4.3 Rebuild

[Scott Danforth]

hammer in a screw driver and pry them out.

brass plugs available at any reputable auto parts store (napa or car-quest) complete kit is about $11

 

[greno]

Where did you get your plugs greno?

Found a set at Summit Racing.

 

[alldodge]

hammer in a screw driver and pry them out.

Agree, place the screw driver on the top or bottom edge of the plug, then smack it with the hammer. The plug will twist sideways. Now pry it out with the screw driver of use a pair of channel locks

 

[gergAlicious]

Find it weird that I cannot find a decent description of how many plugs the newer 4.3 has, and their locations. Scoured the web a few times. All I see covered are what I presume are the earlier engines that had them also located in the front of the block, just beneath the head deck.

I'll just run with the 4 I can see. I measured the one that came out as 1 5/8"

Thanks for all of the suggestions also!

Heads shipped - they will be delivered Thursday when I get back home.

 

[Bondo]

I'll just run with the 4 I can see. I measured the one that came out as 1 5/8"

Ayuh,.... There's 2 more behind the flywheel,.... same size,.....

Buy the $11. kit for a 350, 'n use what ya need,.....

 

[gergAlicious]

Thanks Bondo!

Here is an example of what I am finding (and I'll get a better look when I get home) . . . .

4.3 image online, and I see the two I think you are referring to.

And my block:

I have found very few images that resemble my block. It's a 2004. All seem to be earlier?

I have much more 'webbing' on the front and rear of the block.

I'll get a closer look when I get back to Lowsyana

Thanks man!!!

 

[gergAlicious]

So everything is on the way.

Heads, exhaust manifolds, gasket set, water pump, starter, core plugs, repair manual, alignment tool. Still need to grab a new thermostat.

I removed the other three core plugs this AM. Now I need to 'clean' out the silty crap that has been circulated through the block in it's 14 year existence!

 

[Lou C]

If your block is not internally corroded....strongly consider closed cooling so it can have nice antifreeze running through it with a pressurized system just like GM intended.

So you're keeping your block and installing new heads?
If the block is not corroded inside as well as the intake it might be a good opportunity to make the engine last a lot longer and make winterizing easier.

 

[gergAlicious]

Here is what the back of my block looks like:

 

[gergAlicious]

Nice new cast block/heads....strongly consider closed cooling so it can have nice antifreeze running through it with a pressurized system just like GM intended. Also makes winterizing a lot easier....

Definitely considering that!

 

[Scott Danforth]

I removed the other three core plugs this AM. Now I need to 'clean' out the silty crap that has been circulated through the block in it's 14 year existence!

turn block upside down on stand.....use long piece of 1/8" welding filler wire to break it loose, compressed air to remove the rest, shop vac to clean up the mess

 

[gergAlicious]

So in a closed system is all that is left to drain / winterize the exhaust manifolds?

Looking at this diagram:

 

[gergAlicious]

turn block upside down on stand.....use long piece of 1/8" welding filler wire to break it loose, compressed air to remove the rest, shop vac to clean up the mess

Thanks Scott!

I really pulled the core plugs to get a better look at anything I could see before continuing. Glad I did, I didn't even consider what an open cooling system does over time.

 

[Scott Danforth]

So in a closed system is all that is left to drain / winterize the exhaust manifolds?

Looking at this diagram:

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and the raw water side of the heat exchanger.

if your motor is fresh water only (never in salt), and you clean your block of all debris in the cooling system, you can add a heat exchanger.

normally people dont pull the motor and clean the coolant passages, and that silt, debris, rocks etc. plugs the heat exchanger

if you boat in salt water, the heat exchanger needs to be installed prior to ever putting the boat in the water.

factory heat exchangers are currently made by Alfa Laval / Champ. however after market units from San Juan Engineering are not that bad either.

 

[gergAlicious]

turn block upside down on stand.....use long piece of 1/8" welding filler wire to break it loose, compressed air to remove the rest, shop vac to clean up the mess

Thanks Scott!

I really pulled the core plugs to get a better look at anything I could see before continuing. Glad I did, I didn't even consider what an open cooling system does over time.

 

[gergAlicious]

Heads received. After spending some time reading the ‘new head bolts’ topics and debates I had decided to clean and reuse my originals.

Well, new bolts came with the heads

 

[Lou C]

Use a thread chaser to clean out the bolt holes and make sure each head bolt will thread all the way in before installing your heads. Also the biggest part of the job is cleaning the block deck surface, bolt holes etc and its also a good idea to measure the flatness, it should be less than .003"

 

[Bondo]

Ayuh,.... 'n most, or all of the head bolts run into the water jacket, so thread sealer is required,.....

 

[Scott Danforth]

rtv ultra black on the head bolt threads.

 

[gergAlicious]

Thanks Scott!

While I have used Ultra Grey and Ultra Black on several applications, I've never used it on threads before. Sounds like you have had luck with it?

I have a few thread sealants I had contemplated using here from past experience.

I am having excellent luck getting all the old sediment free and out of the block casting. Using small pointed tool through the water jacket passages from the head deck to loosen them, and push towards the core plugs / drain spots. Pulling loose stuff with shop vac out too. Shooting light into the holes to see what is still to be eradicated.

Got the thermostat out - the plastic insert was damn near welded in, did have one small crack form but it looks to be fine once I get it cleaned up and back into the housing.

Heads look amazing . . .

Gaskets show up tomorrow. Goal is to have the heads on by tomorrow, as well as intake and get prepped for the pressure test. Core plugs will not be here till Monday, along with the water pump and new exhaust manifolds.

There is plenty to do inside the boat to keep me busy till then

Really looking for a remote oil filter kit now . . .