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1997 Chevrolet S10 Pickup
1996-97 ENGINES 4.3L V6 - Trucks
1996-97 ENGINES
4.3L V6 - Trucks
ENGINE IDENTIFICATION
NOTE: For repair procedures not covered in this article, see

ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.
Engine is identified by eighth character of Vehicle Identification Number (VIN). VIN is stamped on a metal tag
on top left end of instrument panel, near windshield. See ENGINE IDENTIFICATION CODES table.
Engine can also be identified by engine identification (ID) number. Number is stamped on front of cylinder
block, immediately forward of right cylinder head or on left side of cylinder block, on engine-to-transmission
mating flange.
ENGINE IDENTIFICATION CODES

Engine (1) VIN Code Engine ID
CSI W L35
CSI X LB4
(1) Eighth character of VIN.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE: Although valve clearance adjustment is not usually required (engine uses
hydraulic valve lifters), perform the following procedure after servicing valve
train.
Engine uses screw-in rocker arm studs with a shoulder. Tighten rocker arm nuts to specification. See TORQUE
SPECIFICATIONS table.
SHIFT CABLE ADJUSTMENT
NOTE: When installing shift cable, DO NOT pull shift lever ball stud forward of
transmission shift lever ball stud.
Express, "C" & "K" Pickup, Savana, Sierra & Tahoe
1. Ensure transmission shift lever is in mechanical park position. Rotate control lever clockwise until it
reaches it's final stop position. Apply parking brake. Raise and support vehicle.
2. Slide Black retaining clip forward on shift cable end far enough to allow White lock button to be pushed
out. Push White lock button on shift cable end out far enough to free metal core adjust body inside cable
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end. DO NOT push White lock button completely out.

3. Inspect metal core adjust body on shift cable end for dirt or debris that may restrict its travel. If travel of
metal core adjust body remains restricted, shift cable assembly must be replaced. Lower vehicle. Ensure
parking brake is applied.
4. Turn ignition switch to ON position. Move transmission shift lever from Park to One and back to Park
position 10 times. Place shift lever to Park. Turn ignition switch to OFF position. Raise and support
vehicle. Ensure transmission control lever is in mechanical park position.
5. Rotate control lever clockwise until it reaches it's final stop position. Push White lock button in to secure
core adjuster body inside shift cable end. Slide Black retainer clip rearward over shift cable end until it
covers White lock button and locks in place over shift cable end. Ensure parking brake is applied. Lower
vehicle.
Astro & Safari
1. Ensure shift cable is not restricted. Place steering column shift lever into Neutral. Position shift cable to
assume a natural routing. Shift cable must be free to move .80" (20 mm) during adjustment.
2. Pull cable end completely forward and release it. When cable is pulled completely forward and released,
adjustment spring will position cable to its most rearward position. Connect end of shift cable to
transmission shift lever stud ball.
TROUBLE SHOOTING
NOTE: To trouble shoot mechanical engine components, see appropriate table in

TROUBLE SHOOTING article in GENERAL INFORMATION.
REMOVAL & INSTALLATION
WARNING: On vehicles equipped with air bag restraint system, see appropriate AIR
BAG RESTRAINT SYSTEM article before servicing steering wheel or
column. Use extreme caution to avoid personal injury and vehicle
damage.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.
FUEL PRESSURE RELEASE
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Disconnect battery terminals. Loosen fuel tank cap to relieve tank pressure. Connect one end of fuel gauge hose
to pressure relief fitting at rear of intake manifold. Place other end of hose in a container. Open relief valve to
release pressure.
COOLING SYSTEM BLEEDING
1. Fill radiator to base of filler neck. Start engine. Place A/C-heater control in any position except MAX.
Select highest temperature setting. Idle engine until lower radiator hose is hot.
2. Increase engine speed to 3000 RPM and then back to idle. Do this 5 times to expel any air trapped in
system. Fill radiator as necessary. Install radiator cap. Allow engine to cool. Fill coolant recovery
reservoir as necessary.
3. Crush and add 2 Coolant Sealant Pellets (GM P/N 3634621) or equivalent to radiator (if reservoir is not
pressurized) or coolant reservoir (if reservoir is pressurized).
POWER STEERING BLEEDING
NOTE: If air was introduced into hydraulic system during servicing, bleed system.
Aerated fluid, which appears Light Tan in color, results in poor steering
performance and will cause pump damage.
1. Turn ignition off. Raise and support vehicle with front wheels off ground. Using steering wheel, turn
wheels fully to left. Add power steering fluid to FULL COLD mark on dipstick. Turn wheels from side to
side at least 20 times, but DO NOT touch steering stops. Add fluid as necessary to maintain level at
FULL COLD mark.
2. Start engine. With engine idling, check fluid level. Add fluid as necessary to bring fluid level to FULL
COLD mark. Return wheels to center position. Lower vehicle. Continue to run engine for 2 to 3 minutes
to raise temperature of fluid and eliminate trapped air. Turn steering wheel in both directions.
3. Road test vehicle. Check for leaks. Ensure fluid level is at FULL HOT mark when fluid is stabilized at
operating temperature.
ENGINE
CAUTION: Minimal clearance exists between oil pump pick-up tube and bottom of oil
pan. DO NOT place jack under oil pan, crankshaft pulley or any sheet
metal when lifting engine.
WARNING: Provide addition support for opposite end from which components are
being removed. When removing major components of vehicle, vehicle
frame should be chained to hoist pads at same end as removed
components to prevent tip-off. Failure to follow these precautionary
measures could result in vehicle damage or serious personal injury.
NOTE: Flush out oil and engine cooling system when installing new engine.
Removal (Astro & Safari)

