Manual Part No.

0E7738

5.0 5.7
&

LITER

GM
GAS
ENGINE

SERVICE
MANUAL

FOREWORD
This manual has been published by GENERAC POWER SYSTEMS,
INC. to aid our dealers mechanics, company service personnel and
general consumers when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing
procedures for these products, or like or similar products, manufactured and marketed by GENERAC POWER SYSTEMS, INC. It is also
assumed that they have been trained in the recommended servicing
procedures for these products, which includes the use of mechanics
hand tools and any special tools that might be required.
Proper service and repair is important to the safe, economical and
reliable operation of the products described herein. The troubleshooting, testing, service and repair procedures recommended by
GENERAC POWER SYSTEMS, INC. and described in this manual are
effective methods of performing such operations. Some of these
operations or procedures may require the use of specialized equipment. Such equipment should be used when and as recommended.
We could not possibly know of and advise the service trade of all
conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation.
Therefore, anyone who uses a procedure or method not recommended by the manufacturer must first satisfy himself that neither
his safety, nor the products safety, will be endangered by the service or operating procedure selected.
All information, illustrations and specifications contained in this
manual are based on the latest product information available at the
time of publication. However, GENERAC POWER SYSTEMS, INC.
reserves the right to change, alter or otherwise improve the product
at any time without prior notice.
Some components or assemblies of the product described in this
manual may not be considered repairable. Disassembly, repair and
reassembly of such components may not be included in this manual.
The engines described herein may be used to power a wide variety
of products. Service and repair instructions relating to any such
products are not covered in this manual. For information pertaining
to use of these engines with other products, refer to any owners or
service manuals pertaining to said products.

5.0/5.7 Liter Gas Engine Table of Contents

SERVICE RECOMMENDATIONS

................................................................................................................ A_2

TORQUE SPECIFICATIONS .......................................................................................................... 6-1 THRU 6-3

ENGINE MECHANICAL SPECIFICATIONS .................................................................................. 6-3 THRU 6-7
COMPONENT LOCATOR ............................................................................................................ 6-9 THRU 6-15
ENGINE IDENTIFICATION

.......................................................................................................................... 6-16

REPAIR INSTRUCTIONS ........................................................................................................ 6-17 THRU 6-139

DESCRIPTION AND OPERATION ........................................................................................ 6-140 THRU 6-141
LUBRICATION............................................................................................................................6-142 THRU 6-143
CLEANLINESS AND CARE............................................................................................................................6-143
REPLACING ENGINE GASKETS ..................................................................................................................6-143
USE OF RTV AND ANAEROBIC SEALER ....................................................................................................6-144
SPECIAL TOOLS AND EQUIPMENT .................................................................................... 6-146 THRU 6-148

The 5.0/5.7 Liter Gas Engine has been engineered

for use in Generac Power Systems products. The
contents of this manual have been reprinted from the
original manufacturers service and repair manual.

5.0/5.7 Liter Gas Engine Service Recommendations

ENGINE OIL RECOMMENDATIONS

DANGER

The unit has been filled with break in engine oil

at the factory. Use a high-quality detergent oil classified For Service CC, SD, SE or SF. Detergent oils
keep the engine cleaner and reduce carbon deposits.
Use oil having the following SAE viscosity rating,
based on the ambient temperature range anticipated
before the next oil change:
Engine Lubrication System:

!
!

Type of Oil Pump .......................................................................... Gear

Oil Filter ................................................................ Full Flow, Cartridge
Crankcase Oil Capacity ...................................... 4.75 L (5.0 U.S. qts.)

COOLANT

Temperature
Above 75 F (24 C)
40 to 75 F (4.4 to 24 C)
10 to 40 F (-12 to 4.4 C)
Below 10 F (-12 C)

Oil Grade (Recommended)

SAE 30W
SAE 20W or 15W-40
SAE 10W or 15W-40
SAE 5W or 5W-20

Use a mixture of half low silicate, ethylene glycol base

antifreeze and half soft water. Use only soft water and
only low silicate antifreeze. If desired, you may add a
high quality rust inhibitor to the recommended
coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
Cooling System:
Type .................................................... Pressurized, Closed Recovery
Coolant Capacity
System ................................................................ 19 L (5 U.S. gals.)

A_2

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous. Do
not use your mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
your hands thoroughly after handling. Never
store used antifreeze in an open container
because animals are attracted to the smell and
taste of antifreeze even though it is poisonous
to them.

Do not use any chromate base rust inhibitor with

ethylene glycol base antifreeze, or chromium
hydroxide (green slime) will form and cause
overheating. Engines that have been operated
with a chromate base rust inhibitor must be
chemically cleaned before adding ethylene glycol
base antifreeze. Using any high silicate antifreeze
boosters or additives also will cause overheating.
We also recommend that you DO NOT use any
soluble oil inhibitor for this equipment.

5.0/5.7 Liter Gas Engine Service Recommendations

PERIODIC MAINTENANCE SCHEDULE:

SERVICE SCHEDULE
AUTHORIZED OPERATOR MAINTENANCE
FUNCTIONS
Every Month or 100 Hours
(whichever comes first)

Test standby generator system.

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

Every Three Months or Every 120 Hours

(whichever comes first)

Inspect and test fuel system and connections.

Inspect exhaust system.
Inspect/test fuel supply system.

AUTHORIZED SERVICE TECHNICIAN

MAINTENANCE FUNCTIONS
After First 30 Hours of Operation

Inspect wiring.
Change engine crankcase oil and oil filter.
Inspect engine fan belts.
Inspect battery and cables.

Annually or Every 600 Hours

(whichever comes first)

Every Two Years

Replace all rubber hoses.

Replace engine fan belts.
Inspect the Standby Generator System.
Drain, flush, refill cooling system.

Every 1,000 Operating Hours

Inspect engine DC alternator.

Inspect engine starter.
Retorque engine mounting brackets.
Remove/test fuel injection pump.
Remove/test cooling system thermostat.

As Required
Bleed engine fuel system.

Every Six Months or Every 100 Hours

(whichever comes first)

Check engine valve clearance.

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

Change engine oil and filter.

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

A_3

Notes

Engine

Engine Mechanical - 5.0L and 5.7L

Engine Mechanical - 5.0L and 5.7L

Specifications
SIE-ID = 784227

Fastener Tightening Specifications

Specification
Application
Accelerator Control Cable Bracket Bolt and Nut
Belt Idler Pulley Bolt

Metric

English

12 Nm

106 lb in

50 Nm

37 lb ft

Camshaft Retainer Bolt

2129 Nm

1521 lb ft

Camshaft Sprocket Bolt

3040 Nm

2230 lb ft

Connecting Rod Nut

First Pass

27 Nm

Final Pass
Crankshaft Balancer Bolt

20 lb ft
70 degrees

95 Nm

70 lb ft

Crankshaft Bearing Cap Bolt and Stud Preferred Method

First Pass Two Bolt Type Bearing Cap

20 Nm

Final Pass Two Bolt Type Bearing Cap

First Pass Four Bolt Type Bearing Cap

15 lb ft
73 degrees

20 Nm

15 lb ft

Final Pass Outboard Bolt Four Bolt Type Bearing Cap

43 degrees

Final Pass Inboard Bolt and Stud Four Bolt Type Bearing Cap

73 degrees

Crankshaft Bearing Cap Bolt and Stud Optional Strategy

Two Bolt Type Bearing Cap

105 Nm

77 lb ft

Inboard Bolt and Stud Four Bolt Type Bearing Cap

105 Nm

77 lb ft

Outboard Bolt Four Bolt Type Bearing Cap

90 Nm

66 lb ft

40 Nm

30 lb ft

Crankshaft Position Sensor Bolt

9 Nm

80 lb in

Crankshaft Pulley Bolt

58 Nm

43 lb ft

Crankshaft Rear Oil Seal Housing Nut and Bolt

12 Nm

106 lb in

Crankshaft Rear Oil Seal Housing Retainer Stud

6 Nm

53 lb in

30 Nm

22 lb ft

Crankshaft Oil Deflector Nut

Cylinder Head Bolt Preferred Method

All Bolts First Pass in Sequence
Long Bolt Final Pass in Sequence

75 degrees

Medium Bolt Final Pass in Sequence

65 degrees

Short Bolt Final Pass in Sequence

55 degrees

Cylinder Head Bolt Optional On-Vehicle Strategy

First Pass in Sequence

35 Nm

26 lb ft

Second Pass in Sequence

60 Nm

44 lb ft

Final Pass in Sequence

90 Nm

66 lb ft

Cylinder Head Core Hole Plug

20 Nm

15 lb ft

Distributor Cap Bolt

2.4 Nm

21 lb in

Distributor Clamp Bolt

25 Nm

18 lb ft

Drive Belt Tensioner Bolt

50 Nm

37 lb ft

First Pass

10 Nm

89 lb in

Final Pass

30 Nm

22 lb ft

EGR Valve Pipe Nut at Intake Manifold

25 Nm

18 lb ft

EGR Valve Pipe Nut at Exhaust Manifold

30 Nm

22 lb ft

EGR Valve Pipe Clamp Bracket Bolt

25 Nm

18 lb ft

EGR Valve Bolt

2002 - Unit Repair (May 25, 2001)

6-1

6-2

Engine Mechanical - 5.0L and 5.7L

Engine

Fastener Tightening Specifications (contd)

