Page 2681 of 6020

Engine Mechanical – V6 Page 6A1–202
1 Install a new oil suction tube seal onto the oil suction
tube.
2 Install the oil suction pipe and tighten the attaching bolts to the correct torque specification.
Oil suction pipe attaching
bolt torque specification .....................................10.0 Nm
3 Install the crankshaft oil deflector into the oil pan assembly and tighten the attaching bolts to the
correct torque specification.
Crankshaft oil deflector
attaching bolt torque specification ......................10.0 Nm
4 Install the oil level sensor into the oil pan assembly and tighten to the correct torque specification.
Oil level sensor torque specification...................20.0 Nm
Figure 6A1 – 358
5 Install the oil pan drain plug into the oil pan assembly and tighten to the correct torque specification. Oil pan drain plug
torque specification ............................................25.0 Nm
Reinstall
1 Install the guide pins, Tool No. EN-46109 (1) into the oil pan rail bolt hole on each side of the engine block.
Figure 6A1 – 359
2 Place a 3mm bead (1) of RTV sealant on the cylinder block pan rail and crankshaft rear oil seal housing to
oil pan mating surfaces.
3 Position the oil pan onto the cylinder block.
4 Remove the guide pins, Tool No. EN-46109 from the cylinder block.
Figure 6A1 – 360
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Page 2682 of 6020
Engine Mechanical – V6 Page 6A1–203
5 Loosely install the oil pan bolts.
6 Tighten the oil pan attaching bolts to the correct torque specification and in the sequence shown.
Oil pan to cylinder block attaching
bolt (1 – 11) torque specification .............20.0 – 26.0 Nm
Oil pan to crankshaft rear oil
seal housing attaching bolt (12 – 13)
torque specification ...................................8.0 – 12.0 Nm
Figure 6A1 – 361
4.3 Flexplate Assembly
Remove
1 Remove the transmission, refer to 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing.
2 Remove the starter motor, refer to 6D1-2 Starting System – V6.
3 Install the flexplate holding tool, Tool No. EN-46106 (1) into the starter motor mounting location.
Figure 6A1 – 362
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Page 2685 of 6020
Engine Mechanical – V6 Page 6A1–206
4 Remove the five bolts (1) attaching the crankshaft
rear seal housing to the rear of the cylinder block (2).
Figure 6A1 – 367
5 Shear the RTV sealant using the prise points located at the edge of the crankshaft rear oil seal housing,
Figure 6A1 – 368
6 Remove the crankshaft rear oil seal housing (1) from the cylinder block (2).
Figure 6A1 – 369
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Page 2686 of 6020
Engine Mechanical – V6 Page 6A1–207
Reinstall
1 Install the guide pins, Tool No. EN-46109 (1) into the
two crankshaft rear oil seal housing bolt holes of the
cylinder block (2).
Figure 6A1 – 370
2 Apply a 3mm bead (1) of RTV sealant to the crankshaft rear oil seal housing.
Figure 6A1 – 371
3 Install the crankshaft rear oil seal housing (1) to the cylinder block (2).
NOTE
• Do not allow any engine oil onto the cylinder
block mating surface, where the crankshaft
rear oil seal housing is to be installed.
• A seal-protector is provided with the new
crankshaft rear seal and housing assembly.
Do not remove the seal protector from the
crankshaft rear oil seal housing until the
crankshaft rear oil seal housing is fully in
position.
4 Remove the guide pins from the cylinder block.
Figure 6A1 – 372
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Page 2687 of 6020

Engine Mechanical – V6 Page 6A1–208
5 Install the crankshaft rear oil seal housing attaching
bolts (1) to the cylinder block (2) and tighten to the
correct torque specification.
Crankshaft rear oil seal housing
attaching bolt torque specification .............8.0 – 12.0 Nm
Figure 6A1 – 373
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings
Remove
1 Remove the engine assembly, refer to 4.1 Engine .
2 Remove both cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
3 Remove the oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly.
4 Mark the top of the piston being removed to identify its specific bore.
5 Install Tool No. EN-46111 (1) onto the crankshaft (2).
6 Rotate the crankshaft until the piston being removed is at the bottom of its stroke; bottom dead centre
(BDC).
Figure 6A1 – 374
CAUTION
If the connecting rod bearings have been
used in a running engine, they must be
replaced with new connecting rod bearings
for reassembly.
7 Before removing the connecting rods, check the connecting rod side clearance using the following procedure: a Tap the connecting rod to one end of the crankshaft journal with a dead blow or wooden hammer.
b Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.
c The connecting rod side clearance should not exceed specifications, refer to 5 Specifications.
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Page 2693 of 6020

Engine Mechanical – V6 Page 6A1–214
3 Using an inside micrometer, measure the piston pin
bore (1). Compare the result with the piston pin
diameter and piston pin to piston pin bore clearance
listed in the specifications, refer to 5 Specifications.
4 If the clearance is excessive, determine which piece is out of specification and replace as required.
5 Replace the piston if any of its dimensions are out of specification.
6 If the new piston does not meet clearance specifications, the cylinder block may need to be
oversized to 0.25 mm. There is only one size of
oversized pistons and rings available for service.
Figure 6A1 – 387
Piston Ring Measurement
1 Measure the piston ring end gap using the following procedure:
a Place the piston ring (1) in the area of the bore where the piston ring will travel, approximately 25 mm below
the deck surface. Ensure the ring is square with the
cylinder bore by positioning the ring with the piston
head.
b Measure the end gap of the piston ring with feeler gauges (2), refer to 5 Specifications.
c If the clearance exceeds the provided specifications, the piston rings must be replaced.
d Repeat the procedure for all piston rings.
Figure 6A1 – 388
2 Measure the piston ring side clearance using the following procedure:
a Roll the piston ring (1) entirely around the piston ring groove. If any binding is caused by the ring groove,
dress the groove with a fine file. If any binding is
caused by a distorted piston ring, replace the ring.
b W ith the piston ring on the piston, use feeler gauges (2) to check clearance at multiple locations.
c Compare the measurements with piston ring side clearance listed in the specifications, refer to 5
Specifications.
d If the clearance is greater than specifications, replace the piston rings.
Figure 6A1 – 389
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Page 2694 of 6020

Engine Mechanical – V6 Page 6A1–215
3 There is a locating dimple (1) on the compression
rings. Install the compression rings with the dimple
facing up.
4 If the new ring does not reduce the clearance to the correct specification, install a new piston.
5 If the new piston does not meet clearance specifications, the cylinder block may need to be
oversized to 0.25 mm. There is only one size of
oversized pistons and rings available for service.
Figure 6A1 – 390
Connecting Rod Cleaning Procedure
1 Clean the connecting rods in solvent.
Safety glasses must be worn when using
compressed air.
2 Dry the connecting rod using compressed air.
3 Remove the connecting rod cap and clean the threads.
4 Remove the connecting rod bearing and discard. Never reuse a connecting rod bearing that has been used in a running engine.
Connecting Rod Visual Inspection Procedure
1 Inspect the piston pin bushing (4) for scoring or
damage.
2 Inspect the connecting rod beam (1) for twisting or bending.
3 Inspect the rod cap (2) for any nicks or damage caused by possible interference.
4 Inspect for scratches or abrasion on the rod bearing seating surface.
5 If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with
a light emery paper.
6 Retain the original bolts (3) for preliminary assembly. They must be replaced for final assembly.
Figure 6A1 – 391
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Page 2698 of 6020

Engine Mechanical – V6 Page 6A1–219
7 Once the rings are installed, set the ring gaps for the
oil control, second and top ring as follows. Use the
piston location arrow for reference.
• Lower oil control ring position (1).
• Upper oil control ring position (2).
• Top ring position (3).
• Oil control ring expander position (4).
• Second ring position (5).
Figure 6A1 – 400
Connecting Rod Bearing
CAUTION
If the connecting rod bearings have been
used in a running engine, they must be
replaced with new connecting rod bearings
for reassembly.
1 Clean the connecting rod (2) and the connecting rod cap bearing bore with a lint-free cloth.
2 Clean the oil from behind the connecting rod bearing halves.
3 Install a new upper connecting rod bearing (1) into position. Roll the bearing into position so the lock tang
engages the alignment slot. The bearing must fit flush
in the connecting rod.
Figure 6A1 – 401
4 Install the lower connecting rod bearing (1) into position in the connecting rod cap (2).
5 Roll the bearing into position so the lock tang engages the alignment slot. The bearing must fit flush
with the connecting rod cap.
Figure 6A1 – 402
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