
OIL PRESSURE
SPECIFICATION SPECIFICATION
At Curb Idle Speed (MIN)* 48 kPa (7 psi)
@ 3000 rpm 240 - 725 kPa (35 - 105 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION Nꞏm Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 —
Bearing Cap Bolts 11 — 100
Timing Chain Cover—Bolts 58 43 —
Connecting Rod Cap—Bolts 27 20 —
PLUS 90° TURN
Bed Plate—Bolts Refer to Procedure
Cylinder Head—Bolts Refer to Procedure
Crankshaft Damper—Bolt 175 130 —
Cylinder Head Cover—Bolts 12 — 105
Exhaust Manifold—Bolts 25 18 —
Exhaust Manifold Heat Shield—Nuts 8 — 72
Then loosen 45°
Flexplate—Bolts 60 45 —
Engine Mount Bracket to Block—Bolts 61 45 —
Rear Mount to Transmission—Bolts 46 34 —
Generator Mounting—Bolts
M10 Bolts 54 40 —
M8 Bolts 28 — 250
Intake Manifold—Bolts 12 — 105
Refer to Procedure for
Tightening Sequence
Oil Pan—Bolts 15 — 130
Oil Pan—Drain Plug 34 25 —
Oil Pump—Bolts 28 — 250
Oil Pump Cover—Bolts 12 — 105
Oil Pickup Tube—Bolt and Nut 28 — 250
Oil Dipstick Tube to Engine
Block—Bolt 15 — 130
Oil Fill Tube—Bolts 12 — 105
Timing Chain Guide—Bolts 28 — 250
Timing Chain Tensioner Arm—Pin Bolt 17 — 150
Hydraulic Tensioner—Bolts 28 — 250
Timing Chain Primary Tensioner—Bolts 28 — 250

DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the engine, particularly at thearea of the suspected leak. If an oil leak
source is not readily identifiable, thefollowingstepsshouldbefollowed:
1. Do not clean or degrease the engine at this time because some solvents maycause rubber to swell, temporarily
stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15
minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color
under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If
the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspec-
tion.If the oil leak source is not positively identified at this time, proceed with the air leak detection test method.
Air Leak Detection Test Method
1. Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
2. Remove the PCV valve from the cylinder head cover. Cap or plug the PCV valvegrommet.
3. Attach an air hose with pressure gauge and regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
4. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applyingsoapy water at the suspected source.
Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak
source. If the oil leak is detected and identified, repair per service manual procedures.
5. If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
6. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV
valve and breather cap hose.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approx-
imately 24 km (15 miles). Inspect the engine for signs of an oil leak by usinga black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in therear seal area of the engine, a more
involved inspection is necessary. The following steps should be followedto help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal area:
1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light
to check for the oil leak:
a. Circular spray pattern generally indicates seal leakage or crankshaftdamage.
b. Where leakage tends to run straight down, possible causes are a porous block, oil galley pipe plugs, oil filter
runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crankcase as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch forleakage. If a leak is detected between
the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged.
The seal area on the crankshaft could have minor nicks or scratches that canbe polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

OIL
STANDARD PROCEDURE - ENGINE OIL SERVICE
The engine oil level indicator (2) is located at the right
rear of the engine on the 4.7L engines.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800 kilometers (500 miles).Unless the engine has exhibited loss of oil
pressure, run the engine for about five minutes before checking oil level.Checking engine oil level on a cold engine
is not accurate.
To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable
levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
1. Position vehicle on level surface.
2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil
dipstick.
3. Wipe dipstick clean.
4. Install dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the ADD mark on dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in Maintenance Schedules.
Run engine until achieving normal operating temperature.
1. Position the vehicle on a level surface and turn engine off.
2. Hoist and support vehicle on safety stands.
3. Remove oil fill cap.
4. Place a suitable drain pan under crankcase drain.
5. Remove drain plug from crankcase and allow oil to drain into pan. Inspectdrain plug threads for stretching or
other damage. Replace drain plug if damaged.
6. Install drain plug in crankcase.
7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section.
8. Install oil fill cap.
9. Start engine and inspect for leaks.

MANIFOLD - INTAKE
DESCRIPTION
The intake manifold is made of a composite material and features long runners which maximizes low end torque.
The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent
leaks. Eight studs and two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifoldvacuum. Also, one or more cylinders may
not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN ADIRECT LINE
WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE CLOTHING.
1. Start the engine.
2. Spray a small stream of water at the suspected leak area.
3. If a change in RPM is observed the area of the suspected leak has been found.
4. Repair as required.
REMOVAL
1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect throttle and speed control cables.
4. Disconnect electrical connectors for the following components:
Manifold Absolute Pressure (MAP) Sensor
Intake Air Temperature (IAT) Sensor
Throttle Position (TPS) Sensor
Coolant Temperature (CTS) Sensor
Idle Air Control (IAC) Motor
5. Disconnect brake booster hose and positive crankcase ventilation (PCV)hose.
6. Disconnect generator electrical connections.
7. Disconnect air conditioning compressor electrical connections.
8. Disconnect left and right radio suppressor straps.
9. Disconnect and remove ignition coil towers (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL -
REMOVAL).
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
12. Remove fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level (Refer to 7 - COOLING - STANDARD PROCEDURE).