Specification
Application

Metric

English

Engine Block Coolant Drain Hole Plug

20 Nm

15 lb ft

Engine Block Oil Gallery Plug

20 Nm

15 lb ft

Engine Coolant Temperature (ECT) Gage Sensor

20 Nm

15 lb ft

Engine Flywheel Bolt

100 Nm

74 lb ft

Engine Front Cover Bolt

12 Nm

106 lb in

Engine Lift Front Bracket Stud

35 Nm

26 lb ft

Engine Mount Bolt to Engine Mount Bracket Through-bolt

95 Nm

70 lb ft

Engine Mount Bolt to Engine Mount Frame Bracket

58 Nm

43 lb ft

Engine Mount Bracket Bolt to Engine

54 Nm

40 lb ft

Engine Mount Bracket Bolt to Frame

45 Nm

33 lb ft

Engine Mount Heat Shield to Engine Mount Bracket

6 Nm

53 lb in

Engine Mount Nut Through-bolt

68 Nm

50 lb ft

Engine Oil Pressure Gage Sensor

30 Nm

22 lb ft

Engine Oil Pressure Gage Sensor Fitting Plus Required Angle

15 Nm

11 lb ft

Engine Wiring Harness Bracket Nut

12 Nm

106 lb in

Evaporative Emission (EVAP) Canister Purge Solenoid Valve Stud

10 Nm

89 lb in

First Pass

15 Nm

11 lb ft

Final Pass

Exhaust Manifold Bolt

30 Nm

22 lb ft

Fan and Water Pump Pulley Bolt

25 Nm

18 lb ft

Fuel Pipe Bracket Bolt

6 Nm

53 lb in

Fuel Pipe Retainer Nut

3 Nm

27 lb in

Generator and Drive Belt Tensioner Bracket Bolt and Nut to Engine

41 Nm

30 lb ft

Generator and Drive Belt Tensioner Bracket Stud to Engine

20 Nm

15 lb ft

Ignition Coil Stud

12 Nm

106 lb in

Knock Sensor

20 Nm

15 lb ft

First Pass in Sequence

3 Nm

27 lb in

Second Pass in Sequence

12 Nm

106 lb in

Final Pass in Sequence

15 Nm

11 lb ft

Lower Intake Manifold Bolt

Oil Filter Adapter Bolt

25 Nm

18 lb ft

Oil Filter Fitting

35 Nm

26 lb ft

Oil Level Indicator Tube Bolt

25 Nm

18 lb ft

Oil Pan Drain Plug

25 Nm

18 lb ft

Oil Pan Stud

6 Nm

53 lb in

Oil Pan Stud Nut

25 Nm

18 lb ft

Oil Pan Bolt or Stud

12 Nm

106 lb in

Oil Pump Bolt to Rear Crankshaft Bearing Cap

First Pass

20 Nm

Final Pass

15 lb ft
65 degrees

Oil Pump Cover Bolt

12 Nm

106 lb in

Power Steering Pump Bolt

50 Nm

37 lb ft

Power Steering Pump Bracket Bolt to Engine

41 Nm

30 lb ft

Power Steering Pump Bracket Stud to Engine

20 Nm

15 lb ft

Power Steering Pump Bracket Stud Nut

41 Nm

30 lb ft

Power Steering Pump Nut to Engine

41 Nm

30 lb ft

Power Steering Pump Rear Bracket Nut

50 Nm

37 lb ft
2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-3

Fastener Tightening Specifications (contd)

Specification
Application

Metric

English

Spark Plug
Initial Installation NEW Cylinder Head

30 Nm

22 lb ft

All Subsequent Installations

15 Nm

11 lb ft

Spark Plug Wire Support Bolt

12 Nm

106 lb in

Square Socket Plug Engine Block Oil Gallery

20 Nm

15 lb ft

Throttle Body Stud

9 Nm

80 lb in

Transmission Cover Bolt

12 Nm

106 lb in

First Pass

5 Nm

44 lb in

Final Pass

Upper Intake Manifold Stud

10 Nm

89 lb in

Valve Lifter Guide Retainer Bolt

25 Nm

18 lb ft

Valve Rocker Arm Cover Bolt

12 Nm

106 lb in

Water Outlet Stud

25 Nm

18 lb ft

Water Pump Bolt

45 Nm

33 lb ft

SIE-ID = 784228

Engine Mechanical Specifications (5.0 L)

Specification
Application

Metric

English

General Data
Engine Type
Displacement

V8
5.0 L

305 CID

RPO VIN Code

L30 (M)

Bore

94.89 mm

Stroke

88.39 mm

Compression Ratio

Oil Pressure Minimum at Normal Operating Temperature

3.480 in
9.4:1

Firing Order
Spark Plug Gap

3.737 in

18436572
1.52 mm

0.060 in

42 kPa at 1,000 RPM

125 kPa at 2,000 RPM
166 kPa at 4,000 RPM

6 psig at 1,000 RPM

18 psig at 2,000 RPM
24 psig at 4,000 RPM

Camshaft
End Play
Journal Diameter
Journal Diameter Out-of-Round
Lobe Lift Exhaust
Lobe Lift Intake
Runout

0.050.30 mm

0.0020.012 in

47.44047.490 mm

1.86771.8697 in

0.025 mm

0.0010 in

7.207.30 mm

0.2830.287 in

6.977.07 mm

0.2740.278 in

0.065 mm Maximum

0.0026 in Maximum

0.0330.078 mm

0.00130.0031 in

Connecting Rod
Connecting Rod Bearing Clearance Production
Connecting Rod Bearing Clearance Service
Connecting Rod Journal Diameter

0.0250.063 mm

0.00100.0025 in

56.50556.533 mm

2.22462.2257 in

Connecting Rod Journal Out-of-Round Production

0.007 mm Maximum

0.0003 in Maximum

Connecting Rod Journal Out-of-Round Service

0.025 mm Maximum

0.0010 in Maximum

Connecting Rod Journal Taper Production

0.007 mm Maximum

0.0003 in Maximum

Connecting Rod Journal Taper Service

0.025 mm Maximum

0.0010 in Maximum

0.150.61 mm

0.0060.024 in

Connecting Rod Side Clearance

2002 - Unit Repair (May 25, 2001)

6-4

Engine Mechanical - 5.0L and 5.7L

Engine

Engine Mechanical Specifications (5.0 L) (contd)

Specification
Application

Metric

English

0.0180.053 mm

0.00070.0021 in

Crankshaft
Crankshaft Bearing Clearance Journal #1 Production
Crankshaft Bearing Clearance Journal #2, #3, and #4 Production

0.0300.068 mm

0.00120.0027 in

Crankshaft Bearing Clearance Journal #5 Production

0.0200.060 mm

0.00080.0024 in

Crankshaft Bearing Clearance Journal #1 Service

0.0250.051 mm

0.00100.0020 in

Crankshaft Bearing Clearance Journal #2, #3, and #4 Service

0.0250.064 mm

0.00100.0025 in

Crankshaft Bearing Clearance Journal #5 Service

0.0380.063 mm

0.00150.0025 in

0.050.20 mm

0.0020.008 in

Crankshaft Journal Diameter Journal #1

62.18962.212 mm

2.44842.4493 in

Crankshaft Journal Diameter Journal #2, #3, and #4

62.18162.207 mm

2.44812.4491 in

Crankshaft End Play

Crankshaft Journal Diameter Journal #5

62.18562.207 mm

2.44822.4491 in

Crankshaft Journal Out-of-Round Production

0.005 mm Maximum

0.0002 in Maximum

Crankshaft Journal Out-of-Round Service

0.025 mm Maximum

0.0010 in Maximum

Crankshaft Journal Taper Production

0.005 mm Maximum

0.0002 in Maximum

Crankshaft Journal Taper Service

0.025 mm Maximum

0.0010 in Maximum

Crankshaft Runout at Rear Flange

0.038 mm

0.0015 in

94.89494.947 mm

3.73603.7381 in

Out-of-Round Production

0.025 mm

0.0010 in

Out-of-Round Service

0.05 mm

0.002 in

Taper Production Relief Side

0.025 mm

0.0010 in

Taper Production Thrust Side

0.012 mm

0.0005 in

Taper Service Limit

0.025 mm

0.0010 in

Surface Flatness Engine Block Deck

0.10 mm

0.004 in

Surface Flatness Exhaust Manifold Deck

0.05 mm

0.002 in

Surface Flatness Intake Manifold Deck

0.10 mm

0.004 in

Surface Flatness Flange to Flange

0.25 mm

0.010 in

Surface Flatness Individual Flange

0.05 mm

0.002 in

Piston Bore Clearance Production

0.0180.061 mm

0.00070.0024 in

Piston Bore Clearance Service

0.0180.068 mm

0.00070.0026 in

Clearance in Piston Production

0.0100.020 mm

0.00040.0008 in

Clearance in Piston Service

0.0130.025 mm

0.00050.0010 in

23.54523.548 mm

0.92700.9271 in

0.0120.050 mm

0.00040.0019 in

Piston Compression Ring Gap Production Top Groove

0.250.51 mm

0.0100.020 in

Piston Compression Ring Gap Production 2nd Groove

0.460.66 mm

0.0180.026 in

Piston Compression Ring Gap Service Top Groove

0.250.65 mm

0.0100.025 in

Piston Compression Ring Gap Service 2nd Groove

0.460.90 mm

0.0180.035 in

Piston Compression Ring Groove Clearance Production Top

Groove

0.0300.070 mm

0.00120.0027 in

Piston Compression Ring Groove Clearance Production

2nd Groove

0.0300.074 mm

0.00120.003 in

Cylinder Bore
Diameter

Cylinder Head

Exhaust Manifold

Piston

Piston Pin

Diameter
Interference Fit in Connecting Rod
Piston Rings End Gap Measured in Cylinder Bore

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-5

Engine Mechanical Specifications (5.0 L) (contd)

Specification
Application

Metric

English

Piston Compression Ring Groove Clearance Service Limit Top

Groove

0.0300.090 mm

0.00120.0035 in

Piston Compression Ring Groove Clearance Service Limit

2nd Groove

0.0300.090 mm

0.00120.0040 in

Piston Oil Ring Gap Production

0.250.76 mm

0.0100.030 in

Piston Oil Ring Gap Service

0.250.89 mm

0.0100.035 in

Piston Oil Ring Groove Clearance Production

0.0510.203 mm

0.0020.008 in

Piston Oil Ring Groove Clearance Service

0.0510.22 mm

0.0020.009 in

Valve System
Valve Face Angle

45 degrees

Valve Head Edge Margin

0.79 mm Minimum

0.031 in Minimum

Valve Lash

Rotate the Valve Rocker Arm Nut Clockwise

360 degrees from Zero Lash

Valve Lifter

Hydraulic Roller

Valve Rocker Arm Ratio

1.5:1

Valve Seat Angle

46 degrees

Valve Seat Runout

0.05 mm Maximum

0.002 in Maximum

Valve Seat Width Exhaust

1.652.49 mm

0.0650.098 in

Valve Seat Width Intake

1.141.78 mm

0.0450.070 in

Valve Spring Free Length

51.3 mm

2.02 in

Valve Spring Installed Height Exhaust

42.9243.43 mm

1.671.70 in

Valve Spring Installed Height Intake

42.9243.43 mm

1.671.70 in

Valve Spring Pressure Closed

338374 N at 43.2 mm

7684 lb at 1.70 in

Valve Spring Pressure Open

832903 N at 32.3 mm

187203 lb at 1.27 in

Valve Stem Clearance Exhaust Production

0.0250.069 mm

0.00100.0027 in

Valve Stem Clearance Intake Production

0.0250.069 mm

0.00100.0027 in

Valve Stem Clearance Exhaust Service

0.0250.094 mm

0.00100.0037 in

Valve Stem Clearance Intake Service

0.0250.094 mm

0.00100.0037 in

Valve Stem Diameter

8.6618.679 mm

0.34100.3416 in

12 mm

0.039370.07874 in

Valve Stem Oil Seal Installed Height Measured from the Top of the
Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem
Oil Seal
SIE-ID = 784231

Engine Mechanical Specifications (5.7 L)

