Engine Mechanical - 2.0l - Repair Instructions - off Vehicle Buick Regal V

Scheme 96

After the flywheel housing has been removed, mount the engine block to a suitable engine stand (1).

Engine Oil Cooler Removal (LDK, LHU)

1. Remove the oil cooler bolt (2).
2. Remove the oil cooler (1).

Draining Fluids and Oil Filter Removal

Special Tools

EN-44887 Oil Filter Wrench

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Use EN-44887 wrench to remove the oil filter cap (1). Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter (2) from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug and tighten to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant to the water pump drain plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
7. Install the water pump drain plug and tighten to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

Special Tools

1. EN-38122-A Crankshaft Balancer Holder
2. EN-43653 Flywheel Holding Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install EN-38122-A holder (1).
2. Remove the balancer retaining bolt and washer. Use EN-38122-A holder and a breaker bar to prevent the crankshaft from rotating when loosening the bolt. Discard the bolt.
3. Remove the crankshaft balancer assembly (1) using a universal removal tool.

Engine Flywheel Removal (Manual Transmission)

Special Tools

EN-43653 Flywheel Holding Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install EN-43653 flywheel holding tool (1) in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
2. Remove the clutch pressure plate bolts and clutch pressure plate (1).
3. Remove the clutch driven plate (2).
4. Remove the flywheel attaching bolts.
5. Remove the flywheel (1).
6. Remove the pilot bearing.
7. Remove EN-43653 flywheel holding tool.

Engine Flywheel Removal (Automatic Transmission)

Special Tools

EN-43653 Flywheel Holding Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install EN-43653 flywheel holding tool (1) in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
2. Remove the flywheel attaching bolts.
3. Remove the flywheel (1).
4. Remove EN-43653 flywheel holding tool.

Oil Level Indicator and Tube Removal (LDK, LHU)

1. Disconnect the knock sensor from the oil level indicator tube (1).
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator (2) and the oil level indicator tube from the oil pan.
5. Inspect the O-rings for damage. Replace if damaged.

Starter Removal

1. Remove the starter bolts.
2. Remove the starter (1).

Intake Manifold Removal

1. Disconnect the charger AIR bypass tube assembly from the intake manifold.
2. Disconnect the charger AIR bypass tube with the retaining clip from the charger AIR bypass valve solenoid.
3. Remove the charger AIR bypass valve tank assembly nut (2).
4. Loosen the charger AIR bypass valve tank assembly bolt.
5. Remove the charger AIR bypass valve tank assembly (1).
6. Disconnect the remaining charger AIR bypass tubes at the turbocharger and vehicle.
7. Remove the charger AIR bypass valve solenoid bolts.
8. Remove the charger AIR bypass valve solenoid (1).
9. Remove the high pressure fuel pump cover bolts.
10. Remove the high pressure fuel pump cover (2).
11. Remove the high pressure fuel pump noise insulator (1).
12. Loosen and disconnect the fuel feed line tube nut (1).
13. Remove the fuel feed line bolts.
14. Remove the fuel feed line (2).
15. Inspect the fuel feed line nut for damaged threads.
16. Inspect the fuel feed line sealing bail for damage or debris.
17. Replace the fuel feed line if any damage is found.
18. Remove the throttle body bolts (2).
19. Remove the throttle body (1).
20. Disconnect the rear knock sensor from the intake manifold brace.
21. Remove the intake manifold brace bolt (1) and nut (3).
22. Remove the intake manifold brace (2).
23. Remove the MAP sensor bolt (1) and MAP sensor (2).
24. Remove the EVAP purge solenoid valve bolt (3) and valve (4).
25. Remove the intake manifold bolts and nuts (3).
26. Remove the intake manifold (2).
27. Remove the intake manifold gasket (1).

Fuel Rail and Injectors Removal (LDK, LHU)

Special Tools

1. DT-2619-01 Slide Hammer
2. EN-37281-A Injector Remover

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Disconnect the electrical harness from the fuel rail harness connection.
2. Remove the fuel injector noise insulator (1).
3. Remove and discard the high pressure fuel line (1).
4. Disconnect all 4 fuel injector electrical connections.
5. Remove the fuel rail bolts.
6. Remove the fuel rail and injectors (1).
7. Remove the fuel injector hold-down clamp before removing the fuel injector.
8. Use EN-37281-A remover (2) and DT-2619-01 slide hammer to remove the fuel injector (1).
9. Remove the high pressure fuel pump bolts.
10. Remove the high pressure fuel pump (3).
11. Remove and discard the high pressure fuel pump gasket (1).
12. Remove and discard the high pressure fuel pump O-ring (2).
13. Remove the high pressure fuel pump roller lifter (1).

Turbocharger Removal (LDK, LHU)

1. Remove the turbocharger heat shield bolts.
2. Remove the turbocharger heat shield (1).
3. Remove the catalytic converter nuts and L-bracket bolts.
4. Remove the catalytic converter (1).
5. Remove the catalytic converter seal (2).
6. Remove the catalytic converter L-bracket nuts and L-bracket (2) from the catalytic converter (1).
7. Remove the turbocharger oil feed pipe bolts.
8. Remove the turbocharger oil feed pipe gaskets.
9. Remove the turbocharger oil feed pipe (1).
10. Remove the turbocharger coolant return pipe bolts.
11. Remove the turbocharger coolant return pipe gaskets.
12. Remove the turbocharger coolant return pipe (1).
13. Remove the turbocharger air cooler outlet pipe bolts.
14. Remove the turbocharger air cooler outlet pipe (1).
15. Remove the turbocharger coolant feed pipe bolts.
16. Remove the turbocharger coolant feed pipe gaskets.
17. Remove the turbocharger coolant feed pipe (1).
18. Remove the catalytic converter bracket bolts.
19. Remove the catalytic converter bracket (1).
20. Remove the turbocharger brace nuts.
21. Remove the turbocharger brace (1).
22. Remove the PCV hose fitting bolt at the turbocharger.
23. Remove the PCV hose fitting from the turbocharger.
24. Remove the turbocharger nuts (1).
25. Remove the turbocharger (2) and the oil return pipe.
26. Remove the turbocharger gasket (3).
27. Remove the turbocharger oil return pipe bolts (3).
28. Remove the turbocharger oil return pipe (2) from the turbocharger.
29. Remove and discard the turbocharger oil return pipe gasket (1).

Exhaust Manifold Removal (LDK, LHU)

1. Remove the exhaust manifold heat shield bolts.
2. Remove the exhaust manifold heat shield (1).
3. Remove the exhaust manifold nuts.
4. Remove the exhaust manifold (1).
5. Remove the exhaust manifold gasket (2).

Camshaft Cover Removal (LDK, LHU)

1. Remove the rear lift bracket bolts and rear lift bracket (1).
2. Remove the front lift bracket bolts and front lift bracket (1).
3. Remove the power brake booster pump bolts.
4. Remove the power brake booster pump (2).
5. Remove and discard the power brake booster O-ring seal (1).
6. Remove the bolt and coil (1).
7. Remove the camshaft housing cover insulator bolts.
8. Remove the camshaft housing cover insulator (1).
9. Remove the camshaft cover assembly (1).
10. Remove and discard the camshaft cover gasket, camshaft cover grommets, and camshaft cover bolts if they are serviced with the grommets.

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner bolt.
2. Remove the accessory drive belt tensioner (1).
3. Remove the engine front cover bolts (1).
4. Remove the long water pump bolt.
5. Remove the engine front cover (1) and gaskets (2).
6. Remove the crankshaft front cover oil seal with an appropriate tool.

Timing Chain and Tensioner Removal (LDK, LHU)

Special Tools

EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU)

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide (1).
3. Remove the timing chain tensioner (1).
4. Rotate intake camshaft actuators to install EN-48953 locking tool (1).
5. Install EN-48953 locking tool onto the cylinder head and tighten to 10N.m (89 lb in). If the intake camshaft actuator is moving independent of cam and is not locked, rotate the intake camshaft counter-clockwise and the tool will hold the actuator, locking the actuator to the cam.
6. Loosen the intake camshaft actuator bolt.
7. Loosen the exhaust camshaft actuator bolt.
8. Remove EN-48953 locking tool.
9. Locate hex on the exhaust camshaft and hold with a wrench (2).
10. Remove the exhaust cam bolt and the exhaust cam actuator (1). Discard the bolt.
11. Remove the adjustable timing chain guide bolt.
12. Remove the adjustable timing chain guide (1).
13. Remove the plug (1) to gain access to the fixed timing chain guide bolt.
14. Remove the fixed timing chain guide bolts.
15. Remove the fixed timing chain guide (1).
16. Locate hex on the intake camshaft and hold with a wrench.
17. Remove the intake cam sprocket bolt, the intake cam sprocket (1) and the timing chain (2) through the top of the cylinder head. Discard the bolt.
18. Mark the cylinder head where the exhaust camshaft actuator locking notch (1) and intake camshaft locking notch (2) are lined up with the cylinder head.
19. Remove the friction washers (1), if equipped.
20. Remove the crankshaft sprocket (2).
21. Remove the timing chain oil nozzle bolt.
22. Remove the timing chain oil nozzle (1).

