Engine Mechanical - 3.6l (ly7) (Repair Instructions - 3 of 5) Buick LaCrosse I

Scheme 131

Remove the valve rocker arms, camshaft followers, from the left cylinder head.

Scheme 132

Remove the valve lifters, stationary hydraulic lash adjuster, (SHLAs) from the left cylinder head.

Cylinder Head Removal - Left

1. Remove the two front M8 left cylinder head bolts.
2. Remove the left cylinder head bolts.
3. Remove the left cylinder head.
4. Remove and discard the left cylinder head gasket.

Tools Required

EN 46105 Camshaft Locking Tool. See Special Tools .

Removal Procedure

1. Remove the EN 46105-1 from the right camshafts.
2. Position the camshaft lobes in a neutral position.
3. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: The raised feature must always be oriented toward the center of the cylinder head. The I indicates the intake camshaft. The E indicates the exhaust camshaft. The number indicates the journal position from the front of the engine.
4. Remove the camshaft bearing cap bolts.
5. Remove the camshaft bearing caps.
6. Remove the camshafts.
7. Replace the camshaft bearing caps and bolts.

Scheme 133

Remove the valve rocker arms, camshaft followers, from the right cylinder head.

Scheme 134

Remove the valve lifters, stationary hydraulic lash adjuster, (SHLAs) from the right cylinder head.

Cylinder Head Removal - Right

1. Remove the right cylinder head bolts.
2. Remove the right cylinder head.
3. Remove and discard the right cylinder head gasket.

Oil Pan Removal

1. Remove the oil pan bolts.
2. Using the pry points located at the edge of the oil pan shear the RTV sealant.
3. Remove the oil pan from the block.

Oil Pump Removal

1. Remove the oil pump bolts.
2. Remove the oil pump.

Crankshaft Rear Oil Seal and Housing Removal

1. Remove the crankshaft rear oil seal housing bolts.
2. Using the pry points located at the edge of the crankshaft rear oil seal housing shear the RTV sealant.
3. Remove and discard the crankshaft rear oil seal housing.

EN 46121 Connecting Rod Guide Pin Set. See Special Tools .

1. Before removing the connecting rods, check the connecting rod side clearance using the following procedure: Tap the connecting rod to one end of the crankshaft journal with a dead-blow or wooden hammer. Using feeler gages, measure the clearance between the crankshaft counterweight and the connecting rod. The connecting rod side clearance should not exceed specifications. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod. Refer to «Piston, Connecting Rod and Bearings Cleaning and Inspection»(/buick/lacrosse/i-2004-2009/remont/mechanical/#engine-mechanical-36l-ly7-repair-instructions-3-of-5) . If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod. If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
2. Using a marker, number each piston face. Draw an arrow along the centerline of the piston pointing toward the front of the engine.
3. Mark the cylinder number on the connecting rod and the connecting rod cap with a scribe, paint stick or permanent marker.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install the EN 46121 into the connecting rod bolt holes. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
7. Using the EN 46121 , push the connecting rod and piston assembly through the top of the cylinder. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . DO NOT scratch the crankshaft journal or cylinder wall and DO NOT damage the oil jets when removing the connecting rod and piston assembly.
8. Remove the EN 46121 from the connecting rod bolt holes. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
9. Remove the upper connecting rod bearing from the connecting rod.
10. Remove the lower connecting rod bearing from the connecting rod cap.
11. Reattach the connecting rod cap to the connecting rod to prevent damage to their mating surfaces. The cap and rod are a matched set and must be kept together.

1. J 6125-1B Slide Hammer Adapter. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. J 41818 Crankshaft Bearing Cap Remover. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Crankshaft End Play Measurement

1. Place a dial indicator at the crankshaft nose.
2. Gently force the crankshaft to the extreme front and rear positions with a pry tool while monitoring the movement of the dial indicator.
3. The crankshaft end play should not exceed specifications. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. If the specifications are exceeded inspect the thrust bearing thrust OD and the crankshaft thrust wall for wear and/or excessive runout. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
5. Replace the thrust bearing or crankshaft as necessary.

Crankshaft Removal

1. Remove the crankshaft bearing cap side bolts.
2. Remove the crankshaft bearing cap outer bolts.
3. Remove the crankshaft bearing cap inner bolts.
4. Remove the crankshaft bearing caps using the J 6125-1B and J 41818 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
5. Using two hands, lift the crankshaft straight up from the engine block.
6. Place the crankshaft in a secure place.
7. Remove the crankshaft sprocket drive pin from the nose of the crankshaft, if damaged.

Crankshaft Bearing Removal

1. Prepare a piece of cardboard or equivalent, numbered 1-4 for bearing identification. Main bearing journals are numbered from the front of the engine.
2. Remove the crankshaft upper bearing halves from the cylinder block. Note the position of the thrust bearing (1) at the number 3 journal (2).
3. Place the crankshaft upper bearing halves on the cardboard in the correct positions. Note that the number 3 bearing is the thrust bearing.
4. Remove the crankshaft lower bearing halves from the crankshaft bearing caps.
5. Place the crankshaft lower bearing halves in the correct positions on the cardboard.

Engine Block Disassemble

1. Remove oil jet bolts.
2. Remove oil jets.
3. Remove the right front oil pan rail oil gallery expansion plug.
4. Remove the cylinder block-to-oil pan alignment dowels.
5. Remove the M14 right side oil gallery threaded plug.
6. Remove the M14 right side coolant drain threaded plug.
7. Remove the M14 rear oil gallery threaded plug.
8. Remove the M14 left side coolant drain threaded plug.
9. Remove the M20 left side oil gallery threaded plug.
10. Remove the coolant expansion plugs.
11. Remove the cylinder block-to-transmission alignment dowels.
12. Remove the front oil gallery expansion plug.
13. Remove the cylinder block-to-cylinder head alignment dowels.

1. J 8087 Cylinder Bore Gage. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. J 28410 Gasket Remover. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Cleaning Procedure

1. Remove any old thread sealant, gasket material or sealant using J 28410 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Clean all the following areas with solvent: Sealing surfaces Cooling passages Oil passages Bearing journals
3. Clean all threaded and through holes with solvent.
4. Dry the engine block with compressed air.

Visual Inspection

1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced.
2. Inspect the primary camshaft drive chain tensioner mounting surface on the engine block for burrs or any defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.
3. Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if necessary.
4. Inspect all threaded and through holes for damage or excessive debris.
5. Inspect all bolts for damage, if damaged replace with NEW bolts only.
6. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.
7. Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
8. Repair any damaged threaded holes. Refer to «Thread Repair Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction) and «THREAD REPAIR»(/buick/lacrosse/i-2004-2009/remont/mechanical/#engine-mechanical-36l-ly7-repair-instructions-4-of-5) .

Scheme 135

Measure the cylinder bore diameter 37 mm (1.457 in) from the deck face using the J 8087 . See Special Tools .

Compare your results with the Engine Mechanical Specifications . If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.

Measuring Cylinder Bore Taper

1. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 10 mm (0.397 in) below the deck surface and record your measurement.
2. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 100 mm (3.976 in) below the deck surface and record your measurement.
3. Calculate the difference between the 2 measurements. The result will be the cylinder taper.
4. Compare your results with the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the cylinders exceed the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.

Measuring Cylinder Bore Out-of-Round

1. Measure both the thrust and non-thrust cylinder diameter at 10 mm (0.397 in) below the deck. Record your measurements.
2. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the upper end of the cylinder.
3. Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.976 in) below the deck surface. Record your measurements.
4. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.
5. Compare your results with the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the cylinders exceed these specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.

Deck Flatness Inspection

1. Ensure the engine block decks are clean and free of gasket material.
2. Inspect the surface for any imperfections or scratches that could inhibit proper cylinder head gasket sealing.
3. Place a straight-edge diagonally across the cylinder block deck face surface.
4. Measure the clearance between the straight-edge and the cylinder block deck face using a feeler gage at 4 points along the straight-edge.
5. If the warpage is less than 0.05 mm (0.002 in), the cylinder block deck surface does not require resurfacing.
6. If the warpage is between 0.05-0.20 mm (0.002-0.008 in) or any imperfections or scratches that could inhibit proper cylinder head gasket sealing are present, the cylinder block deck surface requires resurfacing.
7. If resurfacing is required the maximum amount that can be removed is 0.25 mm (0.010 in).
8. If the cylinder block deck surface requires more than 0.25 mm (0.010 in) material removal the block must be replaced.

J 7872 Magnetic Base Dial Indicator. See Special Tools .

1. Clean the following components in solvent: Crankshaft bearings Connecting rod bearings Crankshaft journals Crankpin journals Crankshaft oil passages Crankshaft threaded holes
2. Dry the following components with compressed air: Crankshaft bearings Connecting rod bearings Crankshaft journals Crankpin journals Crankshaft oil passages Crankshaft threaded holes

1. Perform the following visual inspections: Inspect the crankshaft balancer bolt hole (1) for thread damage. Inspect the crankshaft balancer mounting area (2) for damage. Inspect the crankshaft sprocket pin hole (3) for damage. Inspect the oil pump drive flats (4) for damage. Inspect the crankshaft main journals (5) for damage. Inspect the crankshaft connecting rod journals (6) for damage. Inspect the crankshaft oil passages (7) for obstructions. Inspect the crankshaft main bearing thrust wall surfaces (8) for damage. Inspect the crankshaft counterweights (9) for damage. Inspect the crankshaft reluctor ring teeth (10) for damage. Inspect the crankshaft rear main oil seal surface (11) for damage. Inspect the crankshaft engine flywheel mounting surface (12) for damage. Inspect the crankshaft pilot hole (13) for damage. Inspect the crankshaft engine flywheel bolt holes (14) for thread damage.
2. Repair or replace the crankshaft as necessary.

Crankshaft Bearing Inspection

1. Inspect for fatigue indicated by craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
2. Inspect for excessive scoring or discoloration on both front and back of the bearing halves.
3. Inspect the main bearings for dirt embedded into the bearing material.
4. Inspect for improper seating indicated by bright, polished sections.

Crankshaft Measurement

1. Using a suitable fixture, support the crankshaft.
2. Install the J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. Measure the crankshaft runout using the J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. Measure the crankshaft thrust wall width (1) for wear using an inside micrometer. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
5. Measure the crankshaft thrust wall surface (2) for runout using the J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
6. If the crankshaft journals are damaged or worn beyond specifications, the crankshaft may be ground 0.25 mm (0.010 in). There is only 1 size of oversized main bearings available for service.
7. Inspect the crankshaft main journals for undersize, using an outside micrometer.
8. Inspect the crankpins for undersize using an outside micrometer.
9. Compare your measurements with those listed in the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the crankpin journals are worn beyond the specifications, the crankshaft may be ground 0.25 mm (0.010 in). There is only 1 size of oversized connecting rod bearings available for service.
10. Measure the main bearing and crankpin journals for out-of-round using the following procedure: Using an outside micrometer, measure the journal at the extreme front and rear locations on the journal. Call these points A and B. Measure the journal in 2 new locations exactly 90 degrees from the first points. Call these points C and D. Subtract A from C and B from D. The differences will indicate journal out-of-round. The out-of-round should not exceed 0.004 mm (0.00016 in) maximum. If the journals are worn beyond the specifications, the crankshaft may be ground 0.25 mm (0.010 in). There is only 1 size of oversized crankshaft and connecting rod bearings available for service.
11. Measure the main bearing and crankpin journals for taper using the following procedure: Using an outside micrometer, measure the journal at the extreme front (A) and rear (B) of the journal parallel to the crankshaft centerline. Subtract the smallest from the largest measurement. The result will be the journal taper. If the main bearing journal taper exceeds 0.004 mm (0.00016 in), replace the crankshaft. If the journals are worn beyond the specifications, the crankshaft may be ground 0.25 mm (0.010 in). There is only 1 size of oversized crankshaft and connecting rod bearings available for service.

1. Clean the crankshaft balancer in solvent that is compatible with the rubber (3).
2. Dry the crankshaft balancer with compressed air.

Inspection Procedure

1. Inspect the crankshaft balancer for the following: Worn or damaged hub-to-crankshaft surface (1) Worn, grooved or damaged hub seal surface (2) A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. Worn, chunking or deteriorated rubber between the hub and pulley (3) Damaged drive belt ribs (4) Damaged webs (5)
2. Repair or replace the crankshaft balancer as necessary.

1. Clean the engine flywheel in solvent.
2. Dry the engine flywheel with compressed air.

1. Inspect the engine flywheel for the following conditions: Stress cracks around the engine flywheel-to-torque converter mounting bolt hole locations (1) and/or engine flywheel-to-crankshaft (2, 4) IMPORTANT: Do not attempt to repair the welded areas that retain the ring gear to the engine flywheel plate. Install a new engine flywheel. Cracks at welded areas that retain the ring gear onto the engine flywheel (3) Damaged or missing ring gear teeth (5)
2. Replace the engine flywheel as necessary.

EN-46745 Piston Pin Clip Remover/Installer. See Special Tools .

Disassembly Procedure

1. Remove the piston rings using a piston ring expander. Place each ring in a clean shop towel for storage.
2. Using the EN-46745 , remove the piston pin retainers by using the removal access notch (1) in the side of the piston. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Discard the piston pin retainers.
3. Slide the piston pin out of the piston. The piston will disconnect from the connecting rod.

1. Clean the piston skirts and the pins with a cleaning solvent.
2. Clean the piston ring grooves with a groove cleaner. Ensure that the oil ring holes and slots are clean.
3. Dry the piston with compressed air.

Piston Inspection Procedure

1. Inspect the pistons for the following conditions: Cracked ring lands, skirts or pin bosses Ring grooves for nicks, burrs that may cause binding (5) Warped or worn ring lands (5) Piston pin retainer grooves for burrs (2) Eroded areas at the top of the piston (1) Scuffed or damaged skirt coating (4) Worn piston pin bores or worn piston pins (3)
2. Replace pistons that show any signs of damage or excessive wear.

Piston Measurement Procedure

1. Measure piston width using the following procedure: Using an outside micrometer, measure the width of the piston at 30 mm (1.181 in) below the crown, top (1), at the thrust surfaces of the piston, perpendicular to the piston pin centerline. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. Check your measurements with the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the clearance obtained through measurement is greater than the provided specifications and the cylinder bores are within specification, replace the piston.
2. Measure the piston pin bore to piston pin clearances using the following procedure: Piston pin bores and pins must be free of varnish or scuffing. Use an outside micrometer to measure the piston pin in the piston contact areas.
3. Using an inside micrometer, measure the piston pin bore. Compare your result with the piston pin diameter and piston pin to piston pin bore clearance listed in the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. If the clearance is excessive, determine which piece is out of specification and replace as necessary.
5. You must replace the piston if any of its dimensions are out of specification.
6. If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.

Piston Ring Measurement Procedure

1. Measure the piston ring end gap using the following procedure: Place the piston ring in the area of the bore where the piston ring will travel approximately 25 mm (1 in) down from the deck surface. Ensure that the ring is square with the cylinder bore by positioning the ring with the piston head. Measure the end gap of the piston ring with feeler gages. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the clearance exceeds the provided specifications, the piston rings must be replaced. Repeat the procedure for all the piston rings.
2. Measure the piston ring side clearance using the following procedure: Roll the piston ring entirely around the piston ring groove. If any binding is caused by the ring groove, dress the groove with a fine file. If any binding is caused by a distorted piston ring, replace the ring. With the piston ring on the piston, use feeler gages to check clearance at multiple locations. Compare the measurements with piston ring side clearance listed in the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the clearance is greater than specifications, replace the piston rings.
3. There is a locating dimple (1) on the compression rings near the end for identification. Install the compression rings with the dimple facing up.
4. If the new ring does not reduce the clearance to the proper specification, install a new piston.
5. If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.

Connecting Rod Cleaning Procedure

1. Clean the connecting rods in solvent.
2. Dry the connecting rod using compressed air.
3. Remove the connecting rod cap and clean the threads.
4. Remove the connecting rod bearing and discard. Never reuse a connecting rod bearing used in a running engine.

Connecting Rod Visual Inspection Procedure

1. Inspect the piston pin bushing (4) for scoring or damage.
2. Inspect the connecting rod beam (1) for twisting or bending.
3. Inspect the rod cap (2) for any nicks or damage caused by possible interference.
4. Inspect for scratches or abrasion on the rod bearing seating surface.
5. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper.

Connecting Rod Measurement Procedure

Piston Pin End

1. Using an outside micrometer, take 2 measurements of the piston pin in the area of the connecting rod contact.
2. Using an inside micrometer, measure the connecting rod piston pin bore.
3. Subtract the piston pin diameter from the piston pin bore.
4. Compare the clearance measurements with the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
5. If the clearance is excessive, replace the piston pin. If a new pin does not resolve the clearance problem, replace the connecting rod.

Connecting Rod Crankshaft Bearing End

1. Using an inside micrometer, measure the connecting rod crankshaft bearing bore.
2. Compare the bore measurements with the «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
3. Replace the connecting rod if the bore is out of specifications. DO NOT recondition the connecting rod.

1. EN 46121 Connecting Rod Guide Pin Set. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. EN-46745 Piston Pin Clip Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Piston and Piston Pin Installation Procedure

1. Lubricate the piston pin bores in the piston and the connecting rod with GM prelube lubricant GM P/N 1052367 (Canadian P/N 992869) or equivalent.
2. Assemble the piston and piston pin to the connecting rod. Properly orient the piston when reusing a marked connecting rod.
3. Align the piston pin bore with the connecting rod pin bore.
4. Slide the piston pin into the piston and the connecting rod.
5. Install NEW piston pin retainers using the EN-46745 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Align the EN-46745 to the notch (1) in the piston. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
6. Ensure that the piston pin retainers are fully seated in their grooves.
7. Repeat these procedures for the remaining pistons.

Piston Ring Installation Procedure

1. Properly orient the oil control ring expander as shown before installation. The ends of the expander must be facing toward the top of the piston.
2. Using a piston ring expander, install the oil control ring assembly using the following procedure: Install the expander ring (3). Install the 2 oil scraper rings (4). Expand the rings only enough to clear the piston diameter. Overexpanding the piston rings will distort or crack the rings.
3. Install the second and top piston rings using the ring expander. Ensure that you do not overexpand the rings.
4. Once the rings are installed, set the ring gaps for the oil control, second and top ring as follows. Use the piston location arrow for reference. Lower oil control ring - position 1 Upper oil control ring - position 2 Top Ring - position 3 Oil control ring expander - position 4 Second ring - position 5

Connecting Rod Bearing Installation Procedure

1. Clean the connecting rod and the connecting rod cap bearing bore with a lint-free cloth.
2. Clean all the oil from behind the connecting rod bearing halves.
3. Install new upper connecting rod bearings into position. Roll the bearing into position so that the lock tang engages the alignment slot. The bearing must fit flush in the connecting rod.
4. Install the EN 46121 into the connecting rod bolt holes. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
5. Install new lower connecting rod bearings into position in the connecting rod cap. Roll the bearing into position so that the lock tang engages the alignment slot. The bearings must fit flush with the connecting rod cap.

1. EN 46116 Valve Stem Seal Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. EN 46117 Valve Stem Key Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. EN 46119 Off-Vehicle Valve Spring Compressor Adapter. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
4. J 8062 Valve Spring Compressor - Head Off. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

1. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer to loosen the valve keepers.
2. Compress the valve spring using the J 8062 and the EN 46119 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. Use the magnet of the EN 46117 in order to remove the valve keepers. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
4. Remove the valve spring compressor and the adapter.
5. Remove the valve spring retainer.
6. Remove the valve spring.
7. Remove the valve.
8. Remove the valve stem oil seal using the EN 46116 and discard. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
9. Repeat these procedures for the remaining valves.
10. Remove the cylinder head oil gallery expansion plugs.
11. Remove the cylinder head coolant threaded plugs.

1. EN 46122 Camshaft Position Actuator Check-Ball Valve Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. J 8001 Dial Indicator Set. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. J 8358 Carbon Removal Brush. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
4. J 28410 Gasket Remover. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
5. J 42096 Valve Guide Reamer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

1. Remove any old thread sealant, gasket material or sealant using J 28410 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Clean all cylinder head surfaces with non-corrosive solvent.
3. Blow out all the oil galleries using compressed air.
4. Remove any carbon deposits from the combustion chambers using the J 8358 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
5. Clean any debris or build-up from the lifter pockets.

1. Inspect the cylinder head camshaft bearing surfaces for the following conditions: Excessive scoring or pitting Discoloration from overheating Deformation from excessive wear If the camshaft bearing journals appear to be scored or damaged, you must replace the cylinder head. DO NOT machine the camshaft bearing journals.
2. If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head.
3. Inspect the cylinder head for the following: Cracks, damage or pitting in the combustion chambers Debris in the oil galleries - Continue to clean the galleries until all debris is removed. Coolant leaks or damage to the deck face sealing surface - If coolant leaks are present, measure the surface warpage as described under Cylinder Head Measurement - Deck Flatness Inspection. Burrs or any defects that would degrade the sealing of the NEW secondary camshaft drive chain tensioner gasket Damage to any gasket surfaces Damage to any threaded bolt holes Burnt or eroded areas in the combustion chamber Cracks in the exhaust ports and combustion chambers External cracks in the water passages Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged or leaking core plugs
4. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is recommended.
5. Inspect the camshaft position actuator oil feed check valves in order to ensure they are properly positioned in the cylinder head. The camshaft position actuator oil feed check valve should be flush to 2 mm (0.0787 in) below the cylinder head deck surface (a).
6. Damaged, restricted or clogged check valves can be replaced using the EN 46122 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Cylinder Head Measurement

Camshaft Journal Clearance

1. Install the camshaft bearing cap in the cylinder head without the camshaft.
2. Install the camshaft cap bolts. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
3. Measure the camshaft bearings using an inside micrometer.
4. Subtract the camshaft journal diameter from the camshaft bearing diameter. This will provide the running clearance. If the running clearance exceeds specifications and the camshaft journals are within specification, replace the cylinder head.

Camshaft Journal Alignment

1. Ensure the camshafts are serviceable.
2. Inspect the cylinder head camshaft bearing surfaces for any imperfections or scratches that could inhibit proper camshaft clearances. Repair minor imperfections or scratches.
3. Install the camshafts in the cylinder head.
4. Install the camshaft bearing caps.
5. Install the camshaft cap bolts. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
6. Ensure the camshafts spin freely in the cylinder head. If the camshaft does not run freely, replace the cylinder head.

Deck Flatness Inspection

1. Ensure the cylinder head decks are clean and free of gasket material.
2. Inspect the surface for any imperfections or scratches that could inhibit proper cylinder head gasket sealing.
3. Place a straight-edge diagonally across the cylinder head deck face surface.
4. Measure the clearance between the straight-edge and the cylinder head deck face using a feeler gage at 4 points along the straight-edge.
5. If the warpage is less than 0.05 mm (0.002 in), the cylinder head deck surface does not require resurfacing.
6. If the warpage is between 0.05-0.20 mm (0.002-0.008 in) or any imperfections or scratches that could inhibit proper cylinder head gasket sealing are present, the cylinder head deck surface requires resurfacing.
7. If resurfacing is required the maximum amount that can be removed is 0.25 mm (0.010 in).
8. If the cylinder head deck surface requires more than 0.25 mm (0.010 in) material removal the head must be replaced.

Valve Guide Measurement

1. Measure the valve stem (1)-to-guide (2) clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.
2. Clamp the J 8001 to the cylinder head at the camshaft cover rail. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. Locate the dial indicator so that the movement of the valve stem from side to side, crossways to the cylinder head, will cause a direct movement of the indicator stem. The dial indicator stem must contact the side of the valve stem just above the valve guide.
4. Drop the valve head about 0.064 mm (0.0025 in) off the valve seat.
5. Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) for proper clearance. If the clearance for the valve is greater than specifications and a new standard diameter valve stem will not bring the clearance within specifications, the valve guide may be oversized by 0.075 mm (0.003 in) using the J 42096 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . There is 1 size of oversized valve stem available for service. Valve guide wear at the bottom 10 mm (0.390 in) of the valve guide is not significant to normal operation. If oversizing the guide does not bring the clearance within specifications, replace the cylinder head.

J 22738-B Valve Spring Tester. See Special Tools .

1. Clean the valve springs in solvent.
2. Dry the valve springs with compressed air.
3. Inspect the valve springs for broken coils or coil ends.

Measurement Procedure

1. Measure the valve spring tension using the J 22738-B . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
2. If low valve spring load is found, replace the valve springs. DO NOT use shims to increase spring load. The use of shims can cause the valve spring to bottom out before the camshaft lobe is at peak lift.

Valve Cleaning Procedure

1. Use soft bristle wire brush to clean any carbon build-up from the valve head. DO NOT use a wire brush on any part of the valve stem. The valve stem is chrome plated to provide enhanced wear characteristics. Wire brushing the stem could remove the chrome plating.
2. Thoroughly clean the valve with solvent and wipe dry.

Valve Visual Inspection Procedure

1. Inspect the valve for damage from the head to tip for the following conditions: Pitting in the valve seat area (1) Lack of valve margin (2) Bending in the valve stem (3) Pitting or excessive wear in the stem (4) Worn valve key grooves (5) Worn valve tip (6)
2. Replace the valve if any of these conditions exist.

Valve Measurement and Reconditioning Overview

Valve Seat Width Measurement Procedure

1. Measure the valve seat width in the cylinder head using a proper scale.
2. Measure the seat width on the valve face (1) using a proper scale.
3. Compare your measurements with the specifications listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. If the seat widths are acceptable, check the valve seat roundness using the Valve Seat Roundness Measurement Procedure.
5. If the seat width is not acceptable, you must grind the valve seat using the Valve and Seat Reconditioning Procedure to bring the width back into specification. Proper valve seat width is critical to providing the correct amount of valve heat dissipation.

Valve Seat Roundness Measurement Procedure

1. Measure the valve seat roundness using a dial indicator attached to a tapered pilot installed in the guide. The pilot should have a slight bind when installed in the guide.
2. Compare your measurements with the specifications listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
3. If the valve seat exceeds the roundness specification, you must grind the valve and valve seat using the Valve and Seat Reconditioning Procedure.
4. If new valves are being used, the valve seat roundness must be within 0.05 mm (0.002 in).

Valve Margin Measurement Procedure

1. Measure the valve margin using an appropriate scale.
2. Reference the specifications in this information for minimum valve margin and compare them to your measurements.
3. If the valve margins are beyond specification, replace the valves.
4. If the valve margins are within specification and do not require refacing, test the valve for seat concentricity using the Valve-to-Seat Concentricity Measurement Procedure.

Valve-to-Seat Concentricity Measurement Procedure

1. Coat the valve face lightly with blue dye (3).
2. Install the valve in the cylinder head.
3. Turn the valve against the seat with enough pressure to wear off the dye.
4. Remove the valve from the cylinder head.
5. Inspect the valve face. If the valve face is concentric, providing a proper seal, with the valve stem, a continuous mark will be made around the entire face (1). IMPORTANT: The wear mark MUST be at least 0.5 mm (0.020 in) from the outer diameter, the margin, of the valve. If the wear mark is too close to the margin, the seat must be reconditioned to move the contact area away from the margin. If the face is not concentric with the stem, the mark will NOT be continuous around the valve face. The valve should be refaced or replaced and the seat must be reconditioned using the Valve and Seat Reconditioning Procedure.

Valve and Seat Reconditioning Procedure

1. Grind the valve seats (2) to the proper angle specification listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
2. Using the proper angle specification listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) , grind, relieve, the valve seats (1) to correctly position the valve seating surface (2) to the valve.
3. Using the proper angle specification listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) , grind, undercut, the valve seats (3) to narrow the valve seat widths to the specifications listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. If the original valve is being used, grind the valve to the specifications listed in «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . Measure the valve margin again after grinding using the Valve Margin Measurement Procedure. Replace the valve if the margin is out of specification. New valves do not require grinding.
5. When grinding the valves and seats, grind off as little material as possible. Cutting valve seat results in lowering the valve spring pressure.
6. Install the valve in the cylinder head. If you are using refaced valves, lap the valves into the seats with a fine grinding compound. The refacing and reseating operations should leave the refinished surfaces smooth and true so that minimal lapping is required. Excessive lapping will groove the valve face and prevent a good seat when hot. IMPORTANT: Be sure to clean any remaining lapping compound from the valve and seat with solvent and compressed air prior to final assembly. If you are using new valves, do not lap the valves under any condition.
7. After obtaining the proper valve seat width in the cylinder head, you must re-measure the valve stem height using the Valve Stem Height Measurement Procedure.
8. If the valve stem height is acceptable, test the seats for concentricity using the Valve-to-Seat Concentricity Measurement Procedure.

Valve Stem Height Measurement Procedure

1. Install the valve into the valve guide.
2. Ensure the valve is seated to the cylinder head valve seat.
3. Install the valve stem oil seal.
4. Install the valve spring retainer and valve stem locks.
5. Measure the distance (1) between the cylinder head to the bottom of the valve spring retainer. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
6. If the maximum height specification is exceeded, a new valve should be installed and the valve stem height re-measured.
7. If the valve stem height still exceeds the maximum height specification, the cylinder head must be replaced.

1. J 8062 Valve Spring Compressor - Head Off. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. EN 46116 Valve Stem Seal Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
3. EN 46117 Valve Stem Key Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
4. EN 46119 Off-Vehicle Valve Spring Compressor Adapter. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Assembly Procedure

1. Install the cylinder head coolant threaded plugs. Tighten: Tighten the cylinder head coolant threaded plug to 31 N.m (23 lb ft).
2. Install the NEW cylinder head oil gallery expansion plugs.
3. Place the valve stem oil seals onto the guides.
4. Mount a new valve stem oil seal using the EN 46116 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
5. Push and twist the valve stem oil seal into position on the valve guide until the seal positively locks on the guide using the EN 46116 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
6. Lubricate the valve stem and valve guide ID with clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent.
7. Insert the valve into the valve guide until it bottoms on the valve seat.
8. Position the valve spring on the spring seat.
9. Place the valve spring retainer onto the valve spring.
10. Compress the valve spring using the J 8062 and the EN 46119 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
11. With the spring compressed, install the valve keepers into the EN 46117 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
12. Place the keepers into position by pushing the tool downward and releasing tension on the EN 46119 and the J 8062 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
13. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-blow hammer. The valve keepers and the spring should remain in place.

J 7872 Magnetic Base Dial Indicator. See Special Tools .

1. Clean the camshaft in solvent.
2. Dry the camshaft with compressed air.

1. Inspect the camshaft oil feed holes (1) to the camshaft position actuator for dirt, debris or blockage.
2. Inspect the threaded hole (2) for damage.
3. Inspect the camshaft position actuator locating notch (3) for damage or wear.
4. Inspect the camshaft sealing grooves (4) for damage.
5. Inspect the camshaft thrust surface (5) for damage.
6. Inspect the camshaft lobes (6) and journals (7) for the following conditions: Excessive scoring or pitting Discoloration from overheating Deformation from excessive wear, especially the camshaft lobes
7. If any of the above conditions exist on the camshaft, replace the camshaft.

Camshaft Measurement

1. With the camshaft in a suitable fixture, measure the camshaft for wear.
2. Measure the camshaft journals for diameter and out-of-round using an outside micrometer. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the diameter is smaller than specifications, replace the camshaft. If the out-of-round exceeds specifications, replace the camshaft.
3. Measure the camshaft runout using the J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
4. Measure the camshaft thrust width for wear using a depth micrometer. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
5. Measure the camshaft thrust wall surface for runout using J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) .
6. If the camshaft is damaged or worn beyond specifications, replace the camshaft. No machining of the camshaft is allowed.
7. Measure the camshaft lobes for wear using the J 7872 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
8. Place the J 7872 with the indicator tip on the base circle (1) of the camshaft lobe. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Place the J 7872 at zero. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) . Rotate the camshaft until the indicator tip is at the highest point (3) on the lobe. This reading is the lift of the camshaft lobe. Refer to «Engine Mechanical Specifications»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__engine-mechanical-specifications) . If the indicated measurement is significantly lower than these specifications, replace the camshaft or engine performance will be reduced.

Valve Lifters Cleaning and Inspection

1. Inspect the stationary hydraulic lash adjuster (SHLA) in the following areas: A plugged oil passage (1) A scored or worn camshaft follower pivot area (2) A damaged or broken retainer (3) A severely scuffed or worn SHLA body (4)
2. Replace the SHLA or SHLAs as necessary.

Valve Rocker Arms Cleaning and Inspection

1. Inspect the camshaft follower roller (1) for the following: Flat spots Excessive scoring and pitting Ensure the roller spins freely
2. Inspect the camshaft follower valve tip area (2).
3. Inspect the camshaft follower stationary hydraulic lash adjuster (SHLA) pivot area (3).
4. Replace the camshaft follower or followers as necessary.

1. Clean all the following components with solvent: Crankshaft sprocket Primary timing drive chain Primary timing drive chain shoe Primary timing drive chain guides Primary timing drive chain tensioner Secondary timing drive chains Secondary timing drive chain shoes Secondary timing drive chain guides Secondary timing drive chain tensioners Timing component fastening bolts
2. Clean each camshaft position actuator's exterior with solvent.
3. Dry the timing components with compressed air.

Camshaft Position Actuators

1. Inspect the front of the exhaust camshaft position actuators for the following: Sprocket damage (1) Reluctor/sensor wheel damage (2) Camshaft position actuator bolt seating/sealing inner hub flange damage (3)
2. Inspect the back of the exhaust camshaft position actuators for the following: Sprocket damage (1) Camshaft locating pin damage (2) Camshaft seating/sealing inner hub flange damage (3) Blockage to the oil passages (4) Loose or missing housing bolts (5)
3. Inspect the front of the intake camshaft position actuators for the following: Sprocket damage (1) Reluctor/sensor wheel damage (2) Camshaft position actuator oil control valve bolt seating/sealing inner hub flange damage (3)
4. Inspect the back of the intake camshaft position actuators for the following: Sprocket damage (1) Camshaft locating pin damage (2) Camshaft seating/sealing inner hub flange damage (3) Blockage to the oil passages (4) Loose or missing housing bolts (5)
5. Replace a damaged camshaft position actuator.

Camshaft Position Actuator Oil Control Valves

1. Inspect the camshaft position actuator oil control valves for the following: Blockage to the oil passage (1) Missing or damaged oil screen clip (2) Blockage or damage to the oil screen (3) Damage to the sealing surface for the camshaft position actuator oil control valve solenoid oil seal (4) Damage to the bracket (5) Damage to the wiring harness connection and/or terminals (6)
2. Replace a damaged camshaft position actuator oil control valve.

Left Intermediate Sprocket with Primary Inverted Tooth (IT) Chain

1. Inspect the front of the left intermediate sprocket for the following: Damage to the primary camshaft drive chain sprocket (1) Damage to the hub bearing (2)-Ensure the hub bearing spins freely. If the hub bearing wobbles, is noisy or feels rough when rotated, replace the intermediate sprocket. Damage to the bolt flange seating/sealing surface (3)
2. Inspect the back of the intermediate sprocket for the following: Damage to the left secondary camshaft drive chain sprocket (1) Damage to the bearing hub-to-engine block sealing surface (2)
3. Replace a damaged left intermediate sprocket.

Right Intermediate Sprocket with Primary Inverted Tooth (IT) Chain

1. Inspect the front of the right intermediate sprocket for the following: Damage to the right secondary camshaft drive chain sprocket (1) Damage to the bearing hub bearing (2)-Ensure the hub bearing spins freely. If the hub bearing wobbles, is noisy or feels rough when rotated, replace the intermediate sprocket. Damage to the bolt flange seating/sealing surface (3)
2. Inspect the back of the right intermediate sprocket for the following: Damage to the primary camshaft drive chain sprocket (1) Damage to the bearing hub-to-engine block sealing surface (2)
3. Replace a damaged right intermediate sprocket.

Crankshaft Sprocket with Primary Inverted Tooth (IT) Chain

1. Inspect the crankshaft sprocket for the following: Sprocket damage (1) Bore damage (2) Keyway damage (3)
2. Replace a damaged crankshaft sprocket.

Secondary Timing Chains with Roller Chain

1. Inspect the secondary timing chain for the following: Binding or worn rollers (1) Loose links (2) Loose pins (3)
2. Replace a damaged secondary timing chain.

Primary Timing Chain with Inverted Tooth (IT) Chain

1. Inspect the primary timing chain for the following: Binding or worn links (1) Loose links (2) Loose pins (3)
2. Replace a damaged primary timing chain.

Primary Timing Chain Upper Guide

1. Inspect the primary timing chain upper guide for the following: Worn guide surface (1) Cracked or broken guide surface (2) Cracked or damaged guide base (3)
2. Replace a damaged primary timing chain upper guide.

Primary Timing Chain Lower Guide

1. Inspect the primary timing chain lower guide for the following: Worn guide surface (1) Cracked or broken guide surface (2) Cracked or damaged guide base (3)
2. Replace a damaged primary timing chain lower guide.

Left Secondary Timing Chain Guide

1. Inspect the left secondary timing chain guides for the following: Worn guide surface (1) Cracked or broken guide surface (2) Cracked or damaged guide base (3)
2. Replace a damaged left secondary timing chain guide.

Right Secondary Timing Chain Guide

1. Inspect the right secondary timing chain guides for the following: Worn guide surface (1) Cracked or broken guide surface (2) Cracked or damaged guide base (3)
2. Replace a damaged right secondary timing chain guide.

Left Secondary Timing Chain Shoe

1. Inspect the front of the left secondary timing chain shoe for the following: Worn shoe surface (1) Cracked or broken shoe surface (2) Cracked or damaged shoe (3)
2. Inspect the back of the left secondary timing chain shoe for a damaged, worn or missing left secondary timing chain tensioner contact pad (1).
3. Replace a damaged left secondary timing chain shoe.

Right Secondary Timing Chain Shoe

1. Inspect the front of the right secondary timing chain shoe for the following: Worn shoe surface (1) Cracked or broken shoe surface (2) Cracked or damaged shoe (3)
2. Inspect the back of the right secondary timing chain shoe for a damaged, worn or missing right secondary timing chain tensioner contact pad (1).
3. Replace a damaged right secondary timing chain shoe.

Primary Timing Chain Tensioner

1. Inspect the primary timing chain tensioner for worn primary timing chain tensioner shoe surface (1).
2. Inspect the primary timing chain tensioner for locked or binding timing chain tensioner. Reset the plunger (3) and ensure the plunger moves freely (2) in and out of the body of the tensioner. Refer to «PRIMARY CAMSHAFT DRIVE CHAIN TENSIONSER INSTALLATION»(/buick/lacrosse/i-2004-2009/remont/mechanical/#engine-mechanical-36l-ly7-repair-instructions-4-of-5) .
3. Replace a damaged primary timing chain tensioner.

Left Secondary Timing Chain Tensioner

1. Inspect the left secondary timing chain tensioner for damaged plunger-to-shoe contact surface (1).
2. Inspect the left secondary timing chain tensioner for locked or binding timing chain tensioner. Reset the plunger (3) and ensure the plunger moves freely (2) in and out of the body of the tensioner. Refer to «SECONDARY CAMSHAFT DRIVE CHAIN TENSIONER INSTLLATION - LEFT»(/buick/lacrosse/i-2004-2009/remont/mechanical/#engine-mechanical-36l-ly7-repair-instructions-4-of-5) .
3. Replace a damaged left secondary timing chain tensioner.

Right Secondary Timing Chain Tensioner

1. Inspect the right secondary timing chain tensioner for damaged plunger-to-shoe contact surface (1).
2. Inspect the right secondary timing chain tensioner for locked or binding timing chain tensioner. Reset the plunger (3) and ensure the plunger moves freely (2) in and out of the body of the tensioner. Refer to «SECONDARY CAMSHAFT DRIVE CHAIN TENSIONER INSTALLATION - RIGHT»(/buick/lacrosse/i-2004-2009/remont/mechanical/#engine-mechanical-36l-ly7-repair-instructions-4-of-5) .
3. Replace a damaged right secondary timing chain tensioner.

Oil Pump Disassemble

1. Remove the oil pump mounting bolts.
2. Remove the primary camshaft drive chain lower guide bolts.
3. Remove the primary camshaft drive chain lower guide.
4. Remove the bolts holding the oil pump cover to the oil pump housing.
5. Remove the oil pump cover from the oil pump housing.
6. Remove the inner oil pump drive gear.
7. Remove the outer oil pump driven gear.
8. Remove the clip, holding the cap, for the oil relief valve components.
9. Remove the cap, spring and plunger from the oil pump housing.

1. Clean the oil pump components with non-corrosive solvent.
2. Dry the oil pump components with compressed air.

1. Inspect the oil pump housing for the following: Damage, scoring or debris on the housing surface for the driven gear (1) Damage to the oil pump mounting bosses (2) Damage, scoring or debris on the housing surface for the drive gear (3) Damage, scoring or debris in the oil pump relief valve port (4) Damage, scoring or debris in the oil pump intake port (5) Damage, scoring or debris in the oil pump relief valve bore (6) Damage, scoring or debris in the oil pump output port (7) Damage to the threads in the oil pump housing for the oil pump cover bolts (8)
2. Inspect the oil pump cover for the following conditions: Damage to the oil pump cover mounting bosses (1) Damage, scoring or debris in the oil pump cover oil passages (2) Damage to the sealing surface between the oil pump cover and the oil pump housing (3)
3. Inspect the inner drive gear for damage. If inner diameter damage is found, ensure the crankshaft is also inspected.
4. Inspect the outer driven gear for damage.
5. Inspect the oil pump relief valve components for debris or damage.
6. Inspect the primary camshaft drive chain lower guide for damage (1-3).
7. If debris or damage is present within the oil pump, further inspection of all of the engine components is necessary.

Oil Pump Assemble

1. Install the oil pressure relief valve components. Install the oil pressure relief valve. Install the oil pressure relief valve spring. Install the oil pressure relief valve bore plug. Install the oil pressure relief valve bore plug retainer C-clip.
2. The dimpled surface must be face-up in the pump body.
3. Install the inner and the outer rotors in the oil pump cover in the same orientation as removed.
4. The outer rotor has a dimple to indicate the outer surface.
5. Assemble the oil pump housing and cover.
6. Install the oil pump bolts. Tighten: Tighten the oil pump bolts to 10 N.m (89 lb in).

Oil Filter Adapter Disassemble

1. Remove the oil pressure sender.
2. Remove the oil filter fitting.

1. Clean the oil filter adapter components with non-corrosive solvent.
2. Dry the oil filter adapter components with compressed air.

1. Inspect the oil filter adapter housing for cracks, casting imperfections or damage (1).
2. Inspect the threads for the oil pressure sender (2) or the bracket (3) for damage.
3. Inspect the mounting holes (4) for damage.
4. Inspect the oil filter adapter housing gasket sealing surface (1) for damage.
5. Inspect the oil filter adapter housing passages (2) for damage or blockage.
6. Inspect the oil filter sealing surface (3) for damage.
7. Inspect the threads for the oil filter fitting (4) for damage.
8. Inspect the oil filter bypass valve (5) for damage or blockage.
9. Repair or replace the oil filter adapter housing as necessary.

Oil Filter Adapter Assemble

1. Install the oil filter fitting. Tighten: Tighten the oil filter fitting to 50 N.m (37 lb ft).
2. Install the oil pressure sender. Tighten: Tighten the oil pressure sender to 20 N.m (15 lb ft).

Oil Pan Disassemble

1. Remove the oil pan drain plug.
2. Remove the oil pan scraper bolts.
3. Remove the oil pan scraper.
4. Remove the oil suction pipe bolts.
5. Remove the oil suction pipe.
6. Remove the oil suction tube seal from the oil suction tube. Discard the oil suction tube seal.

J 28410 Gasket Remover. See Special Tools .

1. Remove any old thread sealant, gasket material or sealant using J 28410 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Clean the oil pan and oil pan components in solvent.
3. Clean out debris from the bolt holes.
4. Dry the oil pan and oil pan components with compressed air.

1. Inspect the exterior of the oil pan for the following conditions: Damage to the engine mount bracket bolt hole threads (1) Dents, cracks or damage to the exterior (2) Damage to the oil pan mounting holes (3) Damage to the transmission mounting bolt hole threads (4)
2. Inspect the exterior of the oil pan for the following conditions: Dents, cracks or damage to the exterior (1) Damage to the drain plug hole threads (2) Damage to the transmission brace bolt hole threads (3) Damage to the engine mount brace bolt hole threads (4) Damage to the engine front cover bolt hole threads (5) Damage to the A/C compressor mounting bolt hole threads (6) Damage to the oil pan mounting holes (7)
3. Inspect the interior of the oil pan for the following conditions: Damage to the oil pan baffle scraper bolt hole threads (1) Loose, missing or damage to the oil pan baffle fastening (2) Damage to the oil pan baffle (3) Debris or blockage under the oil pan baffle (4) Damage or gouges to the oil pan sealing surface (5) Damage to the oil suction tube mounting upper bracket bolt hole threads (6) Damage to the oil suction tube mounting lower bracket bolt hole threads (7)
4. Inspect the oil pan baffle scraper for damage.
5. Repair or replace the oil pan and/or oil pan components as necessary.

1. Clean the oil pump pipe and screen with solvent.
2. Dry the oil pump pipe and screen with compressed air.

1. Inspect the mounting surface (1) for possible leakage paths.
2. Inspect the oil pump pipe tube (2) for cracks, imperfections and/or damage.
3. Inspect the oil pump pipe support bracket (3) for cracks or damage.
4. Inspect the oil pump screen (4) for blockage, foreign material, tears, cracks and/or damage.

Oil Pan Assemble

1. Install a NEW oil suction tube seal onto the oil suction tube. DO NOT reuse the old oil suction tube seal.
2. Install the oil suction pipe.
3. Install the oil suction pipe bolts. Tighten: Tighten the oil suction pipe bolts to 10 N.m (89 lb in).
4. Install the oil pan scraper.
5. Install the oil pan scraper bolts. Tighten: Tighten the oil pan scraper bolts to 10 N.m (89 lb in).
6. Install the oil pan drain plug and NEW O-ring seal. Tighten: Tighten the oil pan drain plug to 20 N.m (15 lb ft).

J 45000 Seal Remover. See Special Tools .

1. Remove the crankshaft front oil seal from the engine front cover using the J 45000 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Remove the camshaft position actuator valve oil seals from the engine front cover.
3. Remove the water pump seal from the engine front cover.
4. Discard the water pump seal.

J 28410 Gasket Remover. See Special Tools .

1. Remove any RTV sealant (1) from the engine front cover using J 28410 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Clean out debris from the bolt holes.
3. Clean the engine front cover in solvent.
4. Dry the engine front cover with compressed air.

1. Inspect the exterior of the engine front cover for the following conditions: Damage to the camshaft position actuator valve oil seal bores (1) Damage to the engine front cover bolt holes (2) Damage and/or corrosion to the engine coolant passage (3) Dents or damage to the exterior (4) Damage to the crankshaft front oil seal bore (5) Gouges or damage to the water pump sealing surfaces (6) Damage to the water pump bolt hole threads (7)
2. Inspect the interior of the engine front cover for the following conditions: Damage to the engine front cover bolt holes (1) Gouges or damage to the engine front cover sealing surfaces to the engine block (7), oil pan (5), and/or camshaft covers (2) Gouges or damage to the water pump seal area (3) Loose or damaged deadener plates (4) Damage and/or corrosion to the engine coolant passage (6) Damage to the crankshaft front oil seal bore Gouges or damage to the O-ring sealing areas
3. Repair or replace the engine front cover as necessary.

1. EN 46103 Camshaft Actuator Valve Seal Remover/Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. J 29184 Output Shaft Seal Installer. See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

1. Install the NEW crankshaft front oil seal into the engine front cover using the J 29184 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Place the seal into position with the notches (1) in the seal down. The notches (1) will face in board when properly installed.
3. Install the NEW camshaft position actuator valve oil seals into the engine front cover using the EN 46103 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .

Camshaft Cover Disassemble

1. Remove the camshaft cover bolts.
2. Remove and discard the camshaft cover bolt grommets.
3. Remove and discard the camshaft cover gasket.
4. Remove and discard the ignition coil seals.

1. Clean the camshaft covers in solvent.
2. Dry the camshaft covers with compressed air.

1. Inspect each camshaft cover for the dents or damage to the exterior. A dented or damaged camshaft cover may: Leak engine oil Effect crankcase ventilation Interfere with the camshafts Interfere with the ignition coil sealing Allow water or condensation to enter the engine
2. Inspect the exterior of the left camshaft cover for the following conditions: Damage to the camshaft cover bolt holes (1) Damage to the oil fill hole (2) Damage to the mounting holes (3) for the ignition coil assembly Damage to the positive crankcase ventilation (PCV) hose connector (4) - A damaged PCV hose connector is replaceable.
3. Inspect the interior of the left camshaft cover for the following conditions: Gouges or damage to the camshaft cover sealing groove (1) Damaged, loose or missing baffle fasteners (2) Damaged, loose or missing baffle (3) Gouges or damage to the ignition coil seal bore (4) Restrictions to the ventilation system (5)
4. Inspect the exterior of the right camshaft cover for the following conditions: Damage to the camshaft cover bolt holes (1) Damage to the mounting holes (2) for the ignition coil assembly Damage to the PCV orifice (3) - A damaged PCV orifice can be replaced. Refer to PCV Orifice Replacement.
5. Inspect the interior of the right camshaft cover for the following conditions: Gouges or damage to the camshaft cover sealing groove (1) Gouges or damage to the ignition coil seal bore (2) Restrictions to the ventilation system (3)
6. Repair or replace the camshaft cover or covers as necessary.

PCV Orifice Replacement

1. Remove the old PCV orifice by griping the neck of the orifice with pliers and twisting and pulling out of the right camshaft cover.
2. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the NEW PCV orifice (1).
3. Install the NEW PCV orifice into the right camshaft cover. After insertion, twist the PCV orifice in order to eliminate any vertical leak paths in the sealant.

PCV Fitting Replacement

1. Remove the old PCV fitting.
2. Install the new PCV fitting with a NEW O-ring.

J 24254 Oil Seal Installer. See Special Tools .

1. Install the NEW ignition coil seals using the J 24254 . See «Special Tools»(/buick/lacrosse/i-2004-2009/remont/mechanical/#how-to-diagnosis-troubleshooting-the-engine-mechanical-36l-ly7-introduction__special-tools) .
2. Install the NEW camshaft cover gasket.
3. Install the NEW camshaft cover bolt grommets.
4. Install the camshaft cover bolts.

Upper to Lower Intake Manifold Disassemble Procedure

1. Remove the upper-to-lower intake manifold bolts.
2. Remove the fuel rail feed hose bracket bolts from the upper intake manifold.
3. Remove the fuel injector wiring harness bracket bolt from the upper intake manifold.
4. Remove the upper intake manifold from the lower intake manifold.
5. Remove and discard the upper-to-lower intake manifold gaskets.

Upper Intake Manifold Disassemble Procedure

1. Remove the fuel rail support bracket bolt.
2. Remove the fuel rail support bracket.
3. Remove the throttle body bolts.
4. Remove the throttle body.
5. Remove and discard the throttle body gasket.
6. Remove the barometric pressure (BARO) sensor bolt.
7. Remove the BARO sensor.
8. Remove the intake manifold opening cover bolts.
9. Remove the intake manifold opening cover.

Lower Intake Manifold Disassemble Procedure

1. Remove the fuel injector wiring harness.
2. Remove the fuel injector rail bolts.
3. Remove the fuel injector rail.

Upper Intake Manifold Cleaning Procedure

1. Remove any remaining gasket and/or gasket material from the following: Throttle body Intake manifold
2. Clean the following intake manifold areas in solvent. Intake manifold gasket sealing areas Intake manifold passages Brake booster hose passage Evaporative emission (EVAP) solenoid passage Positive crankcase ventilation (PCV) vacuum hose passages Barometric pressure (BARO) sensor passage
3. Dry the upper intake manifold and throttle body with compressed air.

1. Inspect the upper intake manifold for the following conditions: Damage, debris or restrictions to the BARO sensor mounting port Damage, debris or restrictions to the brake vacuum booster hose port Damage to the throttle body bolt holes Damage, debris or restrictions to the PCV system hose ports
2. Inspect the upper intake manifold for the following conditions: Damage to the intake manifold bolt bosses Damage to the EVAP purge solenoid mounting boss Damage, debris or restrictions to the EVAP purge solenoid port Damage, debris or restrictions in the vacuum passage
3. Inspect the upper intake manifold for the following conditions: Damage to the intake manifold opening cover mounting bosses (1) Damage, debris or restrictions to the intake manifold opening cover port (2) Damage to the intake manifold opening cover components
4. Inspect the upper intake manifold for the following conditions: Gouges or damage to the upper intake manifold sealing surfaces (1) Damage to the gasket sealing surface (2) for the throttle body
5. Inspect the upper intake manifold sealing surface for warpage. Locate a straight edge across the upper-to-lower intake manifold sealing surface. Insert a feeler gage between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.
6. Repair or replace the upper intake manifold as necessary.

Lower Intake Manifold Cleaning Procedure

1. Remove any remaining gasket and/or gasket material from the following: Upper-to-lower intake manifold sealing surface Cylinder head-to-lower intake manifold sealing surface
2. Clean the following intake manifold areas in solvent. Intake manifold gasket sealing surfaces Intake manifold passages
3. Dry the intake manifold with compressed air.

1. Inspect the lower intake manifold for the following conditions: Damage, debris or restrictions to the lower intake manifold ports Damage to the fuel rail mounting bolt holes Damage to the fuel rail
2. Inspect the lower intake manifold for the following conditions: Gouges or damage to the intake manifold sealing surfaces Damage to the lower intake manifold bolt bosses Damage to the fuel injector ports
3. Inspect the lower intake manifold sealing surfaces for warpage. Locate a straight edge across the lower intake manifold sealing surfaces. Insert a feeler gage between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.
4. Repair or replace the lower intake manifold as necessary.

Lower Intake Manifold Assemble Procedure

1. Install the fuel injector rail.
2. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
3. Install the fuel injector wiring harness connector.

Upper Intake Manifold Assemble Procedure

1. Install the intake manifold opening cover.
2. Install the intake manifold opening cover bolts. Tighten: Tighten the intake manifold opening cover bolts to 10 N.m (89 lb in).
3. Install the barometric pressure (BARO) sensor.
4. Install the BARO sensor bolt. Tighten: Tighten the BARO sensor bolt to 10 N.m (89 lb in).
5. Install the NEW throttle body gasket.
6. Install the throttle body.
7. Install the throttle body bolts. Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).
8. Install the fuel rail support bracket.
9. Install the fuel rail support bracket bolt. Tighten: Tighten the fuel rail support bracket bolt to 10 N.m (89 lb in).

Upper to Lower Intake Manifold Assemble Procedure

1. Install the NEW upper-to-lower intake manifold gaskets.
2. Install the upper intake manifold to the lower intake manifold.
3. Install the fuel injector wiring harness bracket bolts to the upper intake manifold. Tighten: Tighten the fuel injector wiring harness bracket bolts to 10 N.m (89 lb in).
4. Install the fuel rail feed hose bracket bolt to the upper intake manifold. Tighten: Tighten the fuel rail feed hose bracket bolt to 10 N.m (89 lb in).
5. Install the upper-to-lower intake manifold bolts. Tighten: Tighten the upper-to-lower intake manifold bolts to 23 N.m (17 lb ft).

1. Clean the exhaust manifold in solvent.
2. Dry the exhaust manifold with compressed air.

1. Inspect the left exhaust manifold for the following: Damage or excessive corrosion to the exhaust manifold exterior (1) Damage to the exhaust manifold mounting holes (2) Damage to the threaded holes (3) for the heat shield Damage to the exhaust manifold flange bolt holes (4)
2. Inspect the left exhaust manifold for the following: Damage to the gasket sealing surfaces (1) Damage or restrictions within the exhaust passages (2)
3. Repair or replace the left exhaust manifold and/or components as necessary.
4. Measure the alignment or surface flatness of the exhaust manifold flanges, using a straight edge and a feeler gage. Exhaust manifold surface flatness must not exceed 0.254 mm (0.010 in).
5. If the surface flatness is not within specifications, the exhaust manifold is warped and must be replaced.

1. Clean the exhaust manifold in solvent.
2. Dry the exhaust manifold with compressed air.

1. Inspect the right exhaust manifold for the following: Damage to the exhaust manifold mounting holes (1) Damage to the threaded holes (2) for the heat shield Damage or excessive corrosion to the exhaust manifold exterior (3) Damage to the exhaust manifold flange bolt holes (4)
2. Inspect the right exhaust manifold for the following: Damage to the gasket sealing surfaces (1) Damage or restrictions within the exhaust passages (2)
3. Repair or replace the right exhaust manifold and/or components as necessary.
4. Measure the alignment or surface flatness of the exhaust manifold flanges, using a straight edge and a feeler gage. Exhaust manifold surface flatness must not exceed 0.254 mm (0.010 in).
5. If the surface flatness is not within specifications, the exhaust manifold is warped and must be replaced.

See also:
• Special Tools
• Engine Mechanical Specifications
• Safety Glasses Caution
• Thread Repair Specifications
• THREAD REPAIR
• Fastener Notice
• Piston, Connecting Rod and Bearings Cleaning and Inspection