Specification
Application

Metric

English

General Data
Engine Type
Displacement

V8
5.7 L

350 CID

RPO VIN Code

L31 (R)

Bore

101.63 mm

4.0012 in

Stroke

88.39 mm

3.480 in

Compression Ratio

9.4:1

Firing Order
Spark Plug Gap
Oil Pressure Minimum at Normal Operating Temperature

2002 - Unit Repair (May 25, 2001)

18436572
1.52 mm

0.060 in

42 kPa at 1,000 RPM

125 kPa at 2,000 RPM
166 kPa at 4,000 RPM

6 psig at 1,000 RPM

18 psig at 2,000 RPM
24 psig at 4,000 RPM

6-6

Engine Mechanical - 5.0L and 5.7L

Engine

Engine Mechanical Specifications (5.7 L) (contd)

Specification
Application

Metric

English

0.050.30 mm

0.0020.012 in

Camshaft
End Play
Journal Diameter
Journal Diameter Out-of-Round

47.44047.490 mm

1.86771.8697 in

0.025 mm Maximum

0.0010 in Maximum

Lobe Lift Exhaust

7.207.30 mm

0.2830.287 in

Lobe Lift Intake

6.977.07 mm

0.2740.278 in

0.065 mm Maximum

0.0026 in Maximum

Runout
Connecting Rod
Connecting Rod Bearing Clearance Production

0.0330.078 mm

0.00130.0031 in

Connecting Rod Bearing Clearance Service

0.0250.063 mm

0.00100.0025 in

Connecting Rod Journal Diameter

56.50556.533 mm

2.22462.2257 in

Connecting Rod Journal Out-of-Round Production

0.007 mm Maximum

0.0003 in Maximum

Connecting Rod Journal Out-of-Round Service

0.025 mm Maximum

0.0010 in Maximum

Connecting Rod Journal Taper Production

0.007 mm Maximum

0.0003 in Maximum

Connecting Rod Journal Taper Service

0.025 mm Maximum

0.0010 in Maximum

0.150.61 mm

0.0060.024 in

0.0180.053 mm

0.00070.0021 in

Connecting Rod Side Clearance

Crankshaft
Crankshaft Bearing Clearance Journal #1 Production
Crankshaft Bearing Clearance Journal #2, #3, and #4 Production

0.0300.068 mm

0.00120.0027 in

Crankshaft Bearing Clearance Journal #5 Production

0.0200.060 mm

0.00080.0024 in

Crankshaft Bearing Clearance Journal #1 Service

0.0250.051 mm

0.00100.0020 in

Crankshaft Bearing Clearance Journal #2, #3, and #4 Service

0.0250.064 mm

0.00100.0025 in

Crankshaft Bearing Clearance Service Journal #5 Service

0.0380.063 mm

0.00150.0025 in

0.050.20 mm

0.0020.008 in

Crankshaft Journal Diameter Journal #1

62.18962.212 mm

2.44842.4493 in

Crankshaft Journal Diameter Journal #2, #3, and #4

62.18162.207 mm

2.44812.4491 in

Crankshaft End Play

Crankshaft Journal Diameter Journal #5

62.18562.207 mm

2.44822.4491 in

Crankshaft Journal Out-of-Round Production

0.005 mm Maximum

0.0002 in Maximum

Crankshaft Journal Out-of-Round Service

0.025 mm Maximum

0.0010 in Maximum

Crankshaft Journal Taper Production

0.005 mm Maximum

0.0002 in Maximum

Crankshaft Journal Taper Service

0.025 mm Maximum

0.0010 in Maximum

Crankshaft Runout at Rear Flange

0.038 mm

0.0015 in

101.618101.643 mm

4.00074.0017 in

Out-of-Round Production

0.025 mm

0.0010 in

Out-of-Round Service

0.05 mm

0.002 in

Taper Production Relief Side

0.025 mm

0.0010 in

Taper Production Thrust Side

0.012 mm

0.0005 in

Taper Service Limit

0.025 mm

0.0010 in

Surface Flatness Engine Block Deck

0.10 mm

0.004 in

Surface Flatness Exhaust Manifold Deck

0.05 mm

0.002 in

Surface Flatness Intake Manifold Deck

0.10 mm

0.004 in

Surface Flatness Flange to Flange

0.25 mm

0.010 in

Surface Flatness Individual Flange

0.05 mm

0.002 in

Cylinder Bore
Diameter

Cylinder Head

Exhaust Manifold

Piston
2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-7

Engine Mechanical Specifications (5.7 L) (contd)

Specification
Application

Metric

English

Piston Bore Clearance Production

0.0180.053 mm

0.00070.002 in

Piston Bore Clearance Service

0.0180.061 mm

0.00070.0024 in

0.0130.023 mm

0.00050.0009 in

Piston Pin
Clearance in Piston Production
Clearance in Piston Service
Diameter
Interference Fit in Connecting Rod

0.0130.025 mm

0.00050.0010 in

23.54523.548 mm

0.92700.9271 in

0.0120.050 mm

0.00040.0019 in

Piston Rings End Gap Measured in Cylinder Bore

Piston Compression Ring Gap Production Top Groove

0.250.40 mm

0.0980.015 in

Piston Compression Ring Gap Production 2nd Groove

0.0380.058 mm

0.00150.003 in

Piston Compression Ring Gap Service Top Groove

0.250.50 mm

0.0090.019 in

Piston Compression Ring Gap Service 2nd Groove

0.460.80 mm

0.0180.031 in

Piston Compression Ring Groove Clearance Production Top

Groove

0.0300.070 mm

0.00120.0027 in

Piston Compression Ring Groove Clearance Production

2nd Groove

0.0380.080 mm

0.00150.003 in

Piston Compression Ring Groove Clearance Service Limit Top

Groove

0.0300.090 mm

0.00120.0035 in

Piston Compression Ring Groove Clearance Service Limit

2nd Groove

0.0400.100 mm

0.00150.0040 in

Piston Oil Ring Gap Production

0.250.76 mm

0.0090.029 in

Piston Oil Ring Gap Service

0.250.90 mm

0.0090.035 in

Piston Oil Ring Groove Clearance Production

0.0460.196 mm

0.00180.0077 in

Piston Oil Ring Groove Clearance Service

0.0460.200 mm

0.00180.0079 in

Valve System
Valve Face Angle
Valve Head Edge Margin

45 degrees
0.79 mm Minimum

0.031 in Minimum

Valve Lash

Rotate the Valve Rocker Arm Nut Clockwise

360 degrees from Zero Lash

Valve Lifter

Hydraulic Roller

Valve Rocker Arm Ratio

1.5:1

Valve Seat Angle

Valve Seat Runout
Valve Seat Width Exhaust Heavy Duty

46 degrees
0.05 mm Maximum

0.002 in Maximum

1.502.56 mm

0.0590.101 in

Valve Seat Width Exhaust Light Duty

1.652.49 mm

0.0650.098 in

Valve Seat Width Intake

1.021.65 mm

0.0400.065 in

Valve Spring Free Length

51.3 mm

2.02 in

Valve Spring Installed Height Exhaust

42.9243.43 mm

1.671.70 in

Valve Spring Installed Height Intake

42.9243.43 mm

1.671.70 in

Valve Spring Pressure Closed

338374 N at 43.2 mm

7684 lb at 1.70 in

Valve Spring Pressure Open

832903 N at 32.3 mm

187203 lb at 1.27 in

Valve Stem Clearance Exhaust Production

0.0250.069 mm

0.00100.0027 in

Valve Stem Clearance Intake Production

0.0250.069 mm

0.00100.0027 in

Valve Stem Clearance Exhaust Service

0.0250.094 mm

0.00100.0037 in

Valve Stem Clearance Intake Service

0.0250.094 mm

0.00100.0037 in

Valve Stem Diameter

8.6618.679 mm

0.34100.3416 in

12 mm

0.039370.07874 in

Valve Stem Oil Seal Installed Height Measured from the Top of the
Large Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal
SIE-ID = 378556

2002 - Unit Repair (May 25, 2001)

6-8

Engine Mechanical - 5.0L and 5.7L

Engine

Sealers, Adhesives, and Lubricants

GM Part Number
Application
Camshaft Retainer Bolt
Crankshaft Balancer Keyway
Cylinder Head Bolt
Engine Block Core Hole Plug
Engine Block Coolant Drain Hole Plug

Type of Material

United States

Canada

Threadlock

12345382

10953489

Adhesive

12346141

10953433

Sealant

12346004

10953480

Threadlock

12345382

10953489

Sealant

12346004

10953480

Engine Block to the Crankshaft Rear Oil Seal Housing

Junction at the Oil Pan Sealing Surfaces

Adhesive

12346141

10953433

Engine Block to the Engine Front Cover Junction at the Oil

Pan Sealing Surfaces

Adhesive

12346141

10953433

Engine Block at the Lower Intake Manifold Sealing

Surfaces

Adhesive

12346141

10953433

Engine Block Oil Gallery Plug

Sealant

12346004

10953480

Engine Coolant Sensor

Sealant

12346004

10953480

Engine Coolant Temperature (ECT) Gage Sensor

Sealant

12346004

10953480

SAE 5W-30 Oil

12345610

993193

Sealant

12346004

10953480

Engine Oil
Engine Oil Pressure Gage Sensor
Engine Oil Pressure Gage Sensor Fitting

Sealant

12346004

10953480

Lubricant

1052367

992367

Evaporative Emission (EVAP) Canister Purge Solenoid

Valve Stud

Threadlock

12345382

10953489

Exhaust Manifold Bolt

Threadlock

12345493

10953488

Sealant

12346004

10953480

Engine Oil Supplement

Expansion Cup Plug Camshaft Rear Bearing Hole

Expansion Cup Plug Engine Block Core Hole

Sealant

12346004

10953480

Fuel Meter Body Bracket Bolt

Threadlock

12345382

10953489

Fuel Pipe Bolt

Threadlock

12345382

10953489

Knock Sensor

Sealant

12346004

10953480

Lower Intake Manifold Bolt

Oil Level Indicator Tube
Oil Pump Screen Tube

Threadlock

12345382

10953489

Sealant

12346004

10953480

Sealant

12346004

10953480

Throttle Body Stud

Threadlock

12345382

10953489

Upper Intake Manifold Stud

Threadlock

12345382

10953489

Valve Rocker Arm Ball Stud

Lubricant

1052271

10950849

Valve Train Component Prelube

Lubricant

12345501

992704

Sealant

12346004

10953480

Water Pump Bolt

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-9

Component Locator
Disassembled Views
SIE-ID = 348556

Intake Manifolds and Components

SIO-ID = 67224

66997

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Fuel Pipe Retainer Bracket

Fuel Pipe Retainer Bracket Nuts
Fuel Pipe
Fuel Pipe Attachment Screw
Fuel Seal Retainer
Fuel Seal (Yellow O-ring)
Spacer Ring (Flat Washer)
Fuel Seal (Black O-ring)
Upper Intake Manifold
Upper Intake Manifold to Lower Intake
Gasket

