The purpose of New Product Information is to highlight or indicate important
product changes from the previous model year.
Changes may include one or more of the following items:
| • | Torque values and/or fastener tightening strategies |
| • | Changed engine specifications |
| • | New sealants and/or adhesives |
| • | Disassembly and assembly procedure revisions |
| • | Engine mechanical diagnostic procedure revisions |
| • | New special tools required |
| • | A component comparison from the previous year |
Torque Values and/or Fastener Tightening Strategies
| • | All fasteners and threaded holes on the 4.8, 5.3, and 6.0 liter
engines utilize metric threads. |
| • | Cylinder head, connecting rod, crankshaft balancer, and main bearing
cap bolts now apply a torque angle strategy. |
| • | Certain fasteners should not be reused. Bolts, studs, or other fasteners
that must be replaced will be called out in the specific service procedure. |
New Sealants and/or Adhesives
Canadian SPO Part Numbers have been added.
Changed Engine Specifications
Engine specification tables content and format have been commonized.
Disassembly and Assembly Procedure Revisions
| • | For certain applications, a spacer plate has been added between the flywheel
and rear of the crankshaft. It is necessary to remove the spacer plate prior to removal
and installation of the crankshaft rear oil seal and clutch pilot bearing. |
| • | The piston, pin, and connecting rod are to be serviced as an assembly. |
| • | Newer design pistons have a graphite coated piston skirt. The coated skirt
outside diameter (OD) may be slightly larger than the cylinder bore inside
diameter (ID) and the piston assembly may have a slight interference fit to
the cylinder bore during initial installation. |
Engine Mechanical Diagnostic Procedure Revisions
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 problem. The diagnostic flow is
the place to start when repairs are necessary. For a detailed explanation, refer
to
Strategy Based Diagnosis
in General Information
or
Diagnostic Starting Point - Engine Mechanical
in Engine Mechanical.
New Special Tools Required
| • | A variety of new tools have been developed to assist in engine disassembly,
assembly, and on-vehicle service. |
| • | J 45299 has been
developed to prelube new or remanufactured engines/bearings prior to engine installation.
Refer to
Engine Prelubing
. |
A Component Comparison from the Previous Year
| • | Exhaust gas recirculation (EGR) system has been deleted on all applications. |
| • | A spacer plate between the crankshaft and flywheel is required for applications
using the 4L80-E transmission. |
| • | All 2003 applications use a piston with a graphite coated skirt. |
