is installed in third hole from oil filter housing.
1. Apply a thin coating of O-Ring Lube (Ex. Parker Super-O-Lube) to the block heater (2) O-Ring
and machined surface of core hole (to facilitate installation and prevent O-ring damage).
2. Install block heater (2) in cylinder block (1). Tighten block heater (2) to 23 in-lbs (3 Nm).
Fill coolant system after installing block heater.
172 of 195
BLANK
173 of 195
38 TORQUE SPECIFICATIONS
Thread Locker
Component Bolt Type Qty /Lubricant Torque
(or equivalent)
Air Comp Bracket Idler
1 Blue Loctite 32 ft-lbs (43 Nm)
Pulley 75mm
Air Comp Bracket Idler
Pulley 90mm
Air Comp Bracket
M10-1.5x70 1 53 ft-lbs (72 Nm)
Tensioner
Air Comp Coolant Hardline
2 60 ft-lbs (81 Nm)
Fittings
Air Comp Oil Drain Fittings 2 40 ft-lbs (54 Nm)
Air Comp Oil Drain Pan
3/4-16 1 40 ft-lbs (54 Nm)
Fitting
Air Comp Oil Feed Fittings 2 12 ft-lbs (16 Nm)
Air Comp Oil Feed
M6-1.0 Nut 3 80 in-lbs (9 Nm)
P-Clamps
Air Comp Oil Feed
M6-1.0x16 1 80 in-lbs (9 Nm)
P-Clamps
Air Compressor M10-1.5 Nut 4 53 ft-lbs (72 Nm)
Air Compressor Bracket M10-1.5x45 1 53 ft-lbs (72 Nm)
Air Compressor Pulley Nut 1 150 ft-lbs (203 Nm)
Alt/AC Bracket M10-1.5x60 1 53 ft-lbs (72 Nm)
Alt/AC Bracket M10-1.5x110 3 53 ft-lbs (72 Nm)
Alt/AC Bracket Idler Pulley 1 Blue Loctite 53 ft-lbs (72 Nm)
Alt/AC Bracket Tensioner M10-1.5x60 1 Blue Loctite 53 ft-lbs (72 Nm)
Block Heater 23 in-lbs (2.6 Nm)
Breather Boxes M6-1.0 Nut 8 Blue Loctite 106 in-lbs (12 Nm)
Camshaft Retainer M6-1.0 2 Blue Loctite 106 in-lbs (12 Nm)
Camshaft Sensor M6-1.0x15 1 Blue Loctite 106 in-lbs (12 Nm)
Camshaft Sprocket M8-1.25x25 3 Blue Loctite 22 ft-lbs (30 Nm)
Coil Packs M6-1.0x25 16 106 in-lbs (12 Nm)
Connecting Rod Caps 7/6-20x1.594 in. 16 Anti Seize 70 ft-lbs (95 Nm)
Coolant Crossover M10-1.5x30 4 40 ft-lbs (54 Nm)
Coolant Hardline P-Clamp M8-1.25 Nut 1 18 ft-lbs (24 Nm)
Coolant Outlet M6-1.0x16 1 60 in-lbs (7 Nm)
Coolant Sensor 1 15 ft-lbs (20 Nm)
Crankshaft Balancer 1/2-20 1 Blue Loctite 90 ft-lbs (122 Nm)
Crankshaft Speed Sensor M6-1.0x15 1 Blue Loctite 106 in-lbs (12 Nm)
174 of 195
Thread Locker
(or equivalent)
22 ft-lbs (30 Nm)
Cylinder Head White Permatex
M10-1.5x103 24 - +120 degrees
(Long Bolts) Thread Sealant
- +60 degrees
22 ft-lbs (30 Nm)
M10-1.5x86 4 - +120 degrees
(Medium Bolts) Thread Sealant
- +45 degrees
22 ft-lbs (30 Nm)
M10-1.5x52 8 - +120 degrees
(Short Bolts) Thread Sealant
- +30 degrees
Dipstick M10-1.5x15 1 30 ft-lbs (41 Nm)
Dust Cover Oil Filter Side 1/4-20x1/2 2 90 in-lbs (10 Nm)
Dust Cover Starter Side 1/4-20x1/2 2 90 in-lbs (10 Nm)
ECU Isolators 1/4-20 Nut 4 65 in-lbs (7 Nm)
Engine Ground Stud M10-1.25 1 106 in-lbs (12 Nm)
Exhaust Manifold M8-1.25 16 22 ft-lbs (2.5 Nm)
Exhaust Manifold Head
M6-1.0x10 2 80 in-lbs (9 Nm)
Shield
Flywheel/Hub/Spacer 7/16-20x3.25 6 Blue Loctite 50 ft-lbs (68 Nm)