2002 - Unit Repair (May 25, 2001)

(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)

Fuel Meter Body Seal

Fuel Meter Body
Distributor Assembly
Hex Bolt (Distributor Clamp)
Distributor Clamp
Lower Intake Manifold
Lower Intake Manifold Gasket
EGR Valve Gasket
EGR Valve
EGR Valve Bolt
Engine Coolant Sensor

6-10
(22)
(23)
(24)
(25)

Engine Mechanical - 5.0L and 5.7L

Engine Coolant Thermostat
Water Outlet
Water Outlet Stud
Upper Intake Manifold Stud

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

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

Front of Engine

6-11

SIO-ID = 197523

182828

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)

Engine Front Cover

Camshaft Timing Chain
Camshaft Sprocket
Camshaft Sprocket Bolt
Valve Lifter Guide Retainer Bolt
Valve Lifter Guide Retainer
Valve Lifter Guide
Valve Lifter
Engine Block
Engine Camshaft
Camshaft Sprocket Locator Pin
Camshaft Retainer
Camshaft Retainer Bolt
Water Pump Gasket

2002 - Unit Repair (May 25, 2001)

(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)

Water Pump
Water Pump Bolt
Water Pump Inlet Hose Clamp
Water Pump Inlet Hose
Engine Block Oil Gallery Plug
Camshaft Bearings
Crankshaft Position Sensor
Crankshaft Position Sensor Bolt
Front Groove Pin (Crankshaft Balancer)
Crankshaft Balancer Bolt
Crankshaft Balancer Bolt Washer
Crankshaft Balancer
Crankshaft Front Oil Seal

6-12

Engine Mechanical - 5.0L and 5.7L

Engine

Cylinder Head and Exhaust Manifold Area

SIO-ID = 197712

182825

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)

Valve Rocker Arm Cover Bolt

Valve Rocker Arm Cover Bolt Washer
Valve Rocker Arm Cover
Valve Rocker Arm Cover Gasket
Valve Stem Keys
Valve Spring Cap
Valve Spring
Valve Stem Oil Seal
Valve
Cylinder Head Bolt (Long)
EGR Valve Pipe
EGR Valve Pipe Clamp
EGR Valve Pipe Clamp Bracket Bolt
Cylinder Head Bolt (Medium)
Cylinder Head Bolt (Short)

(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)

Spark Plug Wire Support Bracket

Spark Plug Wire Support Bracket Bolt
EGR Valve Pipe Fitting
Exhaust Manifold Bolts
Engine Coolant Temperature (ECT) Gauge
Sensor
Spark Plug Wire Shields
Exhaust Manifold
Exhaust Manifold Gasket
Cylinder Head Gasket
Valve Pushrod
Valve Rocker Arm
Valve Rocker Arm Ball
Valve Rocker Arm Nut

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

Cylinder Block and Components

6-13

SIO-ID = 348439

317429

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)

Piston Ring Kit

Piston
Connecting Rod
Connecting Rod Bolt
Connecting Rod Bearings
Connecting Rod Cap
Hex Nut (Connecting Rod)
Engine Oil Pressure Gauge Sensor Fitting
Engine Oil Pressure Gauge Sensor
Engine Block
Expansion Cup Plug (Camshaft Rear
Bearing Hole)
Dowel Straight Pin (Transmission Locator)
Engine Block Coolant Drain Hole Plug
Engine Block Core Hole Plug
Crankshaft Rear Oil Seal Housing Bolt

2002 - Unit Repair (May 25, 2001)

(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)

Crankshaft Rear Oil Seal

Engine Flywheel (Automatic Transmission)
Flywheel Bolt
Engine Flywheel (Manual Transmission)
Crankshaft Rear Oil Seal Housing Nut
Crankshaft Rear Oil Seal Housing Stud
Crankshaft Rear Oil Seal Housing
Crankshaft Rear Oil Seal Housing Gasket
Crankshaft Rear Oil Seal Housing Stud
Crankshaft
Crankshaft Bearing (Rear Thrust Bearing)
Crankshaft Bearing Cap (Rear)
Crankshaft Bearing Cap
Crankshaft Bearing Cap Stud
Crankshaft Bearing Cap Bolt
Crankshaft Bearings

6-14
(32)
(33)
(34)
(35)
(36)
(37)

Engine Mechanical - 5.0L and 5.7L

Engine

Crankshaft Sprocket
Crankshaft Position Sensor Reluctor Ring
Woodruff Keys (Crankshaft Balancer)
Crankshaft Bearing
Crankshaft Bearing (Rear Thrust Bearing)
Spring Type S Pin (Flywheel Locator)

(38) Spring Type S Pin (Crankshaft Rear Oil Seal

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

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

Bottom of Engine

6-15

SIO-ID = 197524

182829

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Engine Block
Oil Pump Driveshaft
Oil Pump Driveshaft Retainer
Pin (Oil Pump Locator)
Oil Pump
Oil Pan Gasket
Oil Pan
Oil Pan Drain Plug Seal (O-ring)

2002 - Unit Repair (May 25, 2001)

(9)
(10)
(11)
(12)
(13)
(14)
(15)

Oil Pan Drain Plug

Oil Pan Nut
Oil Pan Bolt
Oil Pan Reinforcement
Crankshaft Oil Deflector Bolt
Crankshaft Oil Deflector Nut
Crankshaft Oil Deflector

6-16

Engine Mechanical - 5.0L and 5.7L

Engine

Engine Identification
SIE-ID = 650058

The Vehicle Identification Number (VIN) is located on

the left side rear of the engine block, near the
transmission bellhousing, and typically is a 9 digit
number stamped onto the engine at the vehicle
assembly plant.
The first digit identifies the division.
The second digit identifies the model year.
The third digit identifies the assembly plant.
The fourth through ninth digits are the last 6 digits
of the Vehicle Identification Number (VIN).

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-17

Repair Instructions
Draining Fluids and Oil Filter Removal
SIE-ID = 194572

1. Remove the oil pan drain plug and allow the

engine oil to drain into a suitable container.

182850

2. Remove the oil filter and discard.

316766

2002 - Unit Repair (May 25, 2001)

6-18

Engine Mechanical - 5.0L and 5.7L

Engine
3. Remove the engine block coolant drain hole plug
and allow the coolant to drain into a suitable
container.

316798

4. Remove the knock sensor and allow the coolant

to drain into a suitable container.

182837

Engine Flywheel Removal

SIE-ID = 527623

1. Remove the engine flywheel bolts.

2. Remove the engine flywheel.

522146

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-19

Exhaust Manifold Removal - Left

SIE-ID = 650059

Notice: SIO-ID = 2878 Twist the spark plug boot

one-half turn in order to release the boot. Pull on the
spark plug boot only. Do not pull on the spark plug
wire or the wire could be damaged.
1. Remove the spark plug wires from the
spark plugs.
1.1. Rotate the spark plug wire boot
one half turn.
1.2. Pull outward on the spark plug wire boot to
release from the spark plug.
2. Remove the bolts and the spark plug wire
supports.

317185

3.
4.
5.
6.

Remove
Remove
Remove
Remove

the exhaust manifold bolts.

the spark plug wire shields.
the exhaust manifold.
and discard the exhaust manifold gasket.

64925

Exhaust Manifold Removal - Right

SIE-ID = 650060

Notice: SIO-ID = 2878 Twist the spark plug boot

one-half turn in order to release the boot. Pull on the
spark plug boot only. Do not pull on the spark plug
wire or the wire could be damaged.
1. Remove the spark plug wires from the
spark plugs.
1.1. Rotate the spark plug wire boot
one half turn.
1.2. Pull outward on the spark plug wire boot to
release from the spark plug.
2. Remove the bolts and the spark plug wire
supports.

317179

2002 - Unit Repair (May 25, 2001)

6-20

Engine Mechanical - 5.0L and 5.7L

Engine
3.
4.
5.
6.

Remove
Remove
Remove
Remove

the exhaust manifold bolts.

the spark plug wire shields.
the exhaust manifold.
and discard the exhaust manifold gasket.

69032

Oil Level Indicator and Tube Removal

SIE-ID = 518523

1. Remove the oil level indicator tube bolt.

2. Remove the oil level indicator tube from the
engine block.

500691

Water Pump Removal

SIE-ID = 69041

Tools Required
J 41240 Fan Clutch Remover and Installer
1. Remove the bolts and the fan and water pump
pulley using the J 41240.

317191

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-21

2. Remove the clamps and the water pump

inlet hose.

182853

3.
4.
5.
6.

Remove the water pump bolts.

Remove the water pump.
Remove the water pump gaskets.
Discard the water pump gaskets.

69011

Crankshaft Balancer Removal

SIE-ID = 66682

Tools Required
J 23523-F Balancer Remover and Installer
1. Remove the crankshaft balancer bolt and washer.

173172

2002 - Unit Repair (May 25, 2001)

6-22

Engine Mechanical - 5.0L and 5.7L

Engine
2. Remove the bolts and the crankshaft pulley.

188055

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Use the J 23523-F in order to remove the
crankshaft balancer.
3.1. Install the J 23523-F plate and bolts onto
the crankshaft balancer.
Tighten
Tighten the bolts to 25 Nm (18 lb ft).
3.2. Install the J 23523-F forcing screw into
the plate.
3.3. Rotate the J 23523-F forcing screw
clockwise in order to remove the crankshaft
balancer.
4. Remove the J 23523-F from the crankshaft
balancer.

66878

5. Note the position and length of any front groove

crankshaft balancer weight pins, if applicable.

182849

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-23

Valve Rocker Arm Cover Removal - Left

SIE-ID = 650061

1. Remove the valve rocker arm cover bolts and

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

39119

Valve Rocker Arm Cover Removal - Right

SIE-ID = 650062

1. Remove the valve rocker arm cover bolts and

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

182833

Distributor Removal
SIE-ID = 69504

1. Remove the ignition coil wire harness from the

ignition coil and distributor cap.

341359

2002 - Unit Repair (May 25, 2001)

6-24

Engine Mechanical - 5.0L and 5.7L

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

69303

4. Remove the distributor gasket and discard.

523516

Intake Manifold Removal

SIE-ID = 66685

1. Remove the evaporative emission canister purge

solenoid valve harness.
1.1. Push the quick disconnect clip and hold
in place.
1.2. Pull outward on the harness elbow.

