GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Mechanical - 7.8L 🢒 Idler Gear Installation

    Object Number: 1682285 Size: SH
  1. Install the idler B shaft.
    2. 1.1. Install the idler gear B shaft to the cylinder body.

    The idler gear shaft oil port must be facing the cylinder block.

    Notice: Refer to Fastener Notice in the Preface section.

    1.2. Install the idler gear shaft bolts.

    Tighten
    Tighten the idler gear shaft bolts to 31 N·m (23 lb ft).


    Object Number: 1682286 Size: SH
  2. Install the idler gear B to the idle gear shaft.
    3. 2.1. Apply engine oil to the idler gear B inside and thrust areas.
    2.2. Install the idler gear to the idler gear shaft.
    2.3. Install the idler gear bolts.

    Tighten
    Tighten the idler gear bolts to 95 N·m (70 lb ft).


    Object Number: 1682287 Size: SH
  3. Install the oil pump to the cylinder block.
    4. 3.1. Carefully wipe any foreign material from the cylinder body rear surface.
    3.2. Apply engine oil to the cylinder body inside bushing.

    Object Number: 1682289 Size: SH

    Important: The sealant must not obstruct the gear oil ports, indicated by arrows.

  4. Apply Three Bond No. TB1201, 1141E or equivalent to the shaded areas as shown.

    5. Object Number: 1682294 Size: SH
  5. Install the oil pump to the cylinder body within 15 minutes of sealant application.
  6. Install the oil pump bolts.

    7. Tighten
    Tighten the oil pump bolts to 24 N·m (17 lb ft).


    Object Number: 1682297 Size: SH
  7. Install the idler gear A and idler gear shaft to the cylinder block.
    8. 7.1. Install the idler gear shaft (1) to the cylinder body. The idler gear shaft oil port must be facing the cylinder head.
    7.2. Apply engine oil to the idler gear A inside and thrust areas.

    Object Number: 1682310 Size: SH
  8. Install the idler gear A (1) to the idler gear shaft.
    9. 8.1. Align the crankshaft gear (2) L mark and the idler gear (1) 0 marks.
    8.2. Install the idler gear bolts.

    Tighten

    1. First Stage

      2. Tighten the idler gear bolts to 29 N·m (22 lb ft).

    2. Second Stage

      3. Tighten the idler gear bolts to 60-90 degrees.


    Object Number: 1682311 Size: SH
  9. Install the flywheel housing.
    10. 9.1. Apply Three Bond No. TE1201, TB1207C or equivalent to the flywheel housing fitting faces and the area marked with an arrow as shown.
    9.2. Install the flywheel housing to the cylinder block. Refer to Engine Flywheel Housing Installation .

    Object Number: 1682313 Size: SH
  10. Install the idler gear D to the cylinder block.
    11. 10.1. Apply engine oil to the idler gear shaft (2).
    10.2. Apply engine oil to the idler gear (1) inside and thrust areas.
    10.3. Install the gear to the gear shaft.
    10.4. Install the gear and shaft to the cylinder block.
    10.5. Install the bolts over the thrust collar.

    Tighten
    Tighten the bolts over the thrust collar to 119 N·m (88 lb ft).


    Object Number: 1682314 Size: SH
  11. Install the cover with a NEW gasket to the flywheel housing.
  12. Install the rear oil seal. Refer to Engine Flywheel Housing Installation .
  13. Install the flywheel to the crankshaft.