Front Breather Fitting 1 Pipe Sealant 106 in-lbs (12 Nm)
Front Mount M12-1.75x50 4 Blue Loctite 70 ft-lbs (95 Nm)
M6-1.0 Nylon
Fuel Rail Hold Down Nuts 4 85 in-lbs (10 Nm)
Lock
Fuel Rail Spacers 4 Blue Loctite 85 in-lbs (10 Nm)
Stage 1 - 40 in-lbs
(4.5 Nm)
Stage 2 - 80 in-lbs
Intake Manifold (9 Nm)
M6-1.0x75 10 Blue Loctite
(Tighten in three stages) Stage 3 - 120 in-lbs
(14 Nm)
Stage 4 - 154 in-lbs
(17 Nm)
Lifter Retainer M8-1.25x16 4 Blue Loctite 22 in-lbs (2.5 Nm)
33 - 66 - 100 ft-lbs
Main Bearing Caps 1/2-13x2.75 10 Anti-Seize
(45 - 89 - 136 Nm)
33 - 66 - 100 ft-lbs
Main Bearing Caps 1/2-13x3.75 10 Anti-Seize
(45 - 89 - 136 Nm)
MAP Sensor M6-1.0x16 1 106 in-lbs (12 Nm)
No AC Bracket M8-1.25x25 3 Blue Loctite 27 ft-lbs (37 Nm)
No AC Bracket Idler Pulley 1 Blue Loctite 53 ft-lbs (72 Nm)
Oil Cooler to Bracket M8-1.25x25 4 14 lb-ft (19 Nm)
Oil Cooler Bracket to
M10-1.5x25 3 37 ft-lbs (50 Nm)
Cylinder Head
Oil Cooler Coolant
1 60 ft-lbs (81 Nm)
Return Hose Fitting
Oil Cooler Coolant
M6-1.0x16 1 60 in-lbs (7 Nm)
Return Hose P-Clamp
175 of 195
Thread Locker
(or equivalent)
Oil Cooler Lines 4 40 ft-lbs (54 Nm)
Oil Cooler Coolant
M8-1.25x12 2 14 ft-lbs (19 Nm)
Return Hose P-Clamp
Oil Cooler PCV Clip Bracket M8-1.25x25 2 14 ft-lbs (19 Nm)
Oil Cooler Top Coolant
1/4-20x1 1 80 in-lbs (9 Nm)
Hose P-Clamp
Oil Distribution Block M10-1.5x60 1 50 ft-lbs (68 Nm)
Oil Distribution Block
2 40 ft-lbs (54 Nm)
Fittings
Oil Filter 1 20 ft-lbs (27 Nm)
Oil Filter Adapter 1 49 ft-lbs (66 Nm)
Oil Pan M8-1.25x25 12 Blue Loctite 22 ft-lbs (30 Nm)
Oil Pan -Trans Housing M12-1.75x40 2 Blue Loctite 70 ft-lbs (95 Nm)
Oil Pan Drain Plug 1 21 ft-lbs (28 Nm)
Oil Pan Heater 30 ft-lbs (41 Nm(
Oil Pressure Switch/Sensor White Permatex 22 ft-lbs (30 Nm)
Oil Pump Assembly M10-1.5x60 1 Red Loctite 60 ft-lbs (81 Nm)
Oil Pump Drive M8-1.25x25 1 Blue Loctite 22 ft-lbs (30 Nm)
Oil Supply Bracket M10-1.5x20 2 32 ft-lbs (43 Nm)
Oxygen Sensor 4 29-44 ft-lbs (40-60 Nm)
PCV Tube P-Clamp M6-1.0x16 1 7 ft-lbs (9.5 Nm)
Power Steering Bracket
Idler Pulley
Power Steering Pump M10-1.5x35 2 53 ft-lbs (72 Nm)
Power Steering Pump
M10-1.5x35 1 53 ft-lbs (72 Nm)
Bracket
Power Steering Pump
M10-1.5x120 3 53 ft-lbs (72 Nm)
Bracket
Power Steering Pump
1/2-20 Nut 1 66 ft-lbs (89 Nm)
Pulley
Rear Lifting Eye Drivers
M10-1.5x25 3 37 ft-lbs (50 Nm)
Side
Rear Lifting Eye
M10-1.5x25 2 37 ft-lbs (50 Nm)
Passengers Side
Rear Lifting Eye
M10-1.5x30 1 37 ft-lbs (50 Nm)
Passengers Side
Rear Mounts M12-1.75x45 8 Blue Loctite 90 ft-lbs (122 Nm)
Spark Plug Wire P-Clamps
M6-1.0 Nut 3 80 in-lbs (9 Nm)
Drivers Side
Spark Plugs 8 22 ft-lbs (30 Nm)
Starter M10-1.5x110 2 37 ft-lbs (50 Nm)
Starter Bracket M8-1.25x16 1 18 ft-lbs (24 Nm)
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Starter Bracket 10-24 Nut 2 20 in-lbs (2 Nm)