317211

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-25

2. Remove the lower intake manifold bolts.

Important: The intake manifold may be removed as
an assembly. Do not remove the specific intake
manifold components unless component service is
required.
Do not allow dirt or debris to enter the fuel system.
Ensure that the ends of the fuel system are properly
sealed.
Do not disassemble the Central Sequential Fuel
Injection (SFI) unit, unless service is required.
3. Remove the intake manifold assembly.
4. Remove and discard the lower intake manifold
gaskets.

66456

Valve Rocker Arm and Push Rod Removal

SIE-ID = 66690

Important: Mark, sort, and organize the components

so that the components can be reinstalled to the
original location.
1. Remove the following components from the
cylinder head:
1.1. The valve rocker arm nuts (1)
1.2. The valve rocker arm balls (2)
1.3. The valve rocker arms (3)

182835

2. Remove the valve pushrods.

22766

2002 - Unit Repair (May 25, 2001)

6-26

Engine Mechanical - 5.0L and 5.7L

Engine
Cylinder Head Removal - Left
SIE-ID = 650064

1. Remove the engine coolant temperature gage

sensor.

521828

2. Remove and discard the spark plugs.

317307

3. Remove the cylinder head bolts.

317217

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-27

Notice: SIO-ID = 13838 After removal, place the

cylinder head on two wood blocks to prevent damage.
4. Remove the cylinder head.

317227

5. Remove and discard the cylinder head gasket.

317233

6. Remove the cylinder head locator dowel pin, if

required.

182846

2002 - Unit Repair (May 25, 2001)

6-28

Engine Mechanical - 5.0L and 5.7L

Engine
Cylinder Head Removal - Right
SIE-ID = 650065

1. Remove and discard the spark plugs.

317307

2. Remove the cylinder head bolts.

317239

Notice: SIO-ID = 13838 After removal, place the

cylinder head on two wood blocks to prevent damage.
3. Remove the cylinder head.

317246

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-29

4. Remove and discard the cylinder head gasket.

317255

5. Remove the cylinder head locator dowel pin, if

required.

182846

Valve Lifter Removal

SIE-ID = 24119

Tools Required
J 3049-A Valve Lifter Remover
1. Remove the bolts and valve lifter guide retainer.

11508

2002 - Unit Repair (May 25, 2001)

6-30

Engine Mechanical - 5.0L and 5.7L

Engine
Important: Place the valve lifters in the rack in the
upright position in order to maintain the oil inside the
valve lifter.
2. Remove the valve lifter guides and valve lifters.
3. Place the components in a rack so that the
components can be reinstalled to the original
location.

11509

Important: Some valve lifters may be stuck in the

valve lifter bores because of gum or varnish deposits.
4. Use the J 3049-A in order to remove the stuck
valve lifters.

31350

Oil Filter Adapter Removal

SIE-ID = 69505

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

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

39122

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-31

Oil Pan Removal

SIE-ID = 66836

1.
2.
3.
4.

Remove
Remove
Remove
Remove

the oil pan bolts and nuts.

the oil pan reinforcements.
the oil pan.
and discard the oil pan gasket.

182851

5. Remove the oil pan studs.

521817

2002 - Unit Repair (May 25, 2001)

6-32

Engine Mechanical - 5.0L and 5.7L

Engine
Oil Pump, Pump Screen and Deflector
Removal
SIE-ID = 195387

1. Remove the nuts (6) and the crankshaft oil

deflector (2).
2. Remove the oil pump bolt (1).
3. Remove the oil pump (3), the oil pump
driveshaft (5), and the oil pump driveshaft
retainer (4).
4. Separate the oil pump (3), the oil pump
driveshaft (5), and the oil pump driveshaft
retainer (4).
Important: Always install a NEW oil pump driveshaft
retainer during assembly.
5. Discard the oil pump driveshaft retainer.

11438

6. Inspect the oil pump locator pins for damage.

Replace the pins if required.

182852

Engine Front Cover Removal

SIE-ID = 195381

1. Remove the crankshaft position sensor bolt.

2. Remove the crankshaft position sensor.

11485

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-33

Important: Always install a NEW crankshaft position

sensor seal, O-ring, during assembly.
3. Remove the crankshaft position sensor seal,
O-ring.
4. Discard the crankshaft position sensor seal,
O-ring.

387759

5. Remove the engine front cover bolts.

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

69010

Timing Chain and Sprockets Removal

SIE-ID = 66838

Tools Required
J 5825-A Crankshaft Gear Remover
1. Remove the crankshaft position sensor
reluctor ring.

69450

2002 - Unit Repair (May 25, 2001)

6-34

Engine Mechanical - 5.0L and 5.7L

Engine
2. Check the camshaft timing chain free play.
If the camshaft timing chain can be moved in
excess of 11 mm (0.43 in), replacement of
the camshaft timing chain and the sprockets is
recommended during assembly.
2.1. Rotate the camshaft sprocket (1)
counterclockwise until all slack is removed
from the camshaft timing chain (2).
2.2. Measure the free play on the slack side (3)
of the camshaft timing chain.

341357

3. Remove the camshaft sprocket bolts.

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

500645

6. Remove the crankshaft sprocket using the

J 5825-A.

11506

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-35

7. Remove the crankshaft balancer woodruff keys, if

required.

182847

Camshaft Removal
SIE-ID = 69031

1. Remove the bolts and the camshaft retainer.

182836

Notice: SIO-ID = 13833 All camshaft journals are the

same diameter, so care must be used in removing or
installing the camshaft to avoid damage to the
camshaft bearings.
2. Remove the engine camshaft.
2.1. Install the three 5/1618 x 4.0 inch bolts in
the engine camshaft front bolt holes.
2.2. Using the bolts as a handle, carefully rotate
and pull the engine camshaft out of the
camshaft bearings.
2.3. Remove the bolts from the front of the
engine camshaft.

69013

2002 - Unit Repair (May 25, 2001)

6-36

Engine Mechanical - 5.0L and 5.7L

Engine
Piston, Connecting Rod, and Bearing
Removal
SIE-ID = 24200

11497

Tools Required
J 5239 Connecting Rod Bolt Guide Set
J 24270 Cylinder Bore Ridge Reamer
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Remove the ring ridge.
1.1. Turn the crankshaft until the piston is at the
bottom of the stroke.
1.2. Place a cloth on the top of the piston.
1.3. Use the J 24270 in order to remove cylinder
ring ridge.
1.4. Turn the crankshaft so the piston is at the
top of the stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris.
Important: Place matchmarks or numbers on the
connecting rods and the connecting rod caps.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.

480549

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-37

4. Use the J 5239 in order to protect the crankshaft

journals and remove the connecting rod and the
piston out of the top of the engine block.

31373

Important: Always assemble the connecting rod caps

to the matching connecting rods.
5. Remove the connecting rod bearings.
Keep the connecting rod bearings with the
original connecting rod and connecting rod cap.
Wipe the oil from the connecting bearings.
Wipe the oil from the crankpins.

188017

Crankshaft Rear Oil Seal and Housing

Removal
SIE-ID = 24222

1. Remove the crankshaft rear oil seal from the

crankshaft rear oil seal housing.
Insert a suitable tool into the access notches and
then carefully pry the crankshaft rear oil seal
from the crankshaft rear oil seal housing.
2. Discard the crankshaft rear oil seal.

31379

2002 - Unit Repair (May 25, 2001)

6-38

Engine Mechanical - 5.0L and 5.7L

Engine
3. Remove the crankshaft rear oil seal housing nut
and bolts.
4. Remove the crankshaft rear oil seal housing.
5. Remove the crankshaft rear oil seal housing
gasket.
6. Discard the crankshaft rear oil seal housing
gasket.
7. Remove the rear oil seal housing retainer stud
from the engine block.

11479

Crankshaft and Bearings Removal

SIE-ID = 69426

1. Mark or identify the crankshaft bearing cap

locations and positions for assembly.
2. Remove the crankshaft bearing cap bolts
and studs.
3. Remove the crankshaft bearing caps.

317268

4. Remove the crankshaft.

317351

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-39

5. Remove the crankshaft bearings from the

crankshaft bearing caps.

317295

6. Remove the crankshaft bearings from the

engine block.

317292

Engine Block Plug Removal

SIE-ID = 348910

Tools Required
J 41712 Oil Pressure Switch Socket

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
1. Remove the transmission locator pins, if required.

182855

2002 - Unit Repair (May 25, 2001)

6-40

Engine Mechanical - 5.0L and 5.7L

Engine
2. Remove the S type pin, and the crankshaft rear
oil seal housing, if required.

521820

3. Remove the expansion cup plug from the

camshaft rear bearing hole.

182854

4. Remove the engine oil pressure gage sensor

using the J 41712.

333649

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-41

5. Remove the engine oil pressure sensor gage

sensor fitting.

333652

6. Remove the engine block oil gallery plugs from

the rear of the engine block and discard.

69847

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

182841

2002 - Unit Repair (May 25, 2001)

6-42

Engine Mechanical - 5.0L and 5.7L

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

182838

9. Remove the engine block core hole plugs.

9.1. Use a suitable tool in order to drive the
engine block core hole plug into the
coolant jacket.
9.2. Use a suitable tool in order to pull the
engine block core hole plug from the
coolant jacket.
9.3. Discard the engine block core hole plug.

500648

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-43

Engine Block Cleaning and Inspection

SIE-ID = 784233

Tools Required
J 8087 Cylinder Bore Gage
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Clean all the remaining sealing or gasket material
from the sealing surfaces.
2. Clean the engine block in cleaning solvent.
3. Flush the engine block with clean water or steam.
4. Clean the cylinder bores.
5. Clean the oil galleries and the oil passages.
6. Clean the scale and the deposits from the coolant
passages.
7. After cleaning the engine block, spray or wipe the
cylinder bores and the machined surfaces with
clean engine oil.
8. Inspect the following areas:
Cylinder bores (1) for scratches or gouging
Valve lifter bores (2) for excessive scoring
or wear
Coolant jackets (3) for cracks
Threaded holes (4) for damage
Crankshaft bearing webs (5) for cracks
Crankshaft bearing caps (6) and the crankshaft
bearing bores (7) for damage
The crankshaft bearing bores should be
round and uniform when measuring the
inside diameter (ID).
The surface where the crankshaft bearings
contact the crankshaft bearing bore should
be smooth.
If a crankshaft bearing cap is damaged and
requires replacement, replace the crankshaft
bearing cap first. Then rebore the engine
block crankshaft bearing bores and
check for the proper alignment. Finally,
check the crankshaft bearings for the proper
clearances.
Expansion cup plug bores (8) for damage
Engine block (9) for cracks or damage
Engine mount bosses (10) for damage

2002 - Unit Repair (May 25, 2001)

317297

6-44

Engine Mechanical - 5.0L and 5.7L

Engine
9. Measure the cylinder bores for taper and
out-of-round.
9.1. Depress the plunger on the J 8087 7 mm
(0.275 in) or until the J 8087 enters the
cylinder bore.
9.2. Center the J 8087 in the cylinder bore and
turn the indicator dial to 0.
9.3. Move the J 8087 up and down the cylinder
bore to determine the taper. Refer to
Engine Mechanical Specifications (5.0 L) or
Engine Mechanical Specifications (5.7 L).
9.4. Turn the J 8087 to different points around
the cylinder bore to determine the
out-of-round condition. Refer to Engine
Mechanical Specifications (5.0 L) or Engine
Mechanical Specifications (5.7 L).

