Engine Mechanical - 3.7l Chevrolet Colorado I

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Adhesives, Fluids, Lubricants, and Sealers

Adhesives, Fluids, Lubricants, and Sealers

Scheme 77

Engine Block - Top View

Scheme 78

Engine Block - Bottom View

Scheme 79

Engine Block - Left Side View

Scheme 80

Engine Block - Right Side View

Scheme 81

Engine Block - Front View

Scheme 82

Engine Block - Rear View

Scheme 83

Cylinder Head - Top View

Scheme 84

Cylinder Head - End - Front View

Scheme 85

Cylinder Head - End - Rear View

Scheme 86

Cylinder Head - Intake Manifold Deck View

Scheme 87

Cylinder Head - Exhaust Manifold Deck View

Scheme 88

Oil Pan - Bottom View

Scheme 89

Oil Pan - Rear View

Scheme 90

Engine Front Cover

Scheme 91

Crankshaft Rear Oil Seal Housing

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , and Lubrication Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform A Diagnostic System Check in Engine Controls before using the symptom tables (if applicable).
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) , «Engine Component Description»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l) , and «Lubrication Description»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds (if applicable) to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Base Engine Misfire without Internal Engine Noises»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__base-engine-misfire-without-internal-engine)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__base-engine-misfire-with-excessive-oil)
6. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-noise-on-start-up-but-only)
7. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__upper-engine-noise-regardless-of-engine)
8. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__lower-engine-noise-regardless-of-engine)
9. «Engine Noise Under Load»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-noise-under-load)
10. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-will-not-crank-crankshaft)
11. «Engine Compression Test»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l)
12. «Oil Consumption Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__oil-pressure-diagnosis-and-testing)
14. «Oil Leak Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__oil-leak-diagnosis)
15. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l)
16. «Drive Belt Rumbling and Vibration Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l)
17. «Drive Belt Falls Off and Excessive Wear Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l)

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Upper Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Engine Noise Under Load

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

J 38722 Compression Tester

A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket.

1. Remove the air duct from the throttle control module.
2. Remove the ignition control modules.
3. Disable the fuel system.
4. Remove the spark plugs.
5. Measure the engine compression, using the following procedure: Firmly install J 38722 to the spark plug hole. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. Check and record the readings on J 38722 at each stroke. Disconnect J 38722 . Repeat the compression test for each cylinder.
6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading.
7. The following are examples of the possible measurements: When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
8. Install the air duct to the throttle body.
9. Install the spark plugs.
10. Enable the fuel system.
11. Install the ignition control modules.

J 35667-A Cylinder Head Leakdown Tester

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke.
4. Install J 35667-A .
5. Apply shop air pressure to J 35667-A and adjust according to the manufacturers instructions.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage sounds at the throttle control module or air inlet hose may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Tools Required

1. J 21867 Pressure Gage and Hose Assembly
2. J 42907 Oil Pressure Tester

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time (2-3 minutes) and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
3. Run the engine briefly (10-15 seconds) and verify low or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following: Oil diluted by water or glycol (anti freeze) Foamy oil
6. Remove the oil filter and install the J 42907 .
7. Install J 21867 or equivalent to the J 42907 .
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to «Engine Mechanical Specifications»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-mechanical-specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: Oil pump worn or dirty Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l__oil-pump-cleaning-and-inspection) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Cracked, porous, or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Plug Installation»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-block-plug-installation) . Broken valve lash adjusters Repair as necessary
11. If the reading on J 21867 or equivalent is within specifications, inspect for the following: Plugged or incorrect oil filter and/or malfunctioning oil bypass valve Malfunctioning vehicle oil pressure gage or sensor Repair as necessary

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation (CV) System Inspection

1. Test for vacuum at the positive crankcase ventilation (PCV) dirty air hose (2) where it connects to the vacuum orifice tube (5) in the camshaft cover. There should be manifold vacuum present at the hose (2). If there is no vacuum, inspect for a plugged hose, leaking hose or a plugged intake manifold passage.
2. If oil has accumulated in the air cleaner resonator (1), inspect for the following conditions: Plugged vacuum orifice tube (5) in the camshaft cover Plugged, restricted, or leaking PCV dirty air hose (2) Plugged or restricted intake manifold passage (3) Excessive crankcase pressure or blow-by, refer to «Engine Compression Test»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l)
3. Additional items to inspect: Plugged or restricted vacuum tube (4) in the camshaft cover Plugged or restricted PCV fresh air hose (6) Plugged or restricted passage in the air cleaner resonator (1) Inspect the cam cover, the oil pan, engine front cover, and other sealing areas for leaks

Results of Incorrect Operation

A plugged crankcase ventilation system may contribute to the following conditions

1. A rough idle
2. Stalling or a slow idle speed
3. Oil leaks
4. Oil accumulation in the air cleaner resonator (1)
5. Sludge in the engine

A leaking hose may contribute to the following conditions

1. A rough idle
2. Stalling
3. Unstable idle speed

The crankcase ventilation system has no serviceable components so no maintenance of the system is required.

Diagnostic Aids

1. A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.
2. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
3. A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise.
4. The drive belts will not cause a whine noise.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
2. 3: The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
3. 4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust.
4. 6: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
5. 10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
6. 12: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
7. 14: This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise.
8. 15: This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction.
9. 16: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
10. 17: This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
11. 19: Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.

Drive Belt Chirping, Squeal, and Whine Diagnosis

The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.

If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
2. 3: This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
3. 4: Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
4. 5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.
5. 9: Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed.
6. 11: This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump.
7. 12: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

Drive Belt Rumbling and Vibration Diagnosis

If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly.

If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
2. 4: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley.
3. 5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
4. 6: Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
5. 7: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
6. 13: The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
7. 14: The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
8. 15: This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle.

Drive Belt Falls Off and Excessive Wear Diagnosis

Inspection Procedure

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Position a hex-head socket on the belt tensioner pulley bolt head.
3. Move the drive belt tensioner through it's full travel. The movement should feel smooth. There should be no binding. The tensioner should return freely.
4. If any binding is observed, replace the tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
5. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Camshaft Position Actuator Diagnosis

For overall description of the camshaft position actuator refer to Exhaust Camshaft Position Actuator Description .

The camshaft position actuator will only phase 25-cam degrees retard (counterclockwise). Full advance (clockwise) is 0 degrees.

Scheme 100

The camshaft position actuator should always be serviced/replaced in the full advanced position (full clockwise or 0 degrees). New replacement (service) camshaft position actuators are shipped at full advance or 0 degrees. To be sure the camshaft position actuator is performing properly, perform the following to help in the diagnostics.

The camshaft position actuator must be removed from the engine to perform the proper diagnostic test.

1. Clamp the camshaft actuator in a vice. Use care not to damage the contact area of the sprocket.
2. Scribe or draw a line (1) on the camshaft position actuator ring face, in the full advanced position. With the engine at TDC on #1 cylinder, the wording should be level.
3. Apply compressed air pressure to the oil port (1) on the back side of the actuator to unlock the locking pin.
4. Turn the actuator, by hand, to the full counterclockwise position.
5. Scribe or draw a line (2) on the camshaft position actuator at that position.
6. Measure the distance between the two lines. The measurement (3) should be 14-15 mm (0.55-0.59 in). The camshaft position actuator must be replaced if it does not unlock when air pressure is applied, does not lock when air pressure is removed, or does not move within the 14-15 mm (0.55-0.59 in).

Removal Procedure

1. Install a 3/8 inch breaker bar into the drive belt tensioner (7) and rotate the tensioner (7) clockwise, enough to relieve the tension on the drive belt (1).
2. Slide the drive belt (1) from the water pump pulley (2).
3. Allow the drive belt tensioner (7) to return to the relaxed position.
4. Remove the drive belt (1) from the remaining pulleys.

Installation Procedure

1. Route the drive belt (1) over all the pulleys, excluding the water pump pulley (2).
2. Install the 3/8 inch breaker bar on the drive belt tensioner (7) and rotate the tensioner (7) clockwise.
3. Route the drive belt (1) over the top of the water pump pulley (2).
4. Slowly release the tension to the drive belt tensioner (7).
5. Inspect for proper installation of the drive belt (1) on the pulleys.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Inspect the drive belt. Change the drive belt as necessary.
3. Using a wrench loosen and remove the drive belt tensioner bolt.
4. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the left front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the air conditioning (A/C) suction hose from the compressor. Refer to «Suction Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the A/C discharge hose from the compressor. Refer to «Discharge Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the bolts securing the drive belt idler pulley to the engine.
6. Remove drive belt idler pulley from the engine.

1. Position drive belt idler pulley to the engine.
2. Install the bolts securing the drive belt idler pulley to the engine. Tighten: Tighten the drive belt idler pulley bolts in sequence to 50 N.m (37 lb ft).
3. Install the A/C suction hose to the compressor. Refer to «Suction Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the A/C discharge hose to the compressor. Refer to «Discharge Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the left front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Engine Mount Inspection

Note. Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses.

Note. When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit.

1. Measure the engine movement at the engine mount in order to inspect for damage to the rubber portions of the mount. Apply the park brake. Start the engine. Firmly apply and hold the primary brakes. Have an assistant stand to the side of the vehicle in order to observe for engine movement. Slightly load the engine shifting from drive to reverse a few times. If the engine moves more than 24 mm (0.945 in) from the at rest position, in either direction, inspect for loose engine mount bolts.
2. If the engine mount bolt torque is within specifications, inspect the condition of the engine mount.
3. Replace the engine mount if any of the following conditions exist: Heat check cracks cover the rubber cushion surface. The rubber cushion is separated from the metal plate of the mount. There is a split through the rubber cushion.

1. Remove the left wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
2. Remove the engine shield, if equipped. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the lower intermediate steering shaft. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
4. Support the engine using a jack stand and a block of wood.
5. Remove the engine mount-to-frame bracket through bolt for the mount being replaced.
6. Loosen the right side through bolt.
7. Remove the heater pipe bracket bolt from the engine mount. Refer to «Heater Outlet Hose Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Raise the engine using the jack stand; the engine will tilt to one side.
9. Remove the engine mount bolts.
10. Remove the engine mount. You will need to articulate the mount in order to remove the mount.

1. Install the engine mount. You will need to articulate the mount in order to install the mount.
2. Install the engine mount bolts.
3. To aid in the installation of the bolts, start a bolt in position (1) first. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Lower the engine.
5. Install the engine mount-to-frame bracket through bolt. Tighten: Tighten the bolts to 85 N.m (63 lb ft).
6. Install the engine coolant pipe bracket bolt from the engine mount. Refer to «Heater Outlet Hose Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Remove the jack stand.
8. Install the lower intermediate steering shaft. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
9. Install the engine shield, if equipped. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
10. Install the left wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
11. Lower the vehicle.

1. Remove the right wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
2. Remove the engine mount-to-frame bracket through bolt for the mount being replaced.
3. Loosen the left side through bolt.
4. Raise the engine using the jack stand. The engine will tilt to one side.
5. Remove the engine mount bolts.
6. Remove the engine mount. You will need to articulate the mount in order to remove the mount.

1. Install the engine mount. You will need to articulate the mount in order to install the mount.
2. Install the engine mount bolts.
3. To aid in the installation of the bolts, start a bolt in position (1) first. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Lower the engine.
5. Install the engine mount-to-frame bracket through bolt. Tighten: Tighten the bolts to 85 N.m (63 lb ft).
6. Remove the jack stand.
7. Install the engine shield, if equipped. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
8. Install the right wheel and tire assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the bolt (3) securing the A/C compressor hose/pipe bracket (2) to the engine lift bracket (1).
3. Carefully disengage the engine wiring harness conduit (4) from the engine lift bracket (1).
4. Remove the 3 generator mounting bolts.
5. Remove the bolts securing engine lift bracket to the engine.
6. Remove the engine lift bracket from the engine.

1. Position the engine lift bracket to the engine.
2. Install the bolts securing engine lift bracket to the engine. Tighten: Tighten the bolts a first pass in sequence to 5 N.m (44 lb in). Tighten the bolts a final pass in sequence to 50 N.m (37 lb ft).
3. Position the generator to the engine.
4. Install the generator mounting bolts. Tighten: Tighten the bolts in sequence to 50 N.m (37 lb ft).
5. Engage the engine wiring harness conduit (4) to the engine lift bracket (1).
6. Install the bolt (3) securing the A/C compressor hose/pipe bracket (2) to the engine lift bracket (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
7. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the air cleaner resonator and outlet duct. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
2. Disconnect the PCV fresh air tube (6) from the air cleaner resonator (1).
3. Disconnect the PCV dirty air tube (2) from the following: The camshaft cover (5) The intake manifold (3)

1. Connect the PCV fresh air tube (6) to the air cleaner resonator (1).
2. Connect the PCV dirty air tube (2) to the following: The camshaft cover (5) The intake manifold (3)
3. Install the air cleaner resonator and outlet duct. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
2. Remove the battery box. Refer to «Battery Box Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
4. Disconnect the brake booster hose (6) from the brake booster.
5. Disconnect the engine wiring harness electrical connector (3) from the manifold absolute pressure (MAP) sensor.
6. Disconnect the engine wiring harness retainer (4) from the intake manifold (5).
7. Disconnect the positive crankcase ventilation (PCV) dirty air tube (2) from the camshaft cover.
8. Remove the generator. Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
9. Disconnect the engine wiring harness retainer (1) from the intake manifold (2).
10. Remove the upper 2 bolts securing the engine wiring harness bracket to the intake manifold.
11. Raise and support the vehicle only high enough to access the remaining components through the wheelhouse. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
12. Remove the left front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
13. Remove the left front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
14. Disconnect the following wiring harness retainers from the engine wiring harness bracket: The battery cable The engine (4, 6) The MAP sensor (5)
15. Remove the remaining engine wiring harness bracket lower bolt. Remove the bracket from the engine compartment through the wheelhouse opening.
16. Remove the intake manifold bolts.
17. Lower the vehicle.
18. Remove the intake manifold from the cylinder head.
19. Remove and discard the seal from the intake manifold. Discard the seal.
20. Mask off the open ports to the cylinder head, in order to prevent foreign objects from entering the engine.