Thread Locker/
Component Bolt Type Qty Lubricant Component
(or equivalent)
Thermostat Tube M8-1.25x25 2 18 ft-lbs (24 Nm)
Throttle Body M6-1.0x45 4 106 in-lbs (12 Nm)
Timing Chain Cover M6-1.0x25 6 Blue Loctite 106 in-lbs (12 Nm)
Trans Housing M10-1.5x35 5 Blue Loctite 40 ft-lbs (54 Nm)
Trans Housing M10-1.5x65 2 Blue Loctite 40 ft-lbs (54 Nm)
Trans Housing-Oil Pan M12-1.75x40 2 Blue Loctite 70 ft-lbs (95 Nm)
Trans Housing Access
1/4-20x1/2 in. 4 90 in-lbs (10 Nm)
Cover
Valley Cover M6-1.0x16 14 Blue Loctite 106 in-lbs (12 Nm)
Valve Covers M6-1.0x24 14 106 in-lbs (12 Nm)
Valve Rocker Bolts 16 5W30 Motor Oil 20 ft-lbs (27 Nm)
Vanity Cover/Cover
M6-1.0x20 8 96 in-lbs (11 Nm)
Brackets
Water Pump M10-1.5x65 4 40 ft-lbs (54 Nm)
Water Pump Pulley M8-1.25x16 4 18 ft-lbs (24 Nm)
Wiring Harness Drivers
M12-1.75x40 1 32 ft-lbs (43 Nm)
Side Mount
Wiring Harness Passengers
1/4-20 nut 1 80 in-lbs (9 Nm)
Side Mount
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BLANK
178 of 195
39 MECHANICAL SPECIFICATIONS
Specification
Application
English Metric
General
Engine Type V8
Displacement 537 CID 8.8L
Bore 4.35 in. 110.49 mm
Stroke 4.50 in. 114.30 mm
Compression Ratio 10:01
Firing Order 1-8-7-2-6-5-4-3
Spark Plug Gap 0.030 0.035
Block
74.5998
Crankshaft Main Bearing Bore Diameter 2.93702.9380 in.
- 74.6252 mm
110.4798
Cylinder Bore Diameter 4.34964.3504 in.
-110.500 mm
Cylinder Bore Out-of-Round
0.0008 in. 0.020 mm
Maximum Minus Minimum Bore Diameter
Cylinder Bore Taper 0.00071 in. 0.0180 mm
Cylinder Head Deck Height - from Centerline of 260.198
10.24410.246 in.
Crankshaft 260.248 mm
Cylinder Head Deck Surface Flatness - Entire Face 0.002 in 0.051 mm
Camshaft Bearing Bore Diameter (1) 2.1395 - 2.1405 in. 54.343 -54.368 mm
Camshaft Bearing Bore Diameter (2) 2.1295 - 2.1305 in. 54.089 -54.114 mm
Camshaft Bearing Bore Diameter (3/4) 2.1195 - 2.1205 in. 53.835 -53.860 mm
Camshaft Bearing Bore Diameter (5) 2.1295 - 2.1305 in. 54.089 -114 mm
Core Plug press (steel) 0.008 - 0.010 in. 203 -.254 mm
Core Plug press, cam tunnel (steel) 0.008 - 0.010 in. 203 -.254 mm
130.835
Crank to Camshaft Centerline 5.151 - 5.153 in.
-130.886 mm
Crank trigger distance - Relative to rear thrust face 0.324 - 0.344 in. 8.229 - 8.737 mm
Camshaft
Camshaft Journal Diameter 1.9491.948 in. 49.50549.479 mm
Camshaft Lobe Lift - Intake 0.2701 in. 6.860 mm
Camshaft Lobe Lift - Exhaust 0.2143 in. 5.443 mm
Camshaft Run out 0.002 in. 0.051 mm
Connecting Rod
Connecting Rod Bearing Clearance Small End 0.00060.0016 in. 0.0150.041 mm
Connecting Rod Bearing Clearance Large End 0.00130.0032 in. 0.0330.081 mm
Connecting Rod Side Clearance 0.020-.025 in. 0.5080.635 mm