Intake Camshaft and Components Removal

1. Remove the intake camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Remove the rear cylinder head opening plate bolts (2) and plate (1).
3. Remove the intake camshaft bearing rear cap bolts and camshaft bearing rear cap (2).
4. Mark camshaft caps to ensure they are installed in the same position.
5. Remove the intake camshaft cap bolts.
6. Remove the camshaft caps (1).
7. Remove the intake camshaft (3).
8. Remove the intake camshaft roller finger followers (1).
9. Remove the hydraulic lash adjusters (1).

Exhaust Camshaft and Components Removal

1. Remove the exhaust camshaft position actuator solenoid valve bolt (1) and valve (2).
2. Remove the exhaust camshaft bearing rear cap bolts and exhaust camshaft bearing rear cap (2).
3. Mark camshaft caps to ensure they are installed in the same position.
4. Remove the exhaust camshaft cap bolts.
5. Remove the camshaft caps (1) ensuring they are marked and refitted in same position on assembly.
6. Remove the exhaust camshaft (3).
7. Remove the exhaust camshaft roller finger followers (1).
8. Remove the hydraulic lash adjusters (1).

Water Pump and Balance Shaft Chain and Tensioner Removal

1. Remove the balance shaft drive chain tensioner bolts.
2. Remove the balance shaft drive chain tensioner (1).
3. Remove the adjustable balance shaft chain guide bolt.
4. Remove the adjustable balance shaft chain guide (1).
5. Remove the small balance shaft drive chain guide bolts.
6. Remove the small balance shaft drive chain guide (1).
7. Remove the upper balance shaft drive chain guide bolts.
8. Remove the upper balance shaft drive chain guide (1).
9. Remove the balance shaft drive chain (1).
10. Remove the balance shaft drive sprocket (2).

Special Tools

EN-43650 Balancer Shaft Bearing Remover and Installer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies (1).
3. Install the EN-43650 remover / installer (1) into the balance shaft hole. Insert the tool with the foot parallel to the shaft.
4. When the EN-43650 remover / installer is inserted in the block turn the EN-43650 remover / installer so that the foot becomes perpendicular to the shaft.
5. Center the foot of the EN-43650 remover / installer on the balance shaft bushing.
6. Once the EN-43650 remover / installer is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. When the EN-43650 remover / installer is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in) (a) from the block face. If the EN-43650 remover / installer is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
7. Tighten the nut on the EN-43650 remover / installer (1) until the tension releases. When the tension releases, remove the EN-43650 remover / installer and the balance shaft bushing (2).

Water Pump Removal (LDK, LHU)

1. Remove the engine coolant temperature sensor (1).
2. Remove the thermostat and water feed pipe retaining bolts.
3. Remove the thermostat housing (1) and water feed pipe (2) from the water pump cover.
4. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
5. Remove the water pump assembly (1).
6. Remove and discard the gasket (2).

Cylinder Head Removal (LDK, LHU)

Special Tools

EN-38188 Cylinder Head Broken Bolt Extractor Kit

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. Remove the cylinder head (1).
3. Remove the cylinder head gasket (2).
4. Clean all of the gasket surfaces.
5. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. NOTE: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. NOTE: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
6. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the bolt holes with a nylon bristle brush.
8. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the EN-38188 extractor kit.

Oil Pan Removal (LDK, LHU)

1. Remove the oil pan bolts.
2. Remove the oil pan (1) at pry points.

Piston, Connecting Rod, and Bearing Removal (LDK, LHU)

Special Tools

EN-43966-1 Connecting Rod Guides

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap (1).
6. Install EN-43966-1 guides (1) on the connecting rod bolts before removing the piston and connecting rod assembly.
7. Remove the piston and connecting rod assembly (2).

Lower Crankcase Removal

1. Remove the bedplate perimeter bolts (3).
2. Remove and discard the crankshaft bearing bolts (2).
3. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase (1).

Crankshaft and Bearing Removal

1. Remove the crankshaft (1) from the block.
2. Remove the crankshaft rear oil seal (2).
3. Remove the bearing inserts (1) from the block (2).
4. Remove the bearing inserts (1) from the bed plate (2).
5. Clean the oil, sludge, and carbon.
6. Inspect the oil passages for obstructions.
7. Inspect the threads.
8. Inspect the bearing journals and the thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating (discoloration)
9. Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists find the cause and repair it.
10. Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selection of bearing inserts. If not within limits the crankshaft must be replaced. Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

Engine Block Disassemble

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plugs (3).
4. Remove the 3 oil passage plugs on each side of the block (2).
5. Remove the 2 water passage plugs on the top of the block (1).
6. Remove the 2 front oil passage plugs.
7. Remove the knock sensors (1).
8. Remove the oil pressure switch (2).
9. Remove the crankshaft position (CKP) sensor (1) and bolt.
10. Inspect the crankshaft position sensor for damage and replace, if necessary.
11. Loosen the piston oil nozzle assembly captured bolts and remove the piston oil nozzle assemblies (1).

1. EN-7872 Magnetic Base Dial Indicator
2. EN-8087 Cylinder Bore Gauge

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Clean the sealing material from the gasket mating surfaces with a suitable tool (1).
2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to «Thread Repair Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications) .
8. Use a straight edge (1) and a feeler gauge (2) to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side with a suitable tool (1).
11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side with a suitable tool (1).
12. Inspect the mating surfaces of the transmission face.
13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the crankshaft and upper bearings. Measure the crankshaft flange runout using the EN-7872 dial indicator (1) Hold the gauge plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in). Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in). Remove the crankshaft and bearings.
14. Install the bed plate and bolts. Tighten the bed plate bolts to specification.
15. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge (1) to measure the bearing bore concentricity and alignment. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
16. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
17. Remove the bed plate.
18. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items: Wear Taper Runout Ridging
19. If the cylinder bores are out of specification, install a NEW cylinder bore sleeve. Refer to «Cylinder Sleeve Removal»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle__cylinder-sleeve-removal) , and «Cylinder Sleeve Installation»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .

EN-8087 Cylinder Bore Gauge

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasket surface.
3. Measure the cylinder bores by setting the EN-8087 gauge (1) dial at zero in the cylinder at the point of the desired measurement. Lock the dial indicator at zero before removing the dial from the cylinder. Measure across the gauge contact points with an outside micrometer, with the gauge at the same zero setting as when the gauge was removed from the cylinder.
4. Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do not hone the cylinder in order to remove these scratches.
5. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings. Refer to «Piston, Connecting Rod, and Bearing Installation (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle__piston-connecting-rod-and-bearing-installation) . The honing stones must be clean, sharp, and straight. Move the hone slowly up and down to produce a 45 degree cross-hatch pattern. Clean the bore thoroughly with soap and water. Dry the bore. Rub clean engine oil in the bore. Re-measure the bore.
6. If the cylinder bore is out of specification, install a new cylinder bore sleeve. Refer to «Cylinder Sleeve Removal»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle__cylinder-sleeve-removal) , and «Cylinder Sleeve Installation»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .
7. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing and drying the bore.

Cylinder Sleeve Removal

Special Tools

EN-45680-850 Cylinder Sleeve Removal and Installation Kit

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install EN-45680-852 cylinder bore sleeve puller (1) through the cylinder bore.
3. Align the shoe (1) of EN-45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of EN-45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install EN-456850-851 fixture (4) onto the threaded shaft of EN-456850-852 cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install the 4 attaching bolts (2) into the cylinder head bolt holes of the block and tighten to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve (1).
10. Remove EN-45680-851 fixture, EN-45680-852 cylinder bore sleeve puller, and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .

EN-45680-850 Cylinder Sleeve Removal and Installation Kit

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture EN-45680-851 fixture and the EN-45680-853 cylinder bore sleeve installer (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. Insert the 4 attachment bolts into the legs of the fixture EN-45680-851 (1).
4. Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) of the EN-45680-853 cylinder bore sleeve installer onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) of the EN-45680-851 cylinder bore sleeve installer into the groove of fixture (1).
8. Using a ratchet, rotate the threaded shaft of the EN-45680-853 (1) cylinder bore sleeve installer in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
10. Using a torque wrench, torque the threaded shaft of EN-45680-851 fixture assembly (1) to 102 N.m (75 lb ft)to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the EN-45680-851 fixture assembly with the EN-45680-853 (1) cylinder bore sleeve installer from the cylinder block (100).