4972

Cylinder Boring and Honing

SIE-ID = 784235

Honing Procedure

186747

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
1. When honing the cylinder bores, follow the
manufacturers recommendations for equipment
use, cleaning, and lubrication.
Use only clean sharp stones of the proper
grade for the amount of material to be
removed.
Dull, dirty stones cut unevenly and generate
excessive heat.
DO NOT hone to a final grade with a coarse or
medium-grade stone.
Leave sufficient metal so that all the stone
marks will be removed with the fine grade
stones.
Perform the final honing with a fine-grade
stone and hone the cylinder bore in a
cross hatch pattern at 4565 degrees to obtain
the proper clearance.
2. During the honing operation, thoroughly check the
cylinder bore.
Repeatedly check the cylinder bore fit with the
selected piston.
All measurements of the piston or cylinder
bore should be made with the components
at normal room temperature.
3. When honing to eliminate taper in the cylinder
bore, use full strokes the complete length of the
cylinder bore.
Repeatedly check the measurement at the top,
the middle, and the bottom of the cylinder bore.
The finish marks should be clean but
not sharp.

2002 - Unit Repair (May 25, 2001)

Engine

4.

5.

6.
7.
8.

The finish marks should be free from imbedded

particles or torn or folded metal.
When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
After the final honing and before the piston is
checked for fit, clean the cylinder bore with hot
water and detergent.
5.1. Scrub the cylinder bores with a stiff
bristle brush.
5.2. Rinse the cylinder bores thoroughly with
clean hot water.
5.3. Dry the cylinder bores with a clean rag.
5.4. Do not allow any abrasive material to
remain in the cylinder bores.
Abrasive material may cause premature
wear of the new piston rings and the
cylinder bores.
Abrasive material will contaminate the
engine oil and may cause premature
wear of the bearings.
Perform final measurements of the piston and the
cylinder bore.
Permanently mark the top of the piston for the
specified cylinder to which it has been fitted.
Apply clean engine oil to each cylinder bore in
order to prevent rusting.

Boring Procedure
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Before starting the honing or reboring operation,
measure all the new pistons with the micrometer
contacting at points exactly 90 degrees from
the piston pin centerline.
2. File the top of the cylinder block in order to
remove any dirt or burrs before using any type of
boring bar.
3. Follow the instructions furnished by the
manufacturer regarding use of the boring
equipment.
4. When reboring the cylinders, make sure all the
crankshaft bearing caps are installed in the
original position and direction.
5. Tighten the crankshaft bearing caps to the proper
torque specifications in order to avoid distortion of
the cylinder bores in the final assembly.
6. When making the final cut with the boring bar,
leave 0.03 mm (0.001 in) on the cylinder bore
diameter for finish honing. This gives the required
position to the cylinder clearance specifications.
Carefully perform the honing and boring operation
in order to maintain the specified clearances
between the pistons, the piston rings, and
the cylinder bores.

2002 - Unit Repair (May 25, 2001)

Engine Mechanical - 5.0L and 5.7L

6-45

6-46

Engine Mechanical - 5.0L and 5.7L

Engine
Piston and Connecting Rod Disassemble
SIE-ID = 195087

Tools Required
J 24086-C Piston Pin Remover/Installer
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Remove the piston rings from the pistons.

4967

2. Press the piston pin from the connecting rod

using the J 24086-C.
The piston pin has an interference fit into the
connecting rod, and is full floating in the piston.

4965

3. Mark, separate, and organize the parts for

assembly.

34671

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-47

Piston, Connecting Rod, and Bearings

Cleaning and Inspection
SIE-ID = 784237

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
Important: Measurement of all the components
should be taken with the components at room
temperature.
Do not use a wire brush in order to clean any part of
the piston.
1. Clean the piston and connecting rod in cleaning
solvent.
2. Dry the components with compressed air.

34671

3. Clean the piston ring grooves with a suitable ring

groove cleaning tool.

4977

4. Clean the piston oil lubrication holes and slots.

5. Inspect the piston for the following:
Eroded areas (1) on the top of the piston
Scuffed or damaged skirt (2)
Damage to the piston pin bore (3)
Cracks in the piston ring lands, the piston skirt,
or the piston pin bosses
Piston ring grooves for nicks, burrs, or other
warpage which may cause the piston ring
to bind.
6. Inspect the piston pin for scoring, wear or other
damage.

156168

2002 - Unit Repair (May 25, 2001)

6-48

Engine Mechanical - 5.0L and 5.7L

Engine
7. Measure the piston ring-to-piston ring groove side
clearance.
7.1. Insert the edge of the piston ring into the
piston ring groove.
7.2. Roll the piston ring completely around the
piston.
If binding is caused by a distorted piston
ring groove, MINOR imperfections may
be removed with a fine file.
If binding is caused by a distorted piston
ring, then replace the piston ring.

4969

8. Measure the piston ring side clearance with a

feeler gage.
If the piston ring side clearance is too small,
try another piston ring set.
If the proper piston ring-to-piston ring groove
clearance cannot be achieved, replace the
piston and pin assembly.
9. To determine the proper piston ring side
clearance, refer to Engine Mechanical
Specifications (5.0 L) or Engine Mechanical
Specifications (5.7 L).

22934

10. Inspect the connecting rod for an out-of-round

bearing bore. Refer to Engine Mechanical
Specifications (5.0 L) or Engine Mechanical
Specifications (5.7 L).

156167

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-49

11. Inspect the connecting rod for twisting.

12. Inspect the connecting rod for damage to the
connecting rod bolt threads.

156169

13. Measure the piston compression ring end gap.

Important: Fit each piston compression ring to the
cylinder in which it will be used.
13.1. Place the piston compression ring into the
cylinder bore.
13.2. Push the piston compression ring into the
cylinder bore to approximately 6.5 mm
(0.25 in) above the piston ring travel.
The piston ring must be square to the
cylinder wall.
13.3. Use a feeler gage in order to measure the
piston ring end gap. Refer to Engine
Mechanical Specifications (5.0 L)
or Engine Mechanical Specifications
(5.7 L).
Select another size piston ring set if the
piston ring end gap exceeds specifications.
4968

Piston and Connecting Rod Assemble

SIE-ID = 195097

Tools Required
J 24086-C Piston Pin Remover/Installer

Caution: SIO-ID = 71607 Avoid contact with HOT

components. Wear safety glasses and protective
gloves to avoid personal injury.
Notice: SIO-ID = 71608 Applying excessive heat to the
connecting rod may damage or distort the rod. Rod
temperature SHOULD NOT exceed 315C (600F). At
this temperature the end of the connecting rod will
turn a straw color upon visual inspection.
Notice: SIO-ID = 38775 After the J 24086-C installer
hub bottoms on the support assembly, DO NOT
exceed 35,000 kPa (5,000 psi) or the tool may be
damaged.
4965

2002 - Unit Repair (May 25, 2001)

6-50

Engine Mechanical - 5.0L and 5.7L

Engine
Important: When assembling the piston and
connecting rod, the mark on the top of the piston must
point to the front of the engine block. The left bank
connecting rods should have the flange face toward
the front of the engine block. The right bank connecting
rods should have the flange face toward the rear of
the engine block.
The new piston pin has an interference fit into the
connecting rod and is full floating in the piston.
1. Install the new piston pin and connecting rod
assembly.
1.1. Lubricate the piston pin bores with clean
engine oil.
1.2. Use a torch and apply MILD heat to the
piston pin end of the connecting rod.
1.3. Use the J 24086-C in order to press the
new piston pin into the piston and
connecting rod assembly.
1.4. Inspect for the proper installation of the
piston and piston pin.
The piston must move freely on the new
piston pin with no binding or interference.
Notice: SIO-ID = 16608 Use a piston ring expander to
install the piston rings. The rings may be damaged if
expanded more than necessary.
2. Install the piston rings onto the piston.
2.1. Install the oil control piston ring spacer.
2.2. Install the lower oil control piston ring.
2.3. Install the upper oil control piston ring.
2.4. Install the lower compression piston ring.
The mark on the side of the piston ring
should face the top of the piston.
2.5. Install the upper compression piston ring.
The mark on the side of the piston ring
should face the top of the piston.

490763

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-51

3. Space the compression piston ring end gaps

120 degrees apart.
4. Space the oil control piston ring end gaps a
minimum of 90 degrees apart.

4967

Crankshaft and Bearings Cleaning and

Inspection
SIE-ID = 69074

Tools Required
J 7872 Magnetic Base Dial Indicator
J 36660-A Torque Angle Meter
J 43690 Rod Bearing Clearance Checking Tool
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
Important: Use care when handling the crankshaft.
Avoid damage to the crankshaft bearing surfaces.
1. Clean the crankshaft in cleaning solvent. Remove
all sludge or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.

59918

3. Clean the crankshaft bearings in cleaning solvent.

Wipe the crankshaft bearings clean with a soft
cloth. Do not scratch the crankshaft bearing
surfaces.
4. Dry the crankshaft and crankshaft bearings with
compressed air.

334386

2002 - Unit Repair (May 25, 2001)

6-52

Engine Mechanical - 5.0L and 5.7L

Engine
5. Inspect the crankshaft for the following:
Crankshaft journals (1) should be smooth with
no evidence of scoring or damage.
Deep grooves (2)
Scratches or uneven wear (3)
Pitted surfaces (4)
Wear or damage to the thrust journal surfaces
Scoring or damage to the rear seal surface
Restrictions to the oil passages
Damage to the threaded bolt holes

156170

6. Inspect the crankshaft balancer woodruff keys (1),

the keyway (2), and the threaded hole (3) for
damage.

188090

7. Measure the crankpins for out-of-round and taper.

Refer to Engine Mechanical Specifications (5.0 L)
or Engine Mechanical Specifications (5.7 L).

188015

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-53

8. Using wooden V-blocks, support the crankshaft on

the front and rear journals.
9. Use the J 7872 in order to measure crankshaft
journal runout.
Refer to Engine Mechanical Specifications (5.0 L)
or Engine Mechanical Specifications (5.7 L).