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Specification
Application
English Metric
Crankshaft
Connecting Rod Journal Diameter 2.19902.1996 in. 55.85455.870 mm
Connecting Rod Journal Out-of-Round 0.0005 in. 0.013 mm
Connecting Rod Journal Taper 0.0005 in. 0.013 mm
Crankshaft End Play 0.0060.012 in. 0.150.30 mm
Crankshaft Main Bearing Clearance - #1, #2, #3, 0.03
0.0010.004 in.
#4 0.10 mm
Crankshaft Main Bearing Clearance - #5 0.00060.0036 in. 0.0150.009 mm
Crankshaft Main Journal Diameter (#1 - #4) 2.750 - 2.7505 in. 69.850-69.863 mm
Crankshaft Main Journal Diameter (#5 Only) 2.7492 - 2.7505 in. 69.830-69.863 mm
Crankshaft Main Journal Out-of-Round 0.0005 in. 0.0127 mm
Crankshaft Main Journal Taper 0.0005 in. 0.0127 mm
Crankshaft Runout 0.002 in 0.051 mm
Cylinder Head
Surface Flatness - Block Deck 0.002 in. 0.051 mm
Surface Flatness - Exhaust Manifold Deck 0.004 in. 0.102 mm
Surface Flatness - Intake Manifold Deck 0.003 in. 0.080 mm
Exhaust Manifold
Surface Flatness 0.004 in. 0.102 mm
Lubrication System
Oil Capacity - Without Filter 7.0 qts 6.62 L
Oil Pressure - Minimum 5psi @ 1,000 RPM 34kPa @ 1,000 RPM
Oil Pressure - Minimum 15psi @ 2,000 RPM 103kPa @ 2,000 RPM
Piston Ring End Gap
First Compression Ring 0.024-.030 in. 0.60960.762 mm
Second Compression Ring 0.029-.035 in 0.7360.889 mm
Oil Control Tension 13 -19.4 Lbs
Piston Ring to Groove Clearance
First Compression Ring 0.002-.0025 in. 0.05080.0635 mm
Second Compression Ring 0.0020.0025 in. 0.05080.0635 mm
Pistons
Piston Major Diameter 4.3478-4.3482 in. 110.434 110.444 mm
Piston to Bore Clearance 0.0014-0.0026 in. 0.036-0.066 mm
Valves
Valve Face Angle - Exhaust 45 degrees
Valve Face Angle - Intake 45 degrees
Valve Lash Exhaust (Hydraulic Lifters) Net Lash Net Lash
Valve Lash Intake (Hydraulic Lifters) Net Lash Net Lash
Valve Seat Angle - Exhaust 45 +/- 0.25 degrees
Valve Seat Angle - Intake 45 +/- 0.25 degrees
Valve Seat Width - Exhaust 0.0700.090 in. 1.7782.286 mm
Valve Seat Width - Intake 0.0700.090 in. 1.7782.286 mm
Valve Stem-to-Guide Clearance - Intake 0.00080.0022 in. 0.00080.0203 mm
Valve Stem-to-Guide Clearance - Intake 0.00190.0032 in. 0.00190.0482 mm
180 of 195
Application Specification
English Metric
Rocker Arms
Valve Rocker Arm Ratio 1.8:1
Valve Springs
Valve Spring Free Length 2.084 in. 52.93 mm
Valve Spring Installed Height - Intake 1.790 - 1.810 in.
Valve Spring Installed Height - Exhaust 1.790 - 1.810 in.
Valve Spring Load, Installed Height, Intake 105 lbs
Valve Spring Load, Installed Height, Exhaust 105 lbs
181 of 195
BLANK
182 of 195
40 SPECIAL TOOLS
Description PSI P/N OEM P/N Equivalent Image

