GM Service Manual Online
For 1990-2009 cars only

Application

Specification

Metric

English

General

  • Engine Type

90 degree V-8

  • Displacement

6.6 Liter

402 cu in

  • Idle Speed

680 RPM

  • Cylinder Block Material

Gray Iron

  • Compression Ratio

17.5

  • Compression Pressure - Production

3158 KPa

458 psi

  • Bore

103 mm

4.0551 in

  • Stroke

99 mm

3.8976 in

  • Upper Oil Pan Material

Aluminum

  • Cylinder Head Material

Aluminum

  • Valve Arrangement

4 Valves

  • Valve Seat Inserts

Yes

  • Head to Block Attachment

6 Bolts/Cylinder

  • Stroke Cycle

Four Stroke

  • Ignition Method

Compression

  • Fuel Injection

High Pressurized Direct Injection

  • Maximum Pressure

160 MPa

  • Intake Manifold Material

Cast Aluminum

  • Exhaust Manifold Material

Cast Nodular Iron & Steel Pipe

  • Air Intake System

Turbocharged, Charge Air Cooled

  • Engine Mounting

Three Point with Transmission

  • Firing Order

1-2-7-8-4-5-6-3

  • Crankcase Ventilation

Open PCV

  • Cylinder Liner

None

  • Start Aid

Glow Plug

Starter Motor

  • Type

Torque Reduction

  • Manufacturer

Hitachi

  • Rated Output

3.5 KW

Camshaft

  • End Play - Production Valve

0.050-0.114 mm

0.0020-0.0045 in

  • End Play - Service Limit

0.2 mm

0.0079 in

  • Number Furnished

1

  • Bearing Material

Steel Backed Pb-Sn-Cu Alloy

  • Number of Bearings

5

  • Camshaft Drive Type

Gears

  • Material

Steel

  • Journal Diameter - Service Limit

60.92 mm

2.3984 in

  • Journal Diameter - Production Value

60.932-60.962 mm

2.3990-2.4001 in

  • Camshaft Bearing Inside Diameter - Service Limit

61.07 mm

2.4043 in

  • Camshaft Bearing Inside Diameter - Production Value

61.00-61.03 mm

2.4016-2.4028 in

  • Lobe Lift (Exhaust) - Production Value

5.907 mm

0.2326 in

  • Lobe Lift (Intake) - Production Value

7.273 mm

0.2863 in

  • Runout - Service Limit

0.05 mm

0.0020 in

Roller Lifter and Push Rod

  • Roller Lifter Roller Projection - Service Limit

0.9 mm

0.0354 in

  • Roller Lifter Roller Projection - Production Value

0.989-1.0 mm

0.0389-0.0394 in

  • Push Rod Bent Condition - Service Limit

Less Than 0.8 mm

Less Than 0.0315 in

Connecting Rods

  • Type & Material

Forged Steel Fracture Split

  • Length Center to Center

163.0 mm

6.42 in

  • Piston Pin Bushing

Steel Backed Pb-Sn-Cu Alloy

  • Lower End Rod Bearing Type

Straight Split

  • Make

Steel Backed Pb-Sn-In Overlay

  • Connecting Rod Bearing Clearance - Service Limits

0.10 mm

0.0039 in

  • Connecting Rod Bearing Clearance - Production Value

0.036-0.077 mm

0.0014-0.0030 in

  • Connecting Rod Side Clearance - Service Limits

0.54 mm

0.0213 in

  • Connecting Rod Side Clearance - Production Value

0.31-0.49 mm

0.0122-0.0193 in

  • Connecting Rod Bearing Inside Diameter - Production Value

62.958-62.979 mm

2.4789-2.4795 in

  • Small End Inside Diameter - Service Limits

34.53 mm

1.3594 in

  • Small End Inside Diameter - Production Value

34.512-34.522 mm

1.3587-1.3591 in

  • Small End Bearing Clearance - Service Limits

0.08 mm

0.0031 in

  • Small End Bearing Clearance - Production Value

0.012-0.027 mm

0.0005-0.0011 in

Crankshaft

  • Material

Forged Steel

  • Heat Treatment

Nitrided

  • Main Journal Diameters

80.0 mm

3.15 in

  • Crankpin Diameter

63.0 mm

2.48 in

  • Harmonic Balancer

Rubber Damper

  • Flywheel Material

Cast Iron

  • Main Bearing Type

Steel Backed Pb-Sn-Cu Overlay

  • Number of Bearings

5

  • End Thrust Taken By

Crank Thrust Bearing

  • Total Bearing Length

103.5 mm

4.07 in

  • Total Projected Area

13,006 mm²

20.16 in²

  • Crankshaft Bearing Clearance - Service Limits

0.014 mm

0.0055 in

  • Crankshaft Bearing Clearance - Production Value

0.037-0.072 mm

0.0015-0.0028 in

  • Crankshaft End Play - Service Limits

0.54 mm

0.0213 in

  • Crankshaft End Play - Production Value

0.04-0.205 mm

0.0016-0.0081 in

  • Crankshaft Journal Diameter - Main - Service Limits

79.89 mm

3.1453 in

  • Crankshaft Journal Diameter - Main - Production Value

79.905-79.925 mm

3.1459-3.1466 in

  • Crankshaft Runout - Service Limits

0.44 mm

0.0173 in

  • Crankshaft Runout - Production Value

