Engine Mechanical - 4.4l (3 of 5) Cadillac XLR I

Camshaft Intermediate Drive Shaft Removal - Off Vehicle

1. Remove the intermediate sprocket shaft retaining bolts.
2. Remove the intermediate sprocket shaft.

Exhaust Camshaft Removal - Left Side - Off Vehicle

1. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: The arrow points toward the front of the engine. The "E" indicates the exhaust camshaft. The number indicates the journal position from the front of the engine.
2. Remove the left exhaust camshaft bearing cap bolts.
3. Remove the left exhaust camshaft bearing caps. Store the bearing caps in a clean shop towel.
4. Remove the left exhaust camshaft. Place the camshaft in a secure location.
5. Cover the camshaft with an oil soaked towel in order to prevent corrosion.

Intake Camshaft Removal - Left Side - Off Vehicle

1. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: The arrow points toward the front of the engine. The "I" indicates the intake camshaft. The number indicates the journal position from the front of the engine.
2. Remove the left intake camshaft bearing cap bolts.
3. Remove the left intake camshaft bearing caps. Store the bearing caps in a clean shop towel.
4. Remove the left intake camshaft. Place the camshaft in a secure location.
5. Cover the camshaft with an oil soaked towel in order to prevent corrosion.

Valve Rocker Arm Removal - Left Side - Off Vehicle

1. Remove the camshaft followers from the left cylinder head.
2. Store the camshafts, followers and SHLAs in a clean, secure location.

Valve Lifter Removal - Left Side - Off Vehicle

1. Remove the stationary hydraulic lash adjuster (SHLAs) from the left cylinder head lifter bores.
2. Store the camshafts, followers and SHLAs in a clean, secure location.

Cylinder Head Removal - Left Side - Off Vehicle

Tools Required

J 28410 Gasket Remover. See Special Tools .

1. Remove the 3 M6 external drive bolts from the front portion of the cylinder head.
2. Remove and discard the 10 M11 internal drive cylinder head bolts.
3. Remove the left cylinder head. Ensure that no dowel guide pins are stuck in the cylinder head.
4. After removing the cylinder head, remove any remaining bolt thread sealant material from the threaded cylinder block holes.
5. Remove the left cylinder head gasket.
6. Remove all remaining gasket material from the cylinder head and cylinder block using the J 28410 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .

Exhaust Camshaft Removal - Right Side - Off Vehicle

1. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: The arrow points toward the front of the engine. The "E" indicates the exhaust camshaft. The number indicates the journal position from the front of the engine.
2. Remove the right exhaust camshaft bearing cap bolts.
3. Remove the right exhaust camshaft bearing caps. Store the bearing caps in a clean shop towel.
4. Remove the right exhaust camshaft. Place the camshaft in a secure location.
5. Cover the camshaft with an oil soaked towel in order to prevent corrosion.

Intake Camshaft Removal - Right Side - Off Vehicle

1. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: The arrow points toward the front of the engine. The "I" indicates the intake camshaft. The number indicates the journal position from the front of the engine.
2. Remove the right intake camshaft bearing cap bolts.
3. Remove the right intake camshaft bearing caps. Store the bearing caps in a clean shop towel.
4. Remove the right intake camshaft. Place the camshaft in a secure location.
5. Cover the camshaft with an oil soaked towel in order to prevent corrosion.

Valve Rocker Arm Removal - Right Side - Off Vehicle

1. Remove the camshaft followers from the right cylinder head.
2. Store the camshafts, followers and SHLAs in a clean, secure location.

Valve Lifter Removal - Right Side - Off Vehicle

1. Remove the stationary hydraulic lash adjuster (SHLAs) from the right cylinder head lifter bores.
2. Store the camshafts, followers and SHLAs in a clean, secure location.

Cylinder Head Removal - Right Side - Off Vehicle

Tools Required

J 28410 Gasket Remover. See Special Tools .

1. Remove the 3 M6 external drive bolts from the front portion of the cylinder head.
2. Remove and discard the 10 M11 internal drive cylinder head bolts.
3. Remove the right cylinder head. Ensure that no dowel guide pins are stuck in the cylinder head.
4. After removing the cylinder head, remove any remaining bolt thread sealant material from the threaded cylinder block holes.
5. Remove the right cylinder head gasket.
6. Remove all remaining gasket material from the cylinder head and cylinder block using the J 28410 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .

Oil Pan Removal - Off Vehicle

1. Loosen the oil pan bolts.
2. Remove the oil pan.

Oil Pump Suction Pipe and Screen Assembly Removal - Off Vehicle

1. Remove the oil pump pipe support bracket nut.
2. Remove the oil pump pipe bolt.
3. Remove the oil pump pipe and screen assembly.
4. Remove and discard the oil pump pipe gasket.

Lower Crankcase Removal - Off Vehicle

1. Remove the 4 lower crankcase perimeter retaining bolts along the right side of the engine.
2. Remove the 4 lower crankcase perimeter retaining bolts along the left side of the engine.
3. Remove the main bearing bolts. Note the location of the single stud-end bolt (1) used to attach the oil pump pickup tube.
4. Remove the oil manifold plate bolts.
5. Remove the oil manifold and oil scraper plate assembly.
6. Working on either side of the lower crankcase, separate the crankcase halves by alternately prying in the grooves provided until the lower crankcase is free of the dowel pins.
7. Remove the lower crankcase.
8. If equipped, remove the upper-to-lower crankcase seal.

Piston, Connecting Rod, and Bearing Removal - Off Vehicle

Tools Required

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

1. Note the orientation of paired connecting rods on each crankpin. The notches in the connecting rod cap must be facing each other.
2. Before removing the connecting rods, check the connecting rod end play using the following procedure: Tap the connecting rod to one end of the crankshaft journal with a dead-blow or wooden hammer. Using feeler gages, measure the clearance between the crankshaft counterweight and the connecting rod. The connecting rod end play should not exceed 0.500 mm (0.020 in). If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod. The width of the crankpin end of the connecting rod should be 21.745 - 21.805 mm (0.856 - 0.858 in). If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod. If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
3. Using a paint stick or permanent marker, number each piston face. Draw an arrow along the centerline of the piston pointing toward the front of the engine.
4. Mark the cylinder number on the connecting rod and the connecting rod cap with paint stick, scribe or permanent marker. The connecting rod caps must remain with the original connecting rod.
5. Remove the connecting rod bolts.
6. Remove the connecting rod cap.
7. Install the EN 46121 into the connecting rod bolt holes. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
8. Using the EN 46121 push the connecting rod and piston assembly down through the top of the cylinder. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Do not scratch the crankshaft journal or the cylinder wall when removing the connecting rod and piston assembly.
9. Remove the EN 46121 from the connecting rod bolt holes. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
10. Remove the connecting rod bearings. NEVER reuse the connecting rod bearings. Refer to «Crankshaft and Bearing Cleaning and Inspection»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-3-of-5) for inspection.
11. Reattach the connecting rod cap to the connecting to prevent damage to their mating surfaces. The cap and rod are a matched set and must be kept together.

Crankshaft Removal Procedure

1. Before removing the crankshaft, measure the crankshaft end play using the following procedure: Reinstall the lower crankcase. Place a dial indicator at the crankshaft nose. Gently force the crankshaft to the extreme front and rear positions with a pry tool while monitoring the movement of the dial indicator. The crankshaft end play should not exceed 0.05-0.5 mm (0.002-0.020 in). If the specifications are exceeded, replace the thrust bearing. If a new thrust bearing does not bring the tolerances within specification, replace the crankshaft. Remove the lower crankcase.
2. Locate or fabricate two V-blocks to support the crankshaft.
3. Using two hands, lift the crankshaft straight up from the engine block.
4. Place the crankshaft on the V-blocks in a secure place.
5. If damaged, remove the crankshaft sprocket drive pin (1) from the nose of the crankshaft.

Crankshaft Bearing Removal Procedure

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

Engine Block Disassemble - Upper - Off Vehicle

1. Remove the piston oil nozzle bolts.
2. Remove the piston oil nozzles.
3. Remove the engine coolant drain plug.
4. Remove the engine block to crankcase pins.
5. Remove the engine block to engine front cover pins.
6. Remove and discard the camshaft intermediate drive shaft block plug.
7. Remove and discard the piston oil nozzle oil gallery expansion plug.
8. Remove the left side block deck face to left cylinder head dowels.
9. Remove the right side block deck face to right cylinder head dowels.
10. Remove the engine block to transmission dowels.

Tools Required

J 8087 Cylinder Bore Gage. See Special Tools .

Cleaning Procedure

1. Remove any old thread sealant and gasket material or sealant.
2. Clean all the following areas with solvent: Sealing surfaces Cooling passages Oil passages Bearing journals
3. Clean all threaded and through holes with solvent.
4. Prior to the application of RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the engine block seal groove clean the groove and mating surfaces of the upper engine block and the mating surface of the lower crankcase with cleaner solvent GM P/N 12378392 or 12346139 (Canadian P/N 88901247).
5. Dry the upper engine block with compressed air.

Visual Inspection

1. Inspect the crankshaft bearing journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced.
2. Inspect the crankshaft rear oil seal bore for damage. The crankshaft rear oil seal bore is not repairable, if the crankshaft rear oil seal bore is damaged the cylinder block assembly must be replaced.
3. Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if necessary.
4. Inspect all threaded and through holes for damage or excessive debris.
5. Inspect all bolts for damage, if damaged replace with new bolts only.
6. Inspect the cylinder walls for cracks or damage. The cylinders sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.
7. Inspect the upper engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
8. Repair any damaged threaded holes. Refer to «Thread Repair Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction) and «Thread Repair»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-4-of-5__thread-repair-off-vehicle) .

Cylinder Bore Diameter Measurement Procedure

1. Measure the cylinder bore diameter at 41 mm (1.61 in) below the cylinder block deck surface using the J 8087 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
2. Compare your results with the engine mechanical specifications. If the cylinder diameter exceeds the specifications, the cylinder block must be replaced. There are no oversized pistons available for service.

Deck Face Flatness Measurement Procedure

1. Place a straight edge across the deck face of the cylinder block at an angle starting at the front of the block and sloping downward to the rear of the block.
2. Measure the gap between the straight edge and cylinder block by sliding the feeler gages under the straight edge at the front, center and rear of the block. Insert the greatest thickness gage that will fit.
3. Find the difference between the largest and smallest measurement.
4. Change the position of the straight edge so that the angle travels up from the front of the block to the rear.
5. Measure the gap between the straight edge and the deck face again at the front, center and rear. Insert the greatest thickness gage that will fit.
6. Find the difference between the largest and smallest measurement.
7. Position the straight edge so it travels through the center of the cylinder bores.
8. Measure the gap between the straight edge and the deck face a final time at the front, center and rear. Insert the greatest thickness gage that will fit.
9. Find the difference between the largest and smallest measurement.
10. Compare your measurement to the engine mechanical specifications.

Cylinder Bore Taper Measurement Procedure

1. Measure the cylinder bore along the thrust surfaces at 5 mm (0.200 in) below the deck surface with the bore gage perpendicular to the crankshaft centerline and record the measurements.
2. Measure the cylinder bore along the thrust surfaces at 102 mm (4.000 in) below the deck surface with the bore gage perpendicular to the crankshaft centerline and record the measurements.
3. Calculate the difference between the two measurements. The result will be the cylinder taper.
4. Compare your results with the engine mechanical specifications. If the cylinders exceed these specifications, replace the cylinder block.

Cylinder Bore Out-of-Round Measurement Procedure

1. Measure both the thrust and non-thrust cylinder diameter 5 mm (0.20 in) below the deck surface using the J 8087 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Record your measurements.
2. Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of the cylinder.
3. Measure both the thrust and non-thrust cylinder diameter 102 mm (4.00 in) below the deck surface using the J 8087 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Record your measurements.
4. Calculate the difference between the two measurements. The result will indicate out-of-round at the lower end of the cylinder.
5. Compare your results with the engine mechanical specifications. If the cylinders exceed these specifications, replace the cylinder block.

Engine Block Assemble - Upper - Off Vehicle

1. Install the engine block to transmission dowels.
2. Ensure the dowels are installed to the proper depth. The dowel should protrude (1) 9.0-10.0 mm (0.3543-0.3937 in).
3. Remove the left side block deck face to left cylinder head dowels.
4. Ensure the dowels are installed to the proper depth. The dowel should protrude (1) 13.5-14.5 mm (0.5315-0.5709 in).
5. Install the right side block deck face to right cylinder head dowels.
6. Ensure the dowels are installed to the proper depth. The dowel should protrude (1) 13.5-14.5 mm (0.5315-0.5709 in).
7. Install the NEW piston oil nozzle oil gallery expansion plug.
8. Ensure the plug is installed to the proper depth (1) of 2.0-3.5 mm (0.0787-0.1378 in).
9. Install the NEW camshaft intermediate drive shaft block plug. The installation tool must not deform the rear face of the plug and cause interference with the crankshaft.
10. Ensure the plug (1) is properly seated to the flange (2) in the bore and will not interfere with the engine block oil passages (3) or the crankshaft counter-weight (4).
11. Install the engine block to engine front cover pins.
12. Ensure the pins are installed to the proper depth. The pin should protrude (1) 8.5-9.5 mm (0.3347-0.3740 in).
13. Install the engine block to crankcase pins.
14. Ensure the pins are installed to the proper depth. The pin should protrude (1) 12 mm (0.4724 in).
15. Install the engine coolant drain plug. Tighten: Tighten the engine coolant drain plug to 20 N.m (15 lb ft).
16. Install the piston oil nozzles.
17. Install the piston oil nozzle bolts. Tighten: Tighten the piston oil nozzle bolt to 10 N.m (89 lb in).

1. Remove any old thread sealant and gasket material or sealant.
2. Clean all the following areas with solvent: Sealing surfaces Oil passages Bearing journals
3. Clean all threaded and through holes with solvent.
4. Prior to the application of RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the engine block seal groove clean the groove and mating surfaces of the upper engine block and the mating surface of the lower crankcase with cleaner solvent GM P/N 12378392 or 12346139 (Canadian P/N 88901247).
5. Dry the lower engine block with compressed air.

1. Inspect the crankshaft bearing journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced.
2. Inspect the crankshaft rear oil seal bore for damage. The crankshaft rear oil seal bore is not repairable, if the crankshaft rear oil seal bore is damaged the cylinder block assembly must be replaced.
3. Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if necessary.
4. Inspect all threaded and through holes for damage or excessive debris.
5. Inspect all bolts for damage, if damaged replace with new bolts only.
6. Inspect the crankshaft oil scraper for cracks or damage, replace if cracked or damaged.
7. Inspect the lower engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
8. Repair any damaged threaded holes. Refer to «Thread Repair Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction) and «Thread Repair»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-4-of-5__thread-repair-off-vehicle) .

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

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

Crankshaft Bearing Inspection

The following bearing wear conditions should be used to diagnose engine operating conditions or root cause of a condition.

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

Crankshaft Measurement

Tools Required

J 7872 Magnetic Base Dial Indicator

1. Using a suitable fixture, support the crankshaft.
2. Install the J 7872 .
3. Measure the crankshaft runout using J 7872 . Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
4. Measure the crankshaft thrust wall width (1) for wear using an inside micrometer. Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
5. Measure the crankshaft thrust wall surface (2) for runout using J 7872 . Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
6. If the crankshaft thrust walls are damaged or worn beyond specifications, replace the crankshaft. No machining of the crankshaft thrust wall is allowed.
7. Check the crankshaft main journals for undersize using an outside micrometer.
8. Check the crankpins for undersize using an outside micrometer.
9. Compare your measurements with those listed in the «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) . If the crankshaft journals are worn beyond the specified limits, the crankshaft must be replaced. Crankshaft machining is not allowed and there are no undersized bearings available for service.
10. Measure the main bearing and crankpin journals for out-of-round using the following procedure: Using an outside micrometer, measure the journal at the extreme front and rear locations on the journal. Call these points A and B. Measure the journal in two new locations exactly 90 degrees from the first points. Call these points C and D. Subtract A from C and B from D. The differences will indicate journal out-of-round. The out-of-round should not exceed 0.005 mm (0.00020 in) maximum. If the specifications are exceeded, replace the crankshaft.
11. Measure the main bearing and crankpin journals for taper using the following procedure: Using an outside micrometer, measure the journal at the extreme front (A) and rear (B) of the journal parallel to the crankshaft centerline. Subtract the smallest from the largest measurement. The result will be the journal taper. If the main bearing journal taper exceeds 0.008 mm (0.00032 in), replace the crankshaft. If the crankpin journal taper exceeds 0.008 mm (0.00032 in), replace the crankshaft.

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

Inspection Procedure

1. Inspect the exterior of the crankshaft balancer for the following: Damage to the webs (1) between the hub and the drive belt inner pulley Damage to the seating surface (2) for the crankshaft balancer bolt's washer Wear or damage to the hub-to-crankshaft surface (3) Wear, chunking or deteriorated rubber (4) between the drive belt inner and outer pulleys Damage to the drive belt inner and/or outer pulley ribs (5)
2. Inspect the interior of the crankshaft balancer for the following: Wear or damage to the hub-to-crankshaft surface (1) Wear, grooves or damage to the hub sealing surface (2). A crankshaft balancer hub sealing surface with excessive scoring, grooves, rust or other damage must be replaced. Bent, damage or missing crankshaft front oil seal shield (3) Wear, chunking or deteriorated rubber (4) between the drive belt inner and outer pulleys Damage to the drive belt inner and/or outer pulley ribs (5)
3. Repair or replace the crankshaft balancer as necessary.

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

1. Inspect the engine flywheel hub spline for damage (1).
2. Inspect the engine flywheel hub for cracks (2).
3. Inspect the engine flywheel hub to plate rivets for damage or looseness (3).
4. Inspect the engine flywheel plate for cracks (4).
5. Inspect the engine flywheel plate rivets for damage or looseness (5).
6. Inspect the engine flywheel ring gear welds that retain the ring gear to the engine flywheel for cracks (6).
7. Inspect the engine flywheel ring gear teeth for damage (1).
8. Inspect the engine flywheel for stress cracks at rivets (2).
9. Inspect the engine flywheel for stress cracks at the engine flywheel to crankshaft mounting holes (3, 4).

Piston and Connecting Rod Disassemble - Off Vehicle

Tools Required

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

1. Remove the piston rings using a piston ring expander. Place each ring in a clean shop towel for storage.
2. Using the EN-46745 , pry out the piston pin retainers by using the removal access notch in the side of the piston. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
3. Discard the old piston pin retainers.
4. Slide the piston pin (4) out of the piston. The piston will disconnect from the connecting rod (2).

Connecting Rod Cleaning Procedure

1. Clean the connecting rods in solvent.
2. Dry the connecting rods with compressed air.

Connecting Rod Visual Inspection Procedure

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

Connecting Rod Measurement Procedure

Piston Pin End

1. Using an outside micrometer, take 2 measurements of the piston pin in the area of the connecting rod contact.
2. Using an inside micrometer, measure the connecting rod piston pin bore.
3. Subtract the piston pin diameter from the piston pin bore.
4. Compare the clearance measurements with the «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
5. If the clearance is excessive, replace the piston pin. If a new pin does not resolve the clearance problem, replace the connecting rod.

Connecting Rod Crankshaft Bearing End

1. Using an inside micrometer, measure the connecting rod crankshaft bearing bore.
2. Compare the bore measurements with the «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
3. Replace the connecting rod if the bore is out of specifications. DO NOT recondition the connecting rod.

Piston Cleaning Procedure

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

Piston Inspection Procedure

1. Inspect the top of the piston (1) for erosion.
2. Inspect the ring lands and ring grooves (2) for cracks, warpage, wear and nicks/burrs that cause binding.
3. Inspect the piston skirt coating (3) for excessive wear.
4. Inspect the piston skirt (4) for cracks.
5. Inspect the piston pin bore (5) for wear, cracks and pin retainer grooves (6) for burrs.
6. Replace any piston and/or piston pin that have damage or excessive wear.

Piston Diameter Measurement Procedure

1. Using an outside micrometer, measure the width of the piston 40 mm (1.575 in) below the crown (top) of the piston at the thrust surface which is perpendicular to the centerline of the piston pin (1).
2. Compare the measurement to the diameter listed in the engine mechanical specifications.
3. You must replace the piston if any of its dimensions are out of specification. There are no oversized pistons available.

Piston Pin Bore Measurement Procedure

1. Piston pin bores and pins must be free of varnish or scuffing.
2. Use an outside micrometer to measure the piston pin in the piston contact areas.
3. Using an inside micrometer, measure the piston pin bore.
4. Subtract the measurement of the piston pin bore from the piston pin.
5. Compare the result with the engine mechanical specifications.
6. If the clearance is excessive, determine which piece is out of specification and replace as necessary.

Piston Ring End Gap Measurement Procedure

1. Place the piston ring in the area of the bore where the piston ring will travel, approximately 25 mm (1 in) down from the deck surface. Be sure the ring is square with the cylinder bore by positioning the ring with the piston head.
2. Measure the end gap of the piston ring with feeler gages. Compare the measurements with those provided in the engine mechanical specifications.
3. If the clearance exceeds the provided specifications, the piston rings must be replaced.
4. Repeat this procedure for all the piston rings.

Piston Ring Side Clearance Measurement Procedure

1. Roll the piston ring entirely around the piston ring groove. If any binding is caused by the ring groove, dress the groove with a fine file. If any binding is caused by a distorted piston ring, replace the ring.
2. With the piston ring on the piston, use feeler gages to check side clearance at multiple locations.
3. Compare your measurements with those found in the engine mechanical specifications.
4. If the clearance is greater than specifications, replace the piston rings.
5. If new piston rings do not bring the clearance within specification, the piston must be replaced.
6. When replacing the piston rings, only install re-ring sets that have a 1.2 mm (0.047 in) thick nitrided steel upper compression ring and multi-piece oil rings. The top compression ring may be installed with either side up. There is a locating dimple on the 2nd compression ring near the end for identification of the top side. Install the 2nd compression ring with the dimple facing up.

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

Piston and Piston Pin Installation Procedure

1. Properly orient the piston (1) on the connecting rod (2) as follows: The locating mark (4) cast into the underside of the piston should point towards the front of the engine. The locating notch (3) on the connecting rod cap should be pointing towards the rear of the engine on odd-numbered cylinders and towards the front of the engine on even-numbered cylinders.
2. Lubricate the piston pin bores in the piston and connecting rod with GM prelube lubricant GM P/N 1052367 (Canadian P/N 992869) or equivalent.
3. Align the piston pin bore with the connecting rod pin bore.
4. Slide the piston pin (4) into the piston and the connecting rod (3).
5. Install NEW piston pin retainers (1) using the EN-46745 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
6. Ensure that the piston pin retainers are fully seated in their grooves.
7. Repeat these procedures for the remaining pistons.

Piston Ring Installation Procedure

1. Install the piston rings using a piston ring installer.
2. Properly orient the oil control ring expander as shown before installation. The ends of the expander must be facing toward the top of the piston.
3. Install the oil control piston ring spacer onto the piston.
4. Install the lower oil control piston ring onto the piston (1).
5. Install the upper oil control piston ring onto the piston (1).
6. Space the oil control piston ring end gaps (1, 2) a minimum of 90 degrees apart.
7. Install the lower compression piston ring onto the piston (1). The mark on the side of the piston ring should face the top of the piston.
8. Install the upper compression piston ring onto the piston. The top compression ring may be installed with either side up.
9. Once the rings are installed, set the ring gaps for the oil control, second and top rings in the positions shown: Oil control ring expander and second compression ring gaps position 1. Upper oil control ring gap position 2. Top compression ring gap position 3. Lower oil control ring gap position 4.

Connecting Rod Bearing Installation Procedure

1. Clean the connecting rod and the connecting rod cap bearing bore with a lint-free cloth.
2. Clean all the oil from behind the connecting rod bearing halves.
3. Install new upper connecting rod bearings into position. Roll the bearing into position so that the lock tang engages the alignment slot. The bearing must fit flush in the connecting rod.
4. Install new lower connecting rod bearings into position in the connecting rod cap. Roll the bearing into position so that the lock tang engages the alignment slot. The bearings must fit flush with the connecting rod cap.

Cylinder Head Disassemble - Off Vehicle

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
2. J 38820 Valve Stem Seal Installer. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
3. J 38821 Valve Spring Compressor Adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
4. J-43059-A Valve Retainer Remover/Installer. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .

1. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer in order to loosen the valve keepers.
2. Compress the valve spring with the J 8062 (2) and the J 38821 (1). See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
3. Use the magnet of the J-43059-A in order to remove the valve keepers. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
4. Remove the J 8062 and the J 38821 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
5. Remove the valve spring.
6. Remove the valve seal with the J 38820 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Discard the valve seal, NEVER reuse the valve seal.
7. Remove the valve.
8. Repeat the procedure for the remaining valves.
9. Remove and discard the engine coolant expansion plugs.
10. Inspect the engine coolant expansion plug bore of the cylinder head. Ensure the hole is concentric, within specifications (1) and not damaged/corroded (2). Replace the cylinder head if necessary.
11. Remove the oil gallery threaded plugs.
12. Inspect the oil gallery threaded plug hole threads of the cylinder head. Ensure the threads (1) are serviceable and the washer sealing surface (2) is flat and free of defects. Repair the threads in the cylinder head if necessary.
13. Inspect the oil gallery threaded plugs. Ensure the threads (1) are serviceable and the washer sealing ring surface (2) is flat and free of defects. Replace the oil gallery threaded plugs if necessary.
14. Remove the core hole threaded plugs.
15. Inspect the core hole threads of the cylinder head. Ensure the threads (1) are serviceable and the washer sealing surface (2) is flat and free of defects. Repair the threads in the cylinder head if necessary.
16. Inspect the core hole threaded plugs. Ensure the threads (1) are serviceable and the washer sealing ring surface (2) is flat and free of defects. Replace the core hole threaded plugs if necessary.

Cylinder Head Cleaning and Inspection - Off Vehicle

Tools Required

1. J 8001 Dial Indicator Set
2. J 8358 Carbon Removal Brush. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
3. J 28410 Gasket Remover. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .

Visual Inspection Procedure

1. Inspect the cylinder head for the following: Cracks, damage or pitting in the combustion chambers. IMPORTANT: DO NOT machine the camshaft bearing journals. Scoring of the camshaft bearings and/or the journals. If the camshaft bearing journals appear to be scored or damaged, you must replace the cylinder head. Debris in the oil galleries. Continue to clean the galleries until all debris is removed. Coolant leaks or damage to the deck face sealing surface. If coolant leaks are present, measure the surface warpage as described under Cylinder Head Measurement. Damage to any gasket surfaces Damage to any threaded bolt holes Burnt or eroded areas in the combustion chamber Cracks in the exhaust ports and combustion chambers External cracks in the water chamber Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged, or leaking core plugs
2. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is recommended.
3. The oil passage from the left cylinder head deck face that feeds the stationary hydraulic lifters (SHLAs) and the camshafts has a pressed-in restrictor. The orifice within the restrictor is 3 mm (0.1181 in). DO NOT remove the restrictor. Ensure the restrictor and oil passage are clean and free of any debris.
4. Ensure the left cylinder head oil gallery restrictor is installed to the proper depth of 1.5-5.5 mm (0.059-0.216 in).
5. The oil passage from the right cylinder head deck face that feeds the stationary hydraulic lifters (SHLAs) and the camshafts has a pressed-in restrictor. The orifice within the restrictor is 3 mm (0.1181 in). DO NOT remove the restrictor. Ensure the restrictor and oil passage are clean and free of any debris.
6. Ensure the right cylinder head oil gallery restrictor is installed to the proper depth of 1.5-5.5 mm (0.059-0.216 in).

1. Clean all cylinder head surfaces with non-corrosive solvent.
2. Blow out all the oil galleries using compressed air.
3. Remove any carbon deposits from the combustion chambers using the J 8358 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
4. Remove any gasket material with the J 28410 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
5. Clean any debris or build-up from the lifter pockets.
6. Inspect the cylinder head again for the items noted under Visual Inspection.

Cylinder Head Measurement

1. Measure the camshaft clearance specification using the following procedure: Install the camshaft caps. Install the camshaft caps bolts. Tighten: Tighten the camshaft bearing caps bolts to 5 N.m (44 lb in). Measure the camshaft bearings using an inside micrometer. Inspect and measure the camshaft journal diameters. Refer to «Camshaft Cleaning and Inspection»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-3-of-5) . Subtract the camshaft journal diameter from the camshaft bearing diameter in order to obtain the running clearance. If the running clearance exceeds the specifications and the camshaft journals are within specification, replace the cylinder head. Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
2. Measure the camshaft thrust specification using the following procedure: Inspect each camshaft cap thrust surface for excessive scoring/wear. Inspect each camshaft. Refer to «Camshaft Cleaning and Inspection»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-3-of-5) . Install the intake and exhaust camshafts in the cylinder head. Install the camshaft caps. Install the camshaft caps bolts. Tighten: Tighten the camshaft bearing caps bolts to 5 N.m (44 lb in). Measure the camshaft thrust bearing clearance at the front camshaft bearing cap. Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) . If the camshaft thrust bearing clearance is not to specification repair or replace the cylinder head.
3. Measure the cylinder head flatness using the following procedure: Clean any remaining head gasket material from the cylinder head face. Place a straight-edge diagonally across the cylinder head face surface. Measure the clearance between the straight-edge and the cylinder head using a feeler gage at four points along the straight-edge. If warpage is less than 0.05 mm (0.002 in), the cylinder head surface does not require resurfacing. If warpage is between 0.05-0.20 mm (0.002-0.008 in), the cylinder head must be resurfaced.

Valve Guide Measurement Procedure

1. Measure the valve stem (1)-to-guide (2) clearance as follows: Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also case a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness. Clamp the J 8001 to the cylinder head at the camshaft cover rail. 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. Drop the valve head about 1.6 mm (0.0064 in) off the valve seat. Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading.
2. If the clearance for the intake valve is greater than 0.11 mm (0.0045 in) and a new standard diameter valve stem will not bring the clearance within specifications, the cylinder head must be replaced.
3. If the clearance for the exhaust valve is greater than 0.12 mm (0.005 in) and a new standard diameter valve stem will not bring the clearance within specifications, the cylinder head must be replaced.
4. Valve guide wear at the bottom 10 mm (0.39 in) of the valve guide is not significant to normal operation.

Valve Spring Inspection and Measurement - Off Vehicle

Tools Required

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

1. Place the valve spring in the J 22738-B . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
2. Compress the J 22738-B to the valve open, valve spring compressed, dimension listed in the «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
3. If low valve spring load is found to be too low, replace the valve spring, DO NOT shim.

Valve Cleaning Procedure

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

Valve Visual Inspection Procedure

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

Valve Measurement and Reconditioning Overview

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 on the valve face (1) using a proper scale.
3. Compare your measurements with the specifications listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
4. If the seat widths are acceptable, check the valve seat roundness using the Valve Seat Roundness Measurement Procedure.
5. If the seat width is not acceptable, you must grind the valve seat using the Valve and Seat Reconditioning Procedure to bring the width back into specification. Proper valve seat width is critical to providing the correct amount of valve heat dissipation.

Valve Seat Roundness Measurement Procedure

1. Measure the valve seat roundness using a dial indicator attached to a tapered pilot installed in the guide. The pilot should have a slight bind when installed in the guide.
2. Compare your measurements with the specifications listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
3. If the valve seat exceeds the roundness specification, you must grind the valve and valve seat using the Valve and Seat Reconditioning Procedure.
4. If new valves are being used, the valve seat roundness must be within 0.05 mm (0.002 in).

Valve Margin Measurement Procedure

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

Valve-to-Seat Concentricity Measurement Procedure

1. Checking the valve-to-seat concentricity determines whether the valve and seat are sealing properly.
2. You must measure the valve face and the valve seat to ensure proper valve sealing.

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

Valve and Seat Reconditioning Procedure

1. Grind the valve seats (2) to the proper angle specification listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
2. Using the proper angle specification listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) , grind, relieve, the valve seats (1) to correctly position the valve seating surface (2) to the valve.
3. Using the proper angle specification listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) , grind, undercut, the valve seats (3) to narrow the valve seat widths to the specifications listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
4. If the original valve is being used, grind the valve to the specifications listed in «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) . Measure the valve margin again after grinding using the Valve Margin Measurement Procedure. Replace the valve if the margin is out of specification. New valves do not require grinding.
5. When grinding the valves and seats, grind off as little material as possible. Cutting valve seat results in lowering the valve spring pressure.
6. Install the valve in the cylinder head. If you are using refaced valves, lap the valves into the seats with a fine grinding compound. The refacing and reseating operations should leave the refinished surfaces smooth and true so that minimal lapping is required. Excessive lapping will groove the valve face and prevent a good seat when hot. IMPORTANT: Be sure to clean any remaining lapping compound from the valve and seat with solvent and compressed air prior to final assembly. If you are using new valves, do not lap the valves under any condition.
7. After obtaining the proper valve seat width in the cylinder head, you must re-measure the valve stem height using the Valve Stem Height Measurement Procedure.
8. If the valve stem height is acceptable, test the seats for concentricity using the Valve-to-Seat Concentricity Measurement Procedure.

Valve Stem Height Measurement Procedure

1. Install the valve into the valve guide.
2. Ensure the valve is seated to the cylinder head valve seat.
3. Install the valve stem oil seal.
4. Install the valve spring retainer and valve stem locks.
5. Measure the distance (1) between the valve stem oil seal spring seat to the bottom of the valve spring retainer.
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 - Off Vehicle

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
2. J 38820 Valve Stem Seal Installer. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
3. J 38821 Valve Spring Compressor Adapter. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
4. J-43059-A Valve Retainer Remover/Installer. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .

1. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) to the threads (1) of the core hole threaded plugs.
2. Install the core hole threaded plugs. Tighten: Tighten the core hole threaded plugs to 80 N.m (60 lb ft).
3. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) to the threads (1) of the oil gallery threaded plugs.
4. Install the oil gallery threaded plugs. Tighten: Tighten the oil gallery threaded plugs to 60 N.m (44 lb ft).
5. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) to the outside diameter (1) of the NEW engine coolant expansion plugs.
6. Install the NEW engine coolant expansion plugs.
7. Ensure the engine coolant expansion plugs are installed to the proper depth (a) of 0.00-0.50 mm (0.00-0.020 in) deep.
8. Lubricate the valve stem with clean engine oil.
9. Insert the valve into the valve guide until it bottoms on the valve seat.
10. Lubricate the new valve seal with engine oil.
11. Using the J 38820 , install the new valve seal using the following procedure. See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Place the valve lifter bore protector into the lifter bore. Mount the new valve seal in the J 38820 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) . Push and twist the new valve seal into position on the valve guide until the seal positively locks on the guide.
12. Position the valve spring on the spring seat.
13. Compress the valve spring using the J 8062 (2) and the J 38821 (1). See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
14. With the spring compressed, install the valve keepers into the J-43059-A . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
15. Place the keepers into position by pushing the tool downward.
16. Release the tension on the spring compressor and remove the J 38821 . See «Special Tools»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__special-tools) .
17. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-blow hammer. The valve keepers and the spring should remain in place.
18. Repeat this procedure for the remaining valves.

J 7872 Magnetic Base Dial Indicator

1. Clean the camshaft in solvent.
2. Dry the camshaft with compressed air.
3. Cover the camshafts with a clean oil soaked towel in order to prevent corrosion.

1. Inspect the camshaft sprocket locating pin (2) for damage or wear.
2. Inspect the threads (3) for the camshaft sprocket bolt.
3. Inspect the camshaft lobes (1) and journals (4) for the following conditions: Excessive scoring or pitting Discoloration from overheating Deformation from excessive wear, especially the camshaft lobes

Camshaft Measurement Procedure

1. With the camshaft in a suitable fixture, measure the camshaft for wear.
2. Measure the camshaft journals for diameter and out-of-round using an outside micrometer. If the diameter is smaller than 26.948 mm (1.061 in), replace the camshaft. If the out-of-round exceeds 0.022 mm (0.0009 in), replace the camshaft.
3. Measure the camshaft runout using J 7872 . Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
4. Measure the camshaft thrust wall width (1) for wear using an inside micrometer. Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
5. Measure the camshaft thrust wall surface (2) for runout using J 7872 . Refer to «Engine Mechanical Specifications»(/cadillac/xlr/i-2003-2009/remont/mechanical/#engine-mechanical-44l-introduction__engine-mechanical-specifications) .
6. If the camshaft is damaged or worn beyond specifications, replace the camshaft. No machining of the camshaft is allowed.
7. Measure the camshaft lobes for wear using the J 7872 .
8. Place the J 7872 with the indicator tip on the base circle (2) of the camshaft lobe. Place the J 7872 dial at zero. Rotate the camshaft until the indicator tip is at the highest point on the lobe. This reading is the lift (1) of the camshaft lobe. The specifications for lift are as follows: Intake camshaft: 6.166 mm (0.2428 in) Exhaust camshaft: 5.944 mm (0.2336 in)
9. If the indicated measurement is significantly lower than these specifications, replace the camshaft or engine performance will be reduced.

Valve Lifters Cleaning and Inspection - Off Vehicle

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

Valve Rocker Arms Cleaning and Inspection - Off Vehicle

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

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

1. Inspect the camshaft intermediate drive shaft for the following: Worn or damaged hub-to-camshaft intermediate drive shaft sprocket bearing surface (1) Cracks or damage to the camshaft intermediate drive shaft fastener holes (2) Restrictions to the oil passage (3) Damaged or stripped thread (4)
2. Repair or replace the camshaft intermediate drive shaft as necessary.

1. Clean all the following components with solvent: Camshaft position actuator - exterior only Camshaft position actuator oil control valve Intermediate sprocket Crankshaft sprocket Primary timing chain Secondary timing chains Primary timing chain guide Secondary timing chain guides Primary timing chain shoe Secondary timing chain shoes Primary timing chain tensioner Secondary timing chain tensioners Timing component fastening bolts
2. Dry the timing components with compressed air.

Camshaft Position Actuators

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

Camshaft Position Actuator Oil Control Valve

1. Inspect the camshaft position actuator oil control valves for the following: Thread damage (1) Blockage to the oil passages (2) Camshaft position actuator oil control valve seating/sealing flange damage (3) Hex damage (4) Spool valve head damage (5)
2. Replace a damaged camshaft position actuator oil control valve.

Intermediate Sprocket

1. Inspect the front of the intermediate sprocket for the following: Sprocket damage (1) Bearing bore damage (2) Thrust surface damage (3)
2. Inspect the back of the intermediate sprocket for the following: Sprocket damage (1) Bearing bore damage (2) Thrust surface damage (3)
3. Replace a damaged intermediate sprocket.

Crankshaft Sprocket

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

Primary and Secondary Timing Chains

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

Primary Timing Chain Guide

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

Secondary Timing Chain Guides

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

Secondary Timing Chain Shoes

1. Inspect the secondary timing chain shoes for the following: Worn shoe surface (1) Cracked or broken shoe surface (2) Cracked or damaged shoe (3)
2. Replace a damaged secondary timing chain shoe.

Primary Timing Chain Tensioner

1. Inspect the primary timing chain tensioner for worn primary timing chain tensioner shoe surface (1).
2. Inspect the primary timing chain tensioner for locked or binding timing chain tensioner. Release the locking lever (2) and ensure the plunger moves freely (3) in and out of the body of the tensioner.
3. Replace a damaged primary timing chain tensioner.

Secondary Timing Chain Tensioners

1. Inspect the secondary timing chain tensioner for damaged plunger-to-shoe contact surface (1).
2. Inspect the secondary timing chain tensioner for locked or binding timing chain tensioner. Release the locking lever (2) and ensure the plunger moves freely (3) in and out of the body of the tensioner.
3. Replace a damaged primary and/or secondary timing chain tensioner.

Timing Component Fasteners

1. Inspect the timing component fasteners.
2. Replace any damaged timing component fasteners, do not repair.

Mechanical Inspection

Camshaft Position Actuators

1. Inspect the intake camshaft position actuator to ensure the internal lock pin is engaged and the camshaft position actuator is parked in the home position. Attempt to rotate the inner rotor hub (1) within the outer housing (2). If the intake camshaft position actuator can be turned in either direction the camshaft position actuator must be replaced.
2. Locate the internal hub oil passage for the locking pin by observing the external housing locking pin cover (1). The oil passage in the hub for the locking pin is inline with the location of the locking pin cover.
3. Inspect the intake camshaft position actuator for smooth and even movement. Using a pre-bent hex key, smaller than the oil passage, depress the internal lock pin through the oil passage (1) located within the hub of the camshaft position actuator. While viewing the intake camshaft position actuator from the front and with the lock pin depressed, the outer housing should be manually moved in the clockwise direction from the inner rotor hub.
4. Remove the hex key from the oil passage and manually return the outer housing clockwise back to the home position. Ensure the lock pin engages when the outer housing returns to the home position.
5. If the intake camshaft position actuator does not move, the movement is not smooth and even, or the lock pin does not engage in the home position replace the intake camshaft position actuator.
6. Inspect the exhaust camshaft position actuator to ensure the internal lock pin is engaged and the camshaft position actuator is parked in the home position. Attempt to rotate the inner rotor hub (1) within the outer housing (2). If the exhaust camshaft position actuator can be turned in either direction the camshaft position actuator must be replaced.
7. Locate the internal hub oil passage for the locking pin by observing the external housing locking pin cover (1). The oil passage in the hub for the locking pin is inline with the location of the locking pin cover.
8. Inspect the exhaust camshaft position actuators for smooth and even movement. The exhaust camshaft position actuator has return springs and the inspection will require additional assistance to perform. Using a pre-bent hex key, smaller than the oil passage, depress the internal lock pin through the oil passage (1) located within the hub of the camshaft position actuator. While viewing the exhaust camshaft position actuator from the front and with the lock pin depressed, the outer housing should be manually moved in the clockwise direction from the inner rotor hub.
9. Remove the hex key from the oil passage and allow the outer housing to move counter clockwise back to the home position. Ensure the return springs bring the outer housing back to the home position and the lock pin engages.
10. If the exhaust camshaft position actuator does not move, the movement is not smooth and even, the return springs do not return the outer housing to the home position, or the lock pin does not engage in the home position replace the exhaust camshaft position actuator.

Camshaft Position Actuator Oil Control Valve

1. Inspect the camshaft position actuator oil control valves for smooth and even movement of the spool valve within the camshaft position actuator oil control valve body.
2. Inspect the camshaft position actuator oil control valves for proper movement of the spool valve. The valve should move a distance (2) of 4.35 mm (0.1713 in). Measure from the underside of the spool valve head. The home position is 2.25 mm (0.0886 in) above (1) the hex and the fully extended position measures 6.60 mm (0.2598 in) above (3) the hex.
3. Inspect the camshaft position actuator oil control valves for proper return of the spool valve to the home position by the internal spring.

Camshaft Position Actuator Housing Disassemble - Off Vehicle

1. Remove the camshaft position actuator housing gasket and discard.
2. Remove the camshaft position actuator housing alignment pins.
3. If required, remove the camshaft position actuator magnet bolts.
4. If required, remove the camshaft position actuator magnet.
5. Remove the camshaft position actuator magnet alignment plug and discard.

1. Clean the camshaft position actuator housing components, except the camshaft position actuator magnets, with solvent.
2. Dry the camshaft position actuator housing components with compressed air.

1. Inspect the camshaft position actuator housing for the following conditions: The camshaft position actuator housing for damaged threads (1) The camshaft position actuator housing sealing surface (2) for damage The camshaft position sensor mounting bores (3) for damage
2. Inspect the camshaft position actuator magnets for the following conditions: The camshaft position actuator magnet wiring connector (1) for damage The camshaft position actuator magnet sealing surface (2) for damage
3. Repair or replace the camshaft position actuator housing and/or components as necessary.

Camshaft Position Actuator Housing Assemble - Off Vehicle

1. If removed, loosely mount the camshaft position actuator magnet and bolts.
2. In order to allow for camshaft position actuator magnet to camshaft position actuator oil control valve alignment, DO NOT install the NEW camshaft position actuator magnet alignment plugs.
3. Install the camshaft position actuator housing alignment pins.
4. Install the NEW camshaft position actuator housing gasket.

Oil Pump Disassemble - Off Vehicle

1. Remove the oil pump drive spacer.
2. Remove the oil pump body bolts.
3. Remove the oil pump body cover.
4. Remove the oil pump drive and driven gears.
5. Remove the oil pump relief valve plug, relief valve spring and relief valve plunger.
6. Remove the oil pump body to oil pump cover alignment dowels.

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

1. Inspect the oil pump body for cracks, scoring, casting imperfections and damaged threads.
2. Inspect the oil pump cover for cracks, scoring and casting imperfections.
3. Inspect the oil pump driven gear for chipping, galling or wear.
4. Inspect the oil pump drive gear for chipping, galling or wear.
5. Inspect the oil pump drive spacer for chipping, galling or wear.
6. Inspect the oil pump relief components for embedded particles and/or damage.

Oil Pump Assemble - Off Vehicle

1. Install the oil pump body to oil pump cover alignment dowels.
2. Install the oil pump relief valve plunger, relief valve spring and relief valve plug. Tighten: Tighten the oil pump relief valve plug to 12 N.m (106 lb in).
3. Install the oil pump driven and drive gears. The outer driven gear has one chamfered edge. The chamfered edge of the driven gear must face down into the oil pump body.
4. Pack the pump body housing with clean white petroleum jelly to ensure pump priming.
5. Install the oil pump body cover.
6. Install the oil pump body bolts. Tighten: Tighten the oil pump body bolts to 12 N.m (106 lb in).
7. Install the oil pump drive spacer.

1. Clean the oil pump outlet with solvent.
2. Dry the oil pump outlet tube with compressed air.

1. Inspect the mounting surfaces (1) for possible leakage paths.
2. Inspect the oil pump outlet tube pipe (2) for cracks, imperfections and/or damage.
3. Inspect the oil pump outlet tube for distortion or damage to the pipe (3) and the bracket at the oil pump outlet end.
4. Repair or replace the oil pump outlet tube as necessary.

Oil Filter Adapter Disassemble - Off Vehicle

1. Remove and discard the oil filter adapter gasket (1).
2. Remove and inspect the oil pressure switch (5).
3. Remove and discard the oil pressure switch O-ring (6).
4. Remove and inspect the oil filter adapter hole plug (4).
5. Remove and discard the oil filter adapter hole plug O-ring (3).
6. Remove and inspect the oil filter fitting (2).
7. Remove the oil filter adapter pipe fittings.
8. Remove and discard the oil filter adapter pipe fitting seal.

1. Clean the oil filter adapter in solvent.
2. Dry the oil filter adapter with compressed air.

1. Inspect the exterior of the oil filter adapter for the following: Damage to the mounting holes (1) Damage to the oil filter adapter plug hole threads (3) Damage to the oil pressure switch hole threads (2) Blockage in the oil filter adapter hole passage (3) Damage to the oil cooler line fitting hole threads (4) Blockage in the oil cooler line passages (4)
2. Inspect the interior of the oil filter adapter for the following: Damage to the mounting surface (1) Damage to the oil filter sealing surface (2) Damage to the oil filter fitting hole threads (3) Blockage in the oil filter fitting hole (3) Blockage to the inlet and outlet passages (4)
3. Repair or replace the oil filter adapter as necessary.

Oil Filter Adapter Assemble - Off Vehicle

1. Install a NEW oil filter adapter pipe fitting seal.
2. Apply threadlocker GM P/N 89021297 (Canadian P/N 109534880) to the threads (1) of the oil filter adapter pipe fitting.
3. Install the oil filter adapter pipe fittings into the oil filter adapter. Tighten: Tighten the oil filter adapter pipe fitting to 25 N.m (18 lb ft).
4. Install the oil filter fitting (2). Tighten: Tighten the oil filter fitting to 29 N.m (21 lb ft).
5. Install a NEW O-ring (3) on the oil filter adapter hole plug (4).
6. Install the oil filter adapter hole plug (4). Tighten: Tighten the oil filter adapter hole plug to 65 N.m (48 lb ft).
7. Install a NEW O-ring (6) on the oil pressure switch (5).
8. Install the oil pressure switch (5). Tighten: Tighten the oil pressure switch to 20 N.m (15 lb ft).
9. Install the NEW oil filter adapter gasket (1).

Oil Pan Disassemble - Off Vehicle

1. Drill out the oil pan gasket rivets.
2. Remove and discard the oil pan gasket.
3. Remove the oil drain plug.
4. Remove the oil pan baffle bolts.
5. Remove the oil pan baffle.
6. Remove the oil pan oil level sensor.
7. Remove the oil level sensor and oil drain plug O-rings and discard.

1. Clean the oil pan components with solvent.
2. Dry the oil pan components with compressed air.

1. Inspect the exterior of the oil pan for the following conditions: The drain plug hole (1) for damaged threads The transmission mounting holes (2) for damaged threads The oil level switch hole (3) for damaged threads The exterior surfaces (4) for dents or damage. An oil pan that is damaged or dented may interfere with the position of the oil pump screen or interfere with oil distribution in the oil pan sump area.
2. Inspect the interior of the oil pan for the following conditions: Gouges or damage to the oil pan sealing surface (1) Damage to the oil pan baffle, baffle bolts and baffle mounting features (2) Damage to the oil pan bolt holes (3)
3. Repair or replace the oil pan as necessary.

Oil Pan Assemble - Off Vehicle

1. Install NEW O-rings on the oil level sensor and oil drain plug.
2. Install the oil pan oil level sensor. Tighten: Tighten the oil pan oil level sensor to 20 N.m (15 lb ft).
3. Install the oil pan baffle.
4. Install the oil pan baffle bolts. Tighten: Tighten the oil pan baffle bolts to 12 N.m (106 lb in)
5. Install the oil drain plug. Tighten: Tighten the oil drain plug to 25 N.m (18 lb ft).

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

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

See also:
• Valve Lifter Priming Notice
• Special Tools
• Safety Glasses Caution
• Thread Repair Specifications
• Thread Repair
• Fastener Notice
• Engine Mechanical Specifications
• Crankshaft and Bearing Cleaning and Inspection