P/N
Flywheel Holder 108400 J-42847
Front Cover 12-174-01

108401
Seal Installer
Oil Pressure
108402 J-41712
Socket
Rear Seal Puller 108403 12-183-02
Cylinder Head
108404 OTC5609
Leakdown Tester
Valve Spring
108405 J3049-A
Compressor
183 of 195
40 SPECIAL TOOLS

P/N
Harmonic OTC4531
108406
Balancer Puller
Angle Meter 108407 28100
Spark Plug Boot SES824A

108408 51750
Puller
Oxygen Sensor 88750B

108409 7807
Remover/Installer
Spark Tester 108410 6589 OTC6589
184 of 195
40 SPECIAL TOOLS
Compression 5606 or OTC5606

108411
Tester 5605

P/N
Cooling System 5606 or

108412
Pressure Tester 5605
Oil Pressure Test

108413 5610
Kit
Fuel Pressure 15-127-02

108273
Gauge Testing Kit
"3-Switch" Test
108272 15-127-01
Box
Harmonic Balancer
Installer
108415
(tool assembly
instructions below)
185 of 195
40 SPECIAL TOOLS
12-183-03
Rear Seal Installer 108415
Powerlink
Programming 33001819 12-716-01
Cable

P/N
Tank Evacuation
108270
System
Crankshaft
Protector 12-075-01
Noid Light 15-909-01
Propane Leak
Detector D540
Oil Pressure Test OTC5610

108413 12-889-05
Fitting
Fuel line plug and

cap kit 15-643-01
186 of 195
40 SPECIAL TOOLS
P/N 108415 HARMONIC BALANCER INSTALLATION TOOL
ASSEMBLY INSTRUCTIONS
NOTE
Assemble harmonic balancer installation tool before use.
Apply blue Loctite to threads of 1/2-20x2.5 in. stud (2) on one end. Install 1/2-20x2.5 in. stud (2) in end
of installation rod (1). Leave 1/2-20x2.5 in. stud (2) extending from installation rod by 1.10 in..
187 of 195
42 Servicing Alternative Fuel Tank Assembly
WARNING
Before performing any work on the fuel tank assembly, verify the tank has
been properly drained.
1. Drain/purge fuel from the system Refer to Fuel Tank Draining

2. Remove fuel tank stone shield, if equipped
3. Remove the fuel tank assembly, if necessary Refer to fuel tank assembly removal
according to the original equipment manufacturer (OEM) instructions
4. After draining the tank refer to the proper component replacement procedure below
LIQUID PROPANE DELIVERY MODULE (LPDM) REPLACEMENT
Figure 1. Liquid Propane Delivery Module
188 of 195
WARNING
Fuel line may contain pressurized fuel, wear proper safety equipment, slowly
loosen the lines to relieve pressure.
1. Remove the electrical connector and fuel supply hoses from the LPDM assembly (if
applicable) (Figure 1, item 1)
2. Remove and discard the 8 LPDM bolts (Figure 1, item 2)
3. Pull the LPDM away from the tank to gain access to the fuel pump hose, remove the
fuel line from the LPDM
4. Remove the LPDM assembly
5. Remove and discard the O-ring seal (Figure 1, item 3)
6. Inspect the tank for debris, corrosion, etc. Clean as necessary
FUEL PUMP, FUEL FILTER, SCAVENGE PUMP SERVICE (WITH LPDM