0.05 mm

0.0020 in

  • Crankpin Diameter - Service Limits

62.88 mm

2.4756 in

  • Crankpin Diameter - Production Value

62.902-62.922 mm

2.4764-2.4772 in

Cylinder Bore

  • Diameter - Service Limits

103.11 mm

4.0594 in

  • Diameter - Production Value

103.0-103.014 mm

4.0551-4.0557 in

  • Bore Taper - Production Value

0.015 mm

0.0006 in

  • Bore Out of Round - Production Value

0.015 mm

0.0006 in

Cylinder Head

  • Surface Flatness - Cyl. Block Side - Service Limits

0.2 mm

0.0079 in

  • Surface Flatness - Cyl. Block Side - Production Value

0.075 mm

0.0030 in

  • Surface Flatness - Exhaust Side - Production Value

0.1 mm

0.0039 in

  • Surface Flatness - Intake Side - Production Value

0.1 mm

0.0039 in

Exhaust Manifold

  • Surface Flatness - Production Value

0.3 mm

0.0118 in

Intake Manifold

  • Surface Flatness - Production Value

0.3 mm

0.0118 in

Oil Pump

  • Gear Teeth to Housing Clearance - Service Limit

0.22 mm

0.0087 in

  • Gear Teeth to Housing Clearance - Production Value

0.125-0.221 mm

0.0049-0.0087 in

  • Gear to Cover Clearance - Service Limit

0.109 mm

0.0043 in

  • Gear to Cover Clearance - Production Value

0.064-0.109 mm

0.0025-0.0043 in

  • Gear Shaft to Bushing - Service Limit Clearance

0.14 mm

0.0055 in

  • Drive Gear Shaft Outside Diameter - Service Limit

19.86 mm

0.7819 in

  • Drive Gear Shaft Outside Diameter - Production Value

19.947-19.960 mm

0.7853-0.7858 in

  • Driven Gear Shaft Outside Diameter - Service Limit

19.86 mm

0.7819 in

  • Driven Gear Shaft Outside Diameter - Production Value

19.947-19.960 mm

0.7853-0.7858 in

Pistons

  • Type

1 Piece

  • Material

Aluminum

  • Skirt

Antiscuff/Barrel Shaped

  • Head

Ni-resist Insert for Top Ring Groove

  • Coolant

Oil Cooling Channel

  • Piston Pin Type

Hollow

  • Material

Steel

  • Diameter

34.5 mm

1.36 in

  • Retention Method

Snap Ring

  • Piston Rings Number

3

  • Top Compression Ring Type

Keystone Ring

  • Top Compression Ring Material

Steel

  • 2nd Compression Ring Type

Positive Twist/Inner Cut

  • 2nd Compression Ring Material

Cast Iron

  • Oil Control Ring Type

Bevel-Edged Oil Control Ring

  • Oil Control Ring Material

Steel

  • Piston to Small End Clearance - Production Value

5 mm

0.1969 in

  • Piston Outside Diameter - At 22 mm from Piston Bottom - Production Value

102.948-102.960 mm

4.0531-4.0535 in

  • Bore Inside Diameter for Piston Pin - Production Value

34.504-34.512 mm

1.3584-1.3587 in

Piston Pins

  • Clearance in Piston - Service Limit

0.017 mm

0.0007 in

  • Clearance in Piston - Production Value

0.004-0.017 mm

0.0002-0.0007 in

  • Pin Diameter - Service Limit

34.45 mm

1.3563 in

  • Pin Diameter - Production Value

34.495-34.5 mm

1.3581-1.3583 in

Piston Rings

  • Compression Ring Gap - Service Limit

1.37 mm

0.0539 in

  • Compression Ring Gap - Production Value

0.3-0.45 mm

0.0118-0.0177 in

  • 2nd Ring Gap - Service Limit

1.35 mm

0.0531 in

  • 2nd Ring Gap - Production Value

0.50-0.65 mm

0.0197-0.0256 in

  • Oil Ring Gap - Service Limit

1.20 mm

0.0472 in

  • Oil Ring Gap - Production Value

0.15-0.35 mm

0.0059-0.0138 in

Piston Ring Groove Clearance

  • Compression Ring - Service Limit

0.26 mm

0.0102 in

  • Compression Ring - Production Value

0.08-0.17 mm

0.0030-0.0067 in

  • 2nd Ring - Service Limit

0.10 mm

0.0039 in

  • 2nd Ring - Production Value

0.01-0.03 mm

0.0004-0.0012 in

  • Oil Ring - Service Limit

0.12 mm

0.0047 in

  • Oil Ring - Production Value

0.01-0.03 mm

0.0004-0.0012 in

Rocker Arms

  • Rocker Arm Shaft Outside Diameter - Service Limit

21.85 mm

0.8602 in

  • Rocker Arm Shaft Outside Diameter - Production Value

21.979-22.000 mm

0.8653-0.8661 in

  • Rocker Arm Inside Diameter - Production Value

22.010-22.035 mm

0.8665-0.8675 in

  • Rocker Arm Shaft and Arm Clearance - Service Limit

0.20 mm

0.0079 in

  • Rocker Arm Shaft and Arm Clearance - Production Value

0.010-0.056 mm

0.0004-0.0022 in

Valve Operating Mechanism

  • Type

Overhead Valve

  • Valve Guide Material

Iron

  • Valve Guide Type

Replaceable

  • Lifter Type

Roller

  • Rocker Arm Ratio

1.36:1 (Inlet), 1.69:1 (Exhaust)

  • Rocker Arm Type

Conventional

  • Rocker Arm Material

Forged

  • Rocker Arms Shaft Support

Aluminum Die Casting

  • Rocker Arm Shaft Material

Steel

Valves, Intake

  • Type

Double

  • Material

Silicon Steel

  • Number Per Cylinder

2

  • Rotation

None

  • Seat Insert Material

Sintered Steel

  • Seat Angle - degrees

45 degrees from Vertical

  • Head Diameter - in

33 mm

1.30 in

  • Stem Diameter - in

7 mm

0.28 in

  • Lift - in

9.55 mm

0.376 in

  • Clearance - Cold - in

0.3 mm

0.012 in

Valves, Exhaust

  • Type

Double

  • Material

Silicon Steel

  • Number Per Cylinder

2

  • Rotation

None

  • Seat Angle

45 degrees from Vertical

  • Seat Insert Material

Sintered Steel

  • Head Diameter - in

31 mm

1.22 in

  • Stern Diameter - in

7 mm

0.28 in

  • Lift - in

9.62 mm

0.379 in

Valve System

  • Valve Face Angle - Production Value

45 degrees

  • Valve Margin - Production Value
  • Intake

1.2 mm

0.0472 in

  • Exhaust

1.0 mm

0.0394 in

  • Valve Margin - Service Limit
  • Intake

0.88 mm

0.0346 in

  • Exhaust

0.73 mm

0.0287 in

  • Valve Clearance - Production Value

0.3 mm

0.0118 in

  • Valve Guide Inside Diameter - Intake - Service Limit

7.09 mm

0.2791 in

  • Valve Guide Inside Diameter - Intake - Production Value

7.000-7.015 mm

0.2755-0.2762 in

  • Valve Guide Inside Diameter - Exhaust - Service Limit

7.16 mm

0.2819 in

  • Valve Guide Inside Diameter - Exhaust - Production Value

7.000-7.015 mm

0.2755-0.2762 in

  • Valve Depression - Exhaust - Service Limit

2 mm

0.0787 in

  • Valve Depression - Exhaust - Production Value

0.9 mm

0.0354 in

  • Valve Depression - Intake - Service Limit

2.5 mm

0.0984 in

  • Valve Depression - Intake - Production Valve

0.6 mm

0.0236 in

  • Valve Rocker Arm Ratio - Exhaust

1.69:1

  • Valve Rocker Arm Ratio - Intake

1.36:1

  • Valve Seat Angle - Production Value

45 degrees

  • Valve Contact Width - Exhaust - Service Limit

2.5 mm

0.0984 in

  • Valve Contact Width - Exhaust - Production Value

2.1 mm

0.0827 in

  • Valve Contact Width - Intake - Service Limit

2.5 mm

0.0984 in

  • Valve Contact Width - Intake - Production Value

2.1 mm

0.0827 in

  • Valve Spring Free Length - Production Value

56.6 mm

2.2283 in

  • Valve Spring Squareness - Service Limit

2.0 mm

0.0787 in

  • Valve Spring Installed Height - Exhaust - Production Value

41 mm

1.6142 in

  • Valve Spring Installed Height - Intake - Production Value

41 mm

1.6142 in

  • Valve Spring Tension - Exhaust - Service Limit

275 N at 41 mm

61.8 lb at 1.61 in

  • Valve Spring Tension - Exhaust - Production Value

315-363 N at 41 mm

71.0-81.6 lb at 1.61 in

  • Valve Spring Tension - Intake - Service Limit

306 N at 41 mm

68.8 lb at 1.61 in

  • Valve Spring Tension - Intake - Production Value

315-363 N at 41 mm

71.0-81.6 lb at 1.61 in

  • Valve Stem Outside Diameter - Intake - Service Limit

6.89 mm

0.2713 in

  • Valve Stem Outside Diameter - Intake - Production Value

6.952-6.970 mm

0.2737-0.2744 in

  • Valve Stem Outside Diameter - Exhaust - Service Limit

6.91 mm

0.2720 in

  • Valve Stem Outside Diameter - Exhaust - Production Value

6.942-6.962 mm

0.2734-0.2741 in

  • Valve Stem Clearance - Exhaust - Service Limit

0.20 mm

0.0079 in

  • Valve Stem Clearance - Exhaust - Production Value

0.038-0.071 mm

0.0015-0.0028 in

  • Valve Stem Clearance - Intake - Service Limit

0.20 mm

0.0079 in

  • Valve Stem Clearance - Intake - Production Value

0.030-0.063 mm

0.0012-0.0025 in

  • Valve Stem Seal Installed Height - Measured from the Top of the Cylinder Head to the Bottom of the Valve Stem Seal - Production Value

6.05 mm

0.2382 in

Cooling

  • Water Pump Type

Centrifugal

  • Capacity @ Engine RPM

270 L/min @ 3172 RPM

  • Pump Bearing Type

Shaft Bearing

  • Thermostat Type

Wax Pellet

  • Number of Thermostats

2

  • Drive System

Gear

  • Valve Opening Temperature
  • Thermostat 1

82°C

180°F

  • Thermostat 2 - Jiggle Valve

85°C

185°F

  • Full Open Temperature

110°C

230°F

  • Turbocharger Coolant Bypass Valve

60°C

140°F

Lubrication

  • Type - Main Connecting Rod, Camshaft Bearings, Rocker Arms and Rocker Arm Shaft

Pressurized

  • Type - Camshaft Lobes, Connecting Rod Bushings, Valve Lifters, Piston Pins, Timing Gear and Cylinder Walls

Splash

  • Oil Pump, Type

Gear

  • Oil Pressure-HOT-at Idle

98 kPa

14 psi

  • Oil Capacity-w/Filter Change

10 qt, 9.5 L

  • Oil Capacity-w/o Filter Change

9.2 qt, 8.7 L

  • Oil Filter Type

Full-Flow Throwaway Type

  • Oil Intake

Suction Bell, Front Sump

  • Oil Seal

Axial Type

  • Oil Cooler

Water Cooled Corrugated Fin

  • Oil Relief Valve Opening Pressure

441 kPa

64 psi

  • Piston Cooling Jet Valve Opening Pressure

196 kPa

29 psi

Air Intake System

  • Turbocharger

Yes

  • Turbo Boost

18 psi @ Peak Torque

  • Charge Air Cooler

Charge Air Cooled

  • Air Cleaner

Panel Element A1300 or A1306C for HD Usage

Fuel System

  • Lift Pump

Gear Type, Integral

  • Injector Pump, Pump Model

Bosch

  • Type

Common Rail

  • Drive

Gear

  • Fuel Filter

Number Used = 1

  • Type

Full Flow, Paper Element

  • Location

Left Hand Side of Engine

  • Fuel Shut-Off

Electronic

  • Fuel Injector Type

Electronic Injector

  • Timing Advance

Programmed

Turbocharger

  • Axial Play - maximum

0.11 mm

0.0043 in

  • Manufacturer

Ishikawajima Harima Industries

  • Model

RHG6

  • Radial Play - maximum

0.20 mm

0.0079 in