INSTALLATION
1. Install intake manifold gaskets.
2. Position intake manifold.
3. Install intake manifold retaining bolts and tighten in
sequence shown in to 12 Nꞏm (105 in. lbs.).
4. Install left and right radio suppressor straps.
5. Install throttle body assembly.
6. Install throttle cable bracket.
7. Connect throttle cable and speed control cable to
throttle body.
8. Install fuel rail (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL RAIL - INSTALLATION).
9. Install ignition coil towers (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
10. Position and install heater hoses and tubes onto intake manifold.
11. Install the heater hoses to the heater core and engine front cover.
12. Connect electrical connectors for the following components:
Manifold Absolute Pressure (MAP) Sensor
Intake Air Temperature (IAT) Sensor
Throttle Position (TPS) Sensor
Coolant Temperature (CTS) Sensor
Idle Air Control (IAC) Motor
Ignition coil towers
Fuel injectors
13. Install top oil dipstick tube retaining bolt and ground strap.
14. Connect generator electrical connections.
15. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
16. Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
17. Install resonator assembly and air inlet hose.
18. Connect negative cable to battery.

SPECIFICATION SPECIFICATION
At Curb Idle Speed (MIN)* 25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine
TORQUE
TORQUE CHART 5.7L ENGINE
DESCRIPTION Nꞏm Ft. In.
Lbs. Lbs.
Block Pipe Plugs
(1/4 NPT)20 — 177
(3/8 NPT) 27 — 240
Camshaft Sprocket—Bolt 122 90 —
Camshaft Tensioner Plate—Bolts 28 — 250
Coil to Cylinder Head Cover—Bolts 7 — 62
Timing Chain Case Cover—Bolts 28 — 250
Lifting Stud 55 40 —
Connecting Rod Cap—Bolts 21
plus 90° Turn15
plus 90° Turn—
Main Bearing Cap—Bolts
M-1227
plus 90° Turn——
Crossbolts
M-828 — —
Cylinder Head—Bolts
M-12 Bolts
Step 1 34 25 —
Step 2 54 40 —
Step 3 Turn 90° Turn 90° —
M-8 Bolts —
Step 1 20 15 —
Step 2 34 25 —
Cylinder Head Cover—Bolts 8 — 70
Exhaust Manifold to Cylinder Head 25 — 220
Flexplate to Crankshaft—Bolts 95 70 —
Flywheel to Crankshaft—Bolts 75 55 —
Front Insulator—Thru bolt/nut 95 70 —
Front Insulator to Support Bracket
—Stud Nut (4WD) 41 30 —
—Through Bolt/Nut (4WD) 102 75 —
Front Insulator to Block—Bolts (2WD) 95 70 —
Generator—Mounting Bolt 55 40 —
Intake Manifold—Bolts Refer to Procedure
Lifter Guide Holder 12 — 106
Oil Pan Bolts 12 — 105
Oil Dipstick Tube 12 — 105

TAPPETS - HYDRAULIC ROLLER
DIAGNOSIS AND TESTING - HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, checkthe oil pressure. If vehicle has no oil
pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa
(30-70 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level,
check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on
dipstick. Either of these two conditions could be responsible for noisy tappets.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible for the connecting rods todip into the oil. With the engine running,
this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump
causing them to lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When air is fed to the tappets,they lose length, which allows valves
to seat noisily. Any leaks on intake side of oil pump through which air can bedrawn will create the same tappet
action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer
cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will
be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient
time to allow all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
1. To determine source of tappet noise, crank over engine with cylinder head covers removed.
2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring
and/or rocker arm to vibrate or feel rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisytappets. If such is the case,
noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it
can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for
wear.
3. Valve tappet noise ranges from light noise to a heavy click. A light noiseis usually caused by excessive leak-
down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should
be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between
the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be
accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case,
tappet assembly should be removed for inspection and cleaning.
4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be
taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it’s probably not
the tappets.
REMOVAL
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner (Refer to 9 - ENGINE/AIR INTAKE SYSTEM - REMOVAL).
3. Remove intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD-REMOVAL).
4. Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDERHEAD COVER(S) -
REMOVAL).
5. Remove rocker arm assembly and push rods (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). Identify push rods to ensure installation in original location.
6. Remove the cylinder head (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL).

LUBRICATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
1. Remove oil pressure sending unit and install gauge assembly C-3292.
2. Run engine until thermostat opens.
3. Oil Pressure:
Curb Idle–25 kPa (4 psi) minimum
3000 rpm–170 - 758 kPa (25 - 110 psi)
4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck
open.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the engine, particularly at thearea of the suspected leak. If an oil leak
source is not readily identifiable, thefollowingstepsshouldbefollowed:
1. Do not clean or degrease the engine at this time because some solvents maycause rubber to swell, temporarily
stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15
minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color
under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If
the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspec-
tion.If the oil leak source is not positively identified at this time, proceed with the air leak detection test
method.
Air Leak Detection Test Method
1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet.
2. Attach an air hose with pressure gauge and regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
3. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applyingsoapy water at the suspected source.
Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak
source. If the oil leak is detected and identified, repair per service manual procedures.
4. If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV
valve.
6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approx-
imately 24 km (15 miles). Inspect the engine for signs of an oil leak by usinga black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in therear seal area of the engine, a more
involved inspection is necessary. The following steps should be followedto help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal area:
1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light
to check for the oil leak:
a. Circular spray pattern generally indicates seal leakage or crankshaftdamage.