REMOVED)
Figure 2. Fuel Pump, Fuel Filter, Scavenge Pump
189 of 195
With the LPDM removed the following components may be serviced if required. (Figure 2)
1. Scavenge Pump
2. Scavenge Pump wiring
3. Fuel Pump
4. Fuel Filter
5. Clamp Filter to Tank Bracket
6. Tank Bracket
7. Clamp Scavenge Pump to Tank Bracket
Figure 3. Fuel Tank Assembly (showing general area of magnets)
LPDM REPLACEMENT (CONTINUED)
7. Inspect clean the magnets located inside the tank, 6 located near the front of tank
(Figure 3, item 1) and 2 located towards the rear of the tank (Figure 3, item 2)
8. Lubricate the new O-ring with engine oil
9. Install the fuel pump hose to the LPDM and tighten clamp
10. Install the LPDM (Figure 3, item 3)
11. Install 8 new bolts and hand tighten in the cross pattern
12. Tighten the 8 new bolts in a cross pattern to 27-34 Nm (20-25 ft lbs)
190 of 195
PRESSURE RELIEF VALVE REPLACEMENT
Figure 4. Pressure Relief Valve
Important: Use only the wrench flats (Figure 4, item 1) on the pressure relief valve (Figure 4,
item 2) to remove and install the valve
1. Remove the pressure relief valve (Figure 4, item 2)

2. Clean tank threads
3. Apply approved thread sealer on the pressure relief valve threads only
4. Install the new pressure relief valve and O-ring
5. Hand tighten the pressure relief valve
6. Turn the valve an additional 2-2.5 turns with the proper tool
191 of 195
LIQUID SERVICE VALVE REPLACEMENT
Figure 5. Liquid Service Valve
Important: Use only the wrench flats (Figure 5, item 2) on the liquid service valve (Figure 5,
Note: The model number is stamped on the wrench flat.
1. Remove the liquid service valve (Figure 5, item 1)

3. Apply approved thread sealer on the liquid service valve threads only
4. Install the new liquid service valve
5. Hand tighten and then turn an additional 2-2.5 turns
6. Tighten valve to proper orientation to other components
192 of 195
80% STOP FILL VALVE REPLACEMENT
Figure 6. 80% Stop Fill Valve
Important: Use only the wrench flats (Figure 6, item 1) on the 80% stop fill valve (Figure 6,
1. Remove the 80% stop fill valve (Figure 6, item 2)

3. Apply approved thread sealer on the 80% stop fill valve threads only
4. Install the new 80% stop fill valve
5. Verify a minimum of 6 full threads are in contact with the tank threads
6. Tighten valve until the words TOP are level in relation to the top of the tank. This
ensures the 80% stop fill valve is clocked properly
193 of 195
80% LIQUID LEVEL VALVE (SPIT VALVE) REPLACEMENT
Figure 7. 80% Liquid Level Valve
Important: Use only the wrench flats on the 80% liquid level valve to remove and install the
valve
1. Remove the 80% liquid level valve (Figure 7, Item 1)

3. Apply approved thread sealer on the 80% liquid level valve threads only
4. Install the new 80% liquid level valve and O-ring
5. Hand tighten the 80% liquid level valve and then turn an additional 1-1.5 turns.
6. Tighten valve to proper orientation to other components.
194 of 195
FUEL LEVEL SENSOR REPLACEMENT
Figure 8. Fuel Level Sensor Assembly
CAUTION
Do not over torque the fuel level sensor bolts, damage to the sensor head may
occur.
1. Remove the 4 fuel level sensor assembly bolts (Figure 8, Item 1)

2. Remove the fuel level sensor assembly (Figure 8, Item 2) from the tank
3. Remove the 2 fuel level sensor screws (Figure 8, Item 3)
4. Remove the fuel level sensor (Figure 8, Item 4)
5. Discard the gasket
6. Install the new fuel level gasket
7. Install the fuel level sensor, verify the float arm is in the proper position
8. Install the 4 fuel level sensor bolts and torque in a cross pattern to 2.3-5.6 Nm (20-50
lb in)
195 of 195

PSI 8.8L Service

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PSI 8.8L Service

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PSI 8.