35210

10. Measure the crankshaft end play.

Important: In order to properly measure the crankshaft
end play, the crankshaft, the crankshaft bearings,
the crankshaft bearing caps, and the fasteners must
be installed into the engine block, and the bolts
and studs tightened finger tight.
10.1. Firmly thrust the end of the crankshaft,
first rearward then forward. This will line
up the rear crankshaft bearing and
the crankshaft thrust surfaces. Tighten the
cap bolts and studs. Refer to Engine
Mechanical Specifications (5.0 L)
or Engine Mechanical Specifications
(5.7 L).
10.2. With the crankshaft pushed forward, insert
a feeler gage between the crankshaft and
the crankshaft bearing surface, then
measure the clearance. Refer to Engine
Mechanical Specifications (5.0 L) or
Engine Mechanical Specifications (5.7 L).
10.3. Turn the crankshaft to check for binding. If
the crankshaft does not turn freely, loosen
the crankshaft bearing bolts and studs,
one crankshaft bearing cap at a time, until
the tight crankshaft bearing is located.
Burrs on the crankshaft bearing cap
or engine block, foreign matter between the
crankshaft bearing and the crankshaft
bearing cap or the engine block, or a faulty
crankshaft bearing could cause a lack of
clearance between the crankshaft and
crankshaft bearing.

2002 - Unit Repair (May 25, 2001)

188467

6-54

Engine Mechanical - 5.0L and 5.7L

Engine
11. Inspect the crankshaft bearings for craters or
pockets. Flattened sections on the crankshaft
bearing halves also indicate fatigue.

52051

12. Inspect the crankshaft bearings for excessive

scoring or discoloration.
13. Inspect the crankshaft bearings for dirt or debris
imbedded into the crankshaft bearing material.

52053

14. Inspect the crankshaft bearings for improper

seating indicated by bright, polished sections of
the crankshaft bearings.
If the lower half of the crankshaft bearing is
worn or damaged, both the upper and
lower halves of the crankshaft bearing should
be replaced.
Generally, if the lower half of the crankshaft
bearing is suitable for use, the upper half
of the crankshaft bearing should also be
suitable for use.

52056

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-55

Measuring Crankshaft Bearing Clearances

Notice: SIO-ID = 5016 Do not shim, scrape, or file
bearing inserts. Do not touch the bearing surface of the
insert with bare fingers. Skin oil and acids will etch
the bearing surface.
The crankshaft bearings are precision insert type
and do not use shims for adjustment. If the
clearances are excessive, then new upper and
lower crankshaft bearings will be required.
The service crankshaft bearings are available in
the standard size and an undersize.
The selective fitting of the crankshaft bearings are
necessary in production in order to obtain close
tolerances. For this reason, in one journal
bore you may use one-half of a standard
crankshaft bearing with one-half of an undersize
crankshaft bearing.
In order to determine the correct replacement
bearing size, the bearing clearance must be
measured accurately. When checking main
bearing clearances, either the micrometer or
plastic gage method may be used. The micrometer
method gives more reliable results and is
preferred. When checking connecting rod bearing
clearances, the plastic gage method will result
in unreliable measurements. The use of J 43690
is preferred.
If the crankshaft bearing clearance is within
specifications, the crankshaft bearing is
satisfactory. If the clearance is not within
specifications, replace the crankshaft bearing.
Always replace both the upper and lower
crankshaft bearings as a unit.
A standard, or undersize crankshaft bearing
combination, may result in the proper clearance. If
the proper crankshaft bearing clearance cannot
be achieved using the standard or the undersize
crankshaft bearings, it may be necessary to
repair or replace the crankshaft.

188015

Measuring Crankshaft Bearing Clearances

Micrometer Method
1. Measure the crankshaft journal diameter with a
micrometer in several places, approximately
90 degrees apart. Average the measurements.
2. Determine the taper and out-of-round of the
journal. Refer to Engine Mechanical Specifications
(5.0 L) or Engine Mechanical Specifications
(5.7 L).

188015

2002 - Unit Repair (May 25, 2001)

6-56

Engine Mechanical - 5.0L and 5.7L

Engine
3. Install the bearings into the engine block.

317292

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Install the bearing cap bolts and tighten to
specifications. Refer to Fastener Tightening
Specifications.
5. Measure the bearing inside diameter (ID) at the
top and bottom.
6. In order to determine the bearing clearance,
subtract the average journal diameter from
the bearing inside diameter.
7. Compare the readings to specifications. Refer to
Engine Mechanical Specifications (5.0 L) or
Engine Mechanical Specifications (5.7 L).
8. Replace bearing halves as required to obtain the
proper bearing clearances.

353070

Measuring Connecting Rod Bearing

Clearances J 43690 Method
1. Remove the oil pan and other necessary
components to gain access to the connecting rods.
Remove the oil pump, screen, and deflector,
when applicable.
2. Rotate the crankshaft until the crankshaft
journal/connecting rod to be measured is in the
10 oclock position.
Important: The crankshaft must be secure, with no
movement or rotation, in order to obtain an accurate
reading. Remove an intermediate bearing cap, as
required, in order to secure the crankshaft and allow
measurement of connecting rod bearing clearances.
3. Remove the bearing cap bolts (1), cap (2)
and bearing half.

627138

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-57

4. Insert a piece of paper card stock onto the

crankshaft journal. Install the bearing half, bearing
cap, and bolts. Refer to Fastener Tightening
Specifications.
5. Install the foot (1) and bolt (2) to the pivot arm
assembly (3).
6. Tighten the bolt until snug.

627102

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

assembly (2).

627106

2002 - Unit Repair (May 25, 2001)

6-58

Engine Mechanical - 5.0L and 5.7L

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

627108

9. Position the foot of the pivot arm assembly over

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

627107

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

627109

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-59

12. Align the center of the base (1) with the screw (3)
of the pivot arm assembly.
13. Tighten the bolt (2) until snug.

627115

14. Align the link (1) of the pivot arm assembly on a

plane (3) equal to that of the connecting rod
beam (2).

627113

15. With the link of the pivot arm assembly aligned to

the beam of the connecting rod, position the pivot
arm to the base and insert the pin (1).

627111

2002 - Unit Repair (May 25, 2001)

6-60

Engine Mechanical - 5.0L and 5.7L

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

627116

17. Select the adapter (2), as required, and install to

the swivel base (1).
18. Tighten until snug.

627118

Important: The clamp of the swivel base and the

shaft of the indicator should be free of oil or other
debris. A loose or improperly clamped indicator may
indicate incorrect readings.
19. Install the indicator (2) to the swivel base (1).
20. Tighten the clamp of the base until snug.

627122

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-61

21. Install the swivel base (1) to the oil pan rail of the
engine block.
22. Tighten until snug.

627124

23. Adjust the swivel base as required, and position

the indicator tip slightly above the connecting rod
cap. Lock the swivel base in position by rotating
the locking lever (1). Do not allow the tip of
the indicator to contact the connecting rod at
this time.

627126

24. The tip of the indicator should be positioned

above, and NOT in contact with the cap end of
the connecting rod.

627129

2002 - Unit Repair (May 25, 2001)

6-62

Engine Mechanical - 5.0L and 5.7L

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

627132

26. Lightly actuate the handle of the pivot arm

assembly, multiple times in both directions, to
ensure the oil film is removed from the journal.

627141

27. Load the handle in the forward position and

zero the dial indicator. Load the handle multiple
times in both directions and record the reading.
Important: During this procedure, card stock may
enter the crankshaft journal oil galleries. Remove all
card stock from the bearing journal and oil galleries
prior to reassembly.
28. Remove the bearing cap bolts, cap, and
paper stock.
29. Replace bearing halves, as required, to obtain the
proper bearing clearances.
30. Install the bearings, cap, and bolts. Refer to
Fastener Tightening Specifications.

627135

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-63

Measuring Crankshaft Bearing Clearances

Plastic Gage Method
1. Install the crankshaft bearings into the
engine block.

317292

2. Install the crankshaft.

317351

3. Install the gaging plastic the full width of the

journal.

500655

2002 - Unit Repair (May 25, 2001)

6-64

Engine Mechanical - 5.0L and 5.7L

Engine
4. Install the crankshaft bearings into the crankshaft
bearing caps.

317295

5. Install the crankshaft bearing caps in the original

positions, and the arrow on the crankshaft bearing
caps in the direction of the front of the
engine block.
Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the crankshaft bearing cap bolts and the
crankshaft bearing cap studs. Refer to Fastener
Tightening Specifications.
7. Remove the crankshaft bearing cap bolts
and studs.
8. Remove the crankshaft bearing caps. The gaging
plastic may adhere to either the crankshaft
bearing journal or the crankshaft bearing surface.

317268

9. Without removing the gaging plastic, measure the

compressed width at the widest point, using the
graduated scale on the edge of the gaging plastic
envelope.
If the flattened gaging plastic tapers toward the
middle or the ends, there may be a difference
in clearance indicating taper, low spot or other
irregularity of the crankshaft bearing or the
crankshaft bearing journal.
10. Remove the flattened gaging plastic.
11. Measure the remaining crankshaft bearing
journals.

500656

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-65

Measuring Connecting Rod Bearing Side

Clearance
1. Insert a feeler gage between the connecting rod
caps and measure the connecting rod side
clearance. Refer to Engine Mechanical
Specifications (5.0 L) or Engine Mechanical
Specifications (5.7 L).
2. The connecting rod side clearances may also be
measured with a dial indicator set.

5163

Crankshaft Balancer Cleaning and

Inspection
SIE-ID = 194518

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
1. Clean the crankshaft balancer in cleaning solvent.
2. Dry the crankshaft balancer with compressed air.
3. Inspect the crankshaft balancer for the following:
Worn or damaged bolt hole threads (1)
Worn, chunking, or deteriorated rubber (2)
between the hub and outer ring
Loose or improperly installed balance
weights (3)
A properly installed balance weight should be
installed until flush or below flush with the
face of the crankshaft balancer.
Worn or damaged keyway (4)
Important: A crankshaft front oil sealing surface with
excessive scoring, grooves, rust, or other damage
must be replaced.
Worn, grooved, or damaged crankshaft front
oil sealing surface
Minor imperfections on the crankshaft balancer
crankshaft front oil seal surface may be
removed with a polishing compound or fine
grade emery cloth.

2002 - Unit Repair (May 25, 2001)

334038

6-66

Engine Mechanical - 5.0L and 5.7L

Engine
Engine Flywheel Cleaning and Inspection
SIE-ID = 195065

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
1. Clean the engine flywheel (1 or 2) in cleaning
solvent.
2. Dry the engine flywheel with compressed air.

