3.8L ENGINE

DESCRIPTION

METRIC

STANDARD

Engine Type

60° V-6 Engine

Number of Cylinders

6

Displacement 3.8L

3.8 Liters

231 cu. in.

Bore 3.8L

96.0 mm

3.779 cu.in.

Stroke

87 mm

3.425 in.

Compression Ratio 3.8L

-

9.6:1

Firing Order

-

1-2-3-4-5-6

Compression Pressure-Minimum

689.5 kPa

100 psi.

Cylinder Compression (Max. Difference Between Cylinders

-

0.25

CYLINDER BLOCK

DESCRIPTION

METRIC

STANDARD

Cylinder Bore Diameter (Standard) 3.8L

95.993-96.007 mm

3.7792-3.780 in.

Out of Round (Service Limits)

0.076 mm

0.003 in.

Taper (Service Limits)

0.051 mm

0.002 in.

Lifter Bore Diameter

22.980-23.010 mm

0.905-0.906 in.

Deck Surface Flatness (Max.)

0.1 mm

0.004 in.

CRANKSHAFT

DESCRIPTION

METRIC

STANDARD

Connecting Rod Journal Diameter

57.979-58.005 mm

2.2827-2.2837 in.

Main Bearing Journal Diameter

63.993-64.013 mm

2.5194-2.5202 in.

Journal Out-of-Round (Max.)

0.025 mm

0.001 in.

Journal Taper (Max.)

0.025 mm

0.001 in

End Play

0.09-0.24 mm

0.0036-0.0095 in.

Wear Limit

0.381 mm

0.015 in.

Main Bearing Diametrical Clearance 1-2-3-4

0.011-0.055 mm

0.0005-0.0022 in.

Wear Limit

0.076 mm

0.003 in.

CONNECTING RODS

DESCRIPTION

METRIC

STANDARD

Bearing Clearance

0.019-0.065 mm.

0.017-0.020 in.

Wear Limit

0.074 mm

0.003 in.

Side Clearance

0.13-0.32 mm

0.005-0.013 in.

Wear Limit

0.38 mm

0.015 in.

PISTONS

DESCRIPTION

METRIC

STANDARD

Piston Diameter 3.8L-Measured 33.01 mm (1.30 in) From Piston Top

95.968-95.998 mm.

3.778-3.779 in.

Clearance in Bore @ Size Location (New)

-0.005-0.039 mm

-0.0002–0.0015 in.

Weight 3.8L

426 ± 5 grams

15.03 ± 0.1764 oz.

PISTON PINS

DESCRIPTION

METRIC

STANDARD

Type

Press Fit in Rod (Serviced as a Assembly)

Clearance in Piston @ 21C (70°F)

0.006-0.019 mm

0.0002-0.0007 in.

Clearance in Connecting Rod

Interference Fit

Diameter

22.87-22.88 mm

0.9007-0.9009 in.

Length 3.8L

71.25-71.75 mm

2.805-2.824 in.

PISTON RINGS

DESCRIPTION

METRIC

STANDARD

Ring End Gap

Top Compression Ring

0.18-0.38 mm

0.007-0.015 in.

Second Compression Ring

0.28-0.57 mm

0.011-0.022 in.

Oil Control (Steel Rails)

0.23-0.78 mm

0.009-0.030 in.

Wear Limit-Compression Rings

1.0 mm

0.039 in.

Wear Limit-Oil Control Steel Rails

1.88 mm

0.074 in.

Ring Side Clearance

Top Compression Ring 3.8L

0.030-0.069 mm

0.0012-0.0027 in.

Second Compression Ring 3.8L

0.041-0.085 mm

0.0016-0.0033 in.

Oil Ring (Steel Ring)

0.039-0.200 mm

0.0015-0.0078 in.

Wear Limit- Top Ring

0.10 mm

0.004 in.

Wear Limit-2nd Ring

0.13 mm

0.005

Wear Limit Oil Ring Pack

0.266 mm

0.009

Ring Width-Top Compression Ring 3.8L

1.175-1.190 mm

0.0462-0.0468

Ring Width-2nd Compression Ring 3.8L

1.46-1.49 mm

0.0575-0.058 in.