1. Remove the masking from the cylinder head and ensure the sealing surface is clean and dry.
2. Install a NEW seal into the intake manifold groove.
3. Position the intake manifold to the cylinder head.
4. Raise and support the vehicle only high enough to access the following components through the wheelhouse Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) . The intake manifold bolts The engine wiring harness bracket bolts The wiring harnesses
5. Install the intake manifold bolts. Tighten: Tighten the bolts from the inside working outward to 10 N.m (89 lb in).
6. Position the engine wiring harness bracket to the engine.
7. Install the engine wiring harness bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Secure the following wiring harness retainers to the bracket: The battery cable The engine (4, 6) The MAP sensor (5)
9. Install the left front wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
10. Install the left front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/colorado/i-2004-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
11. Lower the vehicle.
12. Connect the engine wiring harness retainer (1) to the intake manifold (2).
13. Install the generator. Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
14. Connect the PCV dirty air tube (2) to the camshaft cover.
15. Connect the engine wiring harness retainer (4) to the intake manifold (5).
16. Connect the engine wiring harness electrical connector (3) to the MAP sensor.
17. Connect the brake booster hose (6) to the brake booster.
18. Install the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
19. Install the battery box. Refer to «Battery Box Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
20. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
3. Disconnect the following electrical connectors from the camshaft cover. The fuel injector (1) The heated oxygen sensor (HO2S) (2) The engine coolant temperature (ECT) sensor (3)
4. Remove the camshaft cover ground wire bolt (1) from the cover.
5. Remove the ground wire from the cover.
6. Remove the camshaft cover bolts.
7. Remove the camshaft cover from the cylinder head.
8. Remove and discard the seals from the camshaft cover. Do not reuse the seals.
9. Clean and inspect the cylinder head sealing surface.

1. Install a NEW camshaft cover seal into the camshaft cover groove.
2. Install NEW ignition coil seals into the camshaft cover grooves.
3. Place the camshaft cover to the cylinder head.
4. Install the camshaft cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Position the ground wire to the camshaft cover. Ensure that the anti rotation tab is seated against the cover.
6. Install the camshaft ground wire bolt (1) to the cover. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Install the following electrical connectors to the camshaft cover. The fuel injector (1) The HO2S (2) The ECT sensor (3)
8. Install the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
9. Install the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

EN-47945 Valve Spring Compressor

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Rotate the crankshaft until the affected cylinder valve is fully open (cam lobe fully depressing the spring).
3. Install the EN-47945 on the engine cylinder head using either one or two of the supplied fasteners installed in the coil fastener hole.
4. Rotate the engine clockwise enough to ensure the cam is on the base circle (spring will stay compressed by the tool). This will allow the lash adjuster and rocker to be removed.
5. Remove the valve rocker arm and valve lash adjuster.
6. Clean and inspect the valve rocker arm and valve lash adjuster. Refer to «Valve Rocker Arm and Valve Lash Adjuster Cleaning and Inspection»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l__valve-rocker-arm-and-valve-lash) .

1. Lubricate the valve rocker arm and fill the valve lash adjuster with oil.
2. Install the valve rocker arm and valve lash adjuster.
3. When the valve rocker arm and valve lash adjuster are in place, slowly rotate the engine counterclockwise enough that the cam lobe fully depresses the spring again.
4. Remove the EN-47945 from the cylinder head and repeat as required.
5. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. EN 46547 Flywheel Holding Tool
2. J 38820 Valve Stem Seal Installer
3. J 39313 Spark Plug Port Adapter
4. J 43059 Valve Retainer Remover/Installer
5. J-44228-A Valve Spring Compressor

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
2. Remove the service slot plug.
3. Install the EN 46547 (1) into the flywheel teeth.
4. Lower the vehicle.
5. Remove the camshafts. Refer to «Camshaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-replacement) .
6. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
7. Install the base plate of the J-44228-A over the spark plug hole of the cylinder to be serviced.
8. Install the J 39313 in the spark plug hole.
9. Apply constant air pressure to the J 39313 in order to keep the valve closed.
10. Install the arm and swivel nut of the J-44228-A over the stud corresponding to the valve to be serviced.
11. Tighten the swivel nut of the J-44228-A down only enough to allow access for removal of the valve locks.
12. Remove the valve locks. A magnet is the most suitable tool for this activity.
13. Loosen the swivel nut of the J-44228-A and swing the arm away from the valve spring retainer.
14. Remove the valve spring retainer and valve spring.
15. Use the J 38820 in order to grip the seal. Remove the seal by exerting a twisting, pulling motion. Discard the old valve stem seal.

1. Lubricate the valve stem and inner diameter of the new seal with clean engine oil.
2. Using a twisting, pushing motion install the NEW valve stem seal using the J 38820 .
3. Install the valve spring and valve spring retainer.
4. Swing the arm over the valve spring retainer and tighten the swivel nut of the J-44228-A down only enough to allow access for installation of the valve locks.
5. Position the valve locks to the valve stem retainer groove using the J 43059 .
6. Remove the swivel nut and arm of the J-44228-A
7. Install the arm and swivel nut of the J-44228-A over the stud of any other valves being serviced for this cylinder and repeat removal steps 11 through 16 and installation steps 1 through 7.
8. Relieve the air pressure to the cylinder being serviced.
9. Remove the J 39313 from the spark plug hole.
10. Remove the base plate of the J-44228-A .
11. Repeat removal steps 7 through 16 and installation steps 1 through 10 on any other cylinders being serviced.
12. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
13. Install the camshafts. Refer to «Camshaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-replacement) .
14. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
15. Remove the EN 46547 (1) from the flywheel teeth.
16. Install the service slot plug.
17. Lower the vehicle.

1. Remove the fuel line clip (1) from the oil level indicator bracket.
2. Pull the oil level indicator from the tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube from the engine oil pan.

1. Lightly lubricate the O-ring seal with clean engine oil.
2. Install the oil level indicator tube into the engine oil pan.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the oil level indicator into the tube.
5. Install the fuel line clip (1) to the oil level indicator bracket.

Cylinder Head Replacement

Special Tools

1. EN 46547 Flywheel Holding Tool
2. EN-48464 Lower Timing Gear Tensioner Holding Tool
3. J 44221 Camshaft Holding Tool
4. J 45059 Angle Meter

1. Bleed the fuel pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-29l-introduction-2-of-2__fuel-pressure-relief-with-ch-48027) or «Fuel Pressure Relief (Without CH 48027)»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-29l-introduction-2-of-2__fuel-pressure-relief-without-ch-48027) .
2. Remove the air induction assembly from the vehicle. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) and «Air Cleaner Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
3. Remove the battery from the vehicle. Refer to «Battery Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Disconnect the Fuel/EVAP lines from the intake manifold and move aside. Includes fuel line removal from fuel rail. Refer to «Evaporative Emission Hoses/Pipes Replacement - Engine»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
5. Remove the bolt holding the oil indicator tube to the intake manifold and move the oil indicator tube aside. Do not remove.
6. Lift the Vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
7. Remove the engine shield from the vehicle.
8. Remove the oil pan skid plate from the vehicle.
9. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
10. Drain the engine oil.
11. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .
12. Remove the left front wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
13. Remove the fir tree wiring harness connectors from the engine wring harness bracket from the left front wheelhouse opening.
14. From the left front wheelhouse, remove the engine wiring harness bracket from the engine and set aside.
15. Remove the intake manifold bolts from the wheelhouse access. The bolts stay with intake manifold. On two-wheel drive vehicles, the intake manifold bolts are removed from the top of the engine, not through the left front wheelhouse panel. Refer to «Intake Manifold Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
16. Lower the vehicle.
17. Remove the positive crankcase ventilation (PCV) pipes (2, 6) from the cam cover and remove the intake manifold from the vehicle.
18. Remove the generator output BAT terminal nut.
19. Remove the generator lead from the generator.
20. Disconnect the generator electrical connector.
21. Remove the generator bolts and set the generator aside. Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
22. Disconnect the A/C pipe clamp from the engine lift hook bracket.
23. Remove the engine lift hook bracket bolts and bracket from the vehicle.
24. Remove the bolts holding the windshield washer solvent container and coolant recovery reservoir to the right inner fender. Move aside to gain access to the engine wiring harness to the powertrain control module (PCM). Refer to «Windshield Washer Solvent Container Replacement (2nd Design)»(/chevrolet/colorado/i-2004-2012/remont/wiperwasher-systems/#wiper-system-washer-system) .
25. Disconnect the following cross-vehicle engine wiring harness connectors: PCM Engine coolant temperature sensor Manifold absolute pressure (MAP) sensor Ignition coils Harness clamps at power steering pump Wiring harness fastener at right front inner fender Throttle body Camshaft sensors Exhaust camshaft actuator Fuel injectors HO2S 1 Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
26. If equipped, remove the secondary air injection (AIR) injection pipe block-off plate bolts from the cylinder head.
27. If equipped, remove the AIR injection pipe block-off plate.
28. Remove the bolts from the exhaust manifold heat shield.
29. Remove the exhaust manifold heat shield.
30. Remove the exhaust manifold bolts.
31. Move the exhaust manifold back and away from the cylinder head.
32. Remove the bolts to all ignition coil assemblies and remove all ignition coil assemblies from the cam cover.
33. Remove all the spark plugs from the cylinder head.
34. Remove the cam cover from the cylinder head. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
35. Remove the inlet radiator hose and clamp from the cylinder head. Refer to «Radiator Inlet Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
36. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.
37. Perform one of the following methods for the service timing procedure.
38. First Method-Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder.
39. First Method (continued)-The TDC indicator tool graduation marks on the shaft should note top of the piston stroke.
40. First Method (continued)-When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.
41. Second Method-Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gage should not slide under the straight edge (1).
42. Once TDC is located for the number 1 cylinder using above methods, raise the vehicle and lock the flywheel with the EN 46547 .
43. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.
44. Lower the vehicle.
45. Install J 44221 (1) to the back of the camshafts.
46. Remove the upper timing chain guide to the cylinder head.
47. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.
48. Install EN-48464 . It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.
49. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain. Front cover removed for illustration purposes.
50. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer.
51. Once the tool is correctly installed, unscrew the handle and remove the handle.
52. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
53. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
54. Remove both upper timing chain tensioner shoe bolts.
55. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.
56. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts. The illustration shows the exhaust camshaft sprocket already removed.
57. Remove the sprockets from the chain, tie a piece of mechanic's wire on the timing chain and let it drop.
58. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.
59. Remove the cylinder head bolts. Discard the bolts.
60. Remove the cylinder head.
61. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
62. Remove the cylinder head gasket. Discard the gasket.
63. Remove all remaining gasket material from the engine block.
64. Inspect the cylinder head gasket mating surface on the engine block.
65. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
66. Disassemble the cylinder head if necessary. Refer to «Cylinder Head Disassemble»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__cylinder-head-disassemble) .

1. Assemble the cylinder head if necessary. Refer to «Cylinder Head Assemble»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__cylinder-head-assemble) .
2. Install the dowel pins, cylinder head locator, if necessary.
3. Position a NEW cylinder head gasket to the engine block.
4. Install the cylinder head.
5. Install NEW cylinder head bolts.
6. Tighten the NEW cylinder head bolts in the following sequence: Tighten: Tighten the cylinder head bolts (1-12) in sequence to 30 N.m (22 lb ft). Use the J 45059 to rotate the cylinder head bolts (1-12) in sequence an additional 155 degrees. Tighten the (2 Short) end bolts (14-15) to 7 N.m (62 lb in). Use the J 45059 to rotate the short cylinder head end bolts (14-15) an additional 60 degrees. Tighten the (1 Long) end bolt (13) to 7 N.m (62 lb in). Use the J 45059 to rotate the long cylinder head end bolt (13) an additional 120 degrees.
7. Install the camshafts with the flats up using J 44221 (1). Refer to «Camshaft Installation»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
8. Ensure that the camshaft position actuator is in the fully advanced position. Refer to «Camshaft Position Actuator Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-position-actuator-diagnosis) .
9. Install the exhaust camshaft actuator/sprocket and chain onto the exhaust camshaft. Use the paint marks as an alignment guide.
10. Install the intake camshaft sprocket and chain onto the intake camshaft. Use paint marks as alignment guide.
11. Position the timing chain tensioner shoe to the engine.
12. Install the timing chain tensioner shoe bolt. Tighten: Tighten the timing chain tensioner shoe bolt to 25 N.m (18 lb ft).
13. Position the lower timing chain guide to the engine.
14. Install the lower timing chain guide bolts. Tighten: Tighten the lower timing chain guide bolts to 12 N.m (107 lb in).
15. Install both upper cylinder head access hole plugs to the front of the cylinder head. Tighten: Tighten the plugs to 5 N.m (44 lb in).
16. Tighten the new intake camshaft sprocket bolt. Tighten: Using J 45059 , tighten the intake camshaft sprocket bolt to 20 N.m (15 lb ft) plus 100 degrees.
17. Tighten the new exhaust camshaft actuator sprocket bolt. Tighten: Using J 45059 , tighten the exhaust camshaft actuator sprocket bolt to 25 N.m (18 lb ft) plus 135 degrees.
18. Lift the vehicle and remove the EN 46547 .
19. Lower the vehicle.
20. Remove the J 44221 from the back of the camshafts.
21. Install the handle of EN-48464 and remove the wedge portion of the tool from the engine.
22. Rotate the engine clockwise by hand 2 complete revolutions to TDC number 1 on the compression stroke. Refer to First Method or Second Method for TDC. If you go past TDC, rotate the engine back approximately 45 degrees before TDC and then rotate clockwise up to TDC to ensure that the timing chain is tight (no slack) between the crank sprocket and the timing gears.
23. Both intake and exhaust camshaft flats should be facing up and flat and level with the cylinder head. If J 44221 (1) is used to verify cam timing, you could be off approximately one tooth and cause DTC P0017 to set. If a worn or new J 44221 is used to verify timing, the timing will be off.
24. To verify timing, set a straight edge across the flats of the camshafts.
25. A 0.005 inch feeler gage should not be able to slip under the straight edge (1). If the feeler gage slips under one or both camshaft flats, then the timing is off. Repeat step 20 and recheck. If the camshaft flats are still not flat, the camshaft timing will have to be reset. This may require removal and reinstallation of one or both camshaft sprockets.
26. Install the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and tighten the bolts.
27. Position the upper timing chain guide to the cylinder head. Apply threadlocker GM P/N 89021297 (Canadian P/N 10953488) to the upper timing chain guide bolt threads.
28. Install the upper timing chain guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
29. Install the radiator inlet hose and clamp to the cylinder head. Refer to «Radiator Inlet Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
30. Clean and inspect the camshaft cover. Refer to «Camshaft Cover Cleaning and Inspection»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-cover-cleaning-and-inspection) .
31. Install a NEW camshaft cover seal and NEW ignition control module seals to the cam cover. Position the camshaft cover to the cylinder head.
32. Install the camshaft cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
33. Check the gap on all of the spark plugs. The gap should be 1.08 mm (0.042 in). Tighten all of the spark plugs. Tighten: Tighten the spark plug to 18 N.m (13 lb ft).
34. Install the ignition coils into the camshaft cover.
35. Install the ignition coil bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
36. Reposition the exhaust manifold to cylinder head and install the exhaust manifold bolts to the cylinder head. Refer to «Exhaust Manifold Replacement (LLR)»(/chevrolet/colorado/i-2004-2012/remont/exhaust/#engine-exhaust-system) .
37. If equipped, install a NEW AIR injection gasket, then the cover and pipe studs to the cylinder head. Tighten: Tighten the pipe studs to 25 N.m (18 lb ft).
38. Install the exhaust manifold heat shield to the exhaust manifold.
39. Apply anti-seize GM P/N 12371386 (Canadian P/N 89021945) to the exhaust manifold heat shield nuts.
40. Install the exhaust manifold heat shield nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
41. Install the intake manifold to the cylinder head. Refer to «Intake Manifold Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) . Four-wheel drive-Raise the vehicle and install the blind intake manifold bolts from the left front wheelhouse access. Two-wheel drive-The bolts are accessible from the top of the engine.
42. Reposition the engine wiring harness bracket to the engine and harnesses. Install the engine wiring harness bracket bolts. Tighten: Tighten the bracket bolts to 10 N.m (89 lb in).
43. Install the left front wheelhouse panel and the left wheel and tire. Refer to «Front Wheelhouse Liner Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
44. Drain the engine oil again.
45. If removed, install the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
46. Install the oil pan skid plate and the engine shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
47. Install the engine shield.
48. Lower the vehicle.
49. Install the cross-vehicle wiring harness connectors to the following components: PCM Map sensor Ignition coils Harness clamps at power steering pump Wiring harness fastener at right front inner fender Throttle body Camshaft sensors Exhaust camshaft actuator Fuel injectors HO2S 1
50. Install the windshield washer solvent container and coolant recovery reservoir bolts to the right inner fender. Tighten: Tighten the bolts to 10 N.m (89 lb in).
51. Install the PCV pipes to the intake manifold. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
52. Reposition the oil indicator (dipstick) tube and tighten the bolt to the intake manifold. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
53. Reposition the fuel/EVAP lines to the intake manifold retainer. Refer to «Evaporative Emission Hoses/Pipes Replacement - Engine»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
54. Install the following components: Generator-Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) . A/C compressor hose/pipe bracket clamp for the engine lift bracket-Refer to «Engine Lift Bracket Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) . Drive belt-Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
55. Install the battery. Refer to «Battery Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
56. Install the air induction assembly. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) and «Air Cleaner Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
57. Install NEW engine oil. Refer to «Engine Mechanical Specifications»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-mechanical-specifications) .
58. Install NEW coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .
59. Install a scan tool and start the engine. Check for DTCs. Road test the vehicle. DTC P0017 is a Type B diagnostic code. Three consecutive ignition key cycles must be performed during the road test with a minimum of a one minute run time between key cycles to verify that a DTC P0017 did not set. For further information on DTC P0017, refer to «DTC P0016 or P0017»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-dtc-p0013-to-dtc-p0365) .

