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Table of Contents, continuedCrankshaft Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59Crankshaft and Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61Engine Block Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66Engine Block Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66Cylinder Boring and Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67Boring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68Piston and Connecting Rod Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69Piston, Connecting Rod, and Bearings Clean/Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70Piston Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73Piston and Connecting Rod Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74Crankshaft and Bearings Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76Bearing Clearance Measuring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80Crankshaft Balancer Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86Engine Flywheel Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86Camshaft and Bearings Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88Camshaft Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89Camshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91Balance Shaft Bearing and/or Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93Balance Shaft Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94Balance Shaft Bearing and/or Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95Timing Chain and Sprockets Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96Valve Rocker Arm and Push Rods Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96Valve Lifters and Guides Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98Cylinder Head Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99Cylinder Head Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99Valve Guide Reaming/Valve and Seat Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102Cylinder Head Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104Oil Pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106OIl Pump Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108Oil Pump Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109Valve Rocker Arm Cover Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111Oil Pan Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112Intake Manifold Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113Intake Manifold Clean and inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117Intake Manifold Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118Exhaust Manifold Clean and inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123Water Pump Clean and inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124Thread Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125Service Prior to Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128Engine Block Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--128Crankshaft and Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132Crankshaft Rear Oil Seal and Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134Piston, Connecting Rod, and Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136Balance Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139Timing Chain and Sprockets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142Engine Front Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-144Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-146Crankshaft Balancer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-152Table of Contents, continuedTP-6103 1/01

Table of Contents, continuedValve Rocker Arm and Push Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Distributor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Rocker Arm Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Level Indicator and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clutch Pilot Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ne Setup and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-171Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Belt System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .New Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleanliness and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Engine Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use of RTV and Anaerobic Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Separating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179TP-6103 1/01Table of Contents, continued

Table of Contents, continuedTP-6103 1/01

IntroductionThis service manual provides the service technicianwith information to service the General MotorsPowertrain engines.This manual has been reprinted by the generator setmanufacturer with the permission of General MotorsPowertrain.In general, this manual covers the service of the engineand associated standard equipment. In some cases theengine is supplied with accessories and equipment thatare unique to the application. If service information isrequired on such unique accessories or equipment,contact the generator set manufacturer who will forwardthe proper information or advise the service technicianwhere it can be obtained.This manual is a reproduction of a General MotorsPowertrain publication and contains informationpertaining to industrial generator set engines. Someinformation pertains to other applications of the engine.The accuracy and completeness of information is thesole responsibility of General Motors Powertrain.The information in this manual is grouped in sectionsaccording to the type of work being performed. Thevarious sections are indicated in the Table of Contents ofthe manual.TP-6103 1/01The descriptions and specifications contained in thismanual were in effect at the time the book was releasedby General Motors Powertrain. The generator setmanufacturer and General Motors Powertrain reservethe right to discontinue models or change specs ordesign at any time without notice and without incurringobligation.Introductioni

NotesiiIntroductionTP-6103 1/01

Cautions and NoticesDefinition of Caution, Notice, andImportantThe diagnosis and repair procedures in the GMPowertrain Service Manual contain both general andspecific Cautions, Notices, and Importants.GMPowertrain is dedicated to the presentation of serviceinformation that helps the technician diagnose andrepair the systems necessary for the proper operation ofthe equipment; however, certain procedures maypresent a hazard to the technician if they are notfollowed in the recommended manner. Cautions,Notices, and Importants are elements designed toprevent these hazards; however, not all hazards can beforeseen. This information is placed at strategiclocations within the service manual and is designed toprevent the following:D Serious bodily injury to the technician.D Damage to the equipment.D Unnecessary equipment repairs.D Unnecessary component repairs.Notice DefinedNotices call special attention to a necessary action or toa prohibited action. If a Notices not heeded, thefollowing consequences may occur:D Damage to the equipment.D Unnecessary equipment repairs.D Unnecessary component replacement.D Improper operation or performance of the system orcomponent under repair.D Damage to any systems or components that aredependent upon the proper operation of the system orcomponent under repair.D Improper operation or performance of any systems orcomponents that are dependent upon the properoperation or performance of the system orcomponent under repair.D Damage to fasteners, basic tools, or special tools.D Leaks of coolant, lubricant, or other vital fluids.D Improperrepair or replacement equipmentcomponents. Any caution or notice that appears ingeneral information is referenced from the individualservice categories.Caution DefinedWhen encountering a Caution, you will be asked to takea necessary action or avoid a prohibited action. If aCaution is not heeded, the following consequences mayoccur:D Serious bodily injury to the technician.D Serious bodily injury to other technicians in theworkplace area.D Serious bodily injury to the equipment operator if theequipment has been improperly repaired.TP-6103 1/01Important DefinedImportant statements emphasize a necessarycharacteristic of a diagnostic or repair procedure.Important statements are designed to do the following:D Clarify a procedure.D Present additional information for accomplishing aprocedure.D Give insight into the reason or reasons for performinga procedure in the manner recommended.D Present information that will help to accomplish aprocedure in a more effective manner.D Present information that gives the technician thebenefit of past experience in accomplishing aprocedure with greater ease.Safety Precautions and InstructionsI

Moving Parts and Hot Surfaces CautionFastener NoticeCaution: Avoid contact with moving parts and hotsurfaces while working around a running engine in orderto prevent physical injury.Notice: Use the correct fastener in the correct location.Replacement fasteners must be the correct part numberfor that application. Fasteners requiring replacement orfasteners requiring the use of thread-locking compoundor sealant are identified in the service procedure. Do notuse paints, lubricants, or corrosion inhibitors onfasteners or fastener joint surfaces unless specified.These coatings affect fastener torque and joint clampingforce and may damage the fastener. Use the correcttightening sequence and specifications when installingfasteners in order to avoid damage to parts andsystems.Safety Glasses CautionCaution: Always wear safety glasses to avoid eyedamage.Belt Drive NoticeNotice: Do not use belt dressing on the drive belt. Beltdressing causes the breakdown of the composition ofthe drive belt. Failure to follow this recommendation willdamage the drive belt.Component Fastener Tightening NoticeNotice: Replacement components must be the correctpart number for the application. Components requiringthe use of the thread-locking compound, lubricants,corrosion inhibitors, or sealants are identified in theservice procedure. Some replacement componentsmay come with these coatings already applied. Do notuse these coatings on components unless specified.These coatings can affect the final torque, which mayaffect the operation of the component. Use the correcttorque specifications when installing components inorder to avoid damage.IISafety Precautions and InstructionsSpecial Fastener NoticeNotice: This bolt is designed to permanently stretchwhen tightened. The correct part number fastener mustbe used to replace this type of fastener. Do not use a boltthat is stronger in this application. If the correct bolt isnot used, the parts will not be tightened correctly. Thesystem or the components may be damaged.TP-6103 1/01

EngineMarine/Industrial 4.3L 6-1Engine Mechanical - 4.3LSpecificationsFastener Tightening SpecificationsSpecificationApplicationAccelerator Control Cable Bracket Nut to StudAccelerator Control Cable Bracket Nut to Throttle BodyAccelerator Control Cable Bracket Stud to Intake ManifoldAccelerator Control Cable Bracket Stud to Throttle BodyAir Cleaner Adapter StudBalance Shaft Driven Gear BoltFirst PassFinal PassBalance Shaft Retainer BoltBattery Cable Bracket Bolt to Oil PanBattery Negative Cable Bolt to EngineBattery Positive Cable Junction Block Bracket BoltBelt Idler Pulley BoltCamshaft Retainer BoltCamshaft Sprocket BoltConnecting Rod NutFirst PassFinal PassCrankshaft Balancer BoltCrankshaft Bearing Cap (Preferred Method)First PassFinal PassCrankshaft Bearing Cap BoltCrankshaft Position Sensor BoltCrankshaft Pulley BoltCrankshaft Rear Oil Seal Housing Bolt and NutCrankshaft Rear Oil Seal Housing Retainer StudCylinder Head Bolt (Preferred Method)All Bolts First Pass in SequenceLong Bolts Final Pass in SequenceMedium Bolts Final Pass in SequenceShort Bolts Final Pass in SequenceCylinder Head Core Hole PlugDistributor Cap BoltDistributor Clamp BoltDrive Bolt Tensioner BoltEGR Valve BoltFirst PassFinal PassMetric12 N m9 N m6 N m12 N m8 N mEnglish106 lb in80 lb in53 lb in106 lb in71 lb in20 N m15 lb ft35 degrees12 N m12 N m25 N m25 N m50 N m12 N m25 N m106 lb in106 lb in18 lb ft18 lb ft37 lb ft106 lb in18 lb ft27 N m20 lb ft70 degrees95 N m70 lb ft20 N m15 lb ft73 degrees105 N m8 N m58 N m12 N m6 N m77 lb ft71 lb in43 lb ft106 lb in53 lb in30 N m22 lb ft75 degrees65 degrees55 degrees20 N m2.4 N m25 N m50 N m15 lb ft21 lb in18 lb ft37 lb ft7 N m30 N m62 lb in22 lb ft2000 Marine/Industrial

6-2Marine/Industrial 4.3LEngineFastener Tightening Specifications (cont’d)SpecificationApplicationEGR Valve Inlet Pipe Clamp BoltEGR Valve Inlet Pipe Nut at Intake ManifoldEGR Valve Inlet Pipe Nut at Exhaust ManifoldEngine Block Left Side Oil Gallery PlugEngine Block Left Rear Oil Gallery PlugEngine Block Right Rear Oil Gallery PlugEngine Block Coolant Drain Hole PlugEngine Block Oil Gallery PlugEngine Coolant Heater Bolt/ScrewEngine Coolant Temperature (ECT) SensorEngine Flywheel BoltEngine Front Cover BoltEngine Lift Bracket Bolt (Special Tool J 41427)Engine Lift Front Bracket StudEngine Mount Bolt to Engine BracketEngine Mount Engine Bracket Bolt to EngineEngine Mount Frame Bracket Through-BoltEngine Mount Frame Side Mount BoltEngine Oil Level SensorEngine Oil Pressure Gauge SensorEngine Oil Pressure Gauge Sensor Fitting (Plus Required Angle)Engine Wiring Harness Bracket Bolt to Battery Positive Cable JunctionBlock BracketEngine Wiring Harness Bracket Bolt to Generator and Drive BeltTensioner BracketEngine Wiring Harness Bracket Bolt to Rear Right Side Cylinder HeadEngine Wiring Harness Bracket Nut to Evaporative Emission (EVAP)Canister Purge Solenoid Valve StudEngine Wiring Harness Bracket Nut to Intake Manifold StudEvaporitive Emission (EVAP) Canister Purge Solenoid Valve Stud toIntake ManifoldExhaust Manifold Bolt/StudFirst PassFinal PassExhaust Manifold Heat Shield BoltFan and Water Pump Pulley BoltFrame Cross Bar BoltFuel Meter Body Bracket BoltFuel Pipe Bracket BoltFuel Pipe Retainer NutFuel Supply Pipe Nut (Fuel Tank Side)Generator and Drive Belt Tensioner Bracket Bolt to EngineGenerator and Drive Belt Tensioner Bracket Stud to Engine2000 Marine/IndustrialMetric25 N m25 N m30 N m20 N m30 N m20 N m20 N m20 N m2 N m20 N m100 N m12 N m15 N m35 N m50 N m50 N m75 N m65 N m13 N m30 N m15 N mEnglish18 lb ft18 lb ft22 lb ft15 lb ft22 lb ft15 lb ft15 lb ft15 lb ft18 lb in15 lb ft74 lb ft106 lb in11 lb ft26 lb ft37 lb ft37 lb ft55 lb ft50 lb ft115 lb in22 lb ft11 lb ft9 N m80 lb in25 N m18 lb ft25 N m18 lb ft9 N m80 lb in12 N m106 lb in10 N m89 lb in15 N m30 N m9 N m25 N m100 N m10 N m6 N m3 N m30 N m41 N m20 N m11 lb ft22 lb ft80 lb in18 lb ft74 l

Engine Engine Model: General Motors 4.3 L Powertrain Generator Models: 30--45 kW TP-6103 1/01 Service