8L PROPANE ENGINE SERVICE MANUAL

Power Solutions International, Inc (PSI)

Revision Level Release Date Change Description (s)

01 THEORY OF OPERATION AND ENGINE COMPONENTS ..............................

02 ENGINE LUBRICATION ....................................................................................

04 MECHANICAL DIAGNOSTIC PROCEDURES ..................................................

05 FRONT ENGINE ACCESSORY DRIVE (FEAD)................................................

07 LPG FUEL SYSTEM SERVICE .........................................................................

08 INTAKE MANIFOLD ..........................................................................................

09 VALVE COVERS ...............................................................................................

10 EXHAUST MANIFOLD ......................................................................................

11 OIL LEVEL INDICATOR TUBE..........................................................................

15 CYLINDER HEAD INSPECTION .......................................................................

16 CRANKSHAFT BALANCER AND FRONT SEAL ..............................................

17 TIMING COVER, TIMING CHAIN, AND SPROCKETS .....................................

18 OIL PUMP DRIVE..............................................................................................

19 CAMSHAFT REMOVAL, CLEANING AND INSPECTION,

20 CAMSHAFT BEARING REPLACEMANT ..........................................................

21 OIL FILTER ADAPTER AND BYPASS VALVES ..............................................

25 ENGINE OIL FILTER AND OIL REPLACEMENT ..............................................

27 WATER CROSSOVER AND THERMOSTAT ....................................................

28 CRANKSHAFT AND CRANKSHAFT POSITION SENSOR

29 CRANKSHAFT CLEANING AND INSPECTION ................................................

30 CYLINDER BLOCK CLEANING AND INSPECTION .........................................

31 PISTON REMOVAL, CLEANING, INSPECTION, AND INSTALLATION ...........

32 AIR COMPRESSOR AND BRACKET................................................................

34 ALTERNATOR BRACKET .................................................................................

35 OIL COOLER AND OIL COOLER HOSES ........................................................

37 OIL PRESSURE SWITCH/SENSOR .................................................................

38 WINTERIZATION KIT ........................................................................................

39 TORQUE SPECIFICATIONS....................................................................... 174

40 MECHANICAL SPECIFICATIONS............................................................... 179

41 SPECIAL TOOLS LIST ................................................................................ 183

42 FUEL TANK AND FUEL FILL FILTER ......................................................... 188

PISTONS AND CONNECTING RODS

PROPANE FUEL SYSTEM

FIGURE 1. FRONT VIEW

FIGURE 2. REAR VIEW

FIGURE 3. TOP VIEW

FIGURE 4. LEFT VIEW

FIGURE 5. RIGHT VIEW

Figure 1. Oil Flow

1. Oil Pump Drive

Figure 2. Oil Filter Bypass Valve

1. Oil Filter Bypass Valve

Figure 3. Oil Cooler Bypass Valve

1. Oil Cooler Bypass Valve

Figure 4. Plugged Oil Cooler and Oil Filter

1. Oil Cooler Bypass Valve

WARNING: A warning describes actions necessary to prevent or eliminate conditions, hazards,

Always disconnect negative battery cable first.

Ensure all tools are in good condition.

Fluids Under Pressure

Use caution when working on systems under pressure.

Removal of Tools, Parts, and Equipment

Propane Safety Instructions

DISASSEMBLY, CLEANING, AND MARKING

When disassembling the engine internal components MUST be separated, marked or

Separate, mark, or organize the following components:

Piston to cylinder block bore

CLEANING GASKET SURFACES

SEALANT TYPES AND USES

The following two types of sealant are used on this engine: