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CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consistsof:
Drilling out worn or damaged threads.
Tapping the hole with a special Heli-Coil Tap, or equivalent.
Installing an insert into the tapped hole to bring the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what causedthe problem), follow the steps below.
1. Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
2. Disconnect the negative cable(s) from the battery.
3. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
4. Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder
head. Remove the spark plugs.
5. With all spark plugs removed, rotate the crankshaft using a breaker bar and socket.
6. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
7. Be sure all fluid has been removed from the cylinders.
8. Repair engine or components as necessary to prevent this problem from occurring again.
9. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
10. Install new spark plugs. Tighten the spark plugs to 41 Nꞏm (30 ft. lbs.) torque.
11. Drain engine oil. Remove and discard the oil filter.
12. Install the drain plug. Tighten the plug to 34 Nꞏm (25 ft. lbs.) torque.
13. Install a new oil filter.
14. Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE -
SPECIFICATIONS).
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21. Disconnect the starter wires. Remove starter
motor (1) (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
22. Remove the structural dust cover (1) and trans-
mission inspection cover, (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL) .
23. Remove drive plate to converter bolts (Automatic
transmission equipped vehicles).
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24. Remove transmission bell housing to engine block
bolts (2).
25. Lower the vehicle.
NOTE: Do not use air tools to install engine lift fix-
ture (2) special tool # 8984.
26. Install engine lift fixture (2), special tool # 8984.
Do not use adapter (4)
27. Separate engine from transmission, remove
engine from vehicle, and install engine assembly
on a repair stand.
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INSTALLATION
NOTE: Do not use air tools to install engine lift fix-
ture (2) special tool # 8984.
1. Install engine lift fixture (2), special tool # 8984.Do
not use adapter (4).
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine
with transmission:
Manual Transmission: Align clutch disc assembly
(if disturbed). Install transmission input shaft into
clutch disc while mating engine and transmission
surfaces. Install two transmission to engine block
mounting bolts finger tight.
Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine
block mounting bolts finger tight.
4. Position the thru-bolt into the support cushion
brackets.
5. Lower engine assembly until engine mount through
bolts rest in mount perches.
6. Install remaining transmission to engine block
mounting bolts (2) and tighten.
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7. Tighten engine mount through bolts.
8. Install drive plate to torque converter bolts. (Auto-
matic transmission models)
9. Install the structural dust cover (1) and transmis-
sion dust cover, (Refer to 9 - ENGINE/ENGINE
BLOCK/STRUCTURAL COVER - INSTALLATION) .
10. Install the starter (1) and connect the starter wires
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION).
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26. Install the fan shroud (3).
27. Install the fan (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
28. Connect the radiator upper hose.
29. Install the washer bottle.
30. Connect the transmission cooler lines.
31. Install the air cleaner resonator and duct work..
32. Add engine oil to crankcase (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECI-
FICATIONS).
33. Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
34. Connect battery negative cable.
35. Start engine and inspect for leaks.
36. Road test vehicle.
SPECIFICATIONS
5.7L ENGINE
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type 90° V-8 OHV
Displacement 5.7 Liters
345 ( Cubic Inches)
Bore 99.5 mm (3.91 in.)
Stroke 90.9 mm (3.58 in.)
Compression Ratio 9.6:1
Firing Order 1-8-4-3-6-5-7-2
Lubrication Pressure Feed - Full Flow
Filtration
Cooling System Liquid Cooled - Forced
Circulation
Cylinder Block Cast Iron
Cylinder Head Aluminum
Crankshaft Nodular Iron
Camshaft Hollow Assembled Camshaft
Pistons Aluminum Alloy
Connecting Rods Powdered Metal
CYLINDER BLOCK
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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
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Housing Assembly
1. Loosen clamp and disconnect air duct at air
cleaner cover.
2. Lift entire housing (1) assembly from 4 locating
pins (2).
INSTALLATION
1. Install filter element into housing.
2. Position housing cover into housing locating tabs
(4).
3. Pry up 4 spring clips (5) and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose
clamp to 3 Nꞏm (30 in. lbs.) torque.
5. If any other hose clamps were removed from air
intake system, tighten them to 3 Nꞏm (30 in. lbs.)
torque.
6. If any bolts were removed from air resonator hous-
ing or air intake tubing, tighten them to 4 Nꞏm (40
in. lbs.) torque.
Fig. 2 AIR CLEANER HOUSING
1 - AIR CLEANER HOUSING ASSEMBLY
2 - LOCATING PINS (4)