Crankshaft Balancer Replacement

Special Tools

1. EN 46547 Flywheel Holding Tool
2. EN-48034 Harmonic Balancer Installer
3. J 41816-2 Crankshaft End Protector
4. J 45059 Angle Meter

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
3. Remove the service slot plug.
4. Install the EN 46547 (1) into the flywheel teeth.
5. Lower the vehicle.
6. Remove and discard the crankshaft balancer bolt.
7. Install the J 41816-2 into the end of the crankshaft.
8. Use a 3 jaw puller to remove the crankshaft balancer.
9. Remove the J 41816-2 .
10. Remove the crankshaft balancer friction washer. This will be located at the end of the crankshaft balancer or on the crankshaft.

1. Install the crankshaft balancer using the EN-48034 .
2. Remove the EN-48034 .
3. Install the crankshaft balancer washer and NEW bolt. Tighten: Tighten the bolt to 150 N.m (111 lb ft) plus an additional 180 degrees using the J 45059 .
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
5. Remove the EN 46547 (1) from the flywheel teeth.
6. Install the service slot plug.
7. Lower the vehicle.
8. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

J 45951 Front Seal Installer

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-balancer-replacement) .
2. Pry out the crankshaft front oil seal using a suitable tool. Discard the seal.

1. Apply engine oil to the outside diameter of the crankshaft front oil seal.
2. Use the J 45951 to install the NEW crankshaft front oil seal.
3. Remove the J 45951 .
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-balancer-replacement) .

J 44219 Cover Alignment Pins

1. Remove the water pump. Refer to «Water Pump Replacement (LLV,LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-balancer-replacement) .
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
4. Remove the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) .
5. Remove the oil pump pipe and screen assembly. Refer to «Oil Pump Suction Pipe and Screen Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
6. Lower the vehicle.
7. Remove the 7 mm center bolt (1).
8. Remove the remaining engine front cover bolts.
9. Install 2 bolts into the threaded holes to act as jack screws and tighten evenly to release the engine front cover from the engine block.
10. Remove the engine front cover.
11. Remove the 2 bolts from the jack screw holes.
12. Remove the oil pump, if necessary. Refer to «Oil Pump Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
13. Clean and inspect the engine block sealing surface.

1. Install the oil pump, if previously removed. Refer to «Oil Pump Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. To aid in alignment of the cover, thread the J 44219 into the engine block.
3. Apply a 3 mm (0.12 in) bead of sealer to the engine front cover (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
4. Align the oil pump to the crankshaft sprocket splines.
5. Position the engine front cover over the J 44219 , and to the engine block.
6. Install the engine front cover bolts.
7. Remove the J 44219 from the engine block.
8. Install the 2 remaining engine front cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). Tighten the small center bolt (1) last to 8 N.m (71 lb in).
9. Install the oil pump pipe and screen assembly. Refer to «Oil Pump Suction Pipe and Screen Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
10. Install the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) .
11. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
12. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-balancer-replacement) .
13. Install the water pump. Refer to «Water Pump Replacement (LLV,LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

Camshaft Position Exhaust Actuator Replacement

Tools Required

1. J 44217 Timing Chain Retention Tool
2. J-44217-45 Chain Holding Tool
3. J 44221 Camshaft Holding Tool
4. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Ensure the exhaust CMP actuator is functioning properly. Refer to «Camshaft Position Actuator Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-position-actuator-diagnosis) .
3. Remove the exhaust CMP sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
4. Remove the intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
5. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
6. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link adjacent to it.
7. Install the J 44221 to the rear of the camshafts.
8. Complete the following in order to install the J 44217 (1) and J-44217-45 (1). Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. Tighten the wingnuts. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on the edge of the head.
9. Remove and discard the exhaust camshaft position actuator bolt.
10. Remove the exhaust camshaft position actuator.

1. Ensure the camshaft actuator is fully advanced prior to installation.
2. Install the exhaust camshaft actuator into the timing chain. Aligning the marked link (1) on the timing chain with the timing mark (1) on the exhaust camshaft position actuator sprocket.
3. Install the exhaust camshaft actuator onto the exhaust camshaft.
4. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft) plus an additional 135 degrees using the J 45059 .
5. Remove the J 44217 (1) and J-44217-45 (1).
6. Remove the J 44221 from the camshafts.
7. Install the intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
8. Install the exhaust CMP sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Camshaft Intake Sprocket Replacement

Tools Required

1. J-44217-45 Chain Holding Tool
2. J 44217 Timing Chain Retention Tool
3. J 44221 Camshaft Holding Tool
4. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the intake camshaft position (CMP) sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
3. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
4. Using the timing mark on the intake camshaft sprocket as a reference, make a mark on the timing chain link adjacent to it.
5. Install the J 44221 to the rear of the camshafts.
6. Complete the following in order to install the J 44217 (1) and J-44217-45 (1). Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. Tighten the wingnuts. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on the edge of the head.
7. Remove and discard the intake camshaft sprocket bolt.
8. Remove the intake camshaft sprocket.

1. Install the intake camshaft sprocket into the timing chain. Aligning the marked link (1) on the timing chain with the timing mark on the intake camshaft sprocket.
2. Install the intake camshaft sprocket onto the intake camshaft.
3. Install the new intake camshaft sprocket bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft) plus an additional 100 degrees using the J 45059 .
4. Remove the J 44217 (1) and J-44217-45 (1).
5. Remove the J 44221 from the camshafts.
6. Install the intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
7. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Timing Chain and Sprocket Replacement

Tools Required

1. J 44221 Camshaft Holding Tool
2. J 45059 Angle Meter

1. Remove #1 cylinder spark plug. Refer to «Spark Plug Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
3. Remove the exhaust camshaft position (CMP) sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
4. Remove the intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
5. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
6. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
7. Install the J 44221 to the rear of the camshafts.
8. Release the tension on the timing chain by moving the tensioner shoe in.
9. Place the tee into the tensioner to hold the shoe in place.
10. Remove and discard the exhaust camshaft position actuator bolt.
11. Remove the exhaust camshaft position actuator.
12. Remove and discard the intake camshaft sprocket bolt.
13. Remove the intake camshaft sprocket.
14. Remove the timing chain.
15. Remove the crankshaft sprocket.

1. Install the crankshaft sprocket to the crankshaft snout.
2. Install the intake camshaft sprocket into the timing chain. Aligning the dark link (1) of the timing chain with the timing mark on the intake camshaft sprocket.
3. Feed the timing chain down through the opening in the cylinder head.
4. Install the timing chain on the crankshaft sprocket. Align the dark link (2) of the timing chain with the timing mark on to the crankshaft sprocket.
5. Install the intake camshaft sprocket onto the intake camshaft.
6. Install the new intake camshaft sprocket bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft) plus an additional 100 degrees using the J 45059 .
7. Ensure the camshaft actuator is fully advanced prior to installation. Refer to «Camshaft Position Actuator Diagnosis»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__camshaft-position-actuator-diagnosis) .
8. Install the exhaust camshaft actuator into the timing chain. Aligning the dark link (1) of the timing chain with the timing mark (1) on the exhaust camshaft position actuator sprocket.
9. Install the exhaust camshaft actuator onto the exhaust camshaft.
10. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft) plus an additional 135 degrees using the J 45059 .
11. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
12. Remove the J 44221 from the camshafts.
13. The dark links (1) on the timing chain should be aligned with the marks on the sprockets as shown.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
15. Install the intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
16. Install the exhaust CMP sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
17. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
18. Install #1 cylinder spark plug. Refer to «Spark Plug Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .

J 44221 Camshaft Holding Tool

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
3. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
4. Install the J 44221 to the rear of the camshafts.
5. Using the timing marks on the following as a reference, make a mark on the timing chain links (1) adjacent to them: The exhaust camshaft position actuator sprocket The intake camshaft sprocket The crankshaft sprocket
6. Release the tension on the timing chain by moving the tensioner shoe in.
7. Place the tee into the tensioner to hold the shoe in place.
8. Remove the timing chain tensioner bolts.
9. Remove the timing chain tensioner from the engine.

1. Position the timing chain tensioner to the engine.
2. Install the timing chain tensioner bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
4. Remove the J 44221 from the camshafts.
5. Align the marked links (1) on the timing chain with the timing marks on the following: The exhaust camshaft position actuator sprocket The intake camshaft sprocket The crankshaft sprocket
6. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
7. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

J 44221 Camshaft Holding Tool

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
3. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
4. Install the J 44221 to the rear of the camshafts.
5. Using the timing marks on the following as a reference, make a mark on the timing chain links (1) adjacent to them: The exhaust camshaft position actuator sprocket The intake camshaft sprocket The crankshaft sprocket
6. Release the tension on the timing chain by moving the tensioner shoe in.
7. Place the tee into the tensioner to hold the shoe in place.
8. Remove the cylinder head access hole plug.
9. Remove the timing chain tensioner shoe bolt.
10. Remove the timing chain tensioner shoe from the engine.

1. Position the timing chain tensioner shoe to the engine.
2. Install the timing chain tensioner shoe bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Install the cylinder head access hole plug. Tighten: Tighten the plug to 5 N.m (44 lb in).
4. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
5. Remove the J 44221 from the camshafts.
6. Align the marked links (1) of the timing chain with the timing marks on the following: The exhaust camshaft position actuator sprocket The intake camshaft sprocket The crankshaft sprocket
7. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
8. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the upper timing chain guide bolts.
3. Remove the upper timing chain guide from the cylinder head.

1. Position the upper timing chain guide to the cylinder head.
2. Apply threadlock to the upper timing chain guide bolt threads. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
3. Install the upper timing chain guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the timing chain tensioner shoe. Refer to «Timing Chain Tensioner Shoe Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Slide the crankshaft sprocket from the crankshaft sprocket snout, in order to gain slack in the timing chain to remove the lower timing chain guide.
3. Remove the cylinder head access hole plug.
4. Remove the lower timing chain guide bolts.
5. Remove the lower timing chain guide from the engine.

1. Position the lower timing chain guide to the engine.
2. Install the lower timing chain guide bolts. Tighten: Tighten the bolts to 12 N.m (107 lb in).
3. Install the cylinder head access hole plug. Tighten: Tighten the plug to 5 N.m (44 lb in).
4. Install the crankshaft sprocket to the crankshaft sprocket snout. Align the marked link on the timing chain with the timing mark on the crankshaft sprocket.
5. Install the timing chain tensioner shoe. Refer to «Timing Chain Tensioner Shoe Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Camshaft Replacement

Tools Required

1. J 44221 Camshaft Holding Tool
2. J 44222 Camshaft Sprocket Holding Tool
3. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the exhaust camshaft position (CMP) sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
3. Remove the Intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
4. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
5. Install the J 44221 to the rear of the camshafts.
6. Remove and discard the intake and the exhaust camshaft sprocket bolts.
7. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components.
8. Carefully slide the sprockets with the timing chain from the camshafts to the J 44222 .
9. Alternately loosen the camshaft cap bolts a few turns at a time until all valve spring pressure has been released.
10. Remove the camshaft caps.
11. Remove the J 44221 from the camshafts.
12. Remove the camshafts from the cylinder head.

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the J 44221 with the camshaft flats up and the #1 piston at TDC.
3. Install the intake and exhaust camshafts to their original positions.
4. Observe the markings on the camshaft caps. Each camshaft cap is marked in order to identify its location. The markings have the following meanings: The arrow should point to the front of the engine The number indicates the position from the front of the engine The "E" indicates the exhaust camshaft. The "I" indicates the intake camshaft.
5. Install the camshaft caps according to the identification marks.
6. Install the camshaft cap bolts. Tighten the bolts evenly in order to compress the valve springs before final torque. Tighten: Tighten the bolts to 12 N.m (106 lb in).
7. Carefully slide the sprockets with the timing chain from the J 44222 to the camshafts.
8. Remove the J 44222 from the cylinder head.
9. Install the new intake camshaft sprocket bolt.
10. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt to 20 N.m (15 lb ft) plus an additional 100 degrees using the J 45059 . Tighten the exhaust camshaft actuator bolt to 25 N.m (18 lb ft) plus an additional 135 degrees using the J 45059 .
11. Remove the J 44221 from the camshafts.
12. Install the Intake CMP sensor. Refer to «Camshaft Position Sensor Replacement - Intake»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
13. Install the exhaust CMP sensor. Refer to «Camshaft Position Sensor Replacement - Exhaust»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
14. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the oil filter adapter from the engine block.

1. Install the oil filter adapter into the engine block. Tighten: Tighten the adapter to 50 N.m (37 lb ft).
2. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Using a suitable tool, pry the oil filter bypass valve from the engine block. Discard the oil filter bypass valve.

1. Press the new oil filter bypass valve into the engine block.
2. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Scheme 101

1. Remove the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
4. Remove the right front axle. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/axle-shafts/#wheel-drive-shafts) .
5. Remove the applicable components in order to gain clearance to remove the oil pan: RWD Remove the power steering gear. Refer to «Steering Gear Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) . 4WD Remove the differential carrier assembly bushing to frame bolts ONLY. Pull the differential carrier assembly downward. Secure the pinion yoke, in order to prevent the differential carrier from rotating.
6. Remove the service slot plug.
7. Remove the nuts securing the fuel hose/pipe bracket to the transmission, and position aside.
8. Remove 4 lower transmission mounting bolts that are attached to the oil pan.
9. For the 4WD only, remove the power steering gear mounting bolts only. Refer to «Steering Gear Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) .
10. Pull the power steering gear downward in order to gain access to the oil pan.
11. Disconnect the engine wiring harness retainers from the oil pan.
12. Remove the oil pan bolts.
13. Install 2 bolts in the threaded holes at the rear of the oil pan to act as jack screws and tighten evenly to release the oil pan from the engine block.
14. Remove the oil pan.
15. Remove the 2 bolts from the jack screw holes.
16. Clean and inspect the engine block sealing surface.

1. Apply a 5.5 mm (0.22 in) bead of sealer to the oil pan in the areas marked (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
2. Apply a 3 mm (0.12 in) bead of sealer to the oil pan in the area marked (2). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
3. Position the oil pan to the engine block.
4. Use the following applicable step to properly align the oil pan: Transmission Removed Use a straight edge at the rear of the block and oil pan for proper alignment. Transmission Installed Ensure the oil pan is positioned fully rearward against the transmission mounting surface.
5. Install the oil pan bolts.
6. Tighten the oil pan bolts. Tighten: Tighten the (side) oil pan bolts to 25 N.m (18 lb ft). Tighten the (end) oil pan bolts to 10 N.m (89 lb in).
7. Connect the engine wiring harness retainers to the oil pan.
8. For the 4WD only, position the power steering gear upward to the frame assembly.
9. For the 4WD only, install the power steering gear mounting bolts. Refer to «Steering Gear Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) .
10. Install the 4 lower transmission mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
11. Install the nuts securing the fuel hose/pipe bracket to the transmission. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
12. Install the service slot plug.
13. Install the right front axle. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/axle-shafts/#wheel-drive-shafts) .
14. Install the applicable components: RWD Install the power steering gear. Refer to «Steering Gear Replacement»(/chevrolet/colorado/i-2004-2012/remont/manual-power-steering/#power-steering-system) . 4WD Position the differential carrier assembly to the frame. Install the differential carrier assembly bushing to frame bolts. Tighten: Tighten the bolts to 152 N.m (112 lb ft).
15. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
16. Install the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
17. Fill the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
2. Disconnect the engine wiring harness electrical connector (1) from the oil pressure switch (2).
3. Remove the engine oil pressure switch.

1. Install the engine oil pressure switch. Tighten: Tighten the switch to 20 N.m (15 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the oil pressure switch (2).
3. Lower the vehicle.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the oil pump pipe screen brace bolts.
3. Remove the oil pump pipe screen bolt.
4. Remove the oil pump pipe screen from the engine.
5. Remove and discard the oil pump pipe seal.
6. Clean and inspect the oil pump pipe screen.

1. Position a new oil pump pipe seal to the oil pump pipe screen assembly.
2. Position the oil pump pipe screen to the engine.
3. Apply sealant to the oil pump pipe bolt threads. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
4. Install the oil pump pipe screen assembly bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the oil pump cover bolts.
3. Remove the oil pump cover.
4. Mark the inner and the outer gears in relation to the oil pump housing.
5. Remove the inner and the outer oil pump gears.
6. Remove the oil pump pressure relief valve plug.
7. Remove the oil pump pressure relief valve and the spring.

1. Install the oil pump pressure relief valve and the spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the plug to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Crankshaft Rear Oil Seal and Housing Replacement

Tools Required

1. J 8092 Driver Handle
2. J 44215 Rear Seal Installer

1. Remove the flywheel. Refer to «Engine Flywheel Replacement (with Automatic Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) or «Engine Flywheel Replacement (with Manual Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the 2 bolts securing the oil pan to the crankshaft rear oil seal housing.
3. Remove the crankshaft rear oil seal housing bolts.
4. Install 2 bolts into the threaded holes to act as jack screws and tighten evenly to release the crankshaft rear oil seal housing from the engine block and oil pan.
5. Remove the crankshaft rear oil seal housing.
6. Remove the 2 bolts from the jack screw holes.
7. Using a hammer and a punch, remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Discard the seal.
8. Clean and inspect the crankshaft rear oil seal housing.
9. Clean and inspect the engine block and oil pan sealing surface.

1. Apply a 3 mm (0.12 in) bead of sealer (1) to the following: The crankshaft rear oil seal housing, were the housing meets the engine block The surface of the crankshaft rear oil seal housing, were the housing meets the oil pan The surface of the oil pan, were the oil pan meets the housing Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__adhesives-fluids-lubricants-and-sealers) .
2. Complete the following to install the crankshaft rear oil seal housing: Align the housing with the right alignment dowel, tilting the left side up slightly. Align the housing with the left alignment dowel. Press the housing against the engine block into place.
3. Install the crankshaft rear oil seal housing bolts.
4. Install the 2 oil pan bolts. Tighten: Tighten the crankshaft rear oil seal housing bolts to 10 N.m (89 lb in). Tighten the (end) oil pan bolts to 10 N.m (89 lb in).
5. Lightly lubricate the crankshaft rear oil seal lip with clean engine oil.
6. Position the plastic installation sleeve supplied with the new seal to the crankshaft.
7. Use the J 44215 with the J 8092 and a hammer to install the crankshaft rear oil seal into the crankshaft rear oil seal housing. Ensure the seal is installed square. The seal will bottom out in the housing when fully installed.
8. Install the flywheel. Refer to «Engine Flywheel Replacement (with Automatic Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) or «Engine Flywheel Replacement (with Manual Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the crankshaft rear oil seal housing. Refer to «Crankshaft Rear Oil Seal and Housing Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-rear-oil-seal-and-housing) .
2. Rotate the crankshaft until the correct timing chain and timing marks align: The left hand balance shaft sprocket timing mark (1) is at the 12:00 position The right hand balance shaft sprocket timing mark (2) is at the 2:30 position The crankshaft sprocket timing mark (3) is at the 4:30 position The 3 timing marks (1-3) on the sprockets line up with a dark link on the chain
3. Remove the balance shaft chain tensioner bolts.
4. Remove the balance shaft chain tensioner.

1. Collapse the balance shaft chain tensioner using the following procedure: Rotate the ratchet release lever (2) clockwise and hold. Collapse the tensioner shoe (1) and hold. Release the ratchet lever.
2. Slowly release the pressure on the shoe, until the ratchet lever moves to the first detent and a "click" is heard and felt.
3. Insert a pin through the hole in the release lever in order to lock the tensioner shoe in the collapsed position.
4. Install the balance shaft chain tensioner and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Remove the pin holding the tensioner to tighten any slack in the balance shaft drive chain.
6. Verify the correct timing chain and timing mark alignments: The left hand balance shaft sprocket timing mark (1) is at the 12:00 position The right hand balance shaft sprocket timing mark (2) is at the 2:30 position The crankshaft sprocket timing mark (3) is at the 4:30 position The 3 timing marks (1-3) on the sprockets line up with a dark link on the chain
7. Install the crankshaft rear oil seal housing. Refer to «Crankshaft Rear Oil Seal and Housing Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__crankshaft-rear-oil-seal-and-housing) .

1. Remove the balance shaft chain tensioner. Refer to «Balance Chain Tensioner Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the balance shaft drive chain from the following: The crankshaft sprocket The left balance sprocket The right balance sprocket

1. Install the balance shaft drive chain to the following: The left balance sprocket The right balance sprocket The crankshaft sprocket
2. Verify the correct timing chain and timing mark alignments: The left hand balance shaft sprocket timing mark (1) is at the 12:00 position The right hand balance shaft sprocket timing mark (2) is at the 2:30 position The crankshaft sprocket timing mark (3) is at the 4:30 position The 3 timing marks (1-3) on the sprockets line up with a dark link on the chain
3. Install the balance shaft chain tensioner. Refer to «Balance Chain Tensioner Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove and discard the left balance shaft retaining bolt.
3. Remove the left balance shaft assembly.

1. Lubricate the balance shaft bearing journals with clean engine oil.
2. Install the left balance shaft assembly with the counterweight down to prevent damage to the balance shaft bearings.
3. Install a new balance shaft retaining bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
4. Install the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove and discard the right balance shaft bolts.
3. Remove the right balance shaft assembly.

1. Lubricate the balance shaft bearing journals with clean engine oil.
2. Install the right balance shaft assembly with the counterweight down to prevent damage to the balance shaft bearings.
3. Install the new balance shaft bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

1. Remove the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Remove the balance shaft chain guide bolts.
3. Remove the balance shaft chain guide.

1. Install the balance shaft chain guide.
2. Install the balance shaft chain guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the balance shaft drive chain. Refer to «Balance Chain Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Crankshaft Rear Oil Seal Replacement

Tools Required

1. J 8092 Driver Handle
2. J 44215 Rear Seal Installer

1. Remove the flywheel. Refer to «Engine Flywheel Replacement (with Automatic Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) or «Engine Flywheel Replacement (with Manual Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
2. Using a suitable tool, pry the crankshaft rear oil seal from the crankshaft rear oil seal housing. Discard the seal.

1. Lightly lubricate the crankshaft rear oil seal lip with clean engine oil.
2. Position the plastic installation sleeve supplied with the new seal to the crankshaft.
3. Use the J 44215 with the J 8092 and a hammer to install the crankshaft rear oil seal into the crankshaft rear oil seal housing. Ensure the seal is installed square The seal will bottom out in the housing when fully installed
4. Install the flywheel. Refer to «Engine Flywheel Replacement (with Automatic Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) or «Engine Flywheel Replacement (with Manual Transmission)»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Special Tools

J 45059 Angle Meter

1. Remove the transmission. Refer to «Transmission Replacement (RWD)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) or «Transmission Replacement (4WD)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) .
2. Remove and discard the flywheel bolts.
3. Remove the flywheel.

1. Position the flywheel to the crankshaft
2. Install the new flywheel bolts. Tighten: Tighten the flywheel bolts to 40 N.m (30 lb ft) plus an additional 45 degrees using the J 45059 .
3. Install the transmission. Refer to «Transmission Replacement (RWD)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) or «Transmission Replacement (4WD)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) .

J 45059 Angle Meter

1. Remove the clutch assembly. Refer to «Clutch Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/clutches-manual-hydraulic/#manual-transmission-clutch-system) .
2. Remove and discard the flywheel bolts.
3. Remove the flywheel.

1. Position the flywheel to the crankshaft
2. Install the new flywheel bolts. Tighten: Tighten the flywheel bolts to 40 N.m (30 lb ft) plus an additional 45 degrees using the J 45059 .
3. Install the clutch assembly. Refer to «Clutch Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/clutches-manual-hydraulic/#manual-transmission-clutch-system) .

Engine Replacement

Tools Required

1. J 38185 Hose Clamp Pliers
2. J 44220 Engine Lift Bracket

1. Remove the hood. Refer to «Hood Replacement»(/chevrolet/colorado/i-2004-2012/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
2. Remove the battery box. Refer to «Battery Box Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .
4. Remove the outlet radiator hose. «Radiator Outlet Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Remove the cooling fan. Refer to «Fan Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__fan-replacement-29l-37l) .
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
7. Remove the air cleaner resonator and outlet duct. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
8. Remove the generator. Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
9. Reinstall the engine lift bracket. Refer to «Engine Lift Bracket Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
10. Position the J 38185 to the clamp (3) in order to remove the radiator inlet hose (2) from the water outlet housing (4).
11. Remove the washer solvent container/coolant recovery reservoir mounting bolts ONLY, in order to gain clearance to remove the engine wiring harness. Refer to «Windshield Washer Solvent Container Replacement (2nd Design)»(/chevrolet/colorado/i-2004-2012/remont/wiperwasher-systems/#wiper-system-washer-system) .
12. Disconnect the 2 engine wiring harness connectors (2) from the powertrain control module (PCM) (3).
13. Disconnect the engine wiring harness retainers (1) from the wheelhouse (4).
14. Open the engine wiring harness retainer (5).
15. Disconnect the engine wiring harness retainers (1) from the power steering pump (2).
16. Disconnect the engine wiring harness connectors from the following components: The electric motor actuator connector (4WD only) The oil pressure switch
17. Disconnect the engine wiring harness retainer (2) from the camshaft cover (3).
18. Disconnect the engine wiring harness connectors from the following components: The exhaust camshaft position (CMP) sensor (5) The exhaust camshaft actuator (6)
19. Disconnect the following electrical connectors from the camshaft cover: The fuel injector harness (1) The heated oxygen sensor (HO2S) (2) The engine coolant temperature (ECT) sensor (3)
20. Disconnect the engine wiring harness electrical connectors from the ignition coils.
21. Disconnect the engine wiring harness retainer (3) from the camshaft cover (4).
22. Disconnect the engine wiring harness connector (2) from the throttle body (1).
23. Disconnect the engine wiring harness connector from the intake CMP sensor.
24. Carefully disengage the engine wiring harness conduit from the camshaft cover.
25. Remove the transmission filler tube (M30 only). Refer to «Transmission Fluid Filler Tube and Seal Replacement (2.9L and 3.7L)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) .
26. Drain the engine oil, if necessary. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
27. Remove the studs securing the secondary air injection (AIR) pipe cover to the cylinder head. Remove the AIR pipe cover and gasket. Discard the gasket.
28. Install the J 44220 in place of the AIR adapter.
29. Disconnect the inlet heater hose quick connect (1) from the heater core (2), and secure to the engine.
30. Remove the power steering pump mounting bolts ONLY, and position aside.
31. Remove the right engine mount-to-frame bracket bolt.
32. Disconnect the engine wiring harness retainer (1) from the intake manifold (2).
33. Position the engine wiring harness aside.
34. Disconnect the fuel feed pipe from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
35. Disconnect the evaporative emission EVAP pipe at the intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
36. Remove the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
37. Disconnect the brake booster hose (6) from the brake booster.
38. Remove the manifold absolute pressure (MAP) sensor. Refer to «Manifold Absolute Pressure Sensor Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-29l-introduction-2-of-2) .
39. Disconnect the MAP sensor wiring harness retainer (4) from the intake manifold (5).
40. Raise and support the vehicle only high enough to access the wiring harnesses through the wheelhouse. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
41. Disconnect the following wiring harness retainers from the engine wiring harness bracket: The battery cable The engine (4, 6) The MAP sensor (5)
42. Remove the starter solenoid "S" terminal nut (3) and disconnect the lead (4) from the starter.
43. Remove the starter terminal nut (1) and disconnect the battery positive cable (2) from the starter.
44. Remove the bolt (4) securing the battery negative cable (5) to the engine block (1).
45. Disconnect the engine wiring harness connector from the evaporative emission (EVAP) canister purge solenoid valve.
46. Disconnect the engine wiring harness connector (3) from the # 2 knock sensor (KS) (1).
47. Disconnect the coolant heater cord from the coolant heater, if equipped.
48. Disconnect the engine wiring harness connector from the # 1 KS (2).
49. Disconnect the engine wiring harness retainer (4) from the engine oil pan rail.
50. Remove the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4).
51. Position the J 38185 (2) to the clamp (1) in order to remove the heater outlet hose from the heater outlet hose fitting (3).
52. Disconnect the engine wiring harness connector (3) from the crankshaft position (CKP) sensor (1).
53. Raise the vehicle completely. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
54. Remove the 3 bolts securing the engine wiring ground leads (2) to the engine block.
55. Disconnect the engine wiring harness retainer (5) from the engine oil pan rail.
56. Position the engine wiring harness aside.
57. Remove the left engine mount-to-frame bracket bolt.
58. Remove the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only).
59. Remove the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only).
60. Disconnect the fuel hose/pipe retainer (4) from the range selector cable bracket (3), and position aside the fuel hose/pipe bundle (M30 only).
61. Remove the applicable components in order to gain clearance to remove the engine: RWD Remove the crossmember. Refer to «Transmission Support Crossmember Replacement (2WD)»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Transmission Support Crossmember Replacement (4WD)»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) . 4WD Remove the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) . Remove the differential carrier assembly bushing to frame bolts ONLY. Position the differential carrier assembly forward. Secure the pinion yoke, in order to prevent the differential carrier from rotating.
62. Remove the exhaust seal. Refer to «Exhaust Seal Replacement»(/chevrolet/colorado/i-2004-2012/remont/exhaust/#engine-exhaust-system) .
63. Remove the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only).
64. Remove the inspection plug (3) from the transmission (1) (M30 only).
65. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (M30 only).
66. Remove the service slot plug.
67. Repeat the following steps for all 3 torque converter bolts (M30 only): Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot. Remove the torque converter bolt using one of the following: 18 mm crowfoot wrench Short T50 TORX bit
68. Remove the 9 transmission mounting bolts (2).
69. Remove the remaining transmission mounting bolts (2).
70. Lower the vehicle.
71. Place a jack under the transmission for support.
72. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
73. Using the engine lift devise, raise the engine only enough to remove the engine mounts.
74. Remove the bolts securing the following to the engine block: The left engine mount The right engine mount
75. Position the engine mounts away from the engine.
76. Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
77. If equipped with an automatic transmission, remove the automatic transmission flywheel locator. Refer to «Automatic Transmission Flywheel Locator Removal»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l) .
78. Install the engine to an engine stand.
79. Remove the engine lift chain from the engine lift brackets.

1. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
2. Remove the engine from the engine stand.
3. If equipped with an automatic transmission, install the automatic transmission flywheel locator. Refer to «Automatic Transmission Flywheel Locator Installation»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l) .
4. Ensure the torque converter is fully engaged with the transmission oil pump (M30 only).
5. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.
6. Align the engine dowels (1) with the transmission.
7. Loosely install the 2 transmission mounting bolts (2). Ensure the dowels (1) are fully engaged into the transmission.
8. Remove the jack from under the vehicle.
9. Position the engine mounts to the engine.
10. Install the bolts securing the right engine mount to the engine block. The engine lift devise may have to be raised or lowered slightly to install these bolts.
11. To aid in the installation of the bolts, start bolt in this position (1) first. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
12. Install the bolts securing the left engine mount to the engine block. The engine lift devise may have to be raised or lowered slightly to install these bolts.
13. To aid in the installation of the bolts, start bolt in this position (1) first. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
14. Lower the engine fully on to the engine mounts.
15. Remove the engine lift chain from the engine lift brackets.
16. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
17. Tighten the 2 transmission mounting bolts (2) previously installed. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
18. Install the remaining transmission mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
19. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (M30 only).
20. Repeat the following steps for all 3 torque converter bolts (M30 only): Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot. To aid in alignment of the torque converter to the flexplate/flywheel, install all 3 torque converter bolts before fully tightening using one of the following: 18 mm crowfoot wrench Short T50 TORX bit Tighten: Tighten the bolts to 60 N.m (44 lb ft).
21. Install the inspection plug (3) to the transmission (1) (M30 only).
22. Install the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
23. Install the exhaust seal. Refer to «Exhaust Seal Replacement»(/chevrolet/colorado/i-2004-2012/remont/exhaust/#engine-exhaust-system) .
24. Install the service slot plug.
25. Install the applicable components: RWD Install the crossmember. Refer to «Transmission Support Crossmember Replacement (2WD)»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Transmission Support Crossmember Replacement (4WD)»(/chevrolet/colorado/i-2004-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) . 4WD Position the differential carrier assembly to the frame. Install the differential carrier assembly bushing to frame bolts. Tighten: Tighten the bolts to 152 N.m (112 lb ft). Install the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/chevrolet/colorado/i-2004-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
26. Install the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only). Tighten: Tighten the nuts to 20 N.m (15 lb ft).
27. Connect the fuel hose/pipe retainer (4) to the range selector cable bracket (3) (M30 only).
28. Install the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only). Tighten: Tighten the nuts to 20 N.m (15 lb ft).
29. Install the left engine mount-to-frame bracket bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft).
30. Connect the engine wiring harness retainer (5) to the engine oil pan rail.
31. Install the 3 bolts securing the engine wiring ground leads (2) to the engine block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
32. Lower the vehicle to chest level in order to access the components through the wheelhouse.
33. Connect the engine wiring harness connector (3) to the CKP sensor (1).
34. Position the J 38185 (2) to the clamp (1) in order to connect the heater outlet hose to the heater outlet hose fitting (3).
35. Install the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4). Tighten: Tighten the bolt to 9 N.m (80 lb in).
36. Connect the engine wiring harness retainer (4) to the engine oil pan rail.
37. Connect the engine wiring harness connector to the KS 1 (2).
38. Connect the engine wiring harness connector (3) to the KS 2 (1).
39. Connect the coolant heater cord to the coolant heater, if equipped.
40. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.
41. Install the bolt (4) securing the battery negative cable (5) to the engine block (1). Tighten: Tighten the bolt to 35 N.m (26 lb ft).
42. Connect the battery positive cable (2) to the starter and install the starter terminal nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
43. Connect the lead (4) to the starter solenoid and install the starter solenoid "S" terminal nut (3). Tighten: Tighten the nut to 3.5 N.m (31 lb in).
44. Secure the following wiring harness retainers to the engine wiring harness bracket: The battery cable The engine (4, 6) The MAP sensor (5)
45. Lower the vehicle.
46. Connect the MAP sensor wiring harness retainer (4) to the intake manifold (5).
47. Install the MAP sensor. Refer to «Manifold Absolute Pressure Sensor Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-29l-introduction-2-of-2) .
48. Connect the brake booster hose (6) to the brake booster.
49. Install the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .
50. Connect the evaporative emission EVAP pipe at the intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
51. Connect the fuel feed pipe to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
52. Connect the engine wiring harness retainer (1) to the intake manifold (2).
53. Install the right engine mount-to-frame bracket bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft).
54. Position the power steering pump to the power steering pump bracket.
55. Install the power steering pump mounting bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
56. Connect the inlet heater hose quick connect (1) to the heater core (2).
57. Remove the J 44220 from the cylinder head.
58. Position the AIR pipe cover and NEW gasket to the cylinder head.
59. Install the AIR pipe cover studs. Tighten: Tighten the studs to 25 N.m (18 lb ft).
60. Install the transmission filler tube (M30 only). Refer to «Transmission Fluid Filler Tube and Seal Replacement (2.9L and 3.7L)»(/chevrolet/colorado/i-2004-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l60-e4l65-e4l70-e-removal-installation-service-troubleshooting-diagnosis) .
61. Engage the engine wiring harness conduit to the camshaft cover.
62. Connect the engine wiring harness connector to the Intake CMP sensor.
63. Connect the engine wiring harness retainer (3) to the camshaft cover (4).
64. Connect the engine wiring harness connector (2) to the throttle body (1).
65. Connect the engine wiring harness electrical connectors to the ignition coils.
66. Connect the engine wiring harness connectors to the following components: The fuel injector harness (1) The HO2S (2) The ECT sensor (3)
67. Connect the engine wiring harness retainer (2) to the camshaft cover (3).
68. Connect the engine wiring harness connectors to the following components: The exhaust CMP sensor (5) The exhaust camshaft actuator (6)
69. Connect the engine wiring harness retainers (1) to the power steering pump (2).
70. Connect the engine wiring harness connectors to the following components: The electric motor actuator connector (4WD only) The oil pressure switch
71. Connect the engine wiring harness retainers (1) to the wheelhouse (4).
72. Close the engine wiring harness retainer (5).
73. Connect the 2 engine wiring harness connectors (2) to the PCM (3).
74. Install the washer solvent container/coolant recovery reservoir mounting bolts. Refer to «Windshield Washer Solvent Container Replacement (2nd Design)»(/chevrolet/colorado/i-2004-2012/remont/wiperwasher-systems/#wiper-system-washer-system) .
75. Position the J 38185 to the clamp (3) in order to connect the radiator inlet hose (2) to the water outlet housing (4).
76. Install the generator. Refer to «Generator Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
77. Install the air cleaner resonator and outlet duct. Refer to «Air Cleaner Resonator and Outlet Duct Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
78. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2) .
79. Install the cooling fan. Refer to «Fan Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__fan-replacement-29l-37l) .
80. Install the outlet radiator hose. «Radiator Outlet Hose Replacement (LLV, LLR)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
81. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) or «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/colorado/i-2004-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .
82. Install the battery box. Refer to «Battery Box Replacement»(/chevrolet/colorado/i-2004-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
83. Install the hood. Refer to «Hood Replacement»(/chevrolet/colorado/i-2004-2012/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
84. Fill the engine oil, if previously drained. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l) .

Engine Final Test and Inspection

Complete the following procedure after the engine is installed in the vehicle

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1,000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
6. Inspect for oil, coolant, transmission fluid, and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/colorado/i-2004-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-37l-introduction-2-of-2__crankshaft-position-system-variation-learn) .
9. Perform a final inspection for the proper engine oil, transmission fluid and coolant levels.
10. Road test the vehicle.

1. Remove the oil fill cap.
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/colorado/i-2004-2012/remont/hoistjack/#general-information) .
3. Clean any dirt and/or debris away from the oil pan drain plug area.
4. Position a suitable drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug.
6. Allow the oil to drain completely.
7. Clean and inspect the oil pan drain plug, replace if necessary.
8. Clean and inspect the oil pan drain plug hole and reinstall the oil pan drain plug until snug.
9. Wipe and remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
10. Position the container under the engine oil filter drain deflector.
11. Position a suitable drain pan under the oil filter.
12. Remove the oil filter.
13. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter.

1. Apply clean engine oil to the NEW oil filter adapter.
2. Install the NEW oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
3. Wipe any excess oil from the oil filter drain deflector.
4. Tighten the oil pan drain plug. Tighten: Tighten the plug to 26 N.m (19 lb ft).
5. Remove the oil drain pan from under the vehicle.
6. Lower the vehicle.
7. Fill the engine with new engine oil. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/colorado/i-2004-2012/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) and «Approximate Fluid Capacities»(/chevrolet/colorado/i-2004-2012/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) .
8. Start the engine.
9. Inspect for oil leaks after engine start up.
10. Turn off the engine and allow the oil a few minutes to drain back into the oil pan.
11. Remove the oil level indicator from the oil level indicator tube.
12. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
13. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
14. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
15. Check the level of the engine oil on the oil level indicator.
16. If necessary, adjust the oil level by adding or draining oil.
17. Check for oil leaks.
18. Install the oil fill cap.

Engine Flywheel Removal (Automatic Transmission)

1. Remove and discard the flywheel bolts.
2. Remove the flywheel.

Engine Flywheel Removal (Manual Transmission)

1. Remove and discard the flywheel bolts.
2. Remove the flywheel.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.

Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bolt.
2. Remove the drive belt tensioner.

Power Steering Pump Bracket Removal

1. Remove the power steering pump bracket bolts.
2. Remove the power steering pump bracket.

Drive Belt Idler Pulley Removal

1. Remove the drive belt idler pulley bolts.
2. Remove the drive belt idler pulley.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator.
2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
3. Remove the exhaust manifold studs. (if needed)
4. Remove the exhaust manifold bolts.
5. Remove the exhaust manifold.
6. Remove and discard the exhaust manifold gasket.

Oil Filter Adapter Removal

1. Remove the oil filter adapter.
2. Remove the oil filter bypass valve.

Heater Inlet Pipe Removal

1. Remove the heater inlet pipe bolt.
2. Remove the heater inlet pipe.

Scheme 102

Remove the heater outlet hose fitting.

Water Outlet Removal

1. Remove the water outlet bolts.
2. Remove the water outlet.

Tool Required

J 41240 Pulley Holding Tool

Removal

1. Install J 41240 to hold the pulley.
2. Remove the water pump pulley bolts.
3. Remove J 41240 .
4. Remove the water pump pulley
5. Remove the water pump bolts.
6. Remove the water pump.
7. Remove and discard the water pump gasket.

Engine Coolant Thermostat Housing Removal

1. Remove the thermostat housing bolts.
2. Remove the thermostat housing.

Intake Manifold Removal

1. Remove the throttle control module bolts.
2. Remove the throttle control module.
3. Remove and discard the throttle control module gasket.
4. Remove the intake manifold and bolts.
5. Remove and discard the intake manifold gasket.

Fuel Rail and Injectors Removal

1. Remove the fuel injector rail bolts.
2. Remove the fuel injector rail.

Camshaft Position Actuator Solenoid Valve Removal

1. Remove the camshaft position actuator valve bolt.
2. Remove the camshaft position actuator valve.

Camshaft Cover Removal

1. Remove the ignition control modules and bolts.
2. Remove the camshaft cover and bolts.
3. Remove the discard the camshaft cover seal.

Oil Pan Removal

1. Remove the oil pan bolts.
2. Install 2 of the oil pan bolts into the threaded holes (jack bolts) to break the seal of oil pan.
3. Remove the oil pan.

Oil Pump Suction Pipe and Screen Assembly Removal

1. Remove the oil pump pipe bolts.
2. Remove the oil pump pipe.
3. Remove and discard the oil pump pipe gasket.

Crankshaft Balancer Removal

Tools Required

1. J-41816 Crankshaft Balancer Remover
2. J 41816-2 Crankshaft End Protector
3. J-41816-3 Crankshaft Balancer Remover Legs

1. Remove and discard the crankshaft balancer bolt.
2. Install J 41816-2 into the end of the crankshaft.
3. Use J-41816 and J-41816-3 to remove the crankshaft balancer.
4. Remove J 41816-2 .

Scheme 103

Pry out and discard the crankshaft front oil seal using a suitable tool.

Engine Front Cover Removal

1. Remove the 7 mm center bolt (1) first.
2. Loosen the engine front cover bolts.
3. Remove the engine front cover and bolts.
4. Remove the spacer bolt.
5. Remove the crankshaft balancer friction washer from the crankshaft snout.

Oil Pump Removal

1. Remove the oil pump cover bolts.
2. Remove the oil pump cover.
3. Mark the inner and outer gears in relation to the oil pump housing.
4. Remove the inner and outer oil pump gears.
5. Remove the oil pump pressure relief valve plug.
6. Remove the oil pump pressure relief valve and spring.

Timing Chain and Sprockets Removal

1. Remove the exhaust camshaft sensor bolt.
2. Remove the exhaust camshaft sensor.
3. Remove and discard the exhaust camshaft position actuator bolt.
4. Remove the exhaust camshaft position actuator.
5. Remove the intake camshaft sprocket bolt.
6. Remove the intake camshaft sprocket.
7. Remove the timing chain.
8. Remove the crankshaft sprocket.

Crankshaft Rear Oil Seal and Housing Removal

1. Remove the crankshaft rear oil seal housing and bolts.
2. Install 2 bolts (Jack Screws) into the threaded holes to break the seal of the housing.
3. Remove the crankshaft rear oil seal housing.

Scheme 104

Remove the crankshaft rear oil seal and discard.

Balance Shaft Removal

1. Rotate the crankshaft until the left hand balance shaft sprocket timing mark is at 12:00. The right hand balance shaft sprocket timing mark should be at 2:30. The crankshaft sprocket timing mark should be at 4:30. Make sure the 3 timing marks on the sprockets line up with a dark link on the chain (1). Every 11-crankshaft rotations, 3 of the 5 dark links on the timing chain will line up with the timing marks.
2. Remove the balance shaft chain tensioner and bolts.
3. Remove the chain from the crankshaft sprocket.
4. Remove the chain from the balancer sprockets.
5. Remove the balance shaft chain guide bolts.
6. Remove the balance shaft chain guide.
7. Remove the balance shaft assembly retaining bolts.
8. Remove the balance shaft assemblies.

Timing Chain Tensioner Removal

1. Remove the cylinder head access hole plugs.
2. Remove the timing chain tensioner shoe bolt.
3. Remove the timing chain tensioner shoe.
4. Remove and discard the timing chain tensioner guide bolts.
5. Remove the timing chain tensioner guide.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.

Engine Lift Bracket Removal

1. Remove the engine lift bracket bolts.
2. Remove the engine lift bracket.

Camshaft Removal

1. Remove the camshaft cap bolts.
2. Remove the camshaft caps.
3. Remove the camshafts.

Valve Rocker Arm and Valve Lash Adjuster Removal

1. Remove the valve rocker arms.
2. Remove the valve lash adjusters.

Cylinder Head Removal

EN-47702 Bolt Extractor Kit

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

J 41556 Connecting Rod Guides

1. Mark the piston with the number of the cylinder from which the piston is being removed. Also mark the orientation.
2. Mark the connecting rod and the connecting rod cap with the cylinder position. Also mark the orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap and bearing half.
5. Install J 41556 on the connecting rod.
6. Remove the connecting rod and piston assembly. Push out the assembly.
7. Remove J 41556 .

Crankshaft and Bearing Removal

Tools Required

1. EN-47702 Bolt Extractor Kit
2. EN-48268 Main Bearing Cap Remover
3. J 6125-1B Slide Hammer with Adapter

1. Remove and discard the crankshaft main bearing cap bolts.
2. Remove the crankshaft main bearing cap stiffener.
3. Use EN-48268 and J 6125-1B to remove the crankshaft main bearing caps.
4. Remove the lower crankshaft main bearing halves.
5. Remove the crankshaft.
6. Remove the upper crankshaft main bearing halves.

J 43276 Clutch Pilot Bearing Removal Tool

1. Install J 43276 into the pilot bearing.
2. Remove the pilot bearing from the crankshaft.
3. Remove J 43276 .

J 45849 Bearing Remover

1. Install J 45849 into the flywheel locator.
2. Remove the flywheel locator from the crankshaft.
3. Remove J 45849 .

J 44225 Balance Shaft Bearing Remover/Installer

1. Position the cylinder block so the cylinder head deck face is down and identify the following: The left balance shaft bearings are in the shorter length balance shaft journal (3) and (4). The right balance shaft - outer diameter is grooved, bearings are in the longer length balance shaft journal (1) and (2).
2. Identify the following: Bearings (2) and (3) are the front bearings and bearings (1) and (4) are the rear bearings. The rear bearings (1) and (4) have a slightly larger diameter than the front bearings (2) and (3). This allows for easier removal and installation of the front bearings. The rear bearings also have notches on them.
3. Install J 44225 into the right balance shaft bearing bore.
4. Position the swivel end inside lip of J 44225 against the frontside of the rear bearing.
5. Turn the nut clockwise to remove the bearing.
6. Remove and discard the right rear bearing (1).
7. Install J 44225 into the right balance shaft bearing bore.
8. Position the swivel end inside lip of J 44225 against the frontside of the front bearing.
9. Turn the nut clockwise to remove the bearing.
10. Remove and discard the right front bearing (1).
11. Install J 44225 into the left balance shaft bearing bore.
12. Position the swivel end inside lip of J 44225 against the frontside of the rear bearing.
13. Turn the nut clockwise to remove the bearing.
14. Remove and discard the left rear bearing (1).
15. Install J 44225 into the left balance shaft bearing bore.
16. Position the swivel end inside lip of J 44225 against the frontside of the front bearing.
17. Turn the nut clockwise to remove the bearing.
18. Remove and discard the left front bearing (1).

Engine Block Plug Removal

1. Remove the engine block oil gallery plugs.
2. Remove the engine block coolant plug.
3. Remove the crankshaft position sensor.
4. Remove the knock sensor.
5. Remove the EVAP solenoid.
6. Remove the coolant temperature sensor.
7. Remove the oil pressure switch.

Engine Block Cleaning and Inspection

Tools Required

1. J 8001 Dial Indicator Set
2. J 8087 Cylinder Bore Gage
3. J 45059 Angle Meter

Cleaning & Inspection

1. Clean the sealing material from all gasket mating surfaces.
2. Clean the engine block with a cleaning solution.
3. Flush the engine block with clean water.
4. Clean the oil passages.
5. Coat the cylinder bores and the machined surfaces with engine oil.
6. Inspect the threaded holes. Clean the holes with a tap, if needed.
7. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully remove any minor irregularities. Replace the block if there is more than 0.08 mm (0.003 in) gap.
8. Inspect the cylinder bores. Use J 8087 to measure the cylinder bore. Inspect the bores for the following conditions: Wear Taper Runout Ridging
9. Replace the cylinder sleeve if the bore is out of specification.
10. Inspect the oil pan rail for nicks. Use a flat file to remove an nicks.
11. Inspect the front cover attaching area for nicks. Use a flat file to remove any nicks.
12. Inspect the mating surfaces of the transmission case.
13. Use the following procedure to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold a gage plate flat against the crankshaft flange. Place J 8001 (dial indicator stem) on the transmission mounting bolt hole boss. Set the indicator to zero. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 in). Recheck the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is within the specification, replace the engine block.
14. Remove the crankshaft.
15. Re-install the crankshaft bearing caps, stiffener, and bolts. Tighten: Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft). Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees.
16. Inspect the crankshaft main bearing bores. Use J 8087 to measure the bearing bore concentricity and alignment.
17. Remove the crankshaft main bearing cap stiffener and main bearing caps with bearings.

Cylinder Honing

1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. DO NOT hone to a final grade with a coarse or medium-grade stone. Leave sufficient metal so that all the stone marks will be removed with the fine grade stones. Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45-65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore. Repeatedly check the cylinder bore fit with the selected piston. All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
5. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. Scrub the cylinder bores with a stiff bristle brush. Rinse the cylinder bores thoroughly with clean hot water. Dry the cylinder bores with a clean rag. Do not allow any abrasive material to remain in the cylinder bores. Abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
6. Perform final measurements of the piston and the cylinder bore.
7. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Crankshaft and Bearing Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gauge
2. J 45059 Angle Meter

1. Clean the crankshaft of all elements.
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft for the following conditions: Damaged threads (1) Damaged mounting faces Worn crankshaft pin (2) Wear without any grooves or scratches (3) Grooves or scoring (3) Scratches (3) Pitting or embedded bearing material (3) Overheating - discoloration (3) Damaged teeth (4)
4. Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of the material.
5. Inspect the outer surfaces of the crankshaft bearings for the following conditions: Wear - surface wear indicates either movement of the insert or high spots in the surrounding material (spot wear) Overheating or discoloration Looseness or rotation indicated by flattened tangs and wear grooves
6. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
7. Inspect the thrust surfaces of the main thrust bearing for the following conditions: Wear Grooving - Grooves are caused by irregularities of the crankshaft thrust surface.
8. Inspect the crankshaft bearings for excessive scoring or discoloration.
9. Inspect the crankshaft bearings for dirt or imbedded debris.
10. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections.
11. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
12. Inspect the connecting rod bearing bores using the following procedure: Tighten the connecting rod bearing cap to specification. Use J 8087 to measure the bearing bore for taper and out-of-round. Record the readings. No taper or out-of-round should exist.
13. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
14. Measure the crankshaft bearing journal taper and runout.
15. Install the crankshaft bearing caps.
16. Install the crankshaft main bearing cap stiffener.
17. Install the crankshaft bearing cap bolts. Tighten: Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft). Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees.
18. Measure the crankshaft main bearing inside diameter with an inside micrometer.
19. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
20. If the specified clearances cannot be met, the crankshaft, connecting rods, or block may need to be replaced.

Crankshaft Balancer Cleaning and Inspection

1. Inspect the crankshaft balancer sealing area for grooves, nicks, or burs (1).
2. Inspect the crankshaft balancer belt ribs for dents or damage (2).
3. Replace the crankshaft balancer if damage is present.

Engine Flywheel Cleaning and Inspection (Automatic Transmission)

1. Inspect the engine flywheel for cracks (1).
2. Inspect the engine flywheel teeth for damage (2).
3. Replace the engine flywheel if damage is present.

Engine Flywheel Cleaning and Inspection (Manual Transmission)

1. Inspect the engine flywheel for damaged teeth (1).
2. Inspect the engine flywheel for cracks, hot spots, or any surface damage (2).
3. Replace the engine flywheel if damage is present.

EN-46745 Piston Pin Retainer Remover and Installer

Disassemble

1. Remove the piston rings using a piston ring expander.
2. Remove the piston pin retainers using EN-46745 .
3. Remove the piston pin.

J 8087 Cylinder Bore Gage

1. Clean and soak the following components in a carburetor cleaning solution to remove carbon, sludge, and varnish: Piston Piston pin Connecting rod
2. Install the connecting rod cap.
3. Place the connecting rod assembly on a checking fixture.
4. Inspect the connecting rod assembly for bending or twisting.
5. Replace any bent or twisted connecting rods.
6. If the connecting rod large bore contains minor scratches or abrasions, clean the bore in a circular direction with light emery paper. DO NOT scrape the connecting rod or cap.
7. 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 0.018 mm (0.0007 in).
8. If there is excessive clearance, replace the piston pin.
9. If there is still excessive clearance, replace the connecting rod.
10. If there is evidence of pin bore or pin scoring, replace the rod and pin assembly.
11. Inspect the connecting rod bearings for the following conditions: Craters or pockets Flattened sections Excessive scoring or discoloration. Imbedded debris Bright, polished sections
12. Inspect the inside of the connecting rod bearing and outside diameter of the connecting rod bearing journal for wear. This indicates high spots.
13. Inspect the connecting rod bearing bore for taper and out-of-round.
14. Inspect the connecting rod bolts for stretching (compare to new or known good bolt). The callout (1) is a stretched bolt, (2) is a new or good bolt.
15. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
16. Clean the piston ring grooves. Ensure that the oil ring holes and slots are clean.
17. 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 Scuffed or damaged skirts Worn piston pin bores
18. Replace pistons that show any signs or damage or excessive wear.
19. Measure the piston diameter for size with a micrometer or caliper at a right angle to the pin center line, across the skirts, 38 mm (1.50 in) from the top of the piston.
20. Replace the piston if worn beyond specifications or if damaged.
21. Use J 8087 to measure the cylinder bore.
22. Hone to size if necessary. Use the following procedure to hone the cylinder bore to the correct size. Select a piston. Hone the cylinder bore to obtain the recommended clearance. Clean the piston and cylinder bore with soap and water. Dry the cylinder bore and piston. Lubricate the cylinder bore with clean engine oil.
23. Use the following procedure to measure the piston-to-cylinder bore clearance. Subtract the piston diameter from the cylinder bore diameter to determine the piston-to-bore clearance. Compare the piston-to-bore clearance using the specifications to determine if the clearance is in the acceptable range. If the used piston is not acceptable, a new service piston may be selected.
24. When a piston has been selected, mark the piston to identify the cylinder for which the piston was fitted.
25. Select a set of new piston rings.
26. Install each ring, one at a time, into the corresponding cylinder.
27. Install the piston for that cylinder, upside down (top of piston pushing on the ring) and push the ring to approximately 25 mm (1 in) down from the deck surface.
28. Remove the piston.
29. Measure the ring end gap with a feeler gage.
30. If the ring gap is not within the specification range, replace the rings.
31. Measure the piston ring side clearance - compression rings.
32. Use the following procedure to measure the compression ring side clearance. Roll the piston ring around the groove. Measure the side clearance with a feeler gage. If the ring is too tight, inspect the piston ring groove for nicks, burrs, or damage. Use emery cloth to remove any minor burrs. If the ring side clearance is greater than the specification, replace the piston.

EN-45680-450 Cylinder Sleeve Removal and Installation Kit

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 the cylinder bore sleeve puller EN 45680-402 (1) which is part of EN-45680-450 , through the cylinder bore.
3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN 456850-401 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, 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»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-29l) .

EN-45680-450 Cylinder Sleeve Removal and Installation Kit

Installation

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) which is part of EN-45680-450 , 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 45680-401 (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten: 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) onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401 (1).
8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) 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 the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly to 102 N.m (75 lb ft) in order 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 fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100).

Scheme 105

1. EN 45680-865 Debris Collector (3)
2. EN 45680-411 Trim Tool Assembly (2)
3. EN 45680-499 Updated Trimmer Pilot (white in color)
4. Air Control Valve (1 - Part of EN 45680-411
5. 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

Scheme 106

1. Trim Tool Preloader (1)
2. EN 45680-412 Set Gage Ring (2)
3. EN 45680-413 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-414 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 metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves.
4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface.
6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten drive adapter EN 45680-866 (1) into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. 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.
15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411.
16. Turn off the compressed air valve (2).
17. Remove trim tool assembly EN 45680-411 from the engine block.
18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413.
19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413.
20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
21. Using a light, illuminate the backside of the straight edge.
22. Looking at the front of the straight edge, 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, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
23. Looking at the front of the straight edge, 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 is cut correctly.
24. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.

EN-46745 Piston Pin Retainer Remover and Installer

Assemble

1. Lubricate the piston pin with clean engine oil.
2. Install one of the piston pin retainers into the retainer groove using EN-46745 .
3. Install the connecting rod and piston pin. Push the piston pin in until it bottoms against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Install the following components of the bottom ring assembly (oil control ring). The expander The lower oil control ring The upper oil control ring
6. Install the middle ring (compression ring) with the napier groove facing down.
7. Install the top ring.

J 7872 Magnetic Base Dial Indicator Set

Inspection

1. Clean the camshafts with cleaning solvent.
2. Inspect the camshafts for the following conditions: Scored camshaft journals Damaged camshaft lobes Damaged camshaft sprocket locator slots Damaged threads
3. Measure the camshaft lobes using a micrometer. The intake camshaft lobes should be a minimum of 41.5 mm (1.635 in). The exhaust camshaft lobes should be a minimum of 41 mm (1.615 in).
4. Use J 7872 to measure the camshaft runout. Set the camshaft in V-blocks between the centers. Measure the intermediate camshaft journal.
5. Use J 7872 to measure the camshaft lobe lift. Lubricate the camshaft to V-block contact areas with engine oil. Set the camshaft on V-blocks. Measure the camshaft lobe lift.
6. If the runout or camshaft lobe lift is not within specifications, replace the camshaft.

Camshaft Timing Chain and Sprocket Cleaning and Inspection

1. Inspect the timing chain sprockets for cracks or teeth that are worn, broken, or chipped.
2. Inspect the dowel pin for wear or damage.
3. Inspect the timing chain for binding or stretching.
4. Inspect the crankshaft sprocket keyway and locating dowel pin in the crankshaft for damage.
5. Inspect the timing chain shoe and guide for excessive wear or cracks.
6. Inspect the timing chain tensioner for damage.
7. Replace the timing chain and sprockets if damaged.

Valve Rocker Arm and Valve Lash Adjuster Cleaning and Inspection

1. Clean the valve rocker arms and valve lash adjusters in cleaning solvent.
2. Dry the valve rocker arms and valve lash adjusters with compressed air.
3. Inspect the valve rocker arms for the following conditions: Excessive wear at the valve contact or valve lash adjuster socket area A loose or damaged pin A worn or damaged roller. The roller should rotate freely with no binding or roughness.
4. Inspect the valve lash adjusters for the following conditions: Excessive wear Clogging of the oil passage Damage Collapsed or spongy

Cylinder Head Disassemble

Tools Required

1. EN 46119 Off-Vehicle Valve Spring Compressor Adapter
2. J 8062 Valve Spring Compressor
3. J 38820 Valve Stem Seal Remover/Installer

1. Remove the spark plugs.
2. Remove the A.I.R. injection pipe cover studs.
3. Remove the A.I.R. injection pipe cover and gasket.
4. Use J 8062 (2) and EN 46119 (1) to compress the valve spring.
5. Remove the valve keys.
6. Remove J 8062 and EN 46119 .
7. Remove the valve spring retainer and valve spring.
8. Remove the valves.
9. Use J 38820 to remove the valve seals.
10. Inspect the water jacket plug, for leakage. Replace if necessary.
11. Inspect the (inner) oil gallery plug, for leakage. Replace if necessary.
12. Inspect the (end) oil gallery plugs, for leakage. Replace if necessary.

J 9666 Valve Spring Tester

1. Inspect the cylinder head gasket and the mating surface. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure: Improper installation Warped cylinder head Missing or not fully seated dowel pins Low torque on the cylinder head bolts Incorrect length cylinder head bolts A warped engine block surface Scratched surfaces Foreign material Cracked engine block threaded holes
3. Clean the following components: The gasket surfaces Do not use a motorized brush on the head gasket sealing surface. Valve stems and valve heads The bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
4. Inspect the cylinder head mating surfaces for flatness. Use a feeler gauge and a straight edge.
5. Replace the cylinder head if warped more than 0.08 mm (0.003 in).
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion.
8. Inspect the valve springs for squareness.
9. Use J 9666 to measure the valve spring tension. Replace the valve spring if the tension is not within specification.
10. Inspect the valve guides for wear. The valve guides may be reamed oversized 0.075 mm (0.003 in) and oversized stemed valves may be installed. The same size valve seal should be used.
11. Inspect the valve seats for excessive wear, damage, or hot spots.
12. Use the following procedure to measure the valve seat concentricity: Lift the valve off the valve seat. Apply a dab of blue dye to the valve face. Seat and rotate the valve. The blue dye traces transferred to the valve seat are an indication of concentricity of the valve seat.
13. Use the following procedure to measure the valve runout: Clean off the blue dye. Apply blue dye to the valve seat. Seat and rotate the valve. The traces of blue dye transferred to the valve indicates valve runout.
14. Replace the head if the valve seats are damaged.
15. Inspect the valves for the following damage: Grooving (1, 2) Bent valve stem (3). Replace any bent valve. Burrs or scratches (4). Minor burrs or scratches may be removed with a fine oil stone. Chipped or worn key grooves (5). Replace if damaged. Valve tip wear (6). Replace if worn.

Cylinder Head Assemble

Tools Required

1. EN 46119 Off-Vehicle Valve Spring Compressor Adapter
2. J 8062 Valve Spring Compressor
3. J 38820 Valve Stem Seal Remover/Installer

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads.
2. Install the (end) oil gallery plugs. Tighten: Tighten the oil gallery plugs to 38 N.m (28 lb ft).
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plugs.
4. Install the (inner) oil gallery plugs.
5. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plug.
6. Install the water jacket plug.
7. Use J 38820 to install the valve seals. There is only one size valve seal.
8. Install the valves. 0.075 mm (0.003 in) oversized valves are available if the valve guides needed to be reamed. Use the same (original size) valve seal.
9. Install the valve spring and the valve spring retainer.
10. Use J 8062 (2) and EN 46119 (1) to compress the valve spring.
11. Install the valve keys.
12. Remove J 8062 and EN 46119 .
13. Install the remaining valves, springs, and other components.
14. Install the spark plugs. Tighten: Tighten the spark plugs to 18 N.m (13 lb ft).
15. Install the A.I.R. injection pipe gasket.
16. Install the A.I.R. injection pipe cover.
17. Install the A.I.R. injection pipe studs. Tighten: Tighten the studs to 25 N.m (18 lb ft).

Camshaft Cover Cleaning and Inspection

1. Remove and discard the rubber ignition coil seals, and the camshaft cover seal.
2. Clean the camshaft cover with a suitable cleaning solvent.
3. Inspect the camshaft cover for cracks or damage.
4. Inspect the bolt threads for damage.
5. Replace the camshaft cover if necessary.

Oil Pump Cleaning and Inspection

1. Clean all parts of sludge, oil, and varnish by soaking in carburetor cleaner or cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the oil pump housing and engine front cover for the following conditions: Cracks or casting imperfections Scoring Damaged threads
4. Do not attempt to repair the oil pump housing. Replace the oil pump housing if damage is found.
5. Inspect the oil pump gears for damage.
6. Measure the inner oil pump gear tip clearance in several places.
7. Measure the outer oil pump gear tip clearance in several places.
8. Measure the oil pump gear side clearance.
9. Inspect the pressure regulator valve for the following conditions: Scoring Sticking Burrs - Burrs may be removed using a fine oil stone.
10. Inspect the pressure regulator valve spring for loss of tension or bending. Replace the pressure regulator spring if damaged.
11. Inspect the oil pump pipe pickup tube and screen assembly for the following conditions: Looseness - If the oil pump pipe pickup tube is loose or bent, replace the oil pump pipe pickup tube. Broken wire mesh or screen Inspect the O-ring seal at the base of the oil pump pickup tube for damage.

Oil Pan Cleaning and Inspection

1. Clean the oil pan in solvent. Remove all sludge and debris from the oil pan.
2. Remove all sealing material from the oil pan rails.
3. Inspect the oil pan sealing surfaces for nicks or damage. Remove any minor nicks with a fine flat file.
4. Inspect the threads in the oil drain plug hole.
5. Replace the oil pan if necessary.

Engine Front Cover Cleaning and Inspection

1. Clean the engine front cover with cleaning solvent.
2. Remove all sealing material.
3. Inspect the engine front cover sealing surfaces for nicks or damage. Use a fine flat file to remove any minor nicks.
4. Inspect the engine front cover threaded holes for damage.
5. Repair or replace the engine front cover as necessary.

Intake Manifold Cleaning and Inspection

1. Clean the intake manifold gasket mating surface.
2. Inspect the threads on the retaining bolts.
3. Inspect the intake manifold for cracks.
4. Clean the internal ports of all debris.
5. Replace the intake manifold if necessary.

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold.
2. Inspect the exhaust manifold for cracks or damage.
3. Inspect the exhaust manifold threads and studs (if necessary).
4. Check the exhaust manifold mating surface for flatness. Use a straight edge and a feeler gage.
5. Replace the exhaust manifold if necessary.

Water Pump Cleaning and Inspection

1. Remove all sealing material from the sealing surface.
2. Inspect the water pump impeller for damage.
3. Inspect the water pump shaft for looseness.
4. Inspect the threads for damage.
5. Replace the water pump if necessary.

Thread Repair

Tools Required

1. J 42385-400 Thread Repair Kit
2. J 43965 Extension Kit

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external threads of the insert into the base material. This action mechanically locks the insert into place.

Scheme 107

The tool kit J 42385-400 is designed for use with either a suitable tap wrench or drill motor. Limited access and larger hole repair may process better using a tap wrench. An extension J 43965 may also be necessary to drive the thread repair tooling dependent on access to the hole being repaired.

Scheme 108

It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as the original hole.

Scheme 109

During the drilling and tapping of the hole being repaired ensure the tooling is consistently machining perpendicular to the surface of the base material.

Scheme 110

If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are available to aid in tapping the hole.

Thread Repair

Scheme 111

When installed to the proper depth, the flange (1) of the insert will be seated against the counterbore of the drilled/tapped hole and just below the surface (2) of the base material.

1. Drill out the threads of the damaged hole. 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 drilled hole to the full depth permitted by the tool (1).
4. Using compressed air, clean out any chips.
5. Using a suitable tapping wrench, 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 GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
8. Using compressed air, clean out any chips.
9. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
10. Install the insert (2) onto the driver installation tool (1).
11. Apply threadlock sealant GM P/N 12345493 (Canadian P/N 10953488), J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
12. Install the insert (2) into the tapped hole.
13. Install the insert until the flange (2) of the insert contacts the counterbored surface.
14. Continue to rotate the driver installation tool (1) through the insert (2).
15. Inspect the insert for proper installation into the tapped hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).
16. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Scheme 112

When installed to the proper depth, the flange of the insert (1) will be seated against the counterbore (2) of the drilled/tapped hole.

1. Install a stop collar (2) on the counterbore drill (1), if required.
2. Drill out the threads of the damaged hole.
3. Using compressed air, clean out any chips.
4. Using a suitable tapping wrench, tap the threads of the drilled hole.
5. Using compressed air, clean out any chips.
6. Spray cleaner GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
7. Using compressed air, clean out any chips.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N 12345493 (Canadian P/N 10953488), J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole.
12. Install the insert until the flange (2) of the insert contacts the counterbored surface.
13. Continue to rotate the driver installation tool (1) through the insert (2).
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Tapered Pipe Thread Repair

The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

Scheme 113

When installed to the proper depth, the flange (1) of the insert will be seated against surface (2) of the base material of the drilled/tapped hole.

1. Drill out the threads of the damaged hole.
2. Using compressed air, clean out any chips.
3. Using a suitable tapping wrench, tap the threads of the drilled hole.
4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.
5. Using compressed air, clean out any chips.
6. Spray cleaner GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
7. Using compressed air, clean out any chips.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N 12345493 (Canadian P/N 10953488), J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole.
12. Install the insert until the flange (2) of the insert contacts the surface of the base material.
13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3).
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Scheme 114

The cylinder head bolt hole required tools consist of the following

1. Drill (1) J 42385-402
2. Tap (2) J 42385-403
3. Installation driver (3) J 42385-404
4. Alignment pin (4) J 42385-303
5. Bushing (5) J 42385-302
6. Bolts (6) J 42385-421
7. Fixture plate (7) J 42385-401

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.
6. Drill out the threads of the damaged hole.
7. Using compressed air, clean out any chips.
8. Using a suitable tapping wrench, tap the threads of the drilled hole.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt hole until the first mark (1) on the tap aligns with the top of the drill bushing (3).
10. Remove the fixture plate bolts (2).
11. Remove the fixture plate (3) and bushing (1).
12. Using compressed air, clean out any chips.
13. Spray cleaner GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
14. Using compressed air, clean out any chips.
15. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
16. Install the insert (2) onto the driver installation tool (1).
17. Apply threadlock sealant GM P/N 12345493 (Canadian P/N 10953488), J 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2).
18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole.
20. Install the insert until the flange of the insert contacts the counterbored surface.
21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the tapped hole.

Scheme 115

The crankshaft main bearing bolt hole required tools consist of the following

1. Drill (1) J 42385-417
2. Tap (2) J 42385-418
3. Installation driver (3) J 42385-419
4. Fixture plate (4) J 42385-401
5. Bushing (5) J 42385-307
6. Alignment pin (6) J 42385-308
7. Bolts (7) J 42385-510

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (2), installed over the crankshaft main cap bolt hole to be repaired.
2. Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.
3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.
6. Drill out the threads of the damaged hole.
7. Using compressed air, clean out any chips.
8. Using a suitable tapping wrench, tap the threads of the drilled hole.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
10. Using compressed air, clean out any chips.
11. Spray cleaner GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
12. Using compressed air, clean out any chips.
13. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
14. Install the insert (2) onto the driver installation tool (1).
15. Apply threadlock sealant GM P/N 12345493 (Canadian P/N 10953488), J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
16. Install the insert and installation driver into the tapped hole.
17. Start the insert into the threaded hole.
18. Install the insert until the flange of the insert contacts the counterbored surface.
19. Continue to rotate the driver installation tool through the insert.
20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
21. Inspect the insert for proper installation into the tapped hole.
22. Remove the fixture plate bolts (1).
23. Remove the fixture plate (3) and bushing (2).

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant (unless otherwise specified). This will provide initial lubrication when the engine is first started.

J 44225 Balance Shaft Bearing Remover/Installer

Scheme 116

Position the cylinder block so the cylinder head deck face is down and identify the following

1. The left balance shaft bearings are in the shorter length balance shaft journal (3) and (4).
2. The right balance shaft - grooved bearings are in the longer length balance shaft journal (1) and (2).

Scheme 117

Identify the following

1. Bearings (2) and (3) are the front bearings and bearings (1) and (4) are the rear bearings.
2. The rear bearings (1) and (4) have a slightly larger diameter than the front bearings (2) and (3). This allows for easier removal and installation of the front bearings. The rear bearings also have notches on them for identification purposes.

1. Install the new right front balance shaft bearing onto J 44225 (2).
2. Install J 44225 into the balance shaft bearing bore and align the front bearing.
3. Turn the threaded rod clockwise until the guide (1) is seated into the rear journal.
4. Install and tighten the balance shaft mounting bolt (1) to hold J 44225 .
5. Turn the threaded rod clockwise until it bottoms to install the right front balance shaft bearing to the proper depth.
6. Remove the balance shaft mounting bolt and J 44225 .
7. Install the new right rear balance shaft bearing onto J 44225 (2).
8. Install J 44225 into the balance shaft bearing bore and align the rear bearing.
9. Turn the threaded rod clockwise until the guide (1) is seated into the rear journal.
10. Install and tighten the balance shaft mounting bolt (1) to hold J 44225 .
11. Install J 44225 - spacer (2) between the guide (3) and the washer (1).
12. Turn the threaded rod clockwise until it bottoms to install the right rear balance shaft bearing to the proper depth.
13. Remove the balance shaft mounting bolt (1) and J 44225 .
14. Install the new left front balance shaft bearing onto J 44225 (2).
15. Install J 44225 into the balance shaft bearing bore and align the front bearing.
16. Turn the threaded rod clockwise until the guide (1) is seated into the rear journal.
17. Install and tighten the balance shaft mounting bolt (1) to hold J 44225 .
18. Turn the threaded rod clockwise until it bottoms to install the left front balance shaft bearing to the proper depth.
19. Remove the balance shaft mounting bolt (1) and J 44225 .
20. Install the new left rear balance shaft bearing onto J 44225 (2).
21. Install J 44225 into the balance shaft bearing bore and align the rear bearing.
22. Turn the threaded rod clockwise until the guide (1) is seated into the rear journal.
23. Install and tighten the balance shaft mounting bolt (1) to hold J 44225 .
24. Install J 44225 - spacer (2) between the guide (3) and the washer (1).
25. Turn the threaded rod clockwise until it bottoms to install the left rear balance shaft bearing to the proper depth.
26. Remove the balance shaft mounting bolt (1) and J 44225 .

Engine Block Plug Installation

1. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the plug threads.
2. Install the engine block coolant plug. Tighten: Tighten the engine block coolant plug to 50 N.m (37 lb ft).
3. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the plug threads.
4. Install the engine block oil gallery plugs to front and left of block. Tighten: Tighten the side engine block oil gallery plugs to 35 N.m (26 lb ft). Tighten the front (1) engine block oil gallery plug to 80 N.m (40 lb ft).
5. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the EVAP solenoid bolt threads. Tighten: Tighten the EVAP solenoid bolt to 10 N.m (89 lb in).
6. Install the knock sensor. Tighten: Tighten the knock sensor to 25 N.m (18 lb ft).
7. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the crankshaft position sensor bolt.
8. Install the crankshaft position sensor and bolt. Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
9. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 20 N.m (15 lb ft).

J 45949 Pilot Bearing and Flywheel Locator Installer

1. Install J 45949 into the pilot bearing.
2. Install the pilot bearing into the crankshaft.
3. Remove J 45949 .

J 45949 Pilot Bearing and Flywheel Locator Installer

1. Install J 45949 into the flywheel locator.
2. Install the flywheel locator into the crankshaft.
3. Remove J 45949 .

Crankshaft and Bearing Installation

J 45059 Angle Meter

1. Install the upper crankshaft main bearings into the block.
2. Lubricate the upper crankshaft main bearing surface with clean engine oil.
3. Install the crankshaft.
4. Install the lower crankshaft main bearings into the main bearing caps.
5. Lubricate the lower crankshaft main bearing surface with clean engine oil.
6. Install the crankshaft main bearing caps.
7. Install the crankshaft main bearing cap stiffener.
8. Install new crankshaft main bearing bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the block surface.
9. Tighten the crankshaft main bearing cap bolts in equal increments. Tighten: Tighten the crankshaft main bearing cap bolts to 25 N.m (18 lb ft) in sequence. Use J 45059 to tighten the crankshaft main bearing cap bolts an additional 180 degrees.
10. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the thrust crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. Refer to «Engine Mechanical Specifications»(/chevrolet/colorado/i-2004-2012/remont/mechanical/#engine-mechanical-37l__engine-mechanical-specifications) for the proper clearance. If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. EN-48260 Piston Ring Compressor
2. J 41556 Connecting Rod Guide
3. J 45059 Angle Meter

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at Bottom Dead Center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Use EN-48260 to compress the rings.
6. Install the connecting rod bearings into the connecting rods and caps (1).
7. Lubricate the connecting rod bearing contact surfaces with engine oil.
8. Install the J 41556 into the connecting rod.
9. Install the connecting rod and piston into the proper cylinder bore.
10. Make sure to install the connecting rod facing the right direction.
11. Hold EN-48260 firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
12. Guide the connecting rod end onto the crankshaft journal. Use J 41556 to pull the connecting rod into place.
13. Install the connecting rod bearing, cap, and bolts. Tighten: Tighten the connecting rod bearing cap bolts on the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the connecting rod bearing cap bolts on the second pass an additional 110 degrees.
14. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankshaft.
15. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be between 0.05-0.35 mm (0.0019-0.0137 in).

Balance Shaft Installation

1. Lubricate the balance shaft bearing journals with clean engine oil.
2. Install NEW balance shaft assemblies with the counterweight down to prevent damage to the balance shaft bearings.
3. Install NEW left balance shaft assembly retaining bolts. Tighten: Tighten the NEW left balance shaft assembly retaining bolts to 10 N.m (89 lb in).
4. Install the balance shaft chain guide.
5. Install the balance shaft chain guide bolts. Tighten: Tighten the balance shaft chain guide bolts to 10 N.m (89 lb in).
6. Install the balance shaft chain onto the balancer sprockets and crankshaft sprocket.
7. Rotate the crankshaft until the left hand balance shaft sprocket timing mark is at 12:00. The right hand balance shaft sprocket timing mark should be at 2:30. The crankshaft sprocket mark should be at 4:30. Make sure the 3 timing marks on the sprockets (1) line up with a dark link on the chain. Every 11 crankshaft rotations, 3 of the 5 dark links on the chain will line up with the timing marks.
8. Rotate the retainer plate clockwise while holding the chain onto the crankshaft sprocket.
9. Install NEW right balance shaft assembly retaining bolts. Tighten: Tighten the NEW right balance shaft assembly retaining bolts to 12 N.m (106 lb in).
10. Install the balance shaft chain tensioner and bolts. Tighten: Tighten the balance shaft chain tensioner bolts to 10 N.m (89 lb in).
11. Remove the small tool from the link plate hole in order to regain chain tension.

Cylinder Head Installation

J 45059 Angle Meter

1. Install the dowel pins - cylinder head locator, if necessary.
2. Install a new cylinder head gasket.
3. Install the cylinder head.
4. Install new cylinder head bolts.
5. Tighten the new cylinder head bolts in the following sequence: Tighten: Tighten the (12) long cylinder head bolts in sequence to 30 N.m (22 lb ft). Use J 45059 to tighten the cylinder head bolts in sequence an additional 155 degrees. Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 45059 to tighten the short cylinder head end bolts an additional 60 degrees. Tighten the (1 Long) end bolt to 7 N.m (62 lb in). Use J 45059 to tighten the long cylinder head end bolt an additional 120 degrees.

Valve Rocker Arm and Valve Lash Adjuster Installation

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm.
4. Install the valve rocker arms in their original locations.

J 44221 Camshaft Holding Tool

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the exhaust camshaft.
3. Install the intake camshaft.
4. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center.
5. Install the exhaust camshaft caps.
6. Install the intake camshaft caps.
7. Install the camshaft cap bolts. Tighten the bolts evenly in order to compress the valve springs before final torque. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in).
8. Remove J 44221 .

Engine Lift Bracket Installation

1. Install the engine lift bracket.
2. Install the engine lift bracket bolts in sequence. Tighten: Tighten the engine lift bracket bolts a first pass in sequence to 5 N.m (44 lb in) Tighten the engine lift bracket bolts a final pass in sequence to 50 N.m (37 lb ft)

Timing Chain Tensioner Installation

1. Install the timing chain tensioner.
2. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
3. Install the timing chain tensioner guide.
4. Install the timing chain tensioner guide bolts. Tighten: Tighten the timing chain tensioner guide bolts to 22 N.m (16 lb ft).
5. Install the timing chain tensioner shoe.
6. Install the timing chain tensioner shoe bolt. Tighten: Tighten the timing chain tension shoe bolt to 25 N.m (18 lb ft).
7. Install the cylinder head access hole plugs. Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).

Timing Chain and Sprockets Installation

Tools Required

1. J 44221 Camshaft Holding Tool
2. J 45059 Angle Meter

1. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. The crankshaft pin should be at 12 o'clock when the number 1 piston is at top dead center.
2. Compress the tensioner and lock in place.
3. Install the crankshaft sprocket.
4. Install the intake camshaft sprocket into the timing chain.
5. Align the (dark) link of the timing chain with the timing mark on the intake camshaft sprocket (1).
6. Feed the timing chain down through the opening in the head.
7. Install the timing chain onto the crankshaft sprocket. Align the (dark) link of the timing chain with the timing mark on the crankshaft sprocket (2).
8. Install the intake camshaft sprocket onto the intake camshaft.
9. Install the intake camshaft sprocket washer and new bolt. Tighten: Tighten the new intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use J 45059 to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
10. Install the exhaust camshaft actuator into the timing chain.
11. Align the (dark) link of the timing chain with the timing mark on the exhaust camshaft actuator (1).
12. Install the exhaust camshaft actuator onto the exhaust camshaft.
13. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the new exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
14. Unlock the tensioner.
15. Remove J 44221 .
16. The dark links (1) on the chain should be aligned with marks on sprockets as shown.
17. Lube the exhaust camshaft position sensor bore with clean engine oil.
18. Install and seat the exhaust camshaft position sensor.
19. Install the exhaust camshaft position sensor bolt. Tighten: Tighten the exhaust camshaft position sensor bolt to 10 N.m (89 lb in).

Camshaft Cover Installation

1. Install a new camshaft cover seal.
2. Install the camshaft cover and bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install new ignition control module seals.
4. Install the ignition control modules and bolts. Tighten: Tighten the ignition control module bolts to 10 N.m (89 lb in).
5. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the coolant temperature sensor threads.
6. Install the coolant temperature sensor. Tighten: Tighten the coolant temperature sensor to 16 N.m (12 lb ft).

Camshaft Position Actuator Solenoid Valve Installation

1. Apply clean engine oil to the camshaft position actuator valve hole.
2. Install the camshaft position actuator valve.
3. Add threadlock GM P/N 12346004 (Canadian P/N 10953480) to the camshaft position actuator valve bolt threads.
4. Install the camshaft position actuator valve bolt. Tighten: Tighten the camshaft position actuator valve bolt to 10 N.m (89 lb in).

Oil Pump Installation

1. Install the oil pump pressure relief valve and spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the oil pump pressure relief valve plug to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).

J 44219 Engine Cover Alignment Pins

1. Install the engine front cover spacer bolt. Tighten: Tighten the engine front cