Page 1
2004 ENGINE
Engine Mechanical - 5.7L - GTO
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
Metric English
Accelerator Control Cable Bracket Bolts 10 N.m 89 lb in
Camshaft Retainer Bolts 25 N.m 18 lb ft
Camshaft Sensor Bolt 25 N.m 18 lb ft
Camshaft Sprocket Bolts 35 N.m 26 lb ft
Connecting Rod Bolts - First Pass 20 N.m 15 lb ft
Connecting Rod Bolts - Final Pass 75 degrees
Coolant Temperature Gage Sensor 20 N.m 15 lb ft
Crankshaft Balancer Bolt - Installation Pass to
Ensure the Balancer is Completely Installed
330 N.m 240 lb ft
Crankshaft Balancer Bolt -
First Pass Install a NEW
Bolt After the Installation Pass and Tighten as
Described in the First and Final Passes
50 N.m 37 lb ft
Crankshaft Balancer Bolt - Final Pass 140 degrees
Crankshaft Bearing Cap Bolts - Inner Bolts - First
Pass in Sequence
20 N.m 15 lb ft
Crankshaft Bearing Cap Bolts - Inner Bolts - Final
Pass in Sequence
80 degrees
Crankshaft Bearing Cap Side Bolts 25 N.m 18 lb ft
Crankshaft Bearing Cap Studs - Outer Studs - First
Pass in Sequence
20 N.m 15 lb ft
Crankshaft Bearing Cap Studs - Outer Studs - Final
Pass in Sequence
53 degrees
Crankshaft Oil Deflector Nuts 25 N.m 18 lb ft
Crankshaft Position Sensor Bolt 25 N.m 18 lb ft
Cylinder Head Bolts - First Design - First Pass all
M11 Bolts in Sequence
30 N.m 22 lb ft
Cylinder Head Bolts - First Design -
Second Pass all
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:24 PM Page 1 ©
2005 Mitchell Repair Information Company, LLC.
MY
Thursday, April 02, 2009 7:59:20 PM Page 1 ©
2005 Mitchell Repair Information Company, LLC.
Page 2
M11 Bolts in Sequence 90 degrees
Cylinder Head Bolts - First Design - Final Pass all
M11 Bolts in Sequence - Excluding the Medium
Length Bolts at the Front and Rear of Each Cylinder
Head
90 degrees
Cylinder Head Bolts - First Design -
Final Pass M11
Medium Length Bolts at the Front and Rear of Each
Cylinder Head
50 degrees
Cylinder Head Bolts - Second Design -
First Pass all
M11 Bolts in Sequence
30 N.m 22 lb ft
Cylinder Head Bolts - Second Design - Second Pass
all M11 Bolts in Sequence
90 degrees
Cylinder Head Bolts - Second Design - Final Pass
all M11 Bolts in Sequence
70 degrees
Cylinder Head Bolts - M8 Inner Bolts in Sequence 30 N.m 22 lb ft
Cylinder Head Coolant Plug 20 N.m 15 lb ft
Cylinder Head Core Hole Plug 20 N.m 15 lb ft
Engine Block Coolant Drain Plugs 60 N.m 44 lb ft
Engine Block Oil Gallery Plugs 60 N.m 44 lb ft
Engine Coolant Air Bleed Pipe Bolts and Studs 12 N.m 106 lb in
Engine Flywheel Bolts - First Pass 20 N.m 15 lb ft
Engine Flywheel Bolts - Second Pass 50 N.m 37 lb ft
Engine Flywheel Bolts - Final Pass 100 N.m 74 lb ft
Engine Front Cover Bolts 25 N.m 18 lb ft
Engine Rear Cover Bolts 25 N.m 18 lb ft
Engine Service Lift Bracket M10 Bolts 50 N.m 37 lb ft
Engine Service Lift Bracket M8 Bolt 25 N.m 18 lb ft
Engine Valley Cover Bolts 25 N.m 18 lb ft
Exhaust Manifold Bolts - First Pass 15 N.m 11 lb ft
Exhaust Manifold Bolts - Final Pass 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Bolts 9 N.m 80 lb in
Fuel Injection Fuel Rail Bolts 10 N.m 89 lb in
Ignition Coil-to-Bracket Bolts 12 N.m 106 lb in
Ignition Coil Bracket-to-Valve Rocker Arm Cover
Bolts
12 N.m 106 lb in
Intake Manifold Bolts - First Pass in Sequence 5 N.m 44 lb in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 2 ©
2005 Mitchell Repair Information Company, LLC.
Page 3
ENGINE MECHANICAL SPECIFICATIONS
Intake Manifold Bolts - Final Pass in Sequence 10 N.m 89 lb in
Knock Sensors 20 N.m 15 lb ft
Oil Filter 30 N.m 22 lb ft
Oil Filter Fitting 55 N.m 40 lb ft
Oil Level Indicator Tube Bolt 25 N.m 18 lb ft
Oil Pan Baffle Bolts 12 N.m 106 lb in
Oil Pan Closeout Cover Bolt - Left Side 12 N.m 106 lb in
Oil Pan Closeout Cover Bolt - Right Side 12 N.m 106 lb in
Oil Pan Drain Plug 25 N.m 18 lb ft
Oil Pan M8 Bolts - Oil Pan-to-Engine Block and
Oil Pan-to-Front Cover
25 N.m 18 lb ft
Oil Pan M6 Bolts - Oil Pan-to-Rear Cover 12 N.m 106 lb in
Oil Pan Oil Gallery Plugs 25 N.m 18 lb ft
Oil Pressure Sensor 20 N.m 15 lb ft
Oil Pump-to-Engine Block Bolts 25 N.m 18 lb ft
Oil Pump Cover Bolts 12 N.m 106 lb in
Oil Pump Relief Valve Plug 12 N.m 106 lb in
Oil Pump Screen Nuts 25 N.m 18 lb ft
Oil Pump Screen-to-Oil Pump Bolt 12 N.m 106 lb in
Oil Transfer Cover Nuts 12 N.m 106 lb in
Oil Transfer Tube Bolts 12 N.m 106 lb in
Oil Transfer Tube Studs 12 N.m 106 lb in
Spark Plugs - New Cylinder Heads 20 N.m 15 lb ft
Spark Plugs - all Subsequent Installations 15 N.m 11 lb ft
Throttle Body Bolts 12 N.m 106 lb in
Timing Chain Guide Bolts 35 N.m 26 lb ft
Valve Lifter Guide Bolts 12 N.m 106 lb in
Valve Rocker Arm Bolts 30 N.m 22 lb ft
Valve Rocker Arm Cover Bolts 12 N.m 106 lb in
Water Inlet Housing Bolts 15 N.m 11 lb ft
Water Pump Bolts - First Pass 15 N.m 11 lb ft
Water Pump Bolts - Final Pass 30 N.m 22 lb ft
Water Pump Cover Bolts 15 N.m 11 lb ft
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 3 ©
2005 Mitchell Repair Information Company, LLC.
Page 4
Engine Mechanical Specifications
Application
Specification
Metric English
General
Engine Type
V 8
Displacement
5.7L - 5665 cc 346 CID
RPO
LS1
VIN
G
Bore
99.0-99.018 mm 3.897-3.898 in
Stroke
92.0 mm 3.622 in
Compression Ratio
10.1:1
Firing Order
1-8-7-2-6-5-4-3
Spark Plug Gap
1.016 mm 0.04 in
Block
Camshaft Bearing Bore 1 and 5 Diameter First Design
59.08-59.13 mm 2.325-2.327 in
Camshaft Bearing Bore 2 and 4 Diameter First Design
58.83-58.88 mm 2.316-2.318 in
Camshaft Bearing Bore 3 Diameter - First
Design
58.58-58.63 mm 2.306-2.308 in
Camshaft Bearing Bore 1 and 5 Diameter Second Design
59.58-59.63 mm 2.345-2.347 in
Camshaft Bearing Bore 2 and 4 Diameter Second Design
59.08-59.13 mm 2.325-2.327 in
Camshaft Bearing Bore 3 Diameter - Second
Design
58.58-58.63 mm 2.306-2.308 in
Crankshaft Main Bearing Bore Diameter
69.871-69.889 mm 2.75-2.751 in
Crankshaft Main Bearing Bore Out-of-Round
0.005 mm 0.0002 in
Cylinder Bore Diameter
99.0-99.018 mm 3.897-3.898 in
Cylinder Bore Taper - Thrust Side
0.018 mm 0.0007 in
Cylinder Head Deck Height - Measuring from
the Centerline of Crankshaft to the Deck Face
234.57-234.82 mm 9.235-9.245 in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 4 ©
2005 Mitchell Repair Information Company, LLC.
Page 5
Cylinder Head Deck Surface Flatness Measured within a 152.4 mm (6.0 in) Area
0.08 mm 0.003 in
Cylinder Head Deck Surface Flatness Measuring the Overall Length of the Block
Deck
0.22 mm 0.008 in
Valve Lifter Bore Diameter
21.417-21.443 mm 0.843-0.844 in
Camshaft
Camshaft End Play
0.025-0.305 mm 0.001-0.012 in
Camshaft Journal Diameter
54.99-55.04 mm 2.164-2.166 in
Camshaft Journal Out-of-Round
0.025 mm 0.001 in
Camshaft Lobe Lift - Exhaust
7.43 mm 0.292 in
Camshaft Lobe Lift - Intake
7.43 mm 0.292 in
Camshaft Runout - Measured at the
Intermediate Journals
0.05 mm 0.002 in
Connecting Rod
Connecting Rod Bearing Clearance Production
0.023-0.065 mm 0.0009-0.0025 in
Connecting Rod Bearing Clearance - Service
0.023-0.076 mm 0.0009-0.003 in
Connecting Rod Bore Diameter - Bearing End
56.505-56.525 mm 2.224-2.225 in
Connecting Rod Bore Out-of-Round - Bearing
End - Production
0.006 mm 0.00023 in
Connecting Rod Bore Out-of-Round - Bearing
End - Service
0.006 mm 0.00023 in
Connecting Rod Side Clearance
0.11-0.51 mm 0.00433-0.02 in
Crankshaft
Connecting Rod Journal Diameter Production
53.318-53.338 mm 2.0991-2.0999 in
Connecting Rod Journal Diameter - Service
53.308 mm 2.0987 in
Connecting Rod Journal Out-of-Round Production
0.005 mm 0.0002 in
Connecting Rod Journal Out-of-Round Service
0.01 mm 0.0004 in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 5 ©
2005 Mitchell Repair Information Company, LLC.
Page 6
Connecting Rod Journal Taper - Maximum for
1/2 of Journal Length - Production
0.005 mm 0.0002 in
Connecting Rod Journal Taper - Maximum for
1/2 of Journal Length - Service
0.02 mm 0.00078 in
Crankshaft End Play
0.04-0.2 mm 0.0015-0.0078 in
Crankshaft Main Bearing Clearance Production
0.02-0.052 mm 0.0008-0.0021 in
Crankshaft Main Bearing Clearance - Service
0.02-0.065 mm 0.0008-0.0025 in
Crankshaft Main Journal Diameter Production
64.992-65.008 mm 2.558-2.559 in
Crankshaft Main Journal Diameter - Service
64.992 mm 2.558 in
Crankshaft Main Journal Out-of-Round Production
0.003 mm 0.000118 in
Crankshaft Main Journal Out-of-Round Service
0.008 mm 0.0003 in
Crankshaft Main Journal Taper - Production
0.01 mm 0.0004 in
Crankshaft Main Journal Taper - Service
0.02 mm 0.00078 in
Crankshaft Rear Flange Runout
0.05 mm 0.002 in
Crankshaft Reluctor Ring Runout - Measured
1.0 mm (0.04 in) Below the Tooth Diameter
0.7 mm 0.028 in
Crankshaft Thrust Surface - Production
26.14-26.22 mm 1.029-1.0315 in
Crankshaft Thrust Surface - Service
26.22 mm 1.0315 in
Crankshaft Thrust Surface Runout
0.025 mm 0.001 in
Cylinder Head
Cylinder Head Height/Thickness - Measured
from the Cylinder Head Deck to the Valve
Rocker Arm Cover Seal Surface
120.2 mm 4.732 in
Surface Flatness - Block Deck - Measured
Within a 152.4 mm (6.0 in) Area
0.08 mm 0.003 in
Surface Flatness - Block Deck -
Measuring the
Overall Length of the Cylinder Head
0.1 mm 0.004 in
Surface Flatness - Exhaust Manifold Deck
0.22 mm 0.008 in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 6 ©
2005 Mitchell Repair Information Company, LLC.
Page 7
Surface Flatness - Intake Manifold Deck
0.22 mm 0.008 in
Intake Manifold
Surface Flatness - Measured at Gasket Sealing
Surfaces
0.5 mm 0.02 in
Lubrication System
Oil Capacity - with Filter
5.7 Liters 6.0 Quarts
Oil Capacity - without Filter
5.1 Liters 5.4 Quarts
Oil Pressure - Minimum - Hot
41 kPa at 1,000
engine RPM
124 kPa at 2,000
engine RPM
165 kPa at 4,000
engine RPM
6 psig at 1,000
engine RPM
18 psig at 2,000
engine RPM
24 psig at 4,000
engine RPM
Oil Pan
Front Cover Alignment - at Oil Pan Surface
0.0-0.5 mm 0.0-0.02 in
Rear Cover Alignment - at Oil Pan Surface
0.0-0.5 mm 0.0-0.02 in
Oil Pan Alignment - to Rear of Engine Block
at Transmission Bellhousing Mounting Surface
0.0-0.25 mm 0.0-0.01 in
Piston Rings
Piston Ring End Gap -
First Compression Ring
- Measured in Cylinder Bore - Production
0.23-0.44 mm 0.009-0.017 in
Piston Ring End Gap -
First Compression Ring
- Measured in Cylinder Bore - Service
0.23-0.5 mm 0.009-0.0196 in
Piston Ring End Gap - Second Compression
Ring - Measured in Cylinder Bore Production
0.44-0.7 mm 0.017-0.027 in
Piston Ring End Gap - Second Compression
Ring - Measured in Cylinder Bore - Service
0.44-0.76 mm 0.0173-0.03 in
Piston Ring End Gap - Oil Control Ring Measured in Cylinder Bore - Production
0.18-0.75 mm 0.007-0.029 in
Piston Ring End Gap - Oil Control Ring Measured in Cylinder Bore - Service
0.18-0.81 mm 0.007-0.032 in
Piston Ring-to-Groove Clearance - First
Compression Ring - Production
0.04-0.086 mm 0.00157-0.0033 in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 7 ©
2005 Mitchell Repair Information Company, LLC.
Page 8
Piston Ring-to-Groove Clearance - First
Compression Ring - Service
0.04-0.068 mm 0.00157-0.0033 in
Piston Ring-to-Groove Clearance - Second
Compression Ring - Production
0.05-0.088 mm 0.002-0.0034 in
Piston Ring-to-Groove Clearance - Second
Compression Ring - Service
0.05-0.088 mm 0.002-0.0034 in
Piston Ring-to-Groove Clearance - Oil
Control Ring - Production
-0.008 to +0.176
mm
-0.0003 to
+0.0069 in
Piston Ring-to-Groove Clearance - Oil
Control Ring - Service
-0.008 to +0.176
mm
-0.0003 to
+0.0069 in
Pistons and Pins
Piston - Piston Diameter - Non Coated Skirt at Size Point
98.969-98.987 mm 3.8964-3.8997 in
Piston - Piston Diameter - Measured Over
Coating
98.984-99.027 mm 3.897-3.899 in
Piston - Piston to Bore Clearance - Non
Coated Skirt - Production
0.013-0.049 mm 0.0005-0.0019 in
Piston - Piston to Bore Clearance - Non
Coated Skirt - Service
0.013-0.074 mm 0.0005-0.0029 in
Piston - Piston to Bore Clearance - Coated
Skirt - Production
-0.027 to +0.029
mm
-0.001 to +0.0011
in
Piston - Piston to Bore Clearance - Coating
Worn Off - Service Limit
0.074 mm 0.0029 in
Pin - First Design Press Fit Pin Fit in
Connecting Rod Bore
0.02-0.043 mm Interference
0.00078-0.00169
in - Interference
Pin - First Design Press Fit Pin Clearance to
Piston Pin Bore - Production
0.01-0.02 mm 0.0004-0.00078 in
Pin - First Design Press Fit Pin Clearance to
Piston Pin Bore - Service
0.01-0.022 mm 0.0004-0.00086 in
Pin - First Design Press Fit Pin Diameter
23.997-24.0 mm 0.9447-0.9448 in
Pin - Second Design Full Floating Pin Fit in
Connecting Rod Bore - Production
0.007-0.02 mm
0.00027-0.00078
in
Pin - Second Design Full Floating Pin Fit in
0.007-0.022 mm
0.00027-0.00086
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 8 ©
2005 Mitchell Repair Information Company, LLC.
Page 9
Connecting Rod Bore - Service in
Pin - Second Design Full Floating Pin
Clearance to Piston Pin Bore - Production
0.002-0.01 mm 0.00008-0.0004 in
Pin - Second Design Full Floating Pin
Clearance to Piston Pin Bore - Service
0.002-0.015 mm 0.00008-0.0006 in
Pin - Second Design Full Floating Pin
Diameter
23.952-23.955 mm 0.943-0.943 in
Valve System
Valves - Valve Face Angle
45 degrees
Valves - Valve Face Width
1.25 mm 0.05 in
Valves - Valve Lash
Net Lash - No Adjustment
Valves - Valve Lift - Intake
11.79 mm 0.464 in
Valves - Valve Lift - Exhaust
12.16 mm 0.479 in
Valves - Valve Seat Angle
46 degrees
Valves - Valve Seat Runout
0.05 mm 0.002 in
Valves - Valve Seat Width - Exhaust
1.78 mm 0.07 in
Valves - Valve Seat Width - Intake
1.02 mm 0.04 in
Valves - Valve Stem Diameter - Production
7.955-7.976 mm 0.313-0.314 in
Valves - Valve Stem Diameter - Service
7.96 mm 0.314 in
Valves - Valve Stem-to-Guide Clearance Production - Intake
0.025-0.066 mm 0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance Service - Intake
0.093 mm 0.0037 in
Valves - Valve Stem-to-Guide Clearance Production - Exhaust
0.025-0.066 mm 0.001-0.0026 in
Valves - Valve Stem-to-Guide Clearance Service - Exhaust
0.093 mm 0.0037 in
Rocker Arms - Valve Rocker Arm Ratio
1.70:1
Valve Springs - Valve Spring Free Length
52.9 mm 2.08 in
Valve Springs - Valve Spring Installed Height
45.75 mm 1.8 in
Valve Springs - Valve Spring Load - Closed
340 N at 45.75
76 lb at 1.8 in
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 9 ©
2005 Mitchell Repair Information Company, LLC.
Page 10
SEALERS, ADHESIVES, AND LUBRICANTS
Sealers, Adhesives, and Lubricants
THREAD REPAIR SPECIFICATIONS
Engine Block - Front View
mm
Valve Springs - Valve Spring Load - Open
980 N at 33.55
mm
220 lb at 1.32 in
Application Type of Material
GM Part Number
United
States Canada
Coolant Sensor Threads Sealant 12346004 10953480
Cylinder Head Core Hole Plugs Threadlock 12345382 10953489
Cylinder Head Expansion Plugs Threadlock 12345382 10953489
Engine Block Front Oil Gallery Plug Threadlock 12345382 10953489
Engine Block Plug Sealing Washers Sealant 12346004 10953480
Engine Flywheel Bolt Threads Threadlock 12345382 10953489
Engine Oil 5W-30 Oil 12345610 993193
Engine Oil Supplement Fluorescent Dye 12345795 10953470
Exhaust Manifold Bolt Threads Threadlock 12345493 10953488
Fuel Rail Bolt Threads Threadlock 12345382 10953489
Ignition Coil and Bracket Assembly Bolts Threadlock 12345382 10953489
Intake Manifold Bolt Threads Threadlock 12345382 10953489
Oil Pan Surface at Front and Rear Covers Sealant 12378190 Oil Pressure Sensor Threads Sealant 12346004 10953480
Thread Repair Component Cleaner Cleaner 12346139 10953463
Thread Repair Component Cleaner Cleaner 12377981 10953463
Thread Repair Cutting Oil Lubricant 1052864 992881
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 10 ©
2005 Mitchell Repair Information Company, LLC.
Page 11
Fig. 1: Engine Block Bolt Holes - Front View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Front View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1-6
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
7
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
25.0
(0.984)
19.5
(0.767)
8
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
32.5 (1.28)
25.0
(0.984)
9
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
10
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
Thru Thru
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 11 ©
2005 Mitchell Repair Information Company, LLC.
Page 12
Engine Block - Rear View
Fig. 2: Engine Block Bolt Holes - Rear View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Rear View
11-13
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
14
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
Thru
18.0
(0.708)
15
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
16
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
Thru
18.0
(0.708)
17-27
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
Drill
Depth -
Tap Depth
-
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 12 ©
2005 Mitchell Repair Information Company, LLC.
Page 13
Engine Block - Left Side View
Fig. 3: Engine Block Bolt Holes - Left Side View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Maximum
mm (in)
Maximum
mm (in)
1
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
27.0 (1.06)
21.5
(0.846)
2-4
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
5-6
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
27.0 (1.06)
21.5
(0.846)
7-13
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
14-16
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
27.0 (1.06)
21.5
(0.846)
17-18
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 13 ©
2005 Mitchell Repair Information Company, LLC.
Page 14
Courtesy of GENERAL MOTORS CORP.
Engine Block - Left Side View
Engine Block - Right Side View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
J 42385
1
M28 x
1.25
N/A N/A N/A N/A N/A N/A N/A
2
M8 x
1.25
210 206 207 208 209
28.5
(1.122)
23.0
(0.905)
3
M8 x
1.25
210 206 207 208 209
21.5
(0.846)
16.0
(0.629)
4
M10 x
1.25
215 211 212 213 214
29.0
(1.141)
23.0
(0.905)
5
M10 x
1.5
215 211 212 213 214
27.0
(1.062)
21.5
(0.846)
6
M16 x
1.5
N/A N/A N/A N/A N/A N/A N/A
7
M11 x
2.0 First
Design
108 105 N/A 106 107
124.0
(4.88)
115.0
(4.52)
7
M11 x
2.0
Second
Design
108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
8
M11 x
2.0
108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
Bolt holes 7, second design, and 8 have a 30 mm (1.18 in) counterbore included in the
69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.
Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0
mm (4.88 in) drill depth.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 14 ©
2005 Mitchell Repair Information Company, LLC.
Page 15
Fig. 4: Engine Block Bolt Holes - Right Side View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Right Side View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
J 42385
1
M28 x
1.25
210 206 207 208 209
22.5
(0.885)
17.5
(0.688)
2
M8 x
1.25
210 206 207 208 209 26.5 (1.04)
19.0
(0.784)
3
M11 x
2.0
108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
4
M10 x
1.25
215 211 212 213 214
29.0
(1.141)
23.0
(0.905)
M10 x 27.0 21.5
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 15 ©
2005 Mitchell Repair Information Company, LLC.
Page 16
Engine Block - Bottom View
Fig. 5: Engine Block Bolt Holes - Bottom View
5 1.5 215 211 212 213 214 (1.062) (0.846)
6
M16 x
1.5
N/A N/A N/A N/A N/A N/A N/A
7
M11 x
2.0 First
Design
108 105 N/A 106 107
124.0
(4.88)
115.0
(4.52)
7
M11 x
2.0
Second
Design
108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
Bolt holes 7, second design, and 3 have a 30 mm (1.18 in) counterbore included in the
69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.
Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0
mm (4.88 in) drill depth.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:25 PM Page 16 ©
2005 Mitchell Repair Information Company, LLC.
Page 17
Courtesy of GENERAL MOTORS CORP.
Engine Block - Bottom View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
2
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
3
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
4
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
5
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
6
M16 x
1.5
- - - - - - 7 N/A - - - - - - 8
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
9
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
10-11
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
12
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
13-14
M10 x
1.5
J 42385-
215
J 42385-
101
-
J 42385-
213
J 42385-
214
42.5 (1.67) 37.0 (1.45)
15
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
16
M16 x
1.5
- - - - - - -
17
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
18
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 17 ©
2005 Mitchell Repair Information Company, LLC.
Page 18
19
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
20
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
21
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
22
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
23
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
24
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
25-26
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
27
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
28-29
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
30
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
31
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
32
M28 x
1.25
- - - - - - -
33
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
34
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
53.5 (2.10) 44.0 (1.73)
35
M10 x
2.0
J 42385-
104
J 42385-
101
-
J 42385-
102
J 42385-
103
31.0 (1.22) 25.5 (1.0)
36
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
22.5
(0.885)
17.5
(0.688)
Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in)
counterbore included in the 53.5 mm (2.10 in) drill depth.
Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore
included in the 31.0 mm (1.22 in) drill depth. Use sleeve J 42385-316 with the drill
and tap.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 18 ©
2005 Mitchell Repair Information Company, LLC.
Page 19
Engine Block - Top View
Fig. 6: Engine Block Bolt Holes - Top View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Top View
Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm
(1.67 in) drill depth. Use sleeve J 42385-311 with the drill and tap.
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1-4
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
26.5 (1.04)
19.0
(0.784)
5
M16 x
1.5
- - - - - - -
M8 x J 42385- J 42385- J 42385- J 42385- 19.0
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 19 ©
2005 Mitchell Repair Information Company, LLC.
Page 20
Cylinder Head - Top View
Fig. 7: Cylinder Head Bolt Holes - Top View
Courtesy of GENERAL MOTORS CORP.
Cylinder Head - Top View
6-7 1.25 210 206 J 42385-207 208 209 26.5 (1.04) (0.784)
8
M10 x
1.5
J 42385-
216
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
22.5
(0.885)
17.0
(0.669)
9-10
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
26.5 (1.04)
19.0
(0.784)
11
M10 x
1.5
J 42385-
216
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
22.5
(0.885)
17.0
(0.669)
12-14
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
26.5 (1.04)
19.0
(0.784)
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1-5
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
26.5 (1.04)
19.0
(0.784)
6-9
M6 x
1.0
J 42385-
205
J 42385-
201
J 42385-202
J 42385-
203
J 42385-
204
20.05
(0.789)
16.05
(0.632)
10-12
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
26.5 (1.04)
19.0
(0.784)
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 20 ©
2005 Mitchell Repair Information Company, LLC.
Page 21
Cylinder Head
-
End View
Fig. 8: Cylinder Head Bolt Holes - End View
Courtesy of GENERAL MOTORS CORP.
Cylinder Head - End View
Cylinder Head - Exhaust Manifold Deck View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
28.0 (1.10)
20.0
(0.787)
2 - N/A - - - - - 3
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
28.0 (1.10)
20.0
(0.787)
4 N/A - - - - - - -
5-6
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
28.0 (1.10)
20.0
(0.787)
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 21 ©
2005 Mitchell Repair Information Company, LLC.
Page 22
Fig. 9: Cylinder Head Bolt Holes - Exhaust Manifold Deck View
Courtesy of GENERAL MOTORS CORP.
Cylinder Head - Exhaust Manifold Deck View
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1-2
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
28.0 (1.10)
20.0
(0.787)
3
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
21.0
(0.826)
16.0
(0.629)
4
M14 x
1.25
- - - - - - -
5
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
21.0
(0.826)
16.0
(0.629)
6
M14 x
1.25
- - - - - - -
7-8
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
21.0
(0.826)
16.0
(0.629)
9
M14 x
1.25
- - - - - - -
10
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
21.0
(0.826)
16.0
(0.629)
11
M14 x
1.25
- - - - - - -
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 22 ©
2005 Mitchell Repair Information Company, LLC.
Page 23
Cylinder Head - Intake Manifold Deck View
Fig. 10: Cylinder Head Bolt Holes - Intake Manifold Deck View
Courtesy of GENERAL MOTORS CORP.
Cylinder Head - Intake Manifold Deck View
COMPONENT LOCATOR
12
M8 x
1.25
J 42385-
210
J 42385-
206
J 42385-207
J 42385-
208
J 42385-
209
21.0
(0.826)
16.0
(0.629)
13
M12 x
1.5
- - - - - - -
14-15
M10 x
1.5
J 42385-
215
J 42385-
211
J 42385-212
J 42385-
213
J 42385-
214
28.0 (1.10)
20.0
(0.787)
Hole
Thread
Size Insert Drill
Counterbore
Tool Tap Driver
Drill
Depth -
Maximum
mm (in)
Tap Depth
-
Maximum
mm (in)
1-2
M6 x
1.0
J 42385-
205
J 42385-
201
J 42385-202
J 42385-
203
J 42385-
204
Thru Thru
3-4
M6 x
1.0
J 42385-
205
J 42385-
201
J 42385-202
J 42385-
203
J 42385-
204
22.5
(0.885)
15.0
(0.688)
5-7
M6 x
1.0
J 42385-
205
J 42385-
201
J 42385-202
J 42385-
203
J 42385-
204
Thru Thru
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 23 ©
2005 Mitchell Repair Information Company, LLC.
Page 24
DISASSEMBLED VIEWS
Fig. 11: Intake Manifold/Upper Engine
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 11
Callout Component Name
307 Engine Coolant Air Bleed Pipe
308 Engine Coolant Air Bleed Pipe/Cover Gasket
308 Engine Coolant Air Bleed Pipe/Cover Gasket
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 24 ©
2005 Mitchell Repair Information Company, LLC.
Page 25
309 Engine Coolant Air Bleed Pipe Stud
310 Engine Coolant Air Bleed Hose Clamp
311 Engine Coolant Air Bleed Hose
312 Engine Coolant Air Bleed Cover Bolt
313 Engine Coolant Air Bleed Cover
500 Intake Manifold
506 Valley Cover Bolt
507 Throttle Body Bolt
508 Throttle Body
509 Throttle Body Gasket
510 Fuel Rail with Injectors
511 Fuel Rail Bolt
512 Intake Manifold Bolt
513 Intake Manifold Insulator
514 Intake Manifold Gaskets
520 Knock Sensor Oil Seals
546 Idle Air Control (IAC) Valve
547 IAC Bolt
548 Throttle Position Sensor (TPS) Bolt
549 TPS Sensor
550 Fuel Rail Ground Strap
554 IAC Valve O-Ring
555 Valley Cover
556 Valley Cover Gasket
708 EVAP Purge Valve
712 Fuel Rail Stop Bracket
713 Intake Manifold Bolt
714 Manifold Absolute Pressure (MAP) Sensor
715 MAP Sensor Grommet
716 Positive Crankcase Ventilation (PCV) Hose
717 Knock Sensor Wire Harness
718 Knock Sensor
729 EVAP Purge Valve Hose
730 EVAP Purge Valve Bracket
731 EVAP Purge Valve Hose
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 25 ©
2005 Mitchell Repair Information Company, LLC.
Page 26
Fig. 12: Cylinder Head/Upper Engine
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 12
Callout Component Name
209 Valve Lifter
210 Valve Lifter Guide
211 Valve Lifter Guide Bolt
212 Pushrod
213 Rocker Arm
214 Rocker Arm Bolt
215 Rocker Arm Pedestal
216 Expansion Plug
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 26 ©
2005 Mitchell Repair Information Company, LLC.
Page 27
217 Cylinder Head Gasket
218 Cylinder Head
219 Cylinder Head Bolt - M8 Short
220 Cylinder Head Bolt - M11 Medium
221 Cylinder Head Bolt - M11 Long - First Design
222 Valve Stem Oil Seal and Shim
222 Valve Stem Oil Seal and Shim
223 Valve Spring
223 Valve Spring
224 Valve Spring Cap
224 Valve Spring Cap
225 Valve Stem Key
226 Expansion Plug
227 Intake Valve
228 Exhaust Valve
229 Cylinder Head Coolant Plug
230 Cylinder Head Locating Pin
422 Oil Fill Tube O-Ring
423 Oil Fill Tube
424 Oil Fill Cap
450 Oil Fill Cap O-Ring
504 Valve Cover Gasket
504 Valve Cover Gasket
505 Valve Cover
505 Valve Cover
515 Valve Cover Bolt Grommet
516 Valve Cover Bolt
557 Valve Cover Grommet
558 Valve Cover Grommet Plug
600 Exhaust Manifold
601 Exhaust Manifold Gasket
602 Exhaust Manifold Bolt
603 Exhaust Manifold Heat Shield
604 Exhaust Manifold Heat Shield Bolt
700 Fresh Air Hose
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 27 ©
2005 Mitchell Repair Information Company, LLC.
Page 28
Fig. 13: Front of Engine
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 13
Ignition Coil and Bracket Assembly
720 Ignition Coil and Bracket Assembly Bolt
721 Ignition Coil Wire Harness
722 Ignition Coil
723 Ignition Coil Bolt
724 Spark Plug Wire
725 Coolant Temperature Sensor
726 Spark Plug
Callout Component Name
100 Engine Block
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 28 ©
2005 Mitchell Repair Information Company, LLC.
Page 29
138 Crankshaft Balancer
139 Crankshaft Balancer Bolt
140 Crankshaft Front Oil Seal
200 Camshaft
201 Camshaft Bearings
202 Camshaft Sprocket Locating Pin
203 Camshaft Retainer Plate
204 Camshaft Retainer Plate Bolt
205 Camshaft Sprocket
206 Camshaft Sprocket Bolt
207 Crankshaft Sprocket
208 Timing Chain
231 Timing Chain Guide Bolt
232 Timing Chain Guide
300 Water Pump
301 Water Pump Bolt
302 Thermostat Housing Bolt
303 Thermostat Housing
304 O-Ring
305 Thermostat
306 Water Pump Gaskets
404 Crankshaft Oil Deflector Nut
405 Oil Pump Screen Bolt
406 Oil Pump Screen O-Ring
407 Oil Pump Screen
408 Oil Pump Cover Bolt
409 Oil Pump Cover
410 Drive Gear
411 Oil Pump Bolt
412 Driven Gear
413 Oil Pump Assembly
414 Pressure Relief Valve
415 Pressure Relief Valve Spring
416 Plug
417 Oil Level Indicator O-Ring
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 29 ©
2005 Mitchell Repair Information Company, LLC.
Page 30
Fig. 14: Rear of Engine
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 14
Oil Level Indicator
419 Oil Level Indicator Tube Bolt
420 Oil Level Indicator Tube
421 Oil Level Indicator Tube O-Ring
501 Engine Front Cover Bolt
502 Engine Front Cover
503 Engine Front Cover Gasket
Callout Component Name
100 Engine Block
123 Clutch Pilot Bearing - Manual Transmission
132 Flywheel - Automatic Transmission
133 Flywheel Bolt
134 Flywheel - Manual Transmission
135 Clutch Disc - Manual Transmission
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 30 ©
2005 Mitchell Repair Information Company, LLC.
Page 31
Fig. 15: Lower Engine Assembly
Courtesy of GENERAL MOTORS CORP.
136 Pressure Plate - Manual Transmission
137 Pressure Plate Bolt - Manual Transmission
141 Crankshaft Rear Oil Seal
142 Pressure Plate Locating Pin - Manual Transmission
517 Rear Cover Bolt
518 Rear Cover
519 Rear Cover Gasket
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:26 PM Page 31 ©
2005 Mitchell Repair Information Company, LLC.
Page 32
Callouts For Fig. 15
Callout Component Name
100 Engine Block
102 Connecting Rod Bolt
103 Connecting Rod Cap
104 Connecting Rod Bearings
105 Connecting Rod
106 Piston Pin
107 Piston
108 Piston Rings
109 Piston Pin Clip - Second Design with Full-Floating Pin
120 Crankshaft Thrust Bearing
120 Crankshaft Thrust Bearing
121 Crankshaft Main Bearing
121 Crankshaft Main Bearing
122 Crankshaft Sprocket Key
123 Clutch Pilot Bearing - Manual Transmission
124 Crankshaft
126 Bearing Cap
127 Bearing Cap Side Bolt
128 Bearing Cap Bolt/Stud
129 Bearing Cap Bolt
400 Oil Pan
401 Closeout Cover - Right
402 Closeout Cover Bolt - Right
403 Crankshaft Oil Deflector Nut
425 Crankshaft Oil Deflector
426 Oil Pan Gasket
427 Oil Pan Baffle Bolt
428 Oil Pan Baffle
429 Oil Pan Drain Plug O-Ring
430 Oil Pan Drain Plug
431 Closeout Cover - Left
432 Closeout Cover Bolt - Left
433 Oil Pan Cover Gasket
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434 Oil Pan Cover
435 Oil Transfer Tube Bolt
436 Oil Filter Bypass Valve
437 Oil Filter
438 Oil Filter Adapter
439 Oil Pan Bolt
445 Oil Transfer Tube Gasket
447 Oil Transfer Tube
449 Oil Pan Plug
451 Oil Pan Cover Stud
452 Oil Pan Cover Nut
700 Crankshaft Position Sensor Bolt
701 Crankshaft Position Sensor
702 Crankshaft Position Sensor O-Ring
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Fig. 16: Engine Block Plugs/Sensors
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 16
Callout Component Name
100 Engine Block
101 Engine Block Front Oil Gallery Plug
110 Engine Block Rear Oil Gallery Plug O-Ring
110 Engine Block Rear Oil Gallery Plug O-Ring
111 Engine Block Rear Oil Gallery Plug
111 Engine Block Rear Oil Gallery Plug
112 Oil Gallery Plug
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Fig. 17: Exploded View Of Oil Pump Assembly
Courtesy of GENERAL MOTORS CORP.
113 Oil Gallery Plug Washer
114 Coolant Heater
115 Coolant Heater Washer
116 Oil Gallery Plug
117 Oil Gallery Plug Washer
130 Transmission Housing Locating Pin
145 Coolant Drain Plug Washer - Right
146 Coolant Drain Plug - Right
700 Crankshaft Position (CKP) Sensor Bolt
701 CKP Sensor
702 CKP Sensor O-Ring
703 Camshaft Position (CMP) Sensor
704 CMP Sensor O-Ring
705 CMP Sensor Bolt
706 Oil Pressure Sensor
707 Oil Pressure Sensor Washer
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Callouts For Fig. 17
ENGINE IDENTIFICATION
Callout Component Name
408 Cover Bolt
409 Cover
410 Drive Gear
412 Driven Gear
413 Oil Pump
414 Pressure Relief Valve
415 Pressure Relief Valve Spring
416 Plug
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Fig. 18: Location Of Vehicle Identification Number
Courtesy of GENERAL MOTORS CORP.
The vehicle identification number (VIN) is located on the left side rear of the engine block (1 or
2) and is typically a nine digit number stamped or laser-etched 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 six digits of the VIN.
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DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views,Engine Component
Description, Lubrication Description, New Product Information, and the Drive Belt
System Description. Reviewing the description and operation information will help you
determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the
description and operation information will also help you determine if the condition described by
the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify
the correct procedure for diagnosing the system and where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform the Diagnostic System Check - Engine Controls in Engine Controls - 5.7L
before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions.
Refer to Disassembled Views, Engine Component Description, Lubrication
Description, New Product Information, and Drive Belt System Description.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform
approach for repairing all systems. The diagnostic flow may always be used in order to resolve a
system condition. The diagnostic flow is the place to start when repairs are necessary. For a
detailed explanation, refer to Strategy Based Diagnosis in General Information.
Visual/Physical Inspection
Inspect for aftermarket devices which could affect the operation of the engine. Refer to
Checking Aftermarket Accessories in Wiring Systems.
Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as
engine RPM, ambient temperature, engine temperature, amount of engine warm-up time,
and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are
not trying to correct a normal condition.
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Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system
is operating properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the
symptom:
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Compression Test
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Cylinder Leakage Test
Drive Belt Chirping Diagnosis
Drive Belt Squeal Diagnosis
Drive Belt Whine Diagnosis
Drive Belt Rumbling Diagnosis
Drive Belt Vibration Diagnosis
Drive Belt Falls Off Diagnosis
Drive Belt Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
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BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES
Base Engine Misfire without Internal Engine Noises
Cause Correction
Abnormalities, such as severe cracking,
bumps, or missing areas in the accessory drive
belt
Abnormalities in the accessory drive system
and/or components may cause engine RPM
variations and lead to a misfire DTC. A
misfire code may be present without an actual
misfire condition.
Replace the drive belt.
Worn, damaged, or mis-aligned accessory
drive components or excessive pulley runout
and may lead to a misfire DTC.
A misfire code may be present without an
actual misfire condition.
Inspect the components, and repair or replace
as required.
Loose or improperly installed engine
flywheel or crankshaft balancer
A misfire code may be present without an
actual misfire condition.
Repair or replace the flywheel and/or
balancer as required.
Restricted exhaust system
A severe restriction in the exhaust flow can
cause significant loss of engine performance
and may set a DTC. Possible causes of
restrictions include collapsed or dented pipes
or plugged mufflers and/or catalytic
converters.
Repair or replace as required.
Improperly installed or damaged vacuum
hoses
Repair or replace as required.
Improper sealing between the intake manifold
and cylinder heads or throttle body.
Replace the intake manifold, gaskets,
cylinder heads, and/or throttle body as
required.
Improperly installed or damaged MAP sensor
The sealing grommet of the MAP sensor
should not be torn or damaged.
Repair or replace the MAP sensor as
required.
Damage to the MAP sensor housing and/or
seal
Replace the intake manifold.
Worn or loose rocker arms Replace the valve rocker arms as required.
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The rocker arm bearing end caps and/or
needle bearings should be intact and in the
proper position.
Worn or bent pushrods Replace the pushrods.
Stuck valves
Carbon buildup on the valve stem can cause
the valve not to close properly.
Repair or replace as required.
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as
required.
Worn camshaft lobes Replace the camshaft and valve lifters.
Excessive oil pressure
A lubrication system with excessive oil
pressure may lead to excessive valve lifter
pump-up and loss of compression.
Perform an oil pressure test. Refer to
Oil Pressure Diagnosis and Testing.
Repair or replace the oil pump as
required.
Faulty cylinder head gaskets and/or cracking
or other damage to the cylinder heads and
engine block cooling system passages.
Coolant consumption may or may not cause
the engine to overheat.
Inspect for spark plugs saturated by
coolant.
Inspect the cylinder heads, engine
block, and/or head gaskets. Refer to
Coolant in Combustion Chamber.
Repair or replace as required.
Worn piston rings
Oil consumption may or may not cause the
engine to misfire.
Inspect the spark plugs for oil deposits.
Inspect the cylinders for a loss of
compression. Refer to Engine
Compression Test.
Perform cylinder leak down and
compression testing to identify the
cause. Refer to Cylinder Leakage
Test.
Repair or replace as required.
A damaged crankshaft reluctor wheel
A damaged crankshaft reluctor wheel can
result in different symptoms depending on the
severity and location of the damage.
Systems with electronic
communications, such as DIS or coil per
Replace the sensor and/or crankshaft as
required.
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MY
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BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
Base Engine Misfire with Abnormal Internal Lower Engine Noises
cylinder, and severe reluctor ring
damage may exhibit periodic loss of
crankshaft position, stop delivering a
signal, and then re-sync the crankshaft
position.
Systems with electronic communication,
such as DIS or coil per cylinder, and
slight reluctor ring damage may exhibit
no loss of crankshaft position and no
misfire may occur. However, a P0300
DTC may be set.
Systems with mechanical
communications, such as high voltage
switch, and severe reluctor ring damage
may cause additional pulses and effect
fuel and spark delivery to the point of
generating a P0300 DTC or P0336.
Cause Correction
Abnormalities, such as severe cracking,
bumps or missing areas, in the accessory
drive belt
Abnormalities in the accessory drive system
and/or components may cause engine RPM
variations, noises similar to a faulty lower
engine and also lead to a misfire condition. A
misfire code may be present without an
actual misfire condition.
Replace the drive belt.
Worn, damaged, or mis-aligned accessory
drive components or excessive pulley runout
A misfire code may be present without an
actual misfire condition.
Inspect the components, repair or replace as
required.
Loose or improperly installed engine
flywheel or crankshaft balancer
A misfire code may be present without an
actual misfire condition.
Repair or replace the flywheel and/or
balancer as required.
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MY
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BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Base Engine Misfire with Abnormal Valve Train Noise
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Base Engine Misfire with Coolant Consumption
Worn piston rings
Oil consumption may or may not cause the
engine to misfire.
Inspect the spark plugs for oil deposits.
Inspect the cylinders for a loss of
compression. Refer to Engine
Compression Test.
Perform cylinder leak down and
compression testing to determine the
cause. Refer to Cylinder Leakage
Test.
Repair or replace as required.
Worn crankshaft thrust bearings
Severely worn thrust surfaces on the
crankshaft and/or thrust bearing may permit
fore and aft movement of the crankshaft and
create a DTC without an actual misfire
condition.
Replace the crankshaft and bearings as
required.
Cause Correction
Worn or loose rocker arms
The rocker arm bearing end caps and/or
needle bearings should intact within the
rocker arm assembly.
Replace the valve rocker arms as required.
Worn or bent pushrods Replace the pushrods.
Stuck valves
Carbon buildup on the valve stem can cause
the valve not to close properly.
Repair or replace as required.
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as
required.
Worn camshaft lobes Replace the camshaft and valve lifters.
Sticking lifters Replace as required.
Cause Correction
Faulty cylinder head gaskets and/or cracking
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BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
Base Engine Misfire with Excessive Oil Consumption
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Engine Noise on Start-Up, but Only Lasting a Few Seconds
or other damage to the cylinder heads and
engine block cooling system passages.
Coolant consumption may or may not cause
the engine to overheat.
Inspect for spark plugs saturated by
coolant.
Perform a cylinder leak down test.
Refer to Cylinder Leakage Test.
Inspect the cylinder heads and engine
block for damage to the coolant
passages and/or a faulty head gasket.
Refer to Coolant in Combustion
Chamber.
Repair or replace as required.
Cause Correction
Worn valves, valve guides and/or valve stem
oil seals
Inspect the spark plugs for oil deposits.
Repair or replace as required.
Worn piston rings
Oil consumption may or may not cause the
engine to misfire.
Inspect the spark plugs for oil deposits.
Inspect the cylinders for a loss of
compression. Refer to Engine
Compression Test.
Perform cylinder leak down and
compression testing to determine the
cause. Refer to Cylinder Leakage
Test.
Repair or replace as required.
Cause Correction
Incorrect oil filter without anti-drainback
feature
Install the correct oil filter.
Incorrect oil viscosity
1. Drain the oil.
2. Install the correct viscosity oil.
High valve lifter leak down rate Replace the lifters as required.
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MY
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UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Upper Engine Noise, Regardless of Engine Speed
Worn crankshaft thrust bearing
Inspect the thrust bearing and
crankshaft.
Repair or replace as required.
Damaged or faulty oil filter by-pass valve
Inspect the oil filter by-pass valve for
proper operation.
Repair or replace as required.
Cause Correction
IMPORTANT:
A cold piston knock which disappears in 1.5 minutes should be considered acceptable. A cold
engine knock usually disappears when the specific cylinder's secondary ignition circuit is
grounded out during diagnosis.
A light rattle/tapping noise may indicate a valve train, upper engine concern.
Low oil pressure
Perform an oil pressure test. Refer to
Oil Pressure Diagnosis and Testing.
Repair or replace as required.
Loose and/or worn valve rocker arm
attachments
Inspect the valve rocker arm, bolt, and
pedestal.
Repair or replace as required.
Worn or damaged valve rocker arm
Inspect the rocker arm for wear or
missing needle bearings
Replace the valve rocker arms as
required.
Bent or damaged push rod Inspect the following components, and
replace as required:
The valve rocker arm
The valve push rod
The valve lifter
Improper lubrication to the valve rocker armsInspect the following components, and repair
or replace as required:
The valve rocker arm
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MY
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LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Lower Engine Noise, Regardless of Engine Speed
The valve push rod
The valve lifter
The oil filter bypass valve
The oil transfer tube
The oil pump and pump screen
The engine block oil galleries
Broken valve spring Replace the valve spring.
Worn or dirty valve lifters Replace the valve lifters.
Stretched or broken timing chain and/or
damaged sprocket teeth
Replace the timing chain and sprockets.
Worn engine camshaft lobes
Inspect the engine camshaft lobes.
Replace the camshaft and valve lifters as
required.
Worn valve guides or valve stems Inspect the following components, and repair
as required:
The valves
The valve guides
Stuck valves
Carbon on the valve stem or valve seat may
cause the valve to stay open.
Inspect the following components, and repair
as required:
The valves
The valve guides
Cause Correction
IMPORTANT:
A cold piston knock which disappears in 1.5 minutes should be considered acceptable. A cold
engine knock usually disappears when the specific cylinder's secondary ignition circuit is
grounded out during diagnosis.
A low rumble/knocking may indicate a crankshaft or piston, lower engine concern.
Low oil pressure
Perform an oil pressure test. Refer to
Oil Pressure Diagnosis and Testing.
Repair or replace damaged components
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as required.
Worn accessory drive components
Abnormalities such as severe cracking, bumps
or missing areas in the accessory drive belt
and/or misalignment of system components.
Inspect the accessory drive system.
Repair or replace as required.
Loose or damaged crankshaft balancer
Inspect the crankshaft balancer.
Repair or replace as required.
Detonation or spark knock Verify the correct operation of the ignition
controls system.
Loose torque converter bolts
Inspect the torque converter bolts and
flywheel.
Repair or replace as required.
Loose or damaged flywheel Repair or replace the flywheel.
Oil pump screen loose, damaged or restricted
Inspect the oil pump screen.
Repair or replace as required.
Oil transfer tube loose, damaged or restricted
Inspect the transfer tube.
Repair or replace as required.
Excessive piston-to-cylinder bore clearance
Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance
Inspect the piston, pin, and connecting
rod.
Replace the piston, pin and connecting
rod as an assembly, as required.
Excessive connecting rod bearing clearance Inspect the following components, and repair
as required:
The connecting rod bearings
The connecting rods
The crankshaft
The crankshaft journals
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required:
The crankshaft bearings
The crankshaft journals
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ENGINE NOISE UNDER LOAD
Engine Noise Under Load
Incorrect piston, piston pin and connecting
rod installation
Pistons must be installed with the mark or
dimple on the top of the piston facing the
front of the engine. Piston pins must be
centered in the connecting rod pin bore.
Verify the pistons, piston pins and
connecting rods are installed correctly.
Repair as required.
Cause Correction
IMPORTANT:
A cold piston knock which disappears in 1.5 minutes should be considered acceptable. A cold
engine knock usually disappears when the specific cylinder's secondary ignition circuit is
grounded out during diagnosis.
A low rumble/knocking may indicate a crankshaft or piston, lower engine concern.
Low oil pressure
Perform an oil pressure test. Refer to
Oil Pressure Diagnosis and Testing.
Repair or replace as required.
Detonation or spark knock Verify the correct operation of the ignition
controls.
Loose torque converter bolts
Inspect the torque converter bolts and
flywheel.
Repair as required.
Cracked flywheel - automatic transmission
Inspect the flywheel bolts and flywheel.
Repair as required.
Excessive connecting rod bearing clearance Inspect the following components, and repair
as required:
The connecting rod bearings
The connecting rods
The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required:
The crankshaft bearings
The crankshaft journals
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ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
Engine Will Not Crank - Crankshaft Will Not Rotate
The cylinder block crankshaft bearing
bore
Cause Correction
Seized accessory drive system component
1. Remove the accessory drive belts.
2. Confirm that the engine will rotate.
Rotate the crankshaft by hand at the
crankshaft balancer or flywheel location.
3. Repair or replace the components as
required.
Seized automatic transmission torque
converter
1. Remove the torque converter-to-
flywheel
bolts.
2. Confirm that the engine will rotate.
Rotate the crankshaft by hand at the
crankshaft balancer or flywheel location.
3. Repair or replace the components as
required.
Seized manual transmission
1. Disengage the clutch by depressing the
clutch pedal.
2. Confirm that the engine will rotate.
Rotate the crankshaft by hand at the
crankshaft balancer or flywheel location.
Refer to Manual Transmission in the
Transmission/Transaxle/Transfer Case
Unit Repair Manual.
Broken timing chain
Inspect the timing chain and gears.
Repair or replace the components as
required.
Seized timing chain or timing gears
Inspect the timing chain and gears for
foreign material or a seized chain.
Repair or replace the components as
required.
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Seized or broken camshaft
Inspect the camshaft and the camshaft
bearings.
Repair or replace the components as
required.
Bent valve in the cylinder head
Inspect the valves and the cylinder heads.
Repair or replace the components as
required.
Seized oil pump
Inspect the oil pump assembly.
Repair or replace as required.
Hydraulically locked cylinder
Coolant/antifreeze in the cylinder
Oil in the cylinder
Fuel in the cylinder
1. Remove spark plugs and check for fluid
in the cylinder. When rotating the engine
with the spark plugs removed, the piston,
on compression stroke, will push fluid
from the combustion chamber. Refer to
Coolant in Combustion Chamber.
2. Inspect for failed/broken head gaskets.
3. Inspect for a cracked engine block or
cylinder head.
4. Inspect for a sticking fuel injector.
5. Repair or replace the components as
required.
Material in the cylinder
Broken valve
Broken piston rings
Piston material
Foreign material
Inspect the cylinder for damaged
components and/or foreign materials.
Repair or replace the components as
required.
Seized crankshaft or connecting rod
bearings
Inspect crankshaft and connecting rod
bearings.
Repair or replace the components as
required.
Bent or broken connecting rod
Inspect the connecting rods.
Replace the piston, pin and connecting
rod as an assembly, as required.
Broken crankshaft
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MY
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COOLANT IN COMBUSTION CHAMBER
Coolant in Combustion Chamber
COOLANT IN ENGINE OIL
Inspect the crankshaft.
Repair or replace the components as
required.
Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust
pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative
cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may
cause engine component damage.
1. A slower than normal cranking speed may indicate coolant entering the combustion
chamber. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate.
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in
the cylinder bore.
3. Inspect by performing a cylinder leak-down test. During this test, excessive air
bubbles within the coolant may indicate a faulty gasket or damaged component.
4. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on
the engine block, with low compression, may indicate a failed cylinder head gasket.
Refer to Engine Compression Test.
Cracked intake manifold or failed gasket Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning
and Inspection and Cylinder Head
Replacement - Left or Cylinder Head
Replacement - Right.
Warped cylinder head Machine the cylinder head to the proper
flatness, if applicable and replace the cylinder
head gasket. Refer to Cylinder Head
Cleaning and Inspection.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
Cylinder head or engine block porosity Replace the components as required.
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MY
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Coolant in Engine Oil
ENGINE COMPRESSION TEST
1. Charge the battery if the battery is not fully charged.
2. Disable the ignition system.
3. Disable the fuel injection system.
4. Remove all the spark plugs.
5. Block the throttle plate wide open.
Cause Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate
coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a
faulty thermostat may lead to an "overtemperature" condition which may cause engine
component damage. Contaminated engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant
may not properly lubricate the crankshaft bearings and may lead to component
damage. Refer to Lower Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a cylinder leak-down test. During this test, excessive air
bubbles within the cooling system may indicate a faulty gasket or damaged
component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on
the engine block with low compression may indicate a failed cylinder head gasket.
Refer to Engine Compression Test.
Faulty external engine oil cooler Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning
and Inspection and Cylinder Head
Replacement - Left or Cylinder Head
Replacement - Right.
Warped cylinder head Machine the cylinder head to proper flatness,
if applicable, and replace the cylinder head
gasket. Refer to Cylinder Head Cleaning
and Inspection.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
Cylinder head, block, or manifold porosity Replace the components as required.
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6. Start with the compression gage at zero, and crank the engine through 4 compression
strokes, 4 puffs.
7. Make the compression check for each cylinder. Record the reading.
8. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil
into the combustion chamber through the spark plug hole.
Recheck the compression and record the reading.
9. The minimum compression in any one cylinder should not be less than 70 percent of the
highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the
highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for
any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105).
Normal - Compression builds up quickly and evenly to the specified compression for
each cylinder.
Piston Rings Leaking -
Compression is low on the first stroke. Compression then builds
up with the following strokes but does not reach normal. Compression improves
considerably when you add oil.
Valves Leaking -
Compression is low on the first stroke. Compression usually does not
build up on the following strokes. Compression does not improve much when you add
oil.
If two adjacent cylinders have lower than normal compression and injecting oil into
the cylinders does not increase the compression, the cause may be a head gasket
leaking between the cylinders.
CYLINDER LEAKAGE TEST
Tools Required
J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools and Equipment.
CAUTION: Refer to Battery Disconnect Caution in Cautions and
Notices.
IMPORTANT: A leakage test may be performed in order to measure
cylinder/combustion chamber leakage. High cylinder leakage
may indicate one or more of the following:
Worn or burnt valves
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1. Disconnect the battery ground negative cable.
2. Remove the spark plugs.
3. Rotate the crankshaft to place the piston in the cylinder being tested at top dead center
(TDC) of the compression stroke.
4. Install the J 35667-A or equivalent. See Special Tools and Equipment.
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers
instructions. See Special Tools and Equipment.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered
excessive and may require component service. In excessive leakage situations, inspect for
the following conditions:
Air leakage noise at the throttle body or air inlet hose that may indicate a worn or
burnt intake valve or a broken valve spring.
Air leakage noise at the exhaust system tailpipe that may indicate a worn or burnt
exhaust valve or a broken valve spring.
Air leakage noise from the crankcase, oil level indicator tube, or oil fill tube that may
indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a
damaged engine block or a damaged cylinder head.
Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged
cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.
Broken valve springs
Stuck valve lifters
Incorrect valve lash
Damaged piston
Worn piston rings
Worn or scored cylinder bore
Damaged cylinder head gasket
Cracked or damaged cylinder head
Cracked or damaged engine block
IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to
prevent the crankshaft from rotating.
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OIL CONSUMPTION DIAGNOSIS
Oil Consumption Diagnosis
Checks Causes
Excessive oil consumption, not due to leaks, is the use of 1 L (1 qt) or more of engine oil
within 3 200 kilometers (2,000 miles).
Preliminary The causes of excessive oil consumption may include the
following conditions:
External oil leaks
Refer to Oil Leak Diagnosis.
Incorrect oil level or improper reading of the oil level
indicator
With the vehicle on a level surface, run the engine for a
few minutes, allow adequate drain down time (2-3
minutes) and check for the correct engine oil level.
Improper oil viscosity
Refer to the vehicle owners manual and use the
recommended SAE grade and viscosity for the prevailing
temperatures.
Continuous high speed driving and/or severe usage
Crankcase ventilation system restrictions or
malfunctioning components
Worn valve guides and/or valve stems
Worn or improperly installed valve stem oil seals
Piston rings broken, worn, not seated properly
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
Piston and rings improperly installed or miss-
fitted to the
cylinder bore
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OIL PRESSURE DIAGNOSIS AND TESTING
Tools Required
J 21867 Pressure Hose and Gage Assembly. See Special Tools and Equipment.
J 42907 Oil Pressure Testing Tool
1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain
down time of 2-3 minutes, and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level
measures full on the oil level indicator.
3. Run the engine briefly, approximately 10-15 seconds, and verify low or no oil pressure on
the vehicle gauge or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following:
Oil diluted by water or glycol - anti freeze
Foamy oil
6. Remove the oil filter and install the J 42907 .
7. Install J 21867 or equivalent to the. See Special Tools and Equipment. J 42907 .
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to Engine Mechanical Specifications.
10. If the engine oil pressure is below specifications, inspect the engine for one or more of the
following:
Oil pump worn or dirty
Refer to Oil Pump Cleaning and Inspection.
Oil pump-to-engine block bolts loose
Refer to Oil Pump, Pump Screen and Deflector Installation.
Oil pump screen loose, plugged, or damaged
Oil pump screen O-ring seal missing or damaged
Malfunctioning oil pump pressure regulator valve
Excessive bearing clearance
Cracked, porous, or restricted oil galleries
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Oil gallery plugs missing or incorrectly installed
Refer to Engine Block Plug Installation.
Broken valve lifters
Repair as necessary
11. If the reading on the J 21867 or equivalent is within specifications, inspect for the
following. See Special Tools and Equipment.
Plugged or incorrect oil filter and/or malfunctioning oil bypass valve
Malfunctioning vehicle oil pressure gage or sensor
Repair as necessary
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Fig. 19: Measuring For Low Oil Level
Courtesy of GENERAL MOTORS CORP.
OIL LEAK DIAGNOSIS
Oil Leak Diagnosis
Step Action Yes No
IMPORTANT:
You can repair most fluid leaks by first visually locating the leak, repairing or replacing the
component, or by resealing the gasket surface. Once the leak is identified, determine the cause of
the leak. Repair the cause of the leak as well as the leak itself.
1. Operate the vehicle until it reaches normal
operating temperature.
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1
2. Park the vehicle on a level surface, over a
large sheet of paper or other clean surface.
3. Wait 15 minutes.
4. Check for drippings.
Are drippings present? Go to Step 2 System OK
2
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 3
3
1. Visually inspect the suspected area. Use a
small mirror to assist in looking at hard to
see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 4
4
1. Completely clean the entire engine and
surrounding components.
2. Operate the vehicle for several kilometers miles at normal operating temperature and
at varying speeds.
3. Park the vehicle on a level surface, over a
large sheet of paper or other clean surface.
4. Wait 15 minutes.
5. Identify the type of fluid, and the
approximate location of the leak.
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 5
1. Visually inspect the suspected area. Use a
small mirror to assist in looking at hard to
see areas.
2. Check for leaks at the following locations:
Sealing surfaces
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5
Fittings
Cracked or damaged components
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 6
6
1. Completely clean the entire engine and
surrounding components.
2. Apply an aerosol-type powder, baby
powder, foot powder, etc., to the suspected
area.
3. Operate the vehicle for several kilometers
(miles) at normal operating temperature
and at varying speeds.
4. Identify the type of fluid, and the
approximate location of the leak, from the
discolorations in the powder surface.
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 7
7
1. Visually inspect the suspected area. Use a
small mirror to assist in looking at hard to
see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 8
8
Use J 28428-E
High Intensity Black Light Kit in
order to identify the type of fluid, and the
approximate location of the leak. See Special
Tools and Equipment. Refer to the
manufacturer's instructions when using the tool.
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 Go to Step 9
1. Visually inspect the suspected area. Use a
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9
small mirror to assist in looking at hard to
see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the
approximate location of the leak? Go to Step 10 System OK
10
1. Inspect the engine for mechanical damage.
Special attention should be shown to the
following areas:
Higher than recommended fluid levels
Higher than recommended fluid
pressures
Plugged or malfunctioning fluid filters
or pressure bypass valves
Plugged or malfunctioning engine
ventilation system
Improperly tightened or damaged
fasteners
Cracked or porous components
Improper sealants or gaskets where
required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer
modifications.
Is there mechanical damage, or customer
modifications to the engine? Go to Step 11 System OK
11
Repair or replace all damaged or modified
components.
Does the engine still leak oil? Go to Step 1 System OK
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CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
Crankcase Ventilation System Inspection/Diagnosis
DRIVE BELT CHIRPING DIAGNOSIS
Diagnostic Aids
The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive
pulley(s). in order to duplicate the customer's concern, It may be necessary to spray a small
amount of water onto the drive belt(s). If spraying water on the drive belt(s) duplicates the
symptom, cleaning the accessory drive pulley(s) may be the most probable solution.
A loose or improper installation of a body or suspension component, or other item(s) on the
vehicle may cause the chirping noise.
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
2: The chirping noise may not be engine related. This step is to verify that the engine is
making the noise. If the engine is not making the noise do not proceed further in this table.
3: The noise may be an internal engine noise. Remove the drive belt(s) and operate the
engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s)
Concern Action
External oil leak Inspect for any of the following conditions:
Plugged or kinked PCV hose(s)
Damaged or incorrectly installed PCV hose(s)
Excessive crankcase pressure
Rough Idle Inspect for any of the following conditions:
Plugged or kinked PCV hose(s)
Leaking (damaged) PCV hose(s)
Stalling or slow idle speed Inspect for any of the following conditions:
Plugged or kinked PCV hose(s)
Leaking (damaged) PCV hose(s)
High idle speed Inspect for a leaking (damaged) PCV hose(s)
Sludge in the engine Inspect for plugged or kinked PCV hose(s)
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or not. With the drive belt(s) removed the water pump will not operate and the engine may
overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with
the drive belt(s) removed.
4: Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in
the drive belt grooves caused by the accumulation of rubber dust.
6: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or
incorrect installation of an accessory drive component, or the pulley may be bent inward or
outward from a previous repair. Test for a misaligned pulley using a straight edge in the
pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory
drive component for the proper removal and installation procedure for that pulley.
10: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer,
or washer was installed.
12: Inspection the accessory drive pulley(s) should include inspecting for bends, dents or
other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in
the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt
is used to drive the pulley.
14: Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will
only be a temporary repair.
Drive Belt Chirping Diagnosis
Step Action Yes No
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt(s) or a
accessory drive pulley.
Chirping may occur on cold damp startup conditions and will subside once the vehicle
reaches normal operating temperature.
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and
perform the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Verify that there is a chirping noise.
Does the engine make the chirping noise? Go to Step 3
Go to Diagnostic
Aids
1. Remove the drive belt. Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
Go to Engine
Noise on Start-
Up, but Only
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3
2. Operate the engine for no longer than 30
to 40 seconds.
Does the chirping noise still exist?
Lasting a Few
Seconds, Upper
Engine Noise,
Regardless of
Engine Speed,
or
Lower Engine
Noise,
Regardless of
Engine Speed
Go to Step 4
4
Inspect for severe drive belt pilling exceeding
1/3 of the drive belt groove depth.
Do the drive belt grooves have pilling? Go to Step 5 Go to Step 6
5
Clean the accessory drive pulley(s) with a
suitable wire brush.
Were the accessory drive pulley(s) cleaned? Go to Step 14 -
6
Inspect for a misaligned accessory drive pulley
(s).
Is there a misaligned accessory drive pulley(s)? Go to Step 7 Go to Step 8
7
Replace and/or repair the misaligned accessory
drive pulley(s).
Were the misaligned accessory drive pulley(s)
replaced and/or repaired? Go to Step 15 -
8
Inspect for a bent or cracked accessory drive
bracket(s).
Did you find any bent or cracked accessory
drive bracket(s)? Go to Step 9 Go to Step 10
9
Replace the bent and/or cracked accessory
drive bracket(s).
Was the bent and/or cracked accessory drive
bracket(s) replaced? Go to Step 15 -
10
Inspect for incorrect, loose, and/or missing
fasteners.
Were there any incorrect, loose, and/or missing
fasteners found? Go to Step 11 Go to Step 12
11
1. Replace any incorrect and/or missing
fasteners.
2. Tighten any loose fasteners. Refer to
Fastener Tightening Specifications.
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DRIVE BELT SQUEAL DIAGNOSIS
Diagnostic Aids
A loose or improper installation of a body, or suspension component, or other item(s) on the
vehicle may cause the squeal noise.
If the noise is intermittent, verify that the accessory drive component(s) by varying their loads,
making sure they are operating to their maximum capacity. An overcharged air conditioning
(A/C) system, a power steering system restriction, or the incorrect fluid, or a failing generator are
suggested items to inspect.
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
2: The squeal may not be engine related. This step is to verify that the engine is making the
noise. If the engine is not making the noise do not proceed further in this table.
3: The noise may be an internal engine noise. Remove the drive belt(s) and operate the
engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s)
or an accessory drive component. With the drive belt(s) removed the water pump will not
operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when
the engine is operated with the drive belt(s) removed.
Were the fasteners replaced and/or tightened?
Go to Step 15 -
12
Inspect for a bent accessory drive pulley(s).
Was a bent accessory drive pulley(s) found? Go to Step 13 Go to Step 14
13
Replace the bent accessory drive pulley(s).
Was the bent accessory drive pulley(s)
replaced? Go to Step 15 -
14
Replace the drive belt(s). Refer to Drive Belt
Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Was the drive belt(s) replaced? Go to Step 15 -
15
1. Clear any codes
2. Run the engine in order to verify the
repair.
Does the chirping noise still exist? Go to Step 3 System OK
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4: This test is to verify that an accessory drive component(s) does not have a seized bearing.
With the belt(s) removed, test the bearings in the accessory drive components for smooth
operation. Also test the accessory drive component(s) with the engine operating by varying
the load on the accessory drive component(s) to verify that the component(s) is operating
properly.
5: This test is to verify that the drive belt(s) tensioner(s) is operating properly. If the drive
belt(s) tensioner(s) is not operating properly, proper belt tension may not be achieved to
keep the drive belt from slipping which could cause a belt squeal noise.
6: This test is to verify that the drive belt(s) is not too long, which would prevent the drive
belt(s) tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was
installed, it may not be routed correctly and may be turning an accessory drive component in
the incorrect direction.
7: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or
incorrect installation of a accessory drive component, or the pulley is bent inward or
outward from a previous repair. Test for a misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that
accessory drive component for the proper removal and installation procedure for that
pulley.
8:
Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width.
Using a known good vehicle, compare the pulley sizes.
Drive Belt Squeal Diagnosis
Step Action Yes No
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt(s) (this is unusual for a
drive belt with multiple ribs)
The noise occurs when a heavy load is applied to the drive belt(s), such as an A/C
compressor engagement, snapping the throttle, or slipping on a seized pulley, or a
faulty accessory drive component.
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and
perform the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Verify that there is a squealing noise.
Does the engine make the squeal noise? Go to Step 3
Go to Diagnostic
Aids
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DRIVE BELT WHINE DIAGNOSIS
Diagnostic Aids
The drive belt(s) will not cause the whine.
3
1. Remove the drive belt(s). Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
2. Operate the engine for no longer than 30
to 40 seconds.
Does the squealing noise still exist?
Go to Engine
Noise on Start-
Up, but Only
Lasting a Few
Seconds, Upper
Engine Noise,
Regardless of
Engine Speed,
or
Lower Engine
Noise,
Regardless of
Engine Speed
Go to Step 4
4
Inspect for a seized accessory drive component
bearing or a faulty accessory drive component.
Did you find and correct the condition? Go to Step 9 Go to Step 5
5
Inspect the drive belt tensioner for proper
operation. Refer to Drive Belt Tensioner
Diagnosis.
Did you find and correct the condition? Go to Step 9 Go to Step 6
6
Check for the correct length drive belt.
Did you find and correct the condition? Go to Step 9 Go to Step 7
7
Inspect for misaligned pulley.
Did you find and correct the condition? Go to Step 9 Go to Step 8
8
Inspect for an incorrect size pulley.
Did you find and correct the condition? Go to Step 9 -
9
1. Install the drive belt(s). Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
2. Clear any codes.
3. Run the engine in order to verify the
repair.
Does the squealing noise still exist? - System OK
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If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their
loads, making sure they are operating to their maximum capacity. An overcharged air
conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or a failing
generator are suggested items to inspect.
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
3: This test is to verify that the whine is being caused by the accessory drive component(s).
Remove the drive belt(s) and operate the engine for a few second, this will verify if the
whining noise is related to the accessory drive component. With the drive belt(s) removed
the water pump will not operate and the engine may overheat. Also diagnostic trouble codes
(DTCs) may set when the engine is operated with the drive belt(s) removed.
4: The inspection should include checking the drive belt tensioner and the drive belt idler
pulley bearings. The drive belt(s) may have to be installed and the accessory drive
components operated separately by varying their loads. Refer to the suspected accessory
drive component for the proper removal and installation procedure.
Drive Belt Whine Diagnosis
Step Action Yes No
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive
component failed bearing.
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and
perform the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Verify that there is a whining noise.
Does the engine make the whining noise? Go to Step 3
Go to Diagnostic
Aids
3
1. Remove the drive belt(s). Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
2. Operate the engine for no longer than 30
to 40 seconds.
Does the whining noise still exist?
Go to Engine
Noise on Start-
Up, but Only
Lasting a Few
Seconds, Upper
Engine Noise,
Regardless of
Engine Speed,
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DRIVE BELT RUMBLING DIAGNOSIS
Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the vehicle
to produce a rumbling noise.
The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive
belt(s) may be the only repair for the symptom.
If after replacing the drive belt(s) and completing the diagnostic table, the noise is only heard
with the drive belt(s) installed, there might be an accessory drive component failure. Varying the
load on the accessory drive component(s) may aid in identifying which accessory drive
component is causing the rumbling noise.
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
2: This test is to verify that the symptom is present during diagnosing. Other vehicle
components may cause a similar symptom.
3: This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be
confused with an internal engine noise due to the similarity in the description. Remove only
or
Lower Engine
Noise,
Regardless of
Engine Speed
Go to Step 4
4
1. Inspect for a failed accessory drive
component bearing.
2. Install the drive belt(s). Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
Did you find and correct the condition? Go to Step 5 -
5
1. Clear any codes.
2. Run the engine in order to verify the
repair.
Does the whining still exist? - System OK
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one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few
seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the
drive belt(s) removed the water pump will not operate and the engine may overheat. Also
diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s)
removed.
4:
Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small
cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is
identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as
a lump in the belt.
5: Small amounts of pilling is a normal condition and acceptable. When the pilling is severe
the drive belt(s) does not have a smooth surface for proper operation.
Drive Belt Rumbling Diagnosis
Step Action Yes No
DEFINITION:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt(s) or a pulley(s).
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in
the drive belt(s) pulley groove
The separation of the drive belt(s)
A damaged drive belt(s)
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and
perform the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Verify that there is a rumbling noise.
Does the engine make the rumbling noise? Go to Step 3
Go to Diagnostic
Aids
3
1. Remove the drive belt(s). Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
2. Operate the engine for no longer than 30
to 40 seconds.
Go to Engine
Noise on Start-
Up, but Only
Lasting a Few
Seconds, Upper
Engine Noise,
Regardless of
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DRIVE BELT VIBRATION DIAGNOSIS
Diagnostic Aids
The accessory drive components may have an affect on engine vibration. An overcharged air
conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra
load placed on the generator are suggested items to inspect. To help identify an intermittent or an
improper condition, vary the loads on the accessory drive components.
Test Description
Does the rumbling noise still exist?
Engine Speed,
or
Lower Engine
Noise,
Regardless of
Engine Speed
Go to Step 4
4
Inspect the drive belt(s) for damage, separation,
or sections of missing ribs.
Were any of these conditions found? Go to Step 7 Go to Step 5
5
Inspect for severe pilling of more than 1/3 of
the drive belt groove depth.
Do the drive belt grooves have pilling? Go to Step 6 Go to Step 7
6
1. Clean the drive belt pulleys using a
suitable wire brush.
2. Reinstall the drive belt. Refer to Drive
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
Did you complete the repair? Go to Step 8 Go to Step 7
7
Install a new drive belt. Refer to Drive Belt
Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Did you complete the replacement? Go to Step 8 -
8
1. Clear any codes.
2. Run the engine in order to verify the
repair.
Does the rumbling noise still exist? - System OK
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The number(s) below refer to the steps) in the diagnostic table.
2: This test is to verify that the vibration is present during diagnosing. Other vehicle
components may cause a similar symptom such as the exhaust system, or the drivetrain.
3: This test is to verify that the drive belt(s) or accessory drive components may be causing
the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will
verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed
the water pump will not operate and the engine may overheat. Also diagnostic trouble codes
(DTCs) may set when the engine is operated with the drive belt (s) removed.
4:
The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best
time to inspect the condition of the drive belt(s).
6: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer,
or washer was installed.
8: This step should only be performed if the fan is driven by the drive belt. Inspect the
engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for
smooth operation. Inspect for a bent fan shaft or a bent mounting flange.
9: Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings
for smooth operation and excessive play. Compare the water pump with a known, good
water pump.
10: Accessory drive component brackets that are bent, cracked, or loose may put an extra
strain on that accessory component causing it to vibrate.
Drive Belt Vibration Diagnosis
Step Action Yes No
DEFINITION: The following items are indications of drive belt vibration:
The vibration is engine-speed related.
The vibration may be sensitive to accessory load.
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and
perform the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Verify that the vibration is engine related.
Does the engine make the vibration? Go to Step 3
Go to Diagnostic
Aids
1. Remove the drive belt (s). Refer to Drive
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DRIVE BELT FALLS OFF DIAGNOSIS
Diagnostic Aids
3
Belt Replacement - Accessory or Drive
Belt Replacement - Air Conditioning.
2. Operate the engine for no longer than 30
to 40 seconds.
Does the engine still make the vibration?
Go to Vibration
Analysis -
Engine in
Vibration
Diagnosis and
Correction Go to Step 4
4
Inspect the drive belt(s) for wear, damage,
debris build-up and missing drive belt ribs.
Were any of these conditions found? Go to Step 5 Go to Step 6
5
Install a new drive belt. Refer to Drive Belt
Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Did you complete the replacement? Go to Step 11 -
6
Inspect for incorrect, loose or missing fasteners.
Were any of these conditions found? Go to Step 7 Go to Step 8
7
1.
Replace the incorrect or missing fasteners.
2. Tighten any loose fasteners. Refer to
Fastener Tightening Specifications.
Were the fasteners replaced and/or tightened? Go to Step 11 -
8
Inspect for damaged fan blades or a bent fan
clutch shaft.
Did you find and correct the condition? Go to Step 11 Go to Step 9
9
Inspect for a bent water pump drive shaft.
Did you find and correct the condition? Go to Step 11 Go to Step 10
10
Inspect for a bent or cracked accessory drive
bracket(s).
Did you find and correct the condition? Go to Step 11 -
11
1. Clear any codes.
2. Run the engine in order to verify the
repair.
Does the vibration still exist? - System OK
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If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by pulley
misalignment.
An extra load that is quickly applied or released by an accessory drive component may also cause
the drive belt(s) to fall off. Verify that the accessory drive component(s) are operate properly.
If the drive belt(s) is the incorrect length, the drive belt tensioner(s) may not maintain the proper
tension on the drive belt(s).
Test Description
The number(s) below refer to the step(s) in the diagnostic table.
2: This inspection is to verify the condition of the drive belt(s). Damage may have occurred
to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for
cuts, tears, sections of ribs missing, or damaged belt plys.
4: Misalignment of the accessory drive pulley(s) may be caused from improper mounting or
incorrect installation of a accessory drive component, or the pulley may bent inward or
outward from a previous repair. Test for a misaligned pulley using a straight edge in the
pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory
drive component for the proper removal and installation procedure of that pulley.
5: Inspection of the accessory drive pulley(s) should include inspecting for bends, dents or
other damage that would prevent the drive belt from seating properly in the pulley grooves
or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive
the pulley.
6: Accessory drive component brackets that are bent or cracked will also cause the drive
belt(s) to fall off.
7: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer,
or washer was installed. Missing, loose, or incorrect fasteners may cause pulley
misalignment from the accessory drive bracket(s) moving under load. Over tightening the
fasteners may cause misalignment of the accessory component bracket(s).
Drive Belt Falls Off Diagnosis
Step Action Yes No
DEFINITION: The drive belt(s) falls off the pulleys or may not ride correctly on the
pulleys.
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
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1
Did you review the Symptoms - Engine
Mechanical diagnostic information, and perform
the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
2
Inspect for a damaged drive belt(s).
Was a damaged drive belt(s) found? Go to Step 3 Go to Step 4
3
Install a new drive belt. Refer to Drive Belt
Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Does the drive belt(s) continue to fall off? Go to Step 4 System OK
4
Inspect for a misaligned accessory drive pulley
(s).
Did you find and correct the condition? Go to Step 12 Go to Step 5
5
Inspect for a bent or dented accessory drive
pulley(s).
Did you find and correct the condition? Go to Step 12 Go to Step 6
6
Inspect for a bent or a cracked accessory drive
bracket(s).
Did you find and correct the condition? Go to Step 12 Go to Step 7
7
Inspect for incorrect, loose or missing fasteners.
Were there any incorrect, loose and/or missing
fasteners? Go to Step 8 Go to Step 9
8
1. Replace any incorrect and/or missing
fasteners.
2. Tighten any loose fasteners. Refer to
Fastener Tightening Specifications.
Does the drive belt continue to fall off? Go to Step 9 System OK
9
Test the drive belt tensioner for correction
operation. Refer to Drive Belt Tensioner
Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
10
Replace the drive belt tensioner. Refer to
Drive
Belt Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Does the drive belt continue to fall off? Go to Step 11 System OK
11
Inspect for a failed drive belt idler(s) and drive
belt tensioner pulley(s) bearings.
Did you find and repair the condition? Go to Step 12 -
2004 Pontiac GTO
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DRIVE BELT EXCESSIVE WEAR DIAGNOSIS
Diagnostic Aids
Excessive wear on a drive belt(s) is usually caused by incorrect installation or the wrong drive
belt(s) for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably
cause the drive belt(s) to make a noise or to fall off the pulley(s).
Excessive misalignment of the drive belt pulleys will cause excessive wear and may also make the
drive belt(s) fall off the pulley(s).
Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2: The inspection is to verify that the drive belt(s) is correctly installed over all of the drive
belt pulleys. Wear on the drive belt(s) may be caused by mis-
positioning the drive belt(s) by
one groove on a pulley.
3: The installation of a drive belt that is to wide or to narrow will cause wear on the drive
belt(s). The drive belt ribs should match all of the grooves on the pulleys.
4: This inspection is to verify the drive belt(s) is not contacting any parts of the engine or
body while the engine is operating. There should be sufficient clearance when the drive belt
accessory drive components load varies. The drive belt(s) should not come in contact with
an engine or a body component when snapping the throttle.
Drive Belt Excessive Wear Diagnosis
12
Run the engine in order to verify the repair.
Does the drive belt still fall off? - System OK
Step Action Yes No
DEFINITION: Wear at the outside ribs of the drive belt(s) due to an incorrectly installed
drive belt(s).
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
1
Did you review the Symptoms - Engine
Mechanical diagnostic information and perform
the necessary inspections?
Go to Step 2
Go to
Symptoms
- Engine
Mechanical
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DRIVE BELT TENSIONER DIAGNOSIS
1. Remove the drive belt. Refer to Drive Belt Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
2. Position a hex-head socket on the belt tensioner pulley bolt.
3. Move the belt tensioner through its full travel.
The movement should feel smooth.
There should be no binding.
The belt tensioner should return freely.
4. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Tensioner
Replacement - Accessory or Drive Belt Tensioner Replacement - Air Conditioning.
5. Install the drive belt. Refer to Drive Belt Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
2
Inspect the drive belt(s) for the proper
installation. Refer to Drive Belt Replacement
- Accessory or Drive Belt Replacement - Air
Conditioning.
Did you find this condition? Go to Step 5 Go to Step 3
3
Inspect for the proper drive belt.
Did you find this condition? Go to Step 5 Go to Step 4
4
Inspect for the drive belt rubbing against a
bracket, hose, or wiring harness.
Did you find and repair the condition? Go to Step 6
Go to Diagnostic
Aids
5
Replace the drive belt. Refer to Drive Belt
Replacement - Accessory or Drive Belt
Replacement - Air Conditioning.
Did you complete the replacement? Go to Step 6 -
6
Run the engine in order to verify the repair.
Is there still excessive drive belt wear? - System OK
NOTE: Allowing the drive belt tensioner to snap into the free position may
result in damage to the tensioner.
IMPORTANT: When the engine is operating, the belt tensioner arm will move.
Do not replace the belt tensioner because of movement in the belt
tensioner arm.
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REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT - ACCESSORY
Removal Procedure
1. Install a breaker bar with hex-head socket to the drive belt tensioner bolt.
2. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt.
3. Remove the belt from the pulleys and the drive belt tensioner.
4. Slowly release the tension on the drive belt tensioner.
5. Remove the breaker bar and socket from the drive belt tensioner bolt.
6. Clean and inspect the belt surfaces of all the pulleys.
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Fig. 20: View Of Accessory Drive Belt
Courtesy of GENERAL MOTORS CORP.
Installation Procedure
1. Route the drive belt around all pulleys, except the water pump and belt tensioner.
2. Install the breaker bar with hex-head socket to the belt tensioner bolt.
3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner.
4. Install the drive belt under the water pump pulley.
5. Install the drive belt onto the belt tensioner.
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6. Slowly release the tension, on the belt tensioner.
7. Remove the breaker bar and socket from the belt tensioner bolt.
8. Inspect the drive belt for proper alignment.
Fig. 21: View Of Accessory Drive Belt
Courtesy of GENERAL MOTORS CORP.
DRIVE BELT REPLACEMENT - AIR CONDITIONING
Removal Procedure
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Fig. 22: View Of A/C Drive Belt
Courtesy of GENERAL MOTORS CORP.
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information
3. Install a breaker bar with hex-head socket to the air conditioning (A/C) drive belt tensioner
bolt.
4. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on the drive belt.
5. Remove the A/C drive belt from the pulleys.
6. Slowly release tension on the A/C drive belt tensioner.
7. Remove the breaker bar and socket from the A/C drive belt tensioner bolt.
8. Clean and inspect the drive belt surfaces of the pulleys.
Installation Procedure
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Fig. 23: View Of A/C Drive Belt
Courtesy of GENERAL MOTORS CORP.
1. Install the A/C drive belt around the crankshaft balancer.
2. Install a breaker bar with hex-head socket to the A/C drive belt tensioner bolt.
3. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on drive belt
tensioner.
4. Install the A/C drive belt under the idler pulley.
5. Install the A/C drive belt over the A/C compressor pulley.
6. Slowly release tension on the A/C belt tensioner.
7. Remove the breaker bar and socket from the A/C drive belt tensioner bolt.
8. Inspect the A/C drive belt for correct alignment.
9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
DRIVE BELT IDLER PULLEY REPLACEMENT - ACCESSORY
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Removal Procedure
Fig. 24: View Of Accessory Drive Idler Pulley & Bolt
Courtesy of GENERAL MOTORS CORP.
1. Loosen the accessory drive belt idler pulley bolt.
2. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
3. Remove the accessory drive belt idler pulley.
Installation Procedure
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Fig. 25: View Of Accessory Drive Idler Pulley & Bolt
Courtesy of GENERAL MOTORS CORP.
1. Install the accessory drive belt idler pulley bolt until snug.
2. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
IMPORTANT: Ensure that the idler pulley and dust shield are fully seated
against the shoulder on the bracket before tightening the
bolt.
CAUTION: Refer to Battery Disconnect Caution in Cautions and
Notices.
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3. Tighten the accessory drive belt idler pulley bolt.
Tighten: Tighten the accessory drive belt idler pulley bolt to 50 N.m (37 lb ft).
DRIVE BELT IDLER PULLEY REPLACEMENT - AIR CONDITIONING
Removal Procedure
Fig. 26: View Of A/C Drive Belt Idler Pulley & Bolt
Courtesy of GENERAL MOTORS CORP.
1. Loosen the air conditioning (A/C) drive belt idler pulley bolt.
2. Remove the A/C drive belt. Refer to Drive Belt Replacement - Air Conditioning.
3. Remove the A/C drive belt idler pulley.
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Installation Procedure
Fig. 27: View Of A/C Drive Belt Idler Pulley & Bolt
Courtesy of GENERAL MOTORS CORP.
1. Install the idler pulley bolt.
2. Install the A/C drive belt idler pulley bolt until snug.
3. Install the A/C drive belt. Refer to Drive Belt Replacement - Air Conditioning.
IMPORTANT: Ensure that the idler pulley is fully seated against the
shoulder on the bracket before tightening the bolt.
NOTE: Refer to Fastener Notice in Cautions and Notices.
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4. Tighten the A/C drive belt idler pulley bolt.
Tighten: Tighten the A/C drive belt idler pulley bolt to 50 N.m (37 lb ft).
DRIVE BELT TENSIONER REPLACEMENT - ACCESSORY
Removal Procedure
Fig. 28: View Accessory Drive Belt Tensioner & Bolts
Courtesy of GENERAL MOTORS CORP.
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
2. Remove the accessory drive belt tensioner bolts.
3. Remove the accessory drive belt tensioner.
Installation Procedure
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Fig. 29: View Accessory Drive Belt Tensioner & Bolts
Courtesy of GENERAL MOTORS CORP.
1. Install the accessory drive belt tensioner.
2. Install the accessory drive belt tensioner bolts.
Tighten: Tighten the accessory drive belt tensioner bolts to 50 N.m (37 lb ft) starting with
the lower bolt first.
3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
DRIVE BELT TENSIONER REPLACEMENT - AIR CONDITIONING
Removal Procedure
NOTE: Refer to Fastener Notice in Cautions and Notices.
2004 Pontiac GTO
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Fig. 30: View Of A/C Drive Belt Tensioner
Courtesy of GENERAL MOTORS CORP.
1. Remove the air conditioning (A/C) drive belt. Refer to Drive Belt Replacement - Air
Conditioning.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
3. Loosen the A/C drive belt tensioner bolt.
4. Remove the A/C drive belt tensioner.
Installation Procedure
2004 Pontiac GTO
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Fig. 31: View Of A/C Drive Belt Tensioner
Courtesy of GENERAL MOTORS CORP.
1. Install the A/C drive belt tensioner.
2. Tighten the A/C drive belt tensioner bolt.
Tighten: Tighten the A/C drive belt tensioner bolt to 25 N.m (18 lb ft).
3. Lower the vehicle.
4. Install the A/C drive belt. Refer to Drive Belt Replacement - Air Conditioning.
NOTE: Refer to Fastener Notice in Cautions and Notices.
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ENGINE MOUNT INSPECTION
1. Measure engine movement at the engine mounts in order to check for damage to the rubber
portions of the mount.
1. Apply the park brake.
2. Start the engine.
3. Firmly apply and hold the primary brakes.
4. Have an assistant stand to the side of the vehicle in order to observe for engine
movement.
5. Slightly load the engine and shift from drive to reverse a few times. If engine
movement is more than 24 mm (0.945 in) from the at rest position, in either direction,
check for loose engine mount or mount bracket attachments.
2. If the engine mount and engine mount bracket bolt torque are to specifications, check the
condition of the engine mount.
3. Replace the engine mount if any of the following conditions exist:
Heat check cracks cover the hard rubber surface.
The rubber cushion is separated from the metal plate of the mount.
There is a split through the rubber cushion.
There is an oil leak coming from the mount.
ENGINE MOUNT BRACKET REPLACEMENT - LEFT
Tools Required
J 28467-B Universal Engine Support Fixture
J 41803 Engine Support Fixture
Removal Procedure
NOTE: Broken or deteriorated mounts can cause misalignment and
destruction of certain drive train components. When a single mount
breaks, the remaining mounts are subjected to abnormally high
stresses.
NOTE: When raising or supporting the engine for any reason, do not use a
jack under the oil pan, any sheet metal, or the crankshaft pulley.
Lifting the engine in an unapproved manner may cause component
damage.
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1. Remove the fuel rail covers from the engine.
2. Install J 41803 andJ 28467-B and support the engine.
3. Remove the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left
in
Engine Exhaust.
4. Remove the engine mount to bracket nut.
5. Remove the engine mount bracket bolts.
6. Remove the engine mount bracket.
Fig. 32: View Of Fuel Rail Covers & Left Engine Mount Bracket
Courtesy of GENERAL MOTORS CORP.
Installation Procedure
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1. Install the engine mount bracket.
2. Install the engine mount bracket bolts.
Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
3. Install the engine mount to bracket nut.
Tighten: Tighten the engine mount to bracket nut to 80 N.m (59 lb ft).
4. Install the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left in
Engine Exhaust.
5. Remove J 41803 andJ 28467-B from the engine.
6. Install the fuel rail covers to the engine.
NOTE: Refer to Fastener Notice in Cautions and Notices.
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Fig. 33: View Of Fuel Rail Covers & Left Engine Mount Bracket
Courtesy of GENERAL MOTORS CORP.
ENGINE MOUNT BRACKET REPLACEMENT - RIGHT
Tools Required
J 28467-B Universal Engine Support Fixture
J 41803 Engine Support Fixture
Removal Procedure
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Fig. 34: View Of Fuel Rail Covers & Right Engine Mount Bracket
Courtesy of GENERAL MOTORS CORP.
1. Remove the fuel rail covers from the engine.
2. Install J 41803 andJ 28467-B and support the engine.
3. Remove the right side exhaust manifold. Refer to Exhaust Manifold Replacement -
Right in Engine Exhaust.
4. Remove the engine mount to bracket nut.
5. Remove the engine mount bracket bolts.
6. Remove the engine mount bracket.
Installation Procedure
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Fig. 35: View Of Fuel Rail Covers & Right Engine Mount Bracket
Courtesy of GENERAL MOTORS CORP.
1. Install the engine mount bracket.
2. Install the engine mount bracket bolts.
Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
3. Install the engine mount to bracket nut.
NOTE: Refer to Fastener Notice in Cautions and Notices.
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Tighten:
Tighten the engine mount to bracket nut to 80 N.m (59 lb ft).
4. Install the right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right
in Engine Exhaust.
5. Remove J 41803 andJ 28467-B from the engine.
6. Install the fuel rail covers to the engine.
ENGINE MOUNT REPLACEMENT - LEFT
Tools Required
J 28467-B Universal Engine Support Fixture
J 41803 Engine Support Fixture
Removal Procedure
1. Remove the fuel rail covers from the engine.
2. Install J 41803 andJ 28467-B and support the engine.
3. Remove the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left
in
Engine Exhaust.
4. Remove the engine mount nuts.
5. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount nuts.
Tighten: Tighten the engine mount nuts to 80 N.m (59 lb ft).
3. Install the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left in
Engine Exhaust.
4. Remove J 41803 andJ 28467-B from the engine.
5. Install the fuel rail covers to the engine.
ENGINE MOUNT REPLACEMENT - RIGHT
NOTE: Refer to Fastener Notice in Cautions and Notices.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:28 PM Page 97 ©
2005 Mitchell Repair Information Company, LLC.
Page 98
Tools Required
J 28467-B Universal Engine Support Fixture
J 41803 Engine Support Fixture
Removal Procedure
1. Remove the fuel rail covers from the engine.
2. Install J 41803 andJ 28467-B and support the engine.
3. Remove the right side exhaust manifold. Refer to Exhaust Manifold Replacement -
Right in Engine Exhaust.
4. Remove the engine mount nuts.
5. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount nuts.
Tighten: Tighten the engine mount nuts to 80 N.m (59 lb ft).
3. Install the right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right
in Engine Exhaust.
4. Remove J 41803 andJ 28467-B from the engine.
5. Install the fuel rail covers to the engine.
CRANKCASE VENTILATION HOSES/PIPES REPLACEMENT
Removal Procedure
1. Remove the fresh air hose from the front fitting of the rocker cover and the throttle body.
2. Remove the foul air hose from the throttle body and restricting orifice external connector.
Installation Procedure
1. Install the foul air hose to the throttle body and restricting orifice external connector.
2. Install the fresh air hose to the front fitting of the rocker cover and the throttle body.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:28 PM Page 98 ©
2005 Mitchell Repair Information Company, LLC.
Page 99
INTAKE MANIFOLD REPLACEMENT
Removal Procedure
Fig. 36: Identifying Air Intake Components
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The intake manifold, throttle body, fuel injection rail, and fuel
injectors may be removed as an assembly. If not servicing the
individual components, remove the manifold as a complete
assembly.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:28 PM Page 99 ©
2005 Mitchell Repair Information Company, LLC.
Page 100
1. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable
Disconnect/Connect Procedure in Engine Electrical.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine
Cooling.
3. Remove the front suspension support brace. Refer to Front Suspension Support Brace
Replacement in Front Suspension.
4. Remove the fuel rail covers.
5. Disconnect the air intake sensor connector (2) from the air intake sensor.
6. Loosen the hose clamps (1, 3) securing the intake duct.
7. Remove the intake duct from the vehicle.
2004 Pontiac GTO
2004 ENGINE Engine Mechanical - 5.7L - GTO
MY
Thursday, April 02, 2009 7:58:28 PM Page 100 ©
2005 Mitchell Repair Information Company, LLC.
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