I6 underhood service specifications

MAY03LT

MAY03LT

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Nov 18, 2011
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Location
Delmarva
Oil grade: 5w30 (All temperatures)
Oil capacity: 7qts w/filter

Battery:
02-09 Group 78 600CA

Alternator:
150A

Spark Plug Torque:
02-09 13ft/lb

Spark Plug Gap:
Note - Posted for reference only. Gapping Iridium plugs is not recommended.
02-04 .050"
05-07 .042"
08-09 .040"

Fuel Pressure:
02 48-54psi
03-09 50-57psi

Oil Pressure (at sending unit, engine warm, MINIMUM):
12psi @1200rpm

Firing Order:
153624

Compression:
215psi - *Lowest cylinder must be more then 70% of highest cylinder

Injectors:
02-09 11-14 ohms @ 50-90°F

Map sensor:
02-05 More then 2.0v at idle less then 4.2v at WOT

TPS1:
02-06 Idle less then 4.67v WOT more then .27v
07-09 Idle .32v WOT 4.75v

TPS2:
02-06 Idle more then .27v WOT less then 4.67v
07-09 Idle .25v WOT 4.59v

Coolant capacity (quarts):
02-04 14
05-06 10.8
07-09 9.7

03-04 EXT 15
05-06 EXT 13.8

Cooling system test pressure: 15psi
Radiator Cap Relief: 15psi

A/C data:
Refrigerant type: R-134a
Compressor oil: PAG 46

Capacities (Refrigerant/Oil):
02-03 1.8lbs/7.4oz
04 1.9lbs/7.4oz
05-06 1.9lbs/8.0oz
07-09 1.9lbs - w/TPS 8.0oz (first design) w/oTPS (second design) 6.0oz

02-03 F/R 2.65lb/8.45oz
04 F/R 3.0lbs/8.45oz
05-06 F/R 2.65lbs/8.0oz
07-09 F/R 2.65lbs - w/TPS 8.0oz (first design) w/oTPS (second design) 6.0oz

Note: TPS - Thermal Protection Switch

Source: MOTOR spec guide 2011 version
 
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Belt routing:

DSCN4571.jpg


SWB - 91.5" belt
LWB - 90.5" belt
 
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reserved for additional information
 
This thread delivers :cool:
 
Great information here, thanks a bunch!

How about adding fluid type and capacities for the other serviceable parts. Transmission, Transfer Case, Front Differential, & Rear Differential.
 
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Regulator said:
Great information here, thanks a bunch!

How about adding fluid type and capacities for the other serviceable parts. Transmission, Transfer Case, Front Differential, & Rear Differential.
Click to expand...

Thanks man. I am going to list those in the "Engine and Drivetrain" forum since those specs can be used for the 4.2/5.3/6.0.

Wooluf1952 said:
Nice to have it all on one page. :wootwoot:
Click to expand...

That's the plan!:cool:
 
Well done! should defiunitely help alleviate some of the simpler questions.
 
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So I have been starving the engine by only using 5 quarts of oil for the last 230,000 miles? :raspberry:
 
This is great and will be a big help!! Thanks :biggrin:
 
Thanks. I got a belt that I need to put on and I didnt notice the diagram on the fan shroud. That's gonna help.
 
How about back pressure for the exhaust?

I'm thinking about testing to see if I have a clogged cat and buying my own gauge
 
Whoa, I never realized there was that huge a coolant capacity difference between the various years. I could see a little bit of a difference on the 06+, but a whole gallon? Weird.
 
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So what are TPS 1 and TPS 2 for and where are they located? This article says that the plug gap for my 03 should be .050" and mine I believe were pregapped at .043", will it change anything if they were at .050"? Lots of info here and it gives me some things to check tomorrow.
 
Mypetropig said:
So what are TPS 1 and TPS 2 for and where are they located? This article says that the plug gap for my 03 should be .050" and mine I believe were pregapped at .043", will it change anything if they were at .050"? Lots of info here and it gives me some things to check tomorrow.
Click to expand...

Hover your cursor over the TPS and it will show the meaning.

One is on the gas pedal and one is in the throttle body.

IIRC, the .043" is an up-date.
 
Wooluf1952 said:
One is on the gas pedal and one is in the throttle body.
Click to expand...
There are TWO sensors in the throttle body, and the shop manual calls these the TPS. There are another two sensors on the Accelerator Pedal assy, and these are typically called the APP (Accel Pedal Position) sensors. The reason for two sensors on each is because their positions are compared by the PCM and if they don't agree, you go into REP (reduced engine power) mode to limp home or to the side of the road so we don't end up in a runaway condition.
 
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Cool trick with the cursor. On some of these items would it be easier to check with a volt meter or a scan tool such as one of these,Actron® or Actron®.
 
the roadie said:
There are TWO sensors in the throttle body, and the shop manual calls these the TPS. There are another two sensors on the Accelerator Pedal assy, and these are typically called the APP (Accel Pedal Position) sensors. The reason for two sensors on each is because their positions are compared by the PCM and if they don't agree, you go into REP (reduced engine power) mode to limp home or to the side of the road so we don't end up in a runaway condition.
Click to expand...

:redface: I stand corrected.
 
I'm not sure who recommended against gapping iridium spark plugs, but it's perfectly fine to gap them as long as you use a wire type gapper and not the slide/coin type.
 
Spalding1028 said:
I'm not sure who recommended against gapping iridium spark plugs, but it's perfectly fine to gap them as long as you use a wire type gapper and not the slide/coin type.
Click to expand...


I think the biggest problem is people prying in the gap itself and breaking off the tiny piece of Iridium and, as you stated, using the flat style gapper.
Also, the AC Iridiums come pre-gapped with a shield to prevent the gap from being damaged in shipping.
 
Wooluf1952 said:
I think the biggest problem is people prying in the gap itself and breaking off the tiny piece of Iridium and, as you stated, using the flat style gapper.
Also, the AC Iridiums come pre-gapped with a shield to prevent the gap from being damaged in shipping.
Click to expand...
I have a 2006 envoy 4.2. Is that AC Delco part that I should # 41-103
MAY03LT said:
Thanks man. I am going to list those in the "Engine and Drivetrain" forum since those specs can be used for the 4.2/5.3/6.0.



That's the plan!:cool:
Click to expand...
Getting new plugs for 2006 envoy 4.2. I'm getting AC Delco but can't remember what part# was recommend. 41-103?
 
hancock said:
I have a 2006 envoy 4.2. Is that AC Delco part that I should # 41-103

Getting new plugs for 2006 envoy 4.2. I'm getting AC Delco but can't remember what part# was recommend. 41-103?
Click to expand...

AcDelco 41-103 is the correct spark plug to use with the I6.
 
Not for the plugs. 41-103 is a new number.

And the manual often goes missing so it's useful to have it available elsewhere.
 
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Mooseman said:
Not for the plugs. 41-103 is a new number.

And the manual often goes missing so it's useful to have it available elsewhere.
Click to expand...

My Chilton Repair manual does not even list 41-103 for the I6. The manual listed a completely different spark plug number. I had to pencil-in the new AcDelco plug number.
 
Right. The Owners Manual for my 2003 Envoy I6, calls for AC 41-981. I've changed to the AC 41-103 Iridium.
 
Does my 06 Saab 9-7X (which is not XL but has rear A/C) also fall into the "05-06 F/R 2.65lbs/8.0oz" category or is it 3 lbs? A shop filled my A/C up to about 850g of refrigerant (as I now found out from the invoice) and my A/C doesn't blow cold (the snowflake symbol doesn't blink though).
 
dkvasnicka said:
Does my 06 Saab 9-7X (which is not XL but has rear A/C) also fall into the "05-06 F/R 2.65lbs/8.0oz" category or is it 3 lbs? A shop filled my A/C up to about 850g of refrigerant (as I now found out from the invoice) and my A/C doesn't blow cold (the snowflake symbol doesn't blink though).
Click to expand...

Check the stickers in your engine compartment. One of them will specify refrigerant type and quantity required. That is likely the number they went by when recharging it.

Verify whether or not the compressor clutch is engaging. If it is not and 850g is the amount listed on the sticker, take it back and have them check it again.

- I'm assuming your ac worked when you left the shop but stopped working after? No way I would leave the shop with it not blowing cold.
 
Just wanted to edit my post to say I went to look for the sticker and found it :) It's 2.65 lbs. It seemed to work when I was leaving the shop but it was quite cold outside (definitely not A/C-requiring temps) so I probably didn't judge it right.
 
So I'm scheduled for fillup of the A/C but they are telling me it's not just the amount that causes it to not work at all. He told me that even with that 50 % of refrigerant it should blow cold, albeit not ice cold. Is that true? Last time it took a year for the refr. to leak out so there definitely is a leak... I just hoped it didn't get worse :(
 
Another member also believed he had a rear A/C and overcharged it. Use the lower amount for the single system.
 
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