Scheme 97

The EN-45680-861 trim tool assembly (2) contains or requires the following components to complete 2.0L, 86 mm cylinder sleeve trimming

1. Debris collector (3) with EN-45680-865 filter.
2. Air control valve (1)
3. Drill motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction
4. EN-45680-869 bore cutter bit and screw.
5. EN-45680-899 Bore trimmer pilot, white in color

Scheme 98

1. EN-45680-862 Gauge ring assembly. Trim tool preloader (1) Set gauge ring (2)
2. EN-45680-412 Set Gauge Ring (2)
3. EN-45680-863 metal shavings catch plug (3)
4. EN-45680-866 drive adapter (4)
5. EN-45680-864 bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place EN-45680-863 metal shaving catch plug (1) into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place an additional EN-45680-863 metal shaving catch plug into all remaining cylinder bore sleeves.
4. Ensure that the EN-45680-863 metal shaving catch plug (1) is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. Ensure that the correct bore trimmer pilot and cutter bit are installed on the EN-45680-861 trimmer base assembly : EN-45680-869 cutter bit and screw EN-45680-899 trimmer pilot, 86 mm sleeve
6. The groove side of the set gauge ring (1) on the EN-45680-862 gage ring assembly should be positioned upward on a flat surface.
7. Carefully position the EN-45680-861 trim tool assembly onto the set gauge ring.
8. Loosen the shaft collar screw (2).
9. Push the shaft collar (2) downward using the trim tool preloader (1) on the EN-45680-862 gage ring assembly until the shaft collar is positioned against the top of the flange bearing (3).
10. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 N.m (14 lb ft).
11. Place the EN-45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
12. Install the EN-45680-864 (2) 4 bolts into the cylinder head bolt holes in the block and tighten to 20 N.m (15 lb ft).
13. Fasten the drive adapter EN-45680-866 (1) into the drill chuck.
14. Connect a compressed air supply 517.10-861.84 kPa (75-125 psi) to the male quick connect (3) located on EN-45680-861 trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
15. Place the EN-45680-866 drive adapter and drill assembly (1) vertically onto the drive adapter end of EN-45680-861 trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, apply firm downward force until the cutting action is complete.
16. Remove the EN-45680-866 drive adapter (1) and drill assembly from the EN-45680-861 trim tool assembly.
17. Turn off the compressed air valve (2).
18. Remove the EN-45680-861 trim tool assembly from the engine block.
19. Remove any material shavings that may be found on the EN-45680-863 metal shaving catch plug.
20. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the EN-45680-863 metal shaving catch plug.
21. Install a straight edge (2) on the cylinder block perpendicular to the crankshaft center line.
22. Using a light (1), illuminate the backside of the straight edge.
23. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve (2), the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
24. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve (2) is cut correctly.
25. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer (1).
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following conditions: Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust, or other damage must be replaced. Axial cracks in and around the keyway NOTE: In order for the belt to track properly, the belt grooves should be free of all dirt or debris. Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. Minor imperfections may be removed with a fine file. Worn, chunking, or deteriorated rubber between the hub and pulley

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel in solvent (1, 2).
2. Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel (1) for the following conditions: Damaged ring gear teeth Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel. A scored, grooved or damaged friction surface
4. Inspect the automatic transmission flywheel (1) for the following conditions: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations Weight saving holes

Crankshaft and Bearing Cleaning and Inspection

Special Tools

EN-7872 Magnetic Base Dial Indicator Set

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Clean the crankshaft (1) with solvent.
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air.
4. Perform a visual inspection of the crankshaft for damage.
5. The crankshaft position reluctor ring (1) may be replaced if damaged. Tighten the crankshaft position reluctor ring bolts to 15 N.m (11 lb ft).
6. Inspect the crankshaft journals for wear (1). The journals should be smooth, with no signs of scoring, wear, or damage.
7. Inspect the crankshaft journals for grooves or scoring (2).
8. Inspect the crankshaft journals for scratches or wear (3).
9. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
10. Measure the crankshaft journals for out-of-round (1).
11. Measure the crankshaft journals for taper.
12. Measure the crankshaft runout. Using wooden V-blocks, support the crankshaft on the front and rear journals.
13. Use the EN-7872 dial indicator (1) in order to measure the crankshaft runout at the front and rear intermediate journals.
14. Use the EN-7872 dial indicator in order to measure the runout of the crankshaft rear flange.
15. Replace the crankshaft if the measurements are not within specifications.
16. Inspect crankshaft bearings for craters or pockets (1). Flattened sections on the bearing halves also indicate fatigue.
17. Inspect the crankshaft bearings for excessive scoring or discoloration (2).
18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing (3). If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

Piston and Connecting Rod Disassemble (LDK, LHU)

Special Tools

1. EN-46745 Piston Clip Retainer Remover/Installer
2. EN-46745-4 Piston Clip Retainer Remover/Installer Adapter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Disassemble the piston rings (1). Use a suitable tool to expand the rings. The piston rings must not be reused.
2. Remove the piston pin retainers using the EN-46745 remover (1) and the EN-46745-4 adapter.
3. Remove the piston pin (1) and connecting rod (3) from the piston (2).

Connecting Rod Measurement

1. Clean the connecting rods (1) in solvent and dry with compressed air.
2. Inspect the connecting rods for the following conditions: Signs of being twisted, bent, nicked, or cracked Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure: Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. Using an inside micrometer, measure the connecting rod piston pin bore. Subtract the piston pin diameter from the piston pin bore diameter. The clearance should not be more than 0.021 mm (0.0008 in).
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.

Piston Measurement

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Ensure the oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston (1) Scuffed or damaged skirts (2) Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. 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. Using an inside micrometer, measure the piston pin bore. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). If the clearance is excessive, determine which component is out of specification.
6. 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 or 1 inch down from the deck surface. Ensure 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 gauges (1). Compare the measurements with those provided below: Specification The top compression ring end gap should be 0.20-0.35 mm (0.0078-0.0138 in). The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in). The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). If the clearance exceeds the provided specifications, the piston rings must be replaced. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure: Roll the piston ring (2) entirely around the piston ring groove. If any binding is caused by a distorted piston ring, replace the ring. With the piston ring on the piston, use feeler gauges (1) to measure clearance at multiple locations. The clearance between the surface of the top piston ring and the ring land should be no greater than 0.055 mm (0.0022 in). If the clearance is greater than specifications, replace the piston ring. If the new ring does not reduce the top ring side clearance to 0.055 mm (0.0022 in) or less, install a new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the second compression ring near the end for identification of the top side. Install the second compression ring with the dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than 0.032 mm (0.0012 in).
10. If the new ring does not reduce the clearance to 0.032 mm (0.0012 in) or less, install a new piston.
11. Measure piston width using the following procedure: Using an outside micrometer (2), measure the width of the piston (1) 12.5 mm (0.4925 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. The proper clearance specification for the piston is 0.010-0.041 mm (0.0006-0.0016 in).
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replace the piston.

Piston Selection

1. Inspect the engine block cylinder bore. Refer to «Engine Block Cleaning and Inspection»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .
2. Inspect the piston and the piston pin. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .
3. Using a bore gauge (1), measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge (1) with a micrometer and record the reading.
5. With a micrometer (2) or caliper at a right angle to the piston, measure the piston (1) 14 mm (0.570 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «Separating Parts»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-description-and-operation__separating-parts) .

Piston and Connecting Rod Assemble (LDK, LHU)

Special Tools

1. EN-46745 Piston Pin Clip Remover/Installer
2. EN-46745-4 Piston Pin Clip Remover/Installer Adapter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Assemble the connecting rod (2) and the piston (1).
2. Use the following procedure to assemble the piston pin and the retainer: Coat the piston pin with oil. Using the EN-46745 installer (1) and the EN-46745-4 adapter, install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Using the EN-46745 installer and the EN-46745-4 adapter, install the second piston pin retainer. Ensure that the piston moves freely.
3. Install the following components of the oil control ring assembly - bottom ring (6): The expander (5) The lower oil control ring (4) The upper control ring (3)
4. Install the lower compression ring - second ring (2). Place the manufacturer's mark facing up.
5. Install the upper compression ring - top ring (1).

Camshaft Cleaning and Inspection (LDK, LHU)

1. Inspect the camshaft journals and lobes for wear or scoring.
2. Inspect the camshaft sprocket alignment notch for damage.
3. Inspect the exhaust camshaft insert (2) for damage.
4. Inspect the camshaft cover for damage or loose oil control baffles.
5. Inspect the PCV hose (1) attached to the camshaft cover. Replace the camshaft cover if damage to the PCV hose is present.
6. Clean the camshaft cover.
7. Wash the camshaft in solvent.
8. Oil the camshaft.
9. Inspect the camshaft cover for cracks or other signs of damage.

Camshaft Timing Chain and Sprocket Cleaning and Inspection (LDK, LHU)

1. Inspect the timing chain guides (1, 4, 6) for cracking or wear.
2. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the timing chain tensioner shoe for wear.
4. Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
5. Inspect the timing chain (2) and actuators (3, 8) for wear.
6. Inspect the camshaft actuator faces for signs of movement.
7. Inspect the camshaft actuator teeth and chain for signs of excessive wear, chipping, or seizure of the timing chain links.
8. Inspect the oil nozzle body (5) for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body if it is damaged.
9. Inspect the timing chain tensioner (7) for the scoring or free movement.
10. Inspect the timing chain seal for damage. If damaged, replace the seal.

Balance Shaft Cleaning and Inspection

1. Clean the balance shafts (2) in solvent.
2. Inspect the bearing (1) surfaces on the balance shafts for scoring or unusual wear.
3. Inspect the balance shaft drive sprockets for wear, damage, or missing teeth.
4. Measure the rear bearing journals on the balance shafts, the journals should be 36.723-36.743 mm (1.4458-1.4466 in) in diameter.
5. Measure the front bearing journals on the balance shafts, the front bearing journals should be 20.020-20.000 mm (0.7881-0.7874 in) in diameter.
6. When the balance shafts have been installed in the engine block, check for smooth rotation, sticking, binding, or roughness.

Water Pump and Balance Shaft Chain and Sprocket Cleaning and Inspection (LDK, LHU)

1. Inspect the balance shaft drive chain guides (3, 5, 8) for cracking or wear.
2. Replace the balance shaft drive chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the balance shaft drive chain tensioner guide shoe for wear. Replace the balance shaft drive chain tensioner guide shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
4. Inspect the balance shaft drive chain (7) and sprockets (2, 4) for wear.
5. Inspect the crankshaft sprocket (6) faces for signs of movement.
6. Inspect the alignment notch in the balance shaft for cracking or damage.
7. Inspect the water pump (1), crankshaft, and balance shaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the balance shaft drive chain links.
8. Inspect the timing chain tensioner (9) for damage or wear.

Cylinder Head Disassemble (LDK, LHU)

Special Tools

1. EN-8062 Valve Spring Compressor
2. EN-36017 Valve Seal Remover
3. EN-43963 Valve Spring Compressor (off car)

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Remove the intake camshaft position sensor (1) and bolt.
2. Using the EN-8062 compressor and the EN-43963 compressor, compress the valve spring.
3. Remove the valve keys (1).
4. Slowly release the EN-8062 compressor and the EN-43963 compressor from the valve spring assembly.
5. Remove the retainers (2).
6. Remove the springs (1).
7. Using the EN-36017 remover, remove the valve seals (1). Do not reuse the valve seals.
8. Remove the valves (1).
9. Remove the cylinder head plugs (1).

1. EN-28410 Gasket Remover
2. J 7872 Magnetic Base Dial Indicator
3. J 22738-B Valve Spring Tester

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Valve Cleaning and Inspection

1. Clean the valves of carbon, oil and varnish. Use a soft bristle wire brush to clean any carbon build-up from the valve head. Varnish can be removed by soaking in Parts Immersion Solvent. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Clean the valve guides.
3. Inspect the valve stem for pitting or wear (4).
4. Inspect the valve keeper groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.
6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.
7. Inspect the valve stem for straightness (3) and the valve head for bending or distortion using V-blocks. Bent or distorted valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must be replaced.
10. Replace the valve if the valve head O.D. and chamfer (2) is worn or out of specification. Refer to «Valve and Seat Grinding»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .
11. The valves may be lightly lapped to the valve seats.
12. Replace the valve if the valve tip (6) is worn.
13. If no apparent wear, pitting, grooving, or distortion is present, perform the valve measurement and reconditioning procedure to verify valve specification. Refer to «Valve and Seat Grinding»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .

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 7872 indicator to the cylinder head at the camshaft cover rail.
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 (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) for proper clearance.
6. If the clearance for the valve is greater than specifications and a new standard diameter valve stem will not bring the clearance within specifications, replace the cylinder head.

Valve Spring Cleaning and Inspection

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.
4. Measure the valve spring tension using the J 22738-B tester. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu)
5. 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 Rocker Arm 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.

Cylinder Head and Gasket Surface Cleaning and Inspection

1. Remove the spark plugs (1).
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blow-by. If the gasket has failed, use the following faults to determine the cause: Improper installation Loose or warped cylinder head Missing, off location or not fully seated dowel pins Corrosion in the seal area around the coolant passages Chips or debris in the cylinder head bolt holes Bolt holes in the cylinder block not drilled or tapped deep enough
3. Inspect the cylinder head gasket surface. The cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1). Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
4. Clean the cylinder head bolts.
5. Remove the sealant from the rear cap mating surface with EN-28410 remover. Care must be used to avoid gouging or scraping the sealing surfaces.
6. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
7. Clean the valve guides.
8. Clean the threaded holes. Use a nylon bristle brush.
9. Clean the remains of the sealer from the plug holes.
10. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
11. Replace all suspect bolts.
12. Inspect the cylinder head for cracks. Inspect between the valve seats and in the exhaust ports.
13. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
14. Inspect the cylinder head deck surface for flatness using a straight edge (1) and feeler gauge (2). Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) . If the cylinder head is out of specification, replace the cylinder head. Do not machine the cylinder head.
15. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
16. Inspect the sealing surfaces.
17. Inspect the cylinder head plugs (1).
18. Clean the sealant from the rear cap mating surface with EN-28410 remover. Care must be used to avoid gouging or scraping the sealing surfaces.
19. Inspect the intake and exhaust camshaft bearing rear caps (1, 2) for damage.
20. Inspect the rear bearing mating surfaces for damage.
21. Inspect the remaining bearing caps (3, 4) for damage.
22. Install the spark plugs (1) and tighten to 20 N.m (15 lb ft).
23. Inspect the lifter bore for damage. Ensure the bore is clean of debris.

Valve Measurement and Reconditioning Overview

1. Proper valve service is critical to engine performance. Therefore, all detailed measurement procedures must be followed to identify components that are out of specification.
2. If the measurement procedures reveal that the valve or valve seat must be reconditioned, it is critical to perform the measurement procedures after reconditioning.

Valve Seat Width Measurement Procedure

1. Measure the valve seat width in the cylinder head using a proper scale.
2. Measure the seat width (b) on the valve face (1) using a proper scale.
3. Compare your measurements with the specifications listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
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 (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
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 Head O.D. and Chamfer Measurement Procedure

1. Measure the valve head O.D. and chamfer (a) using an appropriate scale. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
2. If the valve head O.D. and chamfer is within specification, test the valve (1) for seat concentricity using the Valve-to-Seat Concentricity Measurement Procedure. Reinspect the valve head O.D. and chamfer after completing the concentricity measurement if valve seat reconditioning is performed.

Valve-to-Seat Concentricity Measurement Procedure

1. Coat the valve face (3) lightly with blue dye (1).
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 (2) will be made around the entire face. NOTE: The wear mark MUST be at least 0.5 mm (0.020 in) from the outer diameter, the margin (a), 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. NOTE: Do not grind or condition the intake valve. If the intake valve is out of specification, replace the valve. 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 seating surface (a) to the proper angle specification (2) listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
2. Grind the valve relief surface to the proper angle specification (1) listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) , to correctly position the valve seating surface (a) to the valve.
3. Grind the valve undercut surface to the proper angle specification (3) listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) ,, to narrow the valve seating surface width (a) to the specifications listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
4. Replace the intake valve if it is out of specification. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
5. If the original exhaust valve is being used, grind the valve to the specifications listed in «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) . Measure the valve head O.D. and chamfer again after grinding using the Valve Head O.D. and Chamfer Measurement Procedure. Replace the exhaust valve if it is out of specification. New valves do not require grinding.
6. When grinding the valves and seats, grind off as little material as possible. Cutting valve seat results in lowering the valve spring pressure.
7. Install the valve in the cylinder head. If you are using refaced exhaust 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. Be sure to clean any remaining lapping compound from the valve and seat with solvent and compressed air prior to final assembly.
8. 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.
9. 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 (1) into the valve guide in the cylinder head (2).
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 (a) between the valve seal lip to the bottom of the valve spring retainer. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
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.

Cylinder Head Assemble (LDK, LHU)

Special Tools

1. EN-8062 Valve Spring Compressor
2. EN-9666 Valve Spring Tester
3. EN-43963 Valve Spring Compressor (off car)

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install NEW cylinder head plugs (1). Coat the plugs with sealer. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Inspect the valve springs.
3. Look for the following conditions when inspecting the valve springs: Expanded height Unparallel spring ends Spring tension using EN-9666 tester Any distorted springs should be replaced
4. Inspect the valves (1) and the valve seats. Refer to «Valve and Seat Grinding»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle) .
5. Install the valves (1). Replace any valves, if required.
6. Install the new valve seals (1). Fully seat the seals on the valve guides.
7. Install the springs (1).
8. Install the retainer (2).
9. Using the EN-8062 compressor and the EN-43963 compressor, compress the valve spring.
10. Install the valve keys (1).
11. Slowly release the EN-8062 compressor and the EN-43963 compressor from the valve/spring assembly.
12. Inspect for proper valve key seating.
13. Install the remaining valves, springs, and other components.
14. Lubricate the camshaft position sensor O-ring with clean engine oil.
15. Install the intake camshaft position sensor (1) and bolt. Tighten the intake camshaft position sensor bolt to 10 N.m (89 lb in).

Oil Pump Disassemble

1. Remove the oil pressure relief valve plug (1), spring (2), and plunger (3).
2. Remove the oil pump gerotor cover (1) and bolts.
3. Clean all of the parts in cleaning solvent. Remove varnish, sludge, and dirt.
4. Inspect the oil pump (2, 3) for wear and scoring. Ensure that all components are within specifications. Refer to «Engine Mechanical Specifications (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__engine-mechanical-specifications-ldk-lhu) .
5. Replace the front cover (4) and oil pump assembly if it is out of specification or damaged.

Oil Pump Assemble

1. Lubricate all oil pump parts with engine oil.
2. Install the inner gear (2) into the outer gear (3).
3. Install the gears together into the front cover (4) with the hub of the center gear facing the front cover.
4. Install the oil pump gerotor cover (1) and bolts. Tighten the oil pump gerotor bolts to 6 N.m (53 lb in).
5. Install the pressure relief valve plunger (3).
6. Install the pressure relief valve spring (2).
7. Install the pressure relief valve plug (1) and tighten to 40 N.m (30 lb ft).

Turbocharger Cleaning and Inspection (LDK, LHU)

1. Completely inspect the turbocharger (1) and all other engine components that may cause similar conditions before replacing the turbocharger. Refer to «Symptoms - Engine Mechanical»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-diagnostic-information-and-procedures) .
2. Clean all mating surfaces.
3. Inspect all threaded holes for damage.
4. Inspect the wastegate actuator rod for damage.
5. Inspect the compressor and turbine blades for damage or foreign material.
6. Clean the turbocharger inlet mating surfaces.
7. Inspect the turbocharger inlet mating surfaces for damage. Replace the turbocharger if damage is found.
8. Inspect the turbocharger wastegate regulator solenoid hoses for damage. Replace the hoses if necessary.
9. Inspect the turbocharger wastegate regulator solenoid valve assembly (2) and bracket (1). Replace if necessary.
10. Inspect the turbocharger air bypass diaphragm assembly (2), valve cover (1), and valve spring (3). Replace if necessary.
11. Inspect the positive crankcase ventilation (PCV) O-ring (2) for damage. Replace the O-ring if damaged or leaking.
12. Inspect the PCV hose and PCV fitting (1) for damage. Replace the camshaft cover if damage to the PCV hose or fitting is present.

Fuel Rail and Injectors Cleaning and Inspection (LDK, LHU)

Special Tools

EN-48266 Injector Seal Installer and Sizer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Unplug the electrical connections from the fuel injectors (1).
2. Remove the injectors from the fuel rail by pulling straight out along the fuel injector axis.
3. Remove and discard the fuel injector hold-down clamp (3).
4. Remove and discard the fuel injector O-ring (2) and plastic spacer (1).
5. Remove and discard the fuel injector seal (1).
6. Clean the exterior of the fuel rail (2) and injectors in solvent.
7. Inspect the high pressure fuel sensor (1) for damage. If replacing, dry the fuel pressure sensor bore in the fuel rail with a lint free cloth. The bore should be free of fuel, debris, and burrs. Lubricate the fuel pressure sensor bore, in the fuel rail, with clean engine oil. Lubricate the threads and sealing area on the fuel pressure sensor with clean engine oil. Install the fuel pressure sensor hand tight. Remove the fuel pressure sensor and re-lubricate the bore, threads, and sealing area. Re-install the fuel pressure sensor. Tighten the high pressure fuel sensor to 33 N.m (25 lb ft).
8. Inspect the fuel rail and components for the following conditions: Damage, debris, or restrictions to the fuel rail Damage, debris, or restrictions to the fuel ports in the fuel rail Damage to the mounting area for the fuel rail Damage to the fuel rail mounting bolts Damage to the threads on the fuel rail fuel feed fitting
9. Inspect the fuel injectors for the following conditions: Damage to the fuel injector connector (7) Damage to the fuel injector harness connector Damage to the fuel injector tip (1) Damage to the tolerance ring (2) Damage to the wave guide (3), if equipped
10. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
11. Lubricate the NEW O-ring (5) with 5W30 engine oil.
12. Install a NEW O-ring and plastic spacer (4) on the injector. The plastic spacer has a top (6) and a bottom. The top, O-ring sealing area, is wider.
13. Install EN-48266 installer (2) onto the fuel injector tip. Install a NEW seal (1) over EN-48266 installer on the injector. The seal must be installed/slid into the recessed area (3) of the fuel injector. Compress the seal with your fingers before resizing the seal using the EN-48266 sizer.
14. Using the EN-48266 sizer (4), resize the seal.
15. Install a NEW fuel injector hold-down clamp (2) on the fuel injector (1).
16. Repeat the fuel injector cleaning and inspection process for all 4 fuel injectors.
17. Install the fuel injectors (1) by pushing the injectors straight into the fuel rail along the fuel injector axis.
18. Connect the electrical connection to the fuel rail for each injector.

Intake Manifold Cleaning and Inspection (LDK, LHU)

1. Clean the intake manifold mating surfaces (1).
2. Inspect the intake manifold (2) for damage.
3. Inspect the intake manifold for cracks near metallic inserts.
4. Inspect the crankcase ventilation passages in the intake manifold face for blockage.
5. Clean the crankcase ventilation passages (1) with compressed air, if necessary. Use a maximum of 172 kPa (25 psi) of air pressure.
6. Replace the intake manifold, as necessary.

Exhaust Manifold Cleaning and Inspection (LDK, LHU)

1. Clean the exhaust manifold in solvent.
2. Dry the exhaust manifold (1) with compressed air.
3. Inspect the heat shield for damage.
4. Internal heat cracks are allowed. Do not replace the exhaust manifold for this condition.
5. Use a straight edge (2) and a feeler gauge (1) and measure the exhaust manifold mounting face for warpage. An exhaust manifold face with warpage in excess of 0.25 mm (0.0100 in) may cause an exhaust leak and may affect OBD II system performance. Exhaust manifolds not within specifications must be replaced.

Oil Pan Cleaning and Inspection (LDK, LHU)

1. Remove the engine oil level sensor retainer ring (2).
2. Remove the oil level indicator plate bolts.
3. Remove the engine oil level sensor assembly (1).
4. Clean the oil pan (1) mating surface.
5. Remove the oil pan baffle bolts.
6. Remove the oil pan baffle (1).
7. Clean the oil pan (2). Remove all the sludge and the oil deposits.
8. Inspect the engine oil drain plug threads.
9. Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
10. Inspect the oil pan for cracking resulting from impact or flying road debris.
11. Inspect the oil pan baffle and pickup screen.
12. Install the oil pan baffle.
13. Install the oil pan baffle bolts and tighten to 14 N.m 10 lb ft.
14. Clean and inspect the oil level sensor (1). Ensure that the float (2) moves freely within the sensor and the oil holes are clear of debris and not obstructed.
15. Install the engine oil level sensor assembly (1) into the oil pan with the oil level indicator plate bolts. Tighten the bolts to 10 N.m (89 lb in).
16. Install the engine oil level sensor connector and secure with a retaining ring (2).

EN-43600 Thread Repair Kit

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Scheme 99

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

Note. The use of a cutting fluid is recommended when performing the drilling, counterboring, and tapping procedures. Driver oil MUST be used on the installer driver tool. The tool kits are designed for use with either a suitable tap wrench or drill motor.

Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended cutting fluid and driver oil.

1. Drill out the threads of the damaged hole (1). M6 inserts require a minimum drill depth of 15 mm (0.59 in). M8 inserts require a minimum drill depth of 20 mm (0.79 in). M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
2. Using compressed air, clean out any chips.
3. Counterbore the hole to the full depth permitted by the tool (1).
4. Using compressed air, clean out any chips.
5. Using a tap wrench (2), tap the threads of the drilled hole. M6 inserts require a minimum tap depth of 15 mm (0.59 in). M8 inserts require a minimum tap depth of 20 mm (0.79 in). M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
6. Using compressed air, clean out any chips.
7. Spray cleaner into the hole. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
8. Using compressed air, clean any cutting oil and chips out of the hole.
9. Lubricate the threads of the installer tool (2) with the driver oil (1).
10. Install the insert (2) onto the driver tool (1).
11. Apply threadlock LOCTITE™ 277, EN-43600-109 (1) loctite, or equivalent to the insert OD threads (2).
12. Install the insert (2) into the hole. Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
13. Inspect the insert for proper installation into the hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).

Cylinder Head Bolt Hole Thread Repair

Note. The use of a cutting fluid is recommended when performing the drilling, counterboring, and tapping procedures. Driver oil MUST be used on the installer driver tool. The tool kits are designed for use with either a suitable tap wrench or drill motor.

Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended cutting fluid and driver oil.

1. The cylinder head bolt hole thread repair kit consists of the following items: Drill (1) Tap (2) Installer (3) Sleeve (4) Alignment Pin (5) Bushing (6) Bolts (7) Fixture Plate (8)
2. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck. Position the fixture plate and bushing over the hole that is to be repaired (4).
3. Position the alignment pin (1) through the bushing and into the hole.
4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6. Install the sleeve (2) onto the drill (1), if required.
7. Drill out the threads of the damaged hole. Drill the hole until the stop collar (1) of the drill bit or the sleeve contacts the bushing.
8. Using compressed air, clean out any chips.
9. Using a tap wrench (1), tap the threads of the drilled hole.
10. Using a TAP wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap align with the top of the drill bushing (2).
11. Remove the fixture plate (1), bushing (2), and bolts.
12. Using compressed air, clean out any chips.
13. Spray cleaner into the hole. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
14. Using compressed air, clean any cutting oil and chips out of the hole.
15. Lubricate the threads of the installer tool (2) with the driver oil (1).
16. Install the insert (2) onto the driver tool (1).
17. Apply threadlock LOCTITE™ 277, EN-43600-109 loctite (1), or equivalent to the insert OD threads (2).
18. Install the insert and driver (1) into the hole. Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

Main Cap Bolt Hole Thread Repair

Note. The use of a cutting fluid is recommended when performing the drilling, counterboring, and tapping procedures. Driver oil MUST be used on the installer driver tool. The tool kits are designed for use with either a suitable tap wrench or drill motor.

Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended cutting fluid and driver oil.

1. The main cap bolt hole thread repair kit consists of the following items: Drill (1) Tap (2) Installer (3) Fixture Plate (4) Long Bolts (5) Short Bolts (6) Alignment Pin (7) Bushing (8)
2. Remove the alignment dowel pins from the holes (1-4), if necessary.
3. Install the fixture plate (1), bolt, and bushing, onto the engine block. Position the fixture plate and bushing over the hole that is to be repaired.
4. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
5. Drill out the damaged hole.
6. Using compressed air, clean out any chips.
7. Using a tap wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap aligns with the top of the bushing (2).
8. Using compressed air, clean out any chips.
9. Spray cleaner into the hole. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
10. Using compressed air, clean any cutting oil and chips out of the hole.
11. Lubricate the threads of the installer tool (2) with the driver oil (1).
12. Install the insert (2) onto the driver tool (1).
13. Apply threadlock LOCTITE™ 277, EN-43600-109 (1), or equivalent to the insert OD threads (2).
14. Install the insert and driver through the bushing (2), fixture plate (1) and into the hole. Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2). The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
15. Remove the driver, bushing (2), fixture plate (1), and bolts.
16. Install the alignment dowel pins in holes (1-4), if necessary.

Service Prior to Assembly

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this service information, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

Engine Block Assemble

1. Install the drain plug with sealant in the water pump. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Install the coolant jacket plugs with sealant and tighten to 35 N.m (26 lb ft). Install the rear oil passage plugs (3) with sealant and tighten to 60 N.m (44 lb ft). Install the other oil passage plugs (1, 2) with sealant and tighten to 35 N.m (26 lb ft).
3. Lubricate the crankshaft position (CKP) sensor O-ring with clean engine oil. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
4. Install the CKP sensor (1) and bolt and tighten to 10 N.m (89 lb in).
5. Install the oil pressure switch (2) and tighten to 26 N.m (19 lb ft).
6. Install the knock sensors (1) and bolts and tighten to 25 N.m (18 lb ft).
7. Install the piston oil nozzle assemblies (1) and tighten to 15 N.m (11 lb ft).

1. EN-8087 Cylinder Bore Gauge
2. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Scheme 100

Note. If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure

1. Tighten the bedplate to specification using the EN-45059 angle meter.
2. Measure the bearing bore for taper and out-of-round using the EN-8087 gauge (1).
3. No taper or out-of-round should exist.

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2 methods to measure bearing clearance. Method A gives more reliable results and is preferred.

1. Method A yields measurement from which the bearing clearance can be computed.
2. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Scheme 101

Note. Do not mix inserts of different nominal size in the same bearing bore.

To measure bearing clearance using Method A, use the following procedure

1. Measure the crankshaft bearing journal diameter with a micrometer (1) in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the lower crankcase and tighten the bearing cap bolts to specification.
4. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements.
5. Subtract journal measurement from bearing ID measurement to determine clearance.
6. Determine whether clearance is within specification.
7. If out of specification, choose different inserts.
8. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
9. Measure the crankshaft main bearing inside diameter with an inside micrometer.

Scheme 102

To measure bearing clearance using Method B, use the following procedure

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps.
5. Install the bearing cap bolts to specification.
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale (1) printed on the gaging plastic package.
8. Remove the gaging plastic.

Lower Crankcase Installation (LDK, LHU)

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the upper crankshaft bearings (1) in the engine block (2) and lubricate bearing surfaces with engine oil.
2. Install the crankshaft (1) on the journals.
3. Install the lower bearing halves (1), without grooves, into the lower crankcase (2). Apply oil to bearing surfaces.
4. Apply a 4.25 mm bead of sealer, dimension a, directly in the groove of the block to bedplate mating surfaces. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
5. Install the lower crankcase (1). Tap gently into place with a suitable tool, if necessary. Ensure the lower crankcase is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight.
7. Tighten the crankshaft bearing bolts: Tighten the crankshaft bearing bolts a first pass in sequence to 20 N.m (15 lb ft). Using the EN-45059 angle meter, tighten the crankshaft bearing bolts a final pass in sequence to 70 degrees.
8. Install the lower crankcase perimeter bolts (1-10) and tighten to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Installation

Special Tools

EN-42067 Rear Main Seal Installer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the EN-42067 installer (1), press the new crankshaft seal into the housing. The EN-42067 installer also establishes the depth of the seal in the crankshaft seal bore. The seal should be flush to 0.5 mm (0.0197 in) deep.

Piston, Connecting Rod, and Bearing Installation (LDK, LHU)

Special Tools

1. EN-43953 Piston Ring Compressor
2. EN-43966-1 Connecting Rod Guides
3. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the NEW connecting rod bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the EN-43966-1 guides (1) into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install the EN-43953 compressor, the piston (2), and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-43953 compressor against the engine block until all the rings have entered the cylinder bore. Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap (1).
5. Install NEW connecting rod bolts and tighten to 25 N.m (18 lb ft)plus 100 degreesusing the EN-45059 angle meter.
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gauge (1). The correct clearance is 0.07-0.37 mm (0.0027-0.0145 in).

Cylinder Head Installation (LDK, LHU)

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the cylinder head gasket (2) to the block.
2. Install the cylinder head (1). Ensure the number 1 cylinder is at top dead center (TDC). The key on the crankshaft should be on top in the 12 o'clock position.
3. Install NEW cylinder head bolts. Tighten the bolts in sequence to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degreesin sequence using the EN-45059 angle meter.
4. Install the front cylinder head bolts (1) and tighten to 35 N.m (26 lb ft).

Exhaust Camshaft and Components Installation

1. Install the hydraulic lash adjusters (1) into their bores in the cylinder head. Apply lubricant to the lash adjusters, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Lubricate the valve tips (1), refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
3. Position the roller followers (1) on the tip of the valve stem and on the lash adjuster. Apply lubricant to the followers, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
4. When installing the camshafts, ensure the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
5. Set the exhaust camshaft (1) on top of the roller followers in the camshaft bearing journals. Lubricate the camshaft, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
6. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12 o'clock position before installing the camshaft caps.
7. Install the exhaust camshaft with the notch on the front (1) at approximately the 7 o'clock position.
8. Install the camshaft caps (1) and hand start the camshaft cap bolts (2).
9. Lubricate and tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft cap bolts to 10 N.m (89 lb in).
10. Apply a 2.5 mm bead of sealer to the cylinder head at the exhaust camshaft bearing rear cap mating surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
11. Install the exhaust camshaft bearing rear cap and bolts. Tighten the cap bolts evenly to 5 N.m (44 lb in). Tighten the cap bolts evenly to 10 N.m (89 lb in). Back the cap bolts out 120 degrees. Tighten the cap bolts evenly a final pass to 10 N.m (89 lb in).
12. Remove all excess sealing material from the power brake booster pump bore (1), and ensure the bore and gasket sealing surface is clean and free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.

Intake Camshaft and Components Installation

1. Install the hydraulic lash adjusters (1) into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
3. Lubricate the valve tips (1).
4. Position the roller followers (1) on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
5. When installing the camshafts, ensure the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
6. Set the intake camshaft (1) on top of the roller followers in the camshaft bearing journals. Lubricate the camshaft, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
7. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.
8. Install the intake camshaft with the notch on the front at approximately the 5 o'clock position (1).
9. Install the camshaft caps (1) and hand start the camshaft cap bolts.
10. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 N.m (89 lb in).
11. Apply a 2.5 mm bead of sealer to the cylinder head at the intake camshaft bearing rear cap mating surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
12. Install the number 6 intake camshaft rear cap. Tighten the cap bolts evenly to 5 N.m (44 lb in). Tighten the cap bolts evenly to 10 N.m (89 lb in). Back the cap bolts out 120 degrees. Tighten the cap bolts evenly a final pass to 10 N.m (89 lb in).
13. Remove all excess sealing material from the fuel pump roller lifter bore (1), and ensure the bore is free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.
14. Remove all excess sealing material from the fuel pump assembly sealing surface (2).
15. Ensure that the opening plate sealing surface is clean and free of excess sealing material. Install the rear cylinder head opening plate (1) and tighten the bolts to 10 N.m (89 lb in).

EN-43650 Balance Shaft Bushing Remover/Installer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the balance shaft bushing (2) using the EN-43650 remover/installer (1).
2. Seat the balance shaft bushing into the bore using the EN-43650 remover/installer (1) and a wrench.
3. When the EN-43650 remover/installer is fully seated in the engine block, remove it with a wrench.
4. Place the number one piston at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts (1) into their bores.
7. Install the balance shaft retaining bolts and tighten to 10 N.m (89 lb in).

Water Pump Installation (LDK, LHU)

Note. Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1. Install the water pump assembly (1) with a new gasket (2).
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts to 25 N.m (18 lb ft).
4. Apply sealant to the water pump drain plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
5. Install the water pump drain plug and tighten to 20 N.m (15 lb ft), if necessary.
6. Install the water feed tube (2).
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing (1) to block bolts and stud and tighten the thermostat housing bolts to 10 N.m (89 lb in).
10. Install the coolant temperature sensor (1) by hand.
11. Tighten the coolant temperature sensor to 20 N.m (15 lb ft).

Balance Shaft to Engine Timing (LDK, LHU)

1. Install the balance shaft drive sprocket and key.
2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. There are 3 colored links on the chain. 2 links are of matching colors, and 1 link is of a unique color. Use the following procedure to line up the links with the sprockets: Orient the chain so that the colored links are visible.
3. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
4. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket - approximately at the 6 o'clock position on the crank sprocket.
5. Place the chain (3) on the water pump drive sprocket. The alignment is not critical.
6. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.

Water Pump and Balance Shaft Chain and Tensioner Installation

1. Install the upper balance shaft chain guide (1) and bolts and tighten to 12 N.m (106 lb in).
2. Install the small balance shaft chain guide (1).
3. Install the balance shaft chain guide bolts and tighten to 12 N.m (106 lb in).
4. Install the adjustable balance shaft drive chain guide (1).
5. Install the adjustable balance shaft drive chain guide bolts and tighten to 10 N.m (89 lb in).
6. Reset the timing chain tensioner (1) by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip (2) through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts and tighten to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Camshaft Timing Chain, Sprocket, and Tensioner Installation (LDK, LHU)

Special Tools

1. EN-45027 Tensioner Tool
2. EN-45059 Angle Meter
3. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install a friction washer (1), if equipped.
3. Install the timing chain drive sprocket (3) to the crankshaft with the timing mark (2) in the 5 o'clock position and the front of the sprocket facing out.
4. Install the remaining friction washer (1), if equipped.
5. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
6. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
7. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
8. Hand tighten the new intake camshaft actuator bolt.
9. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (1) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
10. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
11. Install the adjustable timing chain guide (1) down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
12. Install the exhaust camshaft actuator (1) into the timing chain with the timing mark lined up with the second matching colored link.
13. Install the exhaust camshaft actuator (1) onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
14. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
15. When the actuator (1) seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
16. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
17. Install the fixed timing chain guide (1) and bolts and tighten to 12 N.m (106 lb in).
18. Install the upper timing chain guide (1) and bolts and tighten to 10 N.m (89 lb in).
19. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the EN-45027-2 base (2) into a vise. Install the notch end of the piston assembly into the EN-45027-2 base (2). Using the EN-45027-1 tensioner (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
20. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
21. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
22. Install the timing chain tensioner assembly (1) and tighten to 75 N.m (55 lb ft). Refer to «Crankshaft Balancer Installation (LDK, LHU)»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle__crankshaft-balancer-installation-ldk-lhu) for tensioner release instructions.
23. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 N.m (89 lb in). Using a torque wrench, tighten the camshaft actuator bolt to 30 N.m (22 lb ft), plus 100 degreesusing the EN-45059 angle meter.
24. Using a torque wrench, tighten the camshaft actuator bolt to 30 N.m (22 lb ft), plus 100 degreesusing the EN-45059 angle meter.
25. Remove EN-48953 locking tool.
26. Install the timing chain oiling nozzle (1) and bolt and tighten to 10 N.m (89 lb in).
27. Apply sealant to the thread of the timing chain guide bolt access hole plug (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
28. Install the timing chain guide bolt access hole plug and tighten to 75 N.m (55 lb ft).

Crankshaft Front Oil Seal Installation (LDK, LHU)

Special Tools

EN-34115 Sprocket Bearing Installer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the seal (2) into the front cover using the EN-34115 installer (1).
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

1. Install the engine front cover (1) with a new gasket (2).
2. Install the engine front cover bolts and tighten to 25 N.m (18 lb ft).
3. Install the long water pump bolt (1) and tighten to 25 N.m (18 lb ft).
4. Install the accessory drive belt tensioner (1).
5. Install the accessory drive belt tensioner bolt and tighten to 45 N.m (33 lb ft).

Oil Pan Installation (LDK, LHU)

1. Apply a 2.25 mm bead of sealer (1) on the level part of the flange next to the chamfer around the perimeter of the oil pan and the oil suction port opening. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Install the oil pan (1).
3. Install the oil pan bolts and tighten the oil pan bolts in sequence to 25 N.m (18 lb ft).

Engine Oil Cooler Installation (LDK, LHU)

1. Install the oil cooler (1).
2. Install the oil cooler bolts (2) and tighten to 25 N.m (18 lb ft).

Engine Flywheel Installation (Manual Transmission)

Special Tools

1. EN-43653 Flywheel Holding Tool
2. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the clutch pilot bearing for manual transmission.
2. Install the flywheel (1).
3. Install the NEW bolts.
4. Install EN-43653 flywheel holding tool in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
5. Tighten the flywheel bolts to 53 N.m (39 lb ft) plus 25 degreesusing the EN-45059 angle meter.
6. Install the clutch driven plate (2).
7. Install the clutch pressure plate (1) and bolts.
8. Tighten the clutch pressure plate bolts to 24 N.m (18 lb ft).
9. Remove EN-43653 flywheel holding tool.

Engine Flywheel Installation (Automatic Transmission)

Special Tools

1. EN-43653 Flywheel Holding Tool
2. EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the flywheel (1) for automatic transmission.
2. Install the NEW bolts.
3. Install EN-43653 flywheel holding tool in the starter assembly location, engaging the flywheel, in order to prevent crankshaft rotation.
4. Tighten the flywheel bolts to 53 N.m (39 lb ft) plus 25 degreesusing the EN-45059 angle meter.
5. Remove EN-43653 flywheel holding tool.

Crankshaft Balancer Installation (LDK, LHU)

Special Tools

1. EN-38122-A Crankshaft Balancer Holder
2. EN-43653 Flywheel Holding Tool
3. EN-45059 Angle Meter
4. EN-48585 Crankshaft Balancer Guide
5. EN-48953 Camshaft Actuator Locking Tool

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install the balancer (2) onto the EN-48585 guide (1). Use care to properly align the keyway and flats on the balancer with the oil pump drive.
2. Install the crankshaft balancer into the end of the crankshaft.
3. Install a NEW retaining bolt. Use EN-38122-A holder (1) and a breaker bar to prevent the crankshaft from rotating, and tighten the bolt to 100 N.m (74 lb ft) plus 125 degreesusing the EN-45059 angle meter.
4. Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 N.m (89 lb in).
5. Release the timing chain tensioner by applying 45 N.m (33 lb ft)counterclockwise torque to the crankshaft balancer bolt.
6. Remove EN-48953 locking tool.

Camshaft Cover Installation (LDK, LHU)

1. Install NEW camshaft cover grommets and camshaft cover bolts if they are serviced with the grommets.
2. Assemble the camshaft cover (1) and NEW gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
3. Install the cover on the cylinder head and hand start the bolts.
4. Install the ignition coils (4). Tighten the ignition coil bolts (3) to 10 N.m (89 lb in).
5. Tighten the camshaft cover bolts to 10 N.m (89 lb in).
6. Install the camshaft position actuator solenoid valves (2).
7. Install the camshaft position actuator solenoid valve bolts (1) and tighten to 10 N.m 89 lb in.
8. Install the camshaft housing cover insulator (1) and bolts. Tighten the camshaft housing cover insulator bolts to 10 N.m (89 lb in).
9. Install the front lift bracket (1).
10. Install the front lift bracket bolts and tighten to 25 N.m (18 lb ft).
11. Install the power brake booster pump NEW O-ring seal (1).
12. Install the power brake booster pump (2).
13. Install the power brake booster pump bolts and tighten to 22 N.m (16 lb ft).
14. Install the rear lift bracket (1).
15. Install the rear lift bracket bolts and tighten to 25 N.m (18 lb ft).

Oil Filter with Cap and Seal Installation

Special Tools

EN-44887 Oil Filter Wrench

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Install a new oil filter (2) on the oil filter cap (1).
2. Lubricate the oil filter cap O-ring with engine oil. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
3. Use the EN-44887 wrench to install the oil filter and cap. Tighten the oil filter and cap to 22 N.m (16 lb ft).

Fuel Rail and Injectors Installation (LDK, LHU)

Special Tools

1. EN-47909 Injector Bore and Sleeve Cleaning Kit
2. EN-48896 HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Clean the injector bore in the cylinder head using the EN-47909 cleaning kit.
2. Install the fuel rail with injectors into the cylinder head evenly.
3. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.
4. Start and hand tighten the remaining fuel rail bolts. Tighten the fuel rail bolts in sequence to 22 N.m (16 lb ft). Tighten the fuel rail bolts in sequence a second time to 22 N.m (16 lb ft).
5. Install the fuel injector noise insulator (1).
6. Connect the electrical harness to the fuel rail harness connection.
7. Use the EN-48896 alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
8. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.
9. Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.
10. Install a NEW high pressure fuel pump gasket (1).
11. Install a NEW high pressure fuel pump O-ring (2).
12. Install the high pressure fuel pump (3).
13. Start and hand-tighten the high pressure fuel pump bolts evenly.
14. Tighten the high pressure fuel pump bolts evenly to 15 N.m (11 lb ft).
15. Install and hand-tighten both ends of the NEW high pressure fuel line (1).
16. Tighten the high pressure fuel line fitting nuts to 30 N.m (22 lb ft).

Intake Manifold Installation

1. Install a NEW intake manifold gasket (1).
2. Install the intake manifold (2).
3. Install the intake manifold bolts and nuts (3) finger tight.
4. Tighten the intake manifold bolts and nuts in sequence: Tighten the intake manifold bolts to 25 N.m (18 lb ft). Tighten the intake manifold nuts to 22 N.m (16 lb ft).
5. Install the EVAP purge solenoid valve (4) and bolt (3). Tighten the bolt to 4 N.m (35 lb in).
6. Install the MAP sensor (2) and bolt (1). Tighten the bolt to 10 N.m (89 lb in).
7. Install the intake manifold brace (2).
8. Install the intake manifold brace bolt (1) and nut (3) and tighten to 25 N.m (18 lb ft).
9. Connect the rear knock sensor to the intake manifold brace.
10. Install the throttle body (1).
11. Install the throttle body bolts (2) and tighten to 10 N.m (89 lb in).
12. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
13. Install the fuel feed line. (2)
14. Install the fuel feed line bolts.
15. Connect the low pressure fuel line nut (1) and tighten to 30 N.m (22 lb ft).
16. Tighten the fuel feed line bolts to 10 N.m (89 lb in).
17. Install the high pressure fuel pump noise insulator (1).
18. Install the high pressure fuel pump cover (2).
19. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
20. Install the charger AIR bypass valve solenoid (1) with charger AIR bypass tube assemblies.
21. Install the charger AIR bypass valve solenoid bolts and tighten to 10 N.m (89 lb in).
22. Connect the charger AIR bypass tube assemblies and clips from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
23. Install the charger AIR bypass valve tank assembly (1).
24. Tighten the charger AIR bypass valve tanks assembly bolt to 25 N.m (18 lb ft).
25. Install the charger AIR bypass valve tank assembly nut (2) and tighten to 25 N.m (18 lb ft).
26. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.
27. Connect the final charger AIR Bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.

Oil Level Indicator and Tube Installation (LDK, LHU)

1. Lubricate the oil level indicator tube O-ring, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-specifications__adhesives-fluids-lubricants-and-sealers) .
2. Install the oil level indicator (2) and the oil level indicator tube (1) into the oil pan.
3. Install the oil level indicator tube bracket to the intake manifold.
4. Install the oil level indicator tube bracket bolt and tighten to 10 N.m (89 lb in).
5. Install the electrical wiring harness to the oil level indicator tube.
6. Install the knock sensor wiring clip into the oil level indicator tube.

Exhaust Manifold Installation (LDK, LHU)

1. Install new exhaust manifold studs (1) and tighten to 15 N.m (11 lb ft).
2. Install the exhaust manifold gasket (2).
3. Install the exhaust manifold (1) to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten the exhaust manifold nuts to 14 N.m (10 lb ft). Tighten the exhaust manifold nuts a second time to 14 N.m (10 lb ft).
6. Install the exhaust manifold heat shield (1).
7. Install the exhaust manifold heat shield bolts and tighten to 25 N.m (18 lb ft).

Turbocharger Installation (LDK, LHU)

1. Install a new turbocharger oil return pipe gasket (1).
2. Install the turbocharger oil return pipe (2) on the turbocharger.
3. Install the turbocharger oil return pipe bolts (3) and tighten to 10 N.m (89 lb in).
4. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.
5. Install the PCV hose fitting bolt and tighten to 10 N.m (89 lb in).
6. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
7. Install a new turbocharger gasket (3).
8. Install the turbocharger (2) with the oil return pipe.
9. Install the turbocharger nuts (1). Tighten the turbocharger nuts to 30 N.m (22 lb ft). Tighten the turbocharger nuts a second time to 35 N.m (26 lb ft).
10. Install the turbocharger brace (1).
11. Install the turbocharger brace nuts and tighten to 50 N.m (37 lb ft).
12. Install the catalytic converter bracket (1).
13. Install the catalytic converter bracket bolts and tighten to 50 N.m (37 lb ft).
14. Install the turbocharger coolant feed pipe (1).
15. Install the turbocharger coolant feed pipe gaskets.
16. Install the turbocharger coolant feed pipe bolts. Tighten the turbocharger coolant feed pipe bolts to 35 N.m (26 lb ft). Tighten the turbocharger coolant feed pipe mounting bolt to 10 N.m (89 lb in).
17. Connect the positive crankcase ventilation (PCV) and hose assembly.
18. Install the turbocharger air cooler outlet pipe (1).
19. Install the turbocharger air cooler outlet pipe bolts and tighten to 25 N.m (18 lb ft).
20. Install the turbocharger oil feed pipe (1) on the engine block side.
21. Install the turbocharger oil feed pipe gasket on the engine block side.
22. Install the bolt and tighten to 40 N.m (30 lb ft).
23. Install the turbocharger coolant return pipe (1).
24. Install the turbocharger coolant return pipe gaskets.
25. Install the turbocharger coolant return pipe bolts and tighten to 35 N.m (26 lb ft).
26. Install the turbocharger oil feed pipe (1) onto the turbocharger.
27. Install the turbocharger oil feed pipe gasket for the turbocharger side.
28. Install the turbocharger oil feed pipe bolt and tighten to 40 N.m (30 lb ft).
29. Install the catalytic converter L-bracket (2) onto the catalytic converter (1).
30. Install the catalytic converter L-bracket nuts and tighten to 50 N.m (37 lb ft).
31. Install the catalytic converter seal (2).
32. Install the catalytic converter (1).
33. Install the catalytic converter nuts and tighten to 50 N.m (37 lb ft).
34. Install the catalytic converter bolts and tighten to 50 N.m (37 lb ft).
35. Install the turbocharger heat shield (1).
36. Install the turbocharger heat shield bolts and tighten to 10 N.m (89 lb in).

Starter Installation

1. Install the starter (1).
2. Install the starter bolts and tighten to 53 N.m (39 lb ft).

EN-45299 Engine Preluber

For equivalent regional tools, refer to Special Tools (LDK, LHU) .

1. Remove the oil pressure switch.
2. Install the M12 x 1.75 adapter (1) P/N 509376.
3. Install the flexible hose to the adapter and open the valve.
4. Pump the handle on the EN-45299 preluber (1) in order to flow a minimum of 1-1.9 liters (1-2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
5. Close the valve and remove the flexible hose and adapter from the engine.
6. Install the oil pressure switch to the engine and tighten to 22 N.m (16 lb ft).
7. Top-off the engine oil to the proper level.

See also:
• Special Tools (LDK, LHU)
• Fastener Caution
• Adhesives, Fluids, Lubricants, and Sealers
• Thread Repair Specifications (LDK, LHU)
• Engine Mechanical Specifications (LDK, LHU)
• Safety Glasses Warning
• Separating Parts
• Symptoms - Engine Mechanical
• Safety Glasses and Compressed Air Warning
• Cleaning Solvent Warning
• Cylinder Sleeve Removal
• Cylinder Sleeve Installation
• Piston, Connecting Rod, and Bearing Installation (LDK, LHU)
• Crankshaft Balancer Installation (LDK, LHU)