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1. On this vehicle, engine must be removed out of bottom of vehicle. Release fuel system pressure. See
FUEL PRESSURE RELEASE . Remove battery. Remove air filter assembly and if equipped,
disconnect cruise control cable from throttle body. Disconnect cruise control stepper motor electrical
connector. Drain cooling system. Raise and support vehicle.
2. Remove drive shaft. Disconnect transfer case vent hose. Disconnect exhaust pipes from manifolds and
behind catalytic converter. Remove park brake bracket from frame. Disconnect rear brake line from
metering proportioning valve (combination valve). Remove flywheel cover, 3 torque converter bolts
(A/T), starter and oil filter. Disconnect shift linkage. Disconnect engine wiring harness from transmission
and frame.
3. Disconnect fuel lines from sub-frame. Disconnect transmission fluid lines and engine oil cooler lines
from radiator. Remove lower fan shroud bolts. Disconnect power steering cooler from front air deflector.
Disconnect air bag sensor connector. Remove motor mount through-bolts. Lower vehicle. Remove front
bumper.
4. Remove headlight bezels and grille. Remove lower radiator close-out panel, radiator support braces and
radiator cross brace. Remove hood latch mechanism. Discharge A/C system (if equipped) using approved
refrigerant recovery/recycling equipment. Remove upper fan shroud and radiator.
5. Remove radiator filler panels. Remove engine cover. Disconnect A/C hose from accumulator and
condenser. Remove A/C compressor and bracket. Remove power steering pump. Disconnect master
cylinder and tie to oil fill tube. Disconnect steering shaft. Disconnect wheel housing splash shields. If
equipped, disconnect rear A/C lines at rear crossmember.
6. Disconnect vacuum hoses as necessary. Disconnect fuse box and wiring harness from bulkhead
connector, and all related electrical connectors. Lay harness on engine. Remove right kick panel. Remove
CPI or TBI unit from intake manifold. Push connector and harness through firewall. Remove distributor
cap and A/C accumulator. Disconnect fuel line from injection unit. Pull fuel lines through crossmember
and lay lines on transmission. Remove fuel tank electrical connector.
7. Remove transmission dipstick tube (A/T). Disconnect heater hose from heater core. Remove horn. Attach
side lift hoist. Attach Body Protection Hoist Adapter Set (J41602), Twin Post Hoist Frame Support
(J41617), and Universal Lift Bracket (J41427). Support transmission. On 4WD, disconnect transfer case
to engine block support brace. Remove 9 bellhousing bolts. Lower engine from vehicle.
Installation
1. Place engine in position on sub-frame. Install engine mount through bolts. Torque to specification. See
TORQUE SPECIFICATIONS . Remove engine lift Adapter (J-41427).
2. Connect transmission to engine, torque to specification. See TORQUE SPECIFICATIONS . Install
exhaust "Y" pipe to engine. On 4WD models, install transfer case support brace. Route and connect all
fuel lines, hoses and transmission wiring harness. Connect steering shaft and wheel housing splash
shields.
3. Install distributor cap. Connect heater hose from coolant pump. Connect harness at knock sensor module.
Connect wiring harness at bulkhead. Install CPI or TBI unit to intake manifold. Install A/C compressor.
4. Lower vehicle into position for engine/sub-frame installation. Install sub-frame bolts and tighten in
sequence. See Fig. 1 . Connect engine electrical harness. Route and install remaining accessory, bulkhead
and fuse box wiring. Secure fuse box. Connect wheel housing splash shields to frame. Install steering
shaft and torque to specification. See TORQUE SPECIFICATIONS . Install power steering pump
bracket and pump. Connect A/C compressor hose assembly. Install cruise control servo and bracket.
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5. Connect power steering pump. Connect hydraulic lines at gear-box, pump, hydro boost and reservoir.
Install serpentine belt. Install/connect A/C accumulator and hoses. Install radiator. Install upper radiator
hoses and cooler lines. Connect heater hoses. Install all vacuum hoses.
6. Install fan and fan clutch assembly. Install fan shroud and radiator filler panels. Install grille and
headlamp bezels.
7. Install master cylinder and connect all fittings disconnected previously. Install hood latch and radiator
braces. Install transmission and engine filler tubes. Install cruise control stepper motor cable, wiring and
accelerator cable. Install plug wires.
8. Install air cleaner and ducts. Connect fuel lines at intake manifold. Install fuel line bracket and connect
fuel lines at frame. Raise and support vehicle with safety stands.
9. Connect lower engine oil cooler line to radiator. Install power steering cooler and lines. Install lower
transmission oil cooler line and lower radiator hose to radiator. Install front bumper. Connect drive shaft
and transmission linkage. Torque all fasteners to specification. See TORQUE SPECIFICATIONS .
Connect all fuel hoses. Install air bag sensor wiring. Install starter. Connect remaining wiring at engine
and sub-frame.
10. Install torque converter bolts and cover. See TORQUE SPECIFICATIONS . Connect exhaust pipes and
lower vehicle. Install oil filter and oil. Ensure oil level is correct. See Crankcase Capacity . Ensure
transmission fluid level is correct. Fill and bleed power steering system. See POWER STEERING
BLEEDING . Install air filter assembly. Install battery and negative battery cable. Install engine cover.
Install right kick panel.
11. Install battery. Fill and bleed brake system. Install coolant as needed. See COOLING SYSTEM
BLEEDING . Evacuate and charge A/C system. See appropriate article in REFRIGERANT
RECOVERY/RECYCLING in A/C GENERAL SERVICING.
12. Check all components for leaks, proper fluid levels and proper operation.
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Fig. 1: Tightening sub-frame mounting bolts in sequence (Astro & Safari).

Courtesy of GENERAL MOTORS CORP.
Removal (Pickup, Sierra, & Tahoe)
1. Release fuel system pressure. See FUEL PRESSURE RELEASE . Remove hood. Remove air cleaner,
accessory drive belt, fan and water pump pulley.
2. Drain cooling system. Remove fan shroud and radiator. Disconnect heater hoses from engine. Disconnect
fuel lines, electrical connectors, vacuum hoses, coolant hoses and control cables as necessary. Discharge
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A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Remove A/C
compressor and power steering pump with hoses attached and position aside (if equipped).
3. Mark and remove distributor. Raise and support vehicle. Drain crankcase. Disconnect exhaust pipes from
manifolds. Disconnect strut rods. Remove flywheel cover. Remove starter. Remove torque converter bolts
(A/T). Lower vehicle.
4. Support transmission. Attach engine hoist. Remove bellhousing bolts. Remove front engine mount-to-
frame bolts. Remove engine.
Installation
To install, reverse removal procedure. Fill crankcase and cooling system. Bleed cooling system. See
COOLING SYSTEM BLEEDING . Evacuate and charge A/C system. Bleed power steering. See POWER
STEERING BLEEDING . If necessary adjust shift cable. See SHIFT CABLE ADJUSTMENT . Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
Removal (Commercial Van)
1. Release fuel system pressure. See FUEL PRESSURE RELEASE . Drain crankcase and cooling system.
Remove engine cover and floor panel sections.
2. Remove air cleaner, duct and exhaust heat stove pipe. Remove distributor cap and position aside.
Disconnect all engine harness electrical connectors and position aside. Disconnect fuel lines from
injection unit. Remove fuel line clamps from transmission and position fuel lines aside. Disconnect
electrical connectors, vacuum hoses, coolant hoses and control cables as necessary.
3. Disconnect ground strap from rear end of left cylinder head. Disconnect all transmission harness electrical
connectors and position harness aside. Remove transmission shifter (if necessary). Discharge A/C system
(if equipped) using approved refrigerant recovery/recycling equipment. Remove A/C compressor.
Remove upper radiator hose, all accessory drive belts, fan, fan pulley, fan shroud, lower radiator hose and
radiator.
4. Remove engine oil filler tube. Remove clutch adjuster rod, return spring and pivot arm assembly (M/T).
Disconnect exhaust pipes from manifolds. Disconnect battery cable from clamp on cylinder block.
Disconnect drive shaft from transmission. Remove transmission mount.
5. Disconnect oil cooler lines from oil filter adapter and oil cooler line clamps from engine. Remove torque
converter bolts. Attach engine hoist. Remove engine mount through-bolts. Remove engine.
Installation
STEERING BLEEDING . If necessary adjust shift cable. See SHIFT CABLE ADJUSTMENT . Tighten
Removal (Blazer, Bravada, Jimmy, Sonoma & Pickup)
NOTE: Notice: If the engine is damaged internally and a new engine assembly is
installed in the vehicle, ensure that all foreign material is flushed out of the
cooling system. You must also flush out the oil cooler system. Failure to rid the
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oil cooler system of debris can result in engine damage.
NOTE: Tool Required: J-41427 Universal Lift Bracket.
1. Release fuel system pressure. See FUEL PRESSURE RELEASE . Raise the vehicle.
2. Remove the underbody shield.
3. Remove the braces from the engine to the transmission.
4. Disconnect the exhaust pipe from the exhaust manifolds.
5. Disconnect the slave cylinder or hydraulic line if the cylinder is mounted inside the bellhousing.
6. Disconnect the fuel line clamp at the bellhousing.
7. Remove the starter.
8. Disconnect the torque convertor bolts from the flywheel.
9. Disconnect the front propeller shaft (4WD only).
10. Remove the oil filter.
11. Remove the transmission to engine bolts.
 Remove all the transmission to engine bolts except for the upper left bolt.
 For an automatic transmission refer to Transmission Replacement in Automatic Transmission.
 For a manual transmission refer to Transmission Replacement in Manual Transmission.
12. Remove the front engine mount through bolts. See Fig. 2 .
13. Remove the rear engine mount crossbar nut and washer. See Fig. 3 .
14. Lower the vehicle.
15. Remove the battery ground cable at the engine.
16. Remove the water pump pulley.
17. Remove the air conditioning compressor and bracket.
18. Remove the radiator.
19. Disconnect the power steering hoses from the power steering gear and cap them.
20. Disconnect the heater hoses from the engine.
21. Disconnect the following items:
 The wiring harnesses
 The vacuum lines
 The throttle cable
 The fuel lines
22. Remove the distributor.

23. Support the transmission with a jack and remove the final transmission to engine bolt.
24. Install J-41427 to the right rear and the left front of the intake manifold. Tighten Retaining bolts to 15
N.m (11 lb. ft.). see Fig. 4 .
25. Use an engine lifting device and remove the engine from the vehicle.
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Fig. 2: Removing & Installing Engine Mount Through Bolt
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Fig. 3: Removing & Installing Crossbar Mount
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Fig. 4: Installing J-41427 To Intake Manifold
Installation
1. Install the engine into the vehicle.

2. Install the left upper transmission to engine bolt.
3. Install the front engine mount through bolts and nuts:
 Tighten the bolts to 66 N.m (49 lb ft).
 Tighten the nuts to 56 N.m (41 lb ft).
4. Remove the universal lift brackets and install the intake manifold bolts.
5. Install the distributor.
6. Install the following items:
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 The wiring harnesses

 The vacuum lines
 The throttle cable
 The fuel lines
7. Connect the heater hoses to the engine.

8. Install the power steering hoses.
9. Install the radiator.
10. Install the air conditioning compressor and bracket.
11. Install the water pump pulley.
12. Raise the vehicle.
13. Install the battery ground cable at the engine.
14. Install the remaining transmission to engine bolts.
 For an automatic transmission refer to Transmission Replacement in Automatic Transmission.
 For a manual transmission refer to Transmission Replacement in Manual Transmission.
15. Install the rear engine mount crossbar nut and washer. Tighten the nut to 45 N.m (33 lb ft).
16. Install the oil filter.
17. Connect the torque convertor bolts to the flywheel.
18. Install the front propeller shaft (4WD only).
19. Install the starter.
20. Connect the fuel line clamp at the bellhousing.
21. Connect the slave cylinder or hydraulic line if the cylinder is mounted inside the bellhousing.
22. Connect the exhaust pipe to the exhaust manifolds.
23. Install the braces from the engine to the transmission.
24. Install the underbody shield.
25. Lower the vehicle.
26. Fill the crankcase with oil.
27. Connect the negative battery cable.
Fill cooling system. Bleed cooling system. See COOLING SYSTEM BLEEDING . Evacuate and charge A/C
system. Bleed power steering. See POWER STEERING BLEEDING . If necessary adjust shift cable. See
SHIFT CABLE ADJUSTMENT . Tighten bolts to specification. See TORQUE SPECIFICATIONS table.
Removal (Express & Savana)
1. Release fuel system pressure. See FUEL PRESSURE RELEASE . Drain cooling system. Remove
engine cover and air cleaner. Remove power steering fluid reservoir.
2. Remove upper fan shroud, fan, fan pulley, radiator and lower fan shroud. Remove engine coolant
reservoir. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment.
Remove A/C condenser. Remove A/C compressor and brace. Remove generator and bracket. Remove 2
ground straps. Remove cruise control servo (if equipped).
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3. Disconnect fuel lines, electrical connectors, vacuum hoses, coolant hoses and control cables as necessary.
Remove injection unit. Remove distributor cap with wires attached. Remove diverter valve assembly and
pipe.
4. Remove ignition coil and manifold absolute pressure sensor. Remove upper half of engine oil dipstick
tube. Remove engine oil filler tube. Remove headlight bezels, grille and upper radiator support (sheet
metal cross panel support). Remove front bumper. Remove intake manifold. See INTAKE
MANIFOLD .
5. Raise and support vehicle. Drain crankcase. Disconnect exhaust pipes from manifolds. Remove strut rods.
Remove flywheel cover. Disconnect oil cooler lines from engine. Remove transmission shift cable.
Remove starter, torque converter bolts (A/T) and engine mount through-bolts.
6. Lower vehicle. Attach engine hoist. Remove bellhousing bolts. Support transmission. Remove engine.
Installation
STEERING BLEEDING . If necessary, adjust shift cable. See SHIFT CABLE ADJUSTMENT . Tighten
INTAKE MANIFOLD (UPPER)
CAUTION: Always apply a few drops of clean engine oil to male fuel pipe ends before
connecting fuel pipe fittings in order to reduce risk of fire and personal
injury. This will also prevent a possible fuel leak. During normal operation,
the "O" rings located in the female connector will swell, and may prevent
proper reconnecting if not lubricated.
NOTE: Manufacturer does not provide a torque sequence for upper intake manifold.
Removal
1. Remove negative battery terminal. Release fuel system pressure. See FUEL PRESSURE RELEASE .
Remove air filter assembly and intake duct.
2. Remove wiring harness connectors and brackets and move to the side. Remove throttle and cruise control
(if equipped) cable. Remove fuel lines and bracket at rear of lower intake manifold.
3. Remove brake booster vacuum hose and PCV hose at upper intake manifold. Remove ignition coil and
bracket. Remove purge solenoid and bracket.
4. Remove upper intake manifold bolts and studs. Mark location of all studs for proper assembly. Remove
upper intake manifold. See Fig. 5 . Clean old pieces of gasket from all gasket surfaces. Inspect manifold
for cracks, broken flanges, and damage to gasket surface.
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Fig. 5: Exploded View Of Intake Manifold Assembly (VIN W)

Installation
1. Install upper intake manifold gasket. See Fig. 6 . Install upper intake manifold. DO NOT pinch injector
lines between upper and lower intake manifolds.
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NOTE: Tighten upper intake manifold bolts to specification in a criss-cross

pattern. Manufacturer does not provide a specific torque sequence.
2. Install the 2 corner studs first in order to help align the two halves. Install upper intake manifold bolts.
Tighten first to 44 INCH lbs. (5 N.m) and then tighten to 89 INCH lbs. (10 N.m).
3. Install the purge solenoid and bracket. Install the ignition coil and bracket. Install the PCV hose at the
upper intake manifold. Install the fuel lines and bracket at the rear of the lower intake manifold.
4. Install the throttle linkage and cruise control cable (if equipped). Install the wiring harness connectors and
brackets.
5. Install the air filter assembly and intake duct. Connect the negative battery cable.
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Fig. 6: Installing Upper Intake Manifold Gasket (VIN W)

INTAKE MANIFOLD (LOWER)
Removal
NOTE: Removing upper intake manifold is not necessary when removing lower
intake manifold, they are removed as an assembly.
1. Remove distributor cap. Mark distributor rotor in relation to distributor housing. Mark base of distributor
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housing in relation to intake manifold. Remove distributor.

2. Drain cooling system. Disconnect upper radiator hose at thermostat housing. Disconnect water pump by-
pass hose and heater hose at intake manifold.
3. Remove EGR valve. Disconnect fuel lines at rear of lower intake manifold. Disconnect wiring harness.
4. Disconnect throttle cable and cruise control cable (if equipped). Unbolt throttle cable bracket from intake
manifold. Move throttle cable bracket aside, with cables attached.
5. Unbolt transmission dipstick tube and remove/move aside as necessary. Remove PCV valve and
disconnect vacuum hoses as necessary.
6. Remove serpentine belt. Unbolt A/C compressor/accessory bracketry and move aside as necessary to
allow removal of intake manifold.
7. Remove lower intake manifold bolts, lower intake manifold and gaskets.
Installation
1. Apply a 3/16" (5 mm) bead of RTV (GM P/N 1052289) or equivalent to 4 sealing corners of block.
Extend bead 1/2" (13 mm) up each cylinder head. See Fig. 7 .
2. Apply Loctite(R) 242 (GM P/N 12345382) or equivalent to lower intake manifold bolt threads. Tighten
bolts in sequence to specification. See Fig. 8 . See TORQUE SPECIFICATIONS table.
CAUTION: Always use NEW "O" rings when reconnecting fuel lines at rear of
engine.
3. To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING .
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Fig. 7: Applying RTV Sealant Before Installing Intake Manifold

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Fig. 8: Lower Intake Manifold Bolt Tightening Sequence

EXHAUST MANIFOLD
Removal
Remove engine cover or floor panel. Remove negative battery cable. Remove oil level indicator tube and EGR
inlet pipe. Remove spark plugs and spark pug heat shields. Remove exhaust pipe at manifold. Remove exhaust
manifold bolts and exhaust manifold.
Installation
Install manifold. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse removal procedure.
CYLINDER HEAD
Removal
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Remove negative battery cable. Remove engine cover or floor panel. Remove intake manifold. See appropriate
INTAKE MANIFOLD . Discharge A/C system (if equipped) using approved refrigerant recovery/recycling
equipment and remove A/C compressor and bracket (if equipped). Remove generator and brackets. Remove
spark plugs.
Installation
1. Clean gasket surfaces, bolt threads and bolt holes. If using steel head gasket, thinly coat both sides of
gasket with sealant. DO NOT apply sealant to composite (steel/asbestos) head gaskets. Position head
gasket on cylinder block. Ensure all holes align. Coat head bolt threads with GM Sealant (1052080).
2. Install cylinder head with bolts finger-tight. Tighten head bolts in sequence to specification. See Fig. 9 .
See TORQUE SPECIFICATIONS table. Lubricate valve tip, rocker arm pivot and push rod socket with
Molykote.
3. To complete installation, reverse removal procedure. Adjust valves. See VALVE CLEARANCE
ADJUSTMENT under ADJUSTMENTS.
Fig. 9: Cylinder Head Bolt Tightening Sequence

ROCKER ARMS & PUSHRODS
Removal
Remove negative battery cable. On Commercial Van, remove engine cover of floor panel. Remove PCV valve
and tube. Remove EGR inlet tube. Remove purge solenoid and spark plug wires. Remove valve cover. Remove
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rocker arm bolts. If pushrods are to be replaced only, back off valve rocker arm bolts until valve rocker arm can
be swung away from pushrod and remove pushrod.
Installation
Coat bearing surfaces with High Viscosity Oil/Zinc (GM P/N 12345501). Valve cover gaskets are reusable.
Replace gaskets only if damaged. Tighten to specification. See TORQUE SPECIFICATIONS table. To install
remaining components, reverse removal procedure.
FRONT COVER OIL SEAL
Removal
1. Remove negative battery cable. If equipped, remove engine cover or floor pan. Remove upper fan shroud.
Remove engine cooling fan. Remove accessory drive belt(s) and water pump pulley.
2. Raise and support vehicle. Remove lower fan shroud. Remove crankshaft balancer bolt. Remove
crankshaft pulley bolts and crankshaft pulley.
3. Using Damper Puller/Installer (J-23523-F), remove crankshaft balancer. Carefully pry oil seal from front
cover.
Installation
1. Coat crankshaft front cover oil seal lips with clean engine oil. Using Seal Installer (J-35468), install NEW
seal in front cover with seal lip facing engine. Apply RTV sealant to Woodruff keyway in crankshaft
balancer.
2. Using Damper Puller/Installer (J-23523-F), install crankshaft balancer. Tighten fasteners to specification.
See TORQUE SPECIFICATIONS table. To install remaining components, reverse removal procedure.
FRONT COVER
Removal
NOTE: DO NOT reinstall original composite front cover. Always install a NEW front
cover. Reinstalling original front cover can lead to oil leaks.
1. Remove negative battery cable. If equipped, remove engine cover or floor pan. Remove upper fan shroud.
Remove engine cooling fan. Remove accessory drive belt(s) and water pump pulley.
2. Raise and support vehicle. Remove lower fan shroud. Remove crankshaft balancer bolt. Remove
crankshaft pulley bolts and crankshaft pulley.
3. Using Damper Puller/Installer (J-23523-F), remove crankshaft balancer. Remove water pump. See
WATER PUMP .
4. Disconnect Crankshaft Position (CKP) sensor harness connector. Remove CKP sensor bolt and CKP
sensor. Loosen or remove oil pan as necessary for removal of front cover.
5. Remove front cover bolts, front cover and gasket.
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Installation
1. Install NEW front cover and gasket. Tighten front cover bolts to specification. See TORQUE
SPECIFICATIONS .
CAUTION: Ensure CKP sensor is fully seated and held stationary in bore of front
cover upon installation. A CKP sensor that is not fully seated may
result in erratic engine operation.
2. Install CKP sensor. Tighten CKP sensor holddown bolt to specification. See TORQUE
SPECIFICATIONS .
3. Apply RTV sealant to Woodruff keyway in crankshaft damper. Install crankshaft damper using Damper
Puller/Installer (J-23523-F). Tighten fasteners to specification. See TORQUE SPECIFICATIONS . To
complete installation, reverse removal procedure.
TIMING CHAIN & SPROCKETS
Removal
1. Remove front cover. See FRONT COVER .

2. Remove CKP sensor reluctor ring. See Fig. 10 . Rotate crankshaft until timing marks on camshaft and
crankshaft sprockets are aligned. See Fig. 11 . Remove camshaft sprocket and timing chain. To remove
crankshaft sprocket, use Sprocket Puller (J-5825-A).
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Fig. 10: Removing/Installing CKP Sensor Reluctor Ring

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Fig. 11: Aligning Timing Marks

Installation
1. Install Woodruff key in crankshaft (if removed). Using Crankshaft Sprocket Installer (J-5590), install
crankshaft sprocket. Install camshaft sprocket and timing chain. Ensure timing marks on sprockets are
aligned. See Fig. 11 .
2. Balance shaft drive gear, driven gear and gear bolt are serviced as a set. Install and tighten camshaft
sprocket bolts to specification. See TORQUE SPECIFICATIONS .
CAUTION: Failure to properly align CKP sensor reluctor ring may result in
component damage and could affect system performance. CKP
sensor reluctor ring is shaped like a dish. Dished side of CKP
reluctor ring must face engine front cover.
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NOTE: DO NOT reinstall original composite front cover. Always install a NEW
front cover. Reinstalling original front cover can lead to oil leaks.
3. Install and align CKP sensor reluctor ring. See Fig. 10 . Install NEW front cover and gasket. Tighten front
cover bolts to specification.
CAUTION: Ensure CKP sensor is fully seated and held stationary in bore of front
cover upon installation. A CKP sensor that is not fully seated may
result in erratic engine operation.
4. Install CKP sensor. Tighten CKP sensor holddown bolt to specification. See TORQUE
SPECIFICATIONS .
5. Apply RTV sealant to Woodruff keyway in crankshaft damper. Using Damper Puller/Installer (J-23523-
F), install crankshaft balancer. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
To complete installation, reverse removal procedure.
ROCKER ARM STUDS
Removal & Installation
CAUTION: On models equipped with press in rocker arm studs, ream stud bore
before installing oversize rocker arm stud, or cylinder head may be
damaged.
Unscrew rocker arm stud from cylinder head. To install, insert NEW rocker arm stud. Tighten to 35 ft. lbs. (47
N.m).
VALVE LIFTERS
Removal
Remove upper and lower intake manifold. See INTAKE MANIFOLD (UPPER) and INTAKE MANIFOLD
(LOWER) . Remove valve covers. Remove push rods. See ROCKER ARMS & PUSH RODS . Remove
stuck valve lifter using Valve Lifter Remover (J-9290-01).
Installation
Coat lifter base or roller (if equipped) and body with High Viscosity Oil/Zinc (12345501) or equivalent. Install
lifters in original location. To complete installation, reverse removal procedure. Replace oil and filter, and add
High Viscosity Oil/Zinc (GM P/N 12345501) or equivalent.
CAMSHAFT
Removal
Remove front cover. See FRONT COVER . Remove timing chain and sprockets. See TIMING CHAIN &
Microsoft
SPROCKETS . Install three 5/16" X 18 bolts (4-5 inches long) into camshaft threaded holes. Use bolts to
remove and install camshaft.
Installation
Coat camshaft lobes and bearing journals with High Viscosity Oil/Zinc (12345501). Ensure bearing oil holes
align with oil holes in block. On engines where oil holes are difficult to see, use a piece of 3/32" rod to check
alignment. Install outer camshaft bearing first. Install camshaft. To complete installation, reverse removal
procedure.
BALANCE SHAFT (IF EQUIPPED)
Removal
1. Remove radiator. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling
equipment and remove A/C condenser (if equipped) and grille. Remove valve lifters. See VALVE
LIFTERS .
2. Remove timing chain and camshaft sprocket. See TIMING CHAIN & SPROCKETS . Remove balance
shaft gears. Remove balance shaft retainer plate.
NOTE: Front bearing is removed with balance shaft. Replace front bearing and
balance shaft as a set only. Replace balance shaft timing gears as a set
only.
3. Remove intake manifold. See INTAKE MANIFOLD . Using a soft-faced hammer, tap balance shaft out
toward front of engine.
Installation
1. Apply oil to balance shaft bearings. Using Installers (J-36996 and J-8092), install balance shaft in block.
See Fig. 12 . Install lifter retainer (if equipped). Ensure balance shaft turns.
2. Install thrust plate. Install balance shaft gears. Ensure timing marks on balance shaft gears are aligned.
See Fig. 13 . Install balance shaft timing gear bolt. Tighten bolt to 15 ft. lbs. (20 N.m), then tighten bolt
an additional 35 degrees. To complete installation, reverse removal procedure.
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Fig. 12: Installing Balance Shaft

Microsoft
Fig. 13: Aligning Timing Marks For Balance Shaft Gears

REAR CRANKSHAFT OIL SEAL
Removal
Remove transmission, clutch (M/T) and flywheel. See appropriate TRANSMISSION REMOVAL &
INSTALLATION article in TRANSMISSION SERVICING. Pry seal from housing.
Installation
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1. Lubricate inner and outer diameter of seal with engine oil. Place seal on Seal Installer (J-35621). Position
seal against crankshaft as indicated in illustration. See Fig. 14 .
2. Thread attaching screws into crankshaft flange and tighten with screwdriver. This squares seal with
crankshaft. Rotate seal installer handle until it bottoms. Remove seal installer. Install flywheel, clutch
(M/T) and transmission.
Fig. 14: Installation Position Of Rear Crankshaft Oil Seal.

WATER PUMP
NOTE: DO NOT immerse water pump in solvent. Solvent may cause premature bearing
failure.
Removal
Disconnect battery. Drain cooling system. Remove all drive belts, coolant hoses and mounting brackets attached
to water pump. If necessary, remove fan shroud. Remove fan and pulley. Remove water pump and gaskets.
Installation
Install water pump with NEW gaskets. Tighten water pump bolts to specification. See TORQUE
SPECIFICATIONS table. To complete installation, reverse removal procedure.
Microsoft
OIL PAN
CAUTION: Minimal clearance exists between oil pump pick-up tube and bottom of oil
pan. DO NOT place jack under oil pan, crankshaft pulley or any sheet
metal when lifting engine.
Removal (Except "S" & "T" Series)
1. Disconnect battery. Raise and support vehicle. Drain crankcase. Remove exhaust crossover pipe, strut
rods, strut rod brackets and flywheel cover.
2. Remove starter. Remove or disconnect engine oil cooler lines and/or transmission fluid lines as necessary.
Remove oil pan bolts, oil pan and gasket.
Removal ("S" Series Pickup, Jimmy & Sonoma 2WD)
Raise and support vehicle. Drain crankcase. Remove engine. See ENGINE . Remove oil pan bolts, oil pan and
gasket.
Removal ("T" Series Pickup, Jimmy & Sonoma 4WD)
1. Disconnect battery. Remove engine oil dipstick and accessory drive belt splash shield. Raise and support
vehicle. Drain crankcase. Remove front axle shield and transfer case shield. Remove brake line clips from
crossmember.
2. Remove second crossmember. Remove converter hanger bolts and exhaust pipe clamp from converter.
Disconnect exhaust pipes from manifolds. Slide exhaust pipe rearward. Disconnect front drive shaft from
differential.
3. Remove flywheel cover. Remove starter motor. Remove idler arm-to-frame bolts. Remove differential
housing mounting bolts from bracket (right side) and frame (left side).
4. Move differential housing forward. Remove front engine mount through-bolts. Raise and support engine.
Remove oil pan bolts, oil pan and gasket.
Installation
NOTE: If transmission and oil pans are removed at same time, transmission pan must
be installed before oil pan.
1. Apply RTV sealant to front cover-to-cylinder block junction and rear main bearing-to-cylinder block
junction.
2. Using feeler gauge check clearance between 3 oil pan-to-transmission contact points. If clearance
exceeds .0100" (.025 mm) at any of 3 points, repeat installation steps until clearance is within
specification. See Fig. 15 . Install oil pan. Tighten oil pan bolts to specification. See TORQUE
SPECIFICATIONS table. To complete installation, reverse removal procedure. Fill crankcase.
Microsoft
Fig. 15: Oil Pan Bolt Tightening Sequence.

OVERHAUL
CYLINDER HEAD
Valve Springs
1. Measure valve spring free length, installed height and pressure (tension). Replace valve spring if
measurement is not within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS.
2. Measure installed height between cylinder head spring seat (or top of shim, if shimmed) and top of spring
shield. If installed height exceeds specification, install shims as necessary to bring installed height to
specification.
Valve Stem Oil Seals
Microsoft
1. Intake valve uses upper "O" ring seal and lower umbrella seal; exhaust valve uses upper "O" ring seal.
2. When installing umbrella seal, seat seal against valve guide boss on cylinder head. If equipped, coat
upper "O" ring seal with engine oil before installation and ensure seal is not twisted when installed. A gap
of .040-.080" (1-2 mm) must exist between edge of oil seal and valve guide. See Fig. 16 .
Valve Guides
Valve guides are part of cylinder head (not replaceable). Measure valve guide oil clearance. See CYLINDER
HEAD table under ENGINE SPECIFICATIONS. If not within specification, ream valve guide and install
valves with oversize stems.
Valves
Replace valve if margin is less than .031" (.8 mm).
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Fig. 16: Installation Of Valve Stem Oil Seal

VALVE TRAIN
Rocker Arm Assembly
Clean push rods, rocker arms, balls and nuts with solvent and blow dry. Inspect rocker arms and balls at mating
surface. Surface should be smooth and free of damage. Inspect push rods for bends or wear. Ensure oil passages
are clear.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Mark piston in relation to cylinder bore before removal. Piston pin is press-fit in connecting rod. Mark
piston in relation to connecting rod before separating components.
2. Replace piston and piston pin as matched set. Install piston in bore with notch on top of piston toward
front of engine.
Fitting Pistons
1. Measure piston diameter at 90-degree angle to piston pin, on piston pin center line. Measure cylinder bore
diameter 2 1/2" below cylinder block deck. Determine piston clearance.
2. If piston clearance is not within specification, replace piston and/or machine cylinder bore as necessary.
See CYLINDER BLOCK and PISTONS, PINS & RINGS tables under ENGINE SPECIFICATIONS.
Piston Rings
Measure piston ring end gap and side clearance. If measurement is not within specification, replace piston
and/or rings as necessary. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Install
rings with mark on ring facing upward. Position ring end gaps around circumference of piston as shown. See
Fig. 17 .
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Fig. 17: Positioning Piston Ring End Gaps

Rod Bearings
1. Measure rod bearing journal out-of-round, taper and oil clearance. If measurement is not within
specification, replace rod bearings and/or machine crankshaft. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
2. Ensure rod side play is within specification. See CONNECTING RODS table under ENGINE
SPECIFICATIONS.
Crankshaft & Main Bearings
1. Mark bearing caps for reassembly. Measure journal diameter, out-of-round, taper and oil clearance. If
measurement is not within specification, replace main bearings and/or machine crankshaft. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
2. Align thrust bearing surfaces, and measure crankshaft end play. See THRUST BEARING . Main
bearing caps are press fit. Using Tool (J-6125-B and J-41348), carefully remove caps for service. Install
main bearings and main caps. Tap bearing caps into cylinder block cavity using a brass, lead, or leather
mallet before installing attaching bolts.
3. DO NOT use cap bolts to pull crankshaft bearing caps into seats. Tighten NEW main cap bolts evenly.
Thrust Bearing
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CAUTION: On some 4.3L engines, the distance between rear main bearing thrust
faces is .008" (.20 mm) wider than standard (identified by .008"
stamped on crankshaft rear counterweight). When replacing rear
main bearings on these engines, use only .008" (.20 mm) wider
bearings.
1. Install main bearing caps (except rear), and tighten cap bolts to specification. See TORQUE
SPECIFICATIONS table. Install rear main bearing cap and tighten cap bolts to 10 ft. lbs. (14 N.m).
2. Tap crankshaft rearward then forward to align thrust surfaces. Tighten rear main bearing cap bolts to
specification. Measure crankshaft end play at forward thrust surface of rear main bearing cap. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS .
Cylinder Block
Measure cylinder bore out-of-round and taper. If measurement is not within specification, machine cylinder
bore and/or replace piston. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. Finish bore
with a 45-65 degree cross-hatch pattern.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Gear-type oil pump delivers full pressure lubrication through full-flow oil filter to main oil gallery. Main oil
gallery feeds crankshaft and camshaft bearings through drilled passages in block.
Valve lifter oil gallery feeds valve lifters. From lifters, oil is routed through hollow push rods to upper valve
train components. Timing chain and sprockets are lubricated by oil drainage from No. 1 camshaft bearing.
Pistons and piston pins are lubricated by oil splash. Non-adjustable oil pressure regulator is located in oil pump
body.
Crankcase Capacity
Crankcase capacity is 4.5 qts (4.26L), including oil filter.
Oil Pressure
Measure oil pressure with engine at operating temperature and specified RPM. See OIL PRESSURE
SPECIFICATIONS table.
OIL PRESSURE SPECIFICATIONS (1)

Application psi (kg/cm2 )
1000 RPM 6 (0.4)
2000 RPM 18 (1.3)
4000 RPM 24 (1.7)
Microsoft
(1) Minimum specification.
OIL PUMP
Removal & Disassembly
NOTE: Pick-up tube is serviceable; however, unless tube is damaged, DO NOT remove
tube from pump body.
1. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump bolt. Remove
pump and extension shaft. If necessary, remove pick-up tube.
2. Remove pump cover. Mark relationship between gears at a meshing point for reassembly. Remove gears.
Remove pressure regulator valve retaining pin. Remove pressure regulator valve and spring. Remove oil
pump-to-rear crankshaft bearing cap bolt. Remove oil pump, retainer and driveshaft from rear crankshaft
bearing cap.
Inspection
Inspect pump body and cover for cracks or excessive wear. Inspect pump gears for damage or wear. Check
drive gear shaft for looseness in pump body. Check pressure regulator valve for fit in bore. Replace entire pump
assembly if damaged. Inspect inlet tube and screen assembly for damage.
Reassembly & Installation
1. Install pump gears into pump body with marked gear teeth indexed. If pick-up tube was removed, apply
sealant to tube end. Tap tube end into pump using plastic hammer. Reassemble remaining components in
reverse order of disassembly.
2. Prime oil pump with engine oil. Install pump and extension shaft, ensuring slot on top of extension shaft
engages with drive tang on end of distributor shaft. Tighten oil pump bolt to specification. See TORQUE
SPECIFICATIONS table. Install oil pan.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Balance Shaft Gear Bolt
Step 1 15 (20)
Step 2 Additional 35 Degrees
Bellhousing Bolt 32 (44)
Camshaft Sprocket Bolt 18 (25)
Connecting Rod Cap Nut
Step 1 20 (27)
Step 2 Additional 70 Degrees
Crankshaft Damper Bolt 74 (100)
Microsoft
Crankshaft Oil Deflector Bolt/Nut 27 (36)

Cylinder Head Bolt (1)
Step 1 22 (30)
Step 2
Short Bolts (No. 2, 3, 6, 7, 10, 11) Additional 55 Degrees
Medium Bolts (No. 12, 13) Additional 65 Degrees
Long Bolts (No. 1, 4, 5, 8, 9) Additional 75 Degrees
Exhaust Manifold Bolt
Step 1 11 (15)
Step 2 22 (30)
Flywheel Bolt 74 (100)
Main Bearing Cap Bolt 78 (106)
Oil Filter Adapter Bolt 16 (22)
Oil Pan Nut/Bolt 18 (25)
Oil Pump Bolt 66 (90)
Rear Crankshaft Oil Seal Retainer Bolt 11 (15)
Rocker Arm
With Press-In Studs
Rocker Stud 35 (47)
Rocker Nut 18 (25)
With Screw-In Studs
Rocker Stud 35 (47)
Rocker Nut 19 (26)
Valve Lifter Retainer Bolt 12 (16)
Water Pump Bolt 33 (45)
INCH Lbs. (N.m)
Balance Shaft Retainer Plate Bolts 106 (12)
Camshaft Retainer Bolt 106 (12)
Crankshaft Position Sensor Holddown Bolt 80 (9)
Front Cover Bolt 106 (12)
Intake Manifold
Upper
Step 1 44 (5)
Step 2 89 (10)
Lower
Step 1 27 (3)
Step 2 106 (12)
Step 3 133 (15)
Oil Pump Cover Bolt 106 (12)
Valve Cover Bolt 89 (10)
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(1) Apply GM Sealant (1052080) to head bolt threads. Tighten bolts in sequence. See Fig. 9 .
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 262 Cu. In.
Bore 4.00" (101.6 mm)
Stroke 3.48" (88.4 mm)
Compression Ratio 9.2:1
Fuel System
VIN W CSI
VIN X CSI
Horsepower @ RPM
2WD
VIN W 180 @ 4400
VIN X 175 @ 4400
4WD
VIN W 190 @ 4400
VIN X 180 @ 4400
Torque Ft. Lbs. @ RPM
2WD
VIN W 245 @ 2800
VIN X 240 @ 2800
4WD
VIN W 250 @ 2800
VIN X 240 @ 2800
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft End Play .002-.008 (.05-.20)
Main Bearings
Journal Diameter
No. 1 2.4488-2.4495 (62.199-62.217)
No. 2 & 3 2.4485-2.4494 (62.191-62.215)
No. 4 2.4480-2.4489 (62.179-62.203)
Journal Out-Of-Round .0002-.001 (.005-.03)
Journal Taper (Maximum) .0003 (.008)
Oil Clearance
Standard
Microsoft
No. 1 .0008-.0020 (.020-.051)

No. 2, 3 & 4 .0009-.0024 (.023-.061)
Connecting Rod Bearings
Journal Diameter 2.2487-2.2497 (57.117-57.142)
Journal Out-Of-Round .0002 (.005)
Service Limit .001 (.03)
Journal Taper .0003 (.008)
Service Limit .001 (.03)
Oil Clearance .0013-.0035 (.033-.089)
Service Limit .001-.0030 (.03-.076)
Side Clearance .006-.017 (.15-.43)
CONNECTING RODS
Side Play .015-.046 (.38-1.17)
PISTONS, PINS & RINGS

Pistons
Clearance .0007-.0020 (.018-.051)
Pins
Diameter .9270-.9271 (23.545-23.548)
Piston Fit .0002-.0007 (.005-.018)
Rod Fit .0013-.0019 (.033-.048)
Interference
Rings
No. 1
End Gap .010-.016 (.25-.41)
Side Clearance .001-.003 (.03-.08)
No. 2
End Gap .018-.026 (.46-.66)
Side Clearance .001-.003 (.03-.08)
No. 3 (Oil)
End Gap .015-.055 (.38-1.40)
Side Clearance .002-.007 (.05-.18)
CYLINDER BLOCK
Cylinder Bore
Diameter 4.0007-4.0017 (101.618-
101.643)
Microsoft
Maximum Taper (1) .0005 (.013)
Maximum Out-Of-Round (2) .001 (.03)
(1) Specification is for thrust side. Relief side is .001" (.03 mm).
(2) Production specification is given. Maximum service specification is .002" (.05 mm).
VALVES & VALVE SPRINGS

Valves
Face Angle 45°
Minimum Margin .031" (.79 mm)
Valve Springs
Free Length 2.02" (51.3 mm)
Installed Height 1.69-1.71" (42.9-43.4 mm)
Lbs. @ In. (Kg @ mm)
Pressure
Valve Closed 76-84 @ 1.70 (34-38 @ 43.2)
Valve Open 187-203 @ 1.27 (85-92 @
32.3)
CYLINDER HEAD
Valve Seats
Intake Valve
Seat Angle 46°
Seat Width .035-.060" (.88-1.52 mm)
Maximum Seat Runout .002" (.05 mm)
Exhaust Valve
Seat Angle 46°
Seat Width .062-.093" (1.58-2.36 mm)
Maximum Seat Runout .002" (.05 mm)
Valve Guide Oil Clearance .001-.003" (.03-.07 mm)
Warpage .004" (.10 mm)
CAMSHAFT
End Play .001-.009 (.03-.23)
Journal Diameter 1.8682-1.8692 (47.452-47.478)
Lobe Lift
Intake .286-.290 (.0726-.0736)
Exhaust .292-.296 (.0741-.0751)
Microsoft
BALANCE SHAFT
Journal Diameter
Front Journal 2.1648-2.1654 (54.986-
55.001)
Rear Journal 1.4994-1.5000 (38.085-
38.100)
Oil Clearance (Rear Journal) .001-.004 (.03-.10)
Microsoft

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1997 Chevrolet S10 Pickup

1996-97 ENGINES 4.3L V6 - Trucks

NOTE: For repair procedures not covered in this article, see

ENGINE IDENTIFICATION CODES

SHIFT CABLE ADJUSTMENT

Express, "C" & "K" Pickup, Savana, Sierra & Tahoe

end. DO NOT push White lock button completely out.

Astro & Safari

NOTE: To trouble shoot mechanical engine components, see appropriate table in

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

FUEL PRESSURE RELEASE

COOLING SYSTEM BLEEDING

POWER STEERING BLEEDING

Removal (Astro & Safari)

Fig. 1: Tightening sub-frame mounting bolts in sequence (Astro & Safari).

Removal (Pickup, Sierra, & Tahoe)

Removal (Commercial Van)

Removal (Blazer, Bravada, Jimmy, Sonoma & Pickup)

oil cooler system of debris can result in engine damage.

NOTE: Tool Required: J-41427 Universal Lift Bracket.

 For an automatic transmission refer to Transmission Replacement in Automatic Transmission.

 For a manual transmission refer to Transmission Replacement in Manual Transmission.

 The vacuum lines

 The throttle cable

 The fuel lines

22. Remove the distributor.

Fig. 2: Removing & Installing Engine Mount Through Bolt

Fig. 3: Removing & Installing Crossbar Mount

Fig. 4: Installing J-41427 To Intake Manifold

1. Install the engine into the vehicle.

 Tighten the nuts to 56 N.m (41 lb ft).

 The wiring harnesses

 The throttle cable

 The fuel lines

7. Connect the heater hoses to the engine.

 For a manual transmission refer to Transmission Replacement in Manual Transmission.

Removal (Express & Savana)

INTAKE MANIFOLD (UPPER)

Fig. 5: Exploded View Of Intake Manifold Assembly (VIN W)

NOTE: Tighten upper intake manifold bolts to specification in a criss-cross

Fig. 6: Installing Upper Intake Manifold Gasket (VIN W)

INTAKE MANIFOLD (LOWER)

housing in relation to intake manifold. Remove distributor.

Fig. 7: Applying RTV Sealant Before Installing Intake Manifold

Fig. 8: Lower Intake Manifold Bolt Tightening Sequence

Fig. 9: Cylinder Head Bolt Tightening Sequence

ROCKER ARMS & PUSHRODS

FRONT COVER OIL SEAL

TIMING CHAIN & SPROCKETS

1. Remove front cover. See FRONT COVER .

Fig. 10: Removing/Installing CKP Sensor Reluctor Ring

Fig. 11: Aligning Timing Marks

ROCKER ARM STUDS

Removal & Installation

BALANCE SHAFT (IF EQUIPPED)

Fig. 12: Installing Balance Shaft

Fig. 13: Aligning Timing Marks For Balance Shaft Gears

REAR CRANKSHAFT OIL SEAL