188129

3. Inspect the engine flywheel, automatic

transmission, if equipped, for the following:
Stress cracks around the engine
flywheel-to-torque converter bolt hole
locations (1)
Missing balance weights
Stress cracks around the engine
flywheel-to-crankshaft bolt hole
locations (2 or 3)
Important: Do not attempt to repair the welded areas
that retain the ring gear to the engine flywheel
plate. Always install a NEW engine flywheel.
Welded areas that retain the ring gear onto the
engine flywheel for cracking (4)
Damaged ring gear teeth (5)

381965

4. Inspect the engine flywheel, manual transmission,

if equipped, for loose or improperly installed
flywheel weights, if applicable.
A properly installed flywheel weight should be
installed until flush or below flush with the face of
the engine flywheel.

64126

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-67

5. Inspect the engine flywheel, manual transmission,

if equipped, for the following:
Pitted friction surface (1)
Scoring or grooves (2)
Rust or other surface damage (3)
Damaged ring gear teeth (4)
Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
engine flywheel and the ring gear should
be positioned completely flat against the flange
of the engine flywheel.

188086

Camshaft and Bearings Cleaning and

Inspection
SIE-ID = 32312

Tools Required
J 7872 Magnetic Base Dial Indicator
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Clean the engine camshaft in cleaning solvent.
2. Dry the engine camshaft with compressed air.
3. Inspect the camshaft retainer plate for damage.
If the camshaft retainer plate is damaged, replace
as necessary.
4. Inspect the camshaft bearings for correct fit into
the engine block camshaft bearing bores.
The camshaft bearings have an interference fit to
the engine block camshaft bearing bores and
must not be loose in the engine block camshaft
bearing bores.
Important: If any camshaft bearing is excessively
worn or scored, replace all the camshaft bearings.
5. Inspect the camshaft bearings for excessive wear
or scoring.

2002 - Unit Repair (May 25, 2001)

334499

6-68

Engine Mechanical - 5.0L and 5.7L

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

188095

7. Measure the engine camshaft journals with a

micrometer.
If the camshaft journals are more than 0.025 mm
(0.0010 in) out-of-round, then replace the
engine camshaft.

188014

8. Measure for a bent engine camshaft or excessive

engine camshaft runout using the J 7872.
8.1. Mount the engine camshaft in a suitable
stand between centers.
8.2. Use the J 7872 in order to check the
intermediate engine camshaft journals.
If the runout exceeds 0.065 mm (0.0026 in),
the engine camshaft is bent and must be
replaced.
9. Measure the engine camshaft lobe lift using the
J 7872.
9.1. Place the engine camshaft on the V-blocks.
9.2. Use the J 7872 in order to measure the
engine camshaft lobe lift.
10. Replace the engine camshaft if the engine
camshaft lobe lift is not within specifications.

188012

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-69

Camshaft Bearing Removal

SIE-ID = 195130

Tools Required
J 33049 Camshaft Bearing Service Kit
1. Select the cone (1), the handle (10), the
expanding driver (48), the washer (2 or 3), and
the expander assembly (15) from the J 33049.
2. Assemble the J 33049.

66100

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
Important: A loose camshaft bearing may be caused
by an enlarged, out-of-round, or damaged engine
block camshaft bearing bore.
Important: Always remove the camshaft inner
bearings #2, #3, and #4 first. The camshaft outer
bearings #1 and #5 serve as a guide for the J 33049.
3. Remove the camshaft inner bearings #2, #3,
and #4.
3.1. Insert the J 33049 through the front of the
engine block and into the camshaft inner
bearing #2.
3.2. Tighten the J 33049 expander assembly nut
until snug.
3.3. Push the J 33049 guide cone into the
camshaft front bearing in order to align
the J 33049.
3.4. Drive the camshaft inner bearing #2 from
the camshaft inner bearing bore #2.
3.5. Loosen the J 33049 expander assembly nut.
3.6. Remove the camshaft inner bearing #2
from the J 33049 expander assembly.
3.7. Insert the J 33049 expander assembly into
the camshaft inner bearing #3.
3.8. Tighten the J 33049 expander assembly nut
until snug.
3.9. Push the J 33049 guide cone into the
camshaft front bearing in order to align
the J 33049.
3.10. Drive the camshaft inner bearing #3 from
the camshaft inner bearing bore #3.
3.11. Loosen the J 33049 expander assembly nut.
3.12. Remove the camshaft inner bearing #3
from the J 33049 expander assembly.
3.13. Insert the J 33049 expander assembly into
the camshaft inner bearing #4.
2002 - Unit Repair (May 25, 2001)

4985

6-70

Engine Mechanical - 5.0L and 5.7L

Engine
3.14. Tighten the J 33049 expander assembly nut
until snug.
3.15. Push the J 33049 guide cone into the
camshaft front bearing in order to align
the J 33049.
3.16. Drive the camshaft inner bearing #4 from
the camshaft inner bearing bore #4.
3.17. Loosen the J 33049 expander assembly nut.
3.18. Remove the camshaft inner bearing #4
from the J 33049 expander assembly.
4. Remove the J 33049 from the engine block.

63219

5. Remove the camshaft outer bearings #1 and #5.

5.1. Insert the J 33049 into the camshaft outer
bearing #1.
5.2. Tighten the J 33049 expander assembly nut
until snug.
5.3. Drive the camshaft outer bearing #1 from
the camshaft outer bearing bore #1.
5.4. Loosen the J 33049 expander assembly nut.
5.5. Remove the camshaft outer bearing #1
from the J 33049 expander assembly.
5.6. Remove the J 33049 from the engine block.
5.7. Insert the J 33049 into the camshaft
outer bearing #5.
5.8. Tighten the J 33049 expander assembly nut
until snug.
5.9. Drive the camshaft outer bearing #5 from
the camshaft outer bearing bore #5.
5.10. Loosen the J 33049 expander assembly nut.
5.11. Remove the camshaft outer bearing #5
from the J 33049 expander assembly.
6. Remove the J 33049 from the engine block.
7. Discard the camshaft bearings.

Camshaft Bearing Installation

SIE-ID = 195136

Tools Required
J 33049 Camshaft Bearing Service Kit
Important: Always install the camshaft outer bearings
#1 and #5 first. The camshaft outer bearings serve
as a guide for the J 33049 and help center the
camshaft inner bearings during the installation process.
Look to ensure that the camshaft bearing lubrication
hole or holes align with the oil gallery hole or holes in
the engine block. On some engines, the oil gallery
holes may be difficult to see. Verify that the camshaft
bearing lubrication holes and the oil gallery holes
are aligned.
1. Assemble the J 33049 handle (10), the expanding
driver (48), the washer (2 or 3), and the expander
assembly (15).
66100

2002 - Unit Repair (May 25, 2001)

Engine

Engine Mechanical - 5.0L and 5.7L

6-71

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
Important: The camshaft bearing lubrication holes
must align with the oil gallery holes in the engine block.
After installation of the camshaft bearings, always
inspect the camshaft bearing lubrication holes
for proper alignment with the oil gallery holes.
An improperly aligned camshaft bearing lubrication
hole and oil gallery hole will restrict oil flow to
the camshaft bearing and the camshaft journal.
2. Install the NEW camshaft outer bearings #5
and #1.
2.1. Install the NEW camshaft outer bearing #5
onto the J 33049 expander assembly.
2.2. Tighten the J 33049 expander assembly nut
until snug.
2.3. Align the camshaft outer bearing #5
lubrication hole with the oil gallery hole
in the camshaft outer bearing bore #5 at the
rear of the engine block.
2.4. Drive the camshaft outer bearing #5 into the
camshaft outer bearing bore #5 at the rear
of the engine block.
2.5. Loosen the J 33049 expander assembly nut.
2.6. Remove the J 33049 expander assembly
from the camshaft outer bearing #5.
2.7. Install the NEW camshaft outer bearing #1
onto the J 33049 expander assembly.
2.8. Tighten the J 33049 expander assembly nut
until snug.
2.9. Align the camshaft outer bearing #1
lubrication hole with the oil gallery hole
in the camshaft outer bearing bore #1 at the
front of the engine block.
2.10. Drive the camshaft outer bearing #1 into the
camshaft outer bearing bore #1 at the front
of the engine block.
2.11. Loosen the J 33049 expander assembly nut.
2.12. Carefully slide the J 33049 into the engine
block until the J 33049 expander assembly
is positioned between the camshaft
inner bearing bores #3 and the camshaft
inner bearing bore #4.

2002 - Unit Repair (May 25, 2001)

63219

6-72

Engine Mechanical - 5.0L and 5.7L

4985

Engine
Important: The camshaft bearing lubrication holes
must align with the oil gallery holes in the engine block.
After installation of the camshaft bearings, always
inspect the camshaft bearing lubrication holes
for proper alignment with the oil gallery holes.
An improperly aligned camshaft bearing lubrication
hole and oil gallery hole will restrict oil flow to
the camshaft bearing and the camshaft journal.
3. Install the NEW camshaft inner bearings #4, #3,
and #2.
3.1. Install the NEW camshaft inner bearing #4
onto the J 33049 expander assembly.
3.2. Tighten the J 33049 expander assembly nut
until snug.
3.3. Align the camshaft inner bearing #4
lubrication hole with the oil gallery hole
in the camshaft inner bearing bore #4 of the
engine block.
3.4. Push the J 33049 guide cone into the
camshaft front bearing bore #1 in order
to align the J 33049.
3.5. Drive the camshaft inner bearing #4 into the
camshaft inner bearing bore #4.
3.6. Loosen the J 33049 expander assembly nut.
3.7. Carefully slide the J 33049 until the
J 33049 expander assembly is positioned
between the camshaft inner bearing bore #3
and the camshaft outer bearing bore #2.
3.8. Install the NEW camshaft inner bearing #3
onto the J 33049 expander assembly.
3.9. Tighten the J 33049 expander assembly nut
until snug.
3.10. Align the camshaft inner bearing #3
lubrication hole with the oil gallery hole
in the camshaft inner bearing bore #3 of the
engine block.
3.11. Push the J 33049 guide cone into the
camshaft front bearing bore #1 in order
to align the J 33049.
3.12. Drive the camshaft inner bearing #3 into the
camshaft inner bearing bore #3.
3.13. Loosen the J 33049 expander assembly nut.
3.14. Carefully slide the J 33049 until the
J 33049 expander assembly is positioned
between the camshaft inner bearing bore #2
and the camshaft outer bearing bore #1.
3.15. Install the NEW camshaft inner bearing #2
onto the J 33049 expander assembly.
3.16. Tighten the J 33049 expander assembly nut
until snug.
3.17. Align the camshaft inner bearing #2
lubrication hole with the oil gallery hole
in the camshaft inner bearing bore #2 of the
engine block.
3.18. Push the J 33049 guide cone into the
camshaft front bearing bore #1 in order
to align the J 33049.

2002 - Unit Repair (May 25, 2001)