Ring Width-Oil Ring (Steel Rails) 3.8L

0.435-0.510 mm

0.017-0.020

CAMSHAFT

DESCRIPTION

METRIC

STANDARD

Journal Diameter

#1

50.724-50.775 mm

1.997-1.999 in.

#2

50.317-50.368 mm

1.9809-1.9829 in.

#3

49.936-49.987 mm

1.9659-1.9679 in.

#4

49.530-49.581 mm

1.9499-1.9520 in.

Bearing Clearance-Diametrical

0.025-0.101 mm

0.001-0.004 in.

Bearing Clearance (Max.Allowable)

0.127 mm

0.005 in.

End Play

0.254-0.508 mm

0.010-0.020 in.

Camshaft Bearing Diameter

#1

50.800-50.825

1.9999-2.0009 in.

#2

50.393-50.419 mm

1.9839-1.9849 in.

#3

50.013-50.038 mm

1.9690-1.9699 in.

#4

49.606-49.632 mm

1.9529-1.954 in.

Exhaust Valve Timing

Closes-3.8L (ATDC)

-

18°

Opens-3.8L (BBDC)

-

46°

Duration-3.8L

-

244°

Intake Valve Timing

Closes-3.8L (ABDC)

-

63°

Opens-3.8L (ATDC)

-

1°

Duration-3.8L

-

242°

Valve Overlap-3.8L

-

17°

HYDRAULIC LIFTER

DESCRIPTION

METRIC

STANDARD

Type

Hydraulic Roller

Outside Diameter

22.949-22.962 mm

0.903-0.904 in.

Clearance in Block

0.020-0.061 mm

0.0007-0.0024 in.

CYLINDER HEAD

DESCRIPTION

METRIC

STANDARD

Gasket Thickness (Compressed)

0.65-0.75 mm

0.0007-0.0024 in.

VALVES

DESCRIPTION

METRIC

STANDARD

Face Angle-Intake

-

45-45.5°

Face Angle-Exhaust

-

45-45.5°

Head Diameter-Intake

47.87-48.13 mm

1.88-1.89 in.

Head Diameter-Exhaust

35.37-35.63 mm

1.39-1.40 in.

Valve Lift (Zero Lash)-Intake and Exhaust-3.8L

11.0 mm

0.433 in.

Valve Length-Intake

125.84-126.6 mm

4.95-4.98 in.

Valve Length-Exhaust

127.20-127.96

5.00-5.04 in.

Valve Stem to Tip Height (valve tip to spring seat washer)-Intake

48.1-49.7 mm

1.89-1.95 in.

Valve Stem to Tip Height (valve tip to spring seat washer)-Exhaust

48.53-50.09 mm

1.91-1.97 in.

VALVE SEAT

DESCRIPTION

METRIC

STANDARD

Angle

-

44.5-45°

Run Out (Service Limits)

0.0762 mm

0.003 in.

Width-Intake and Exhaust

1.50-2.00 mm

0.057-0.078 in.

VALVE GUIDE

DESCRIPTION

METRIC

STANDARD

Guide Bore Diameter (Std.)

6.975-7.00 mm

0.274-0.275 in.

VALVE MARGIN

DESCRIPTION

METRIC

STANDARD

Intake

0.825-0.973 mm

0.032-0.038 in.

Exhaust

1.565-1.713 mm

0.061-0.067 in.

VALVE STEM DIAMETER

DESCRIPTION

METRIC

STANDARD

Intake (Standard)

6.935-6.953 mm

0.2718-0.2725 in.

Exhaust (Standard)

6.906-6.924 mm

0.2718-0.2725 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

METRIC

STANDARD

Intake

0.025-0.065 mm

0.001-0.0025 in.

Exhaust

0.059-0.094 mm

0.002-0.0037 in.

Max Allowable-Intake (Rocking Method)

0.247 mm

0.010 in.

Max Allowable-Exhaust (Rocking Method)

0.414 mm

0.016 in.

PUSH RODS

DESCRIPTION

METRIC

STANDARD

Length

135.438 mm

5.33 in.

VALVE SPRING

DESCRIPTION

METRIC

STANDARD

Free Length-Type A

51.4 mm

2.02 in.

Free Length-Type B

53.4 mm

2.10 in.

Wire Diameter Type A

3.95-4.77 mm

0.15-0.19 in.

Wire Diameter Type B

4.19-4.29 mm

0.16-0.17 in.

Number of Coils Type A

7.52

Number of Coils Type B

7.25

Spring Tension (Valve Closed) Type A

376.4-424.4 N @ 41.9 mm

84.6-95.6 lbs. @ 1.65 in.

Spring Tension (Valve Open) Type A

863.9-959.9 N @ 41.9 mm

194.2-215.8 lbs. @ 1.65 in.

Spring Tension (Valve Closed) Type B

377-423 N @ 41.9 mm

84.8-95.2 lbs. @ 1.65 in.

Spring Tension (Valve Open) Type B

880-962 N @ 30.91 mm

197.9-216.3 lbs. @ 122 in.

Installed Height

41.1-42.7 mm

1.61-1.68 in

LUBRICATION

DESCRIPTION

METRIC

STANDARD

At Curb Idle Speed* (Minimum with engine at operating temperature)

34.47 kPa

5 psi

At 3000 RPM

205-551 kPa

30-80 psi

Oil Filter By-Pass Valve Setting

62-103 kPa

9-15 psi

Oil Pressure Switch Actuating Pressure

14-28 Kpa

2-4 psi

CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. 

OIL PUMP

DESCRIPTION

METRIC

STANDARD

Clearance Over rotors-Inner and Outer

0.10 mm

0.004 in.

Cover Out-Of-Flat (Max.)

0.025 mm

0.001 in.

Inner Rotor Thickness

7.64 mm

0.301 in.

Outer Rotor Thickness (Min)

7.64 mm

0.301 in.

Outer Rotor Clearance (Max)

0.039 mm

0.015 in.

Outer Rotor Diameter (Min)

79.95 mm

3.148 in.

Tip Clearance Between Rotors (Max)

0.20 mm

0.008 in.

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Camshaft Sprocket—Bolt

54

40

—

Camshaft Thrust Plate—Bolts

12

—

105

Forged Connecting Rod Cap-Nuts

54 +¼ turn

40 +¼ turn

—

Cracked Connecting Rod Cap-Bolts

Crankshaft Main Bearing Cap-Bolts

41 +¼ turn

30 +¼ turn

—

Crankshaft Main Bearing Cap Cross Bolts (3.8L)

61

45

—

Crankshaft Oil Seal Retainer Rear-Bolts

12

—

105

Crankshaft Damper-Bolt

54

40

—

Cylinder Block Drain Plugs

20

15

—

Cylinder Head-Bolts

Cylinder Head Cover-Bolts

12

—

105

Flex Plate to Crankshaft

88

65

—

Engine Mounting

Exhaust Manifold-Bolts

23

—

200

Intake Manifold - Lower-Bolts

23

—

200

Intake Manifold - Lower Gasket Retainer-Bolts

12

—

105

Intake Manifold Upper-Bolts

12

—

105

Lifter Yoke Retainer-Bolts

12

—

105

Oil Filter Attaching Fitting

54

40

—

Oil Cooler Attaching Fitting

27

20

—

Oil Filter

20

15

—

Oil Filter Adapter-Bolts

28

—

250

Oil Gallery Plug

27

20

—

Oil Pan—Bolts

12

—

105

Oil Pan Drain-Plug

27

20

—

Oil Pressure Switch

23

—

200

Oil Pump Cover Plate-Screws

12

—

105

Oil Pump Pick-up Tube-Bolt

28

—

250

Oil Dipstick Housing-Bolts

48

35

—

Rocker Arm Shaft-Bolts

23

—

200

Spark Plug

16

12

—

Thermostat Housing

12

—

105

Timing Chain Case Cover

—M8 Bolt

27

20

—

—M10 Bolt

54

40

—

Water Pump-Bolts

12

—

105

Water Pump Pulley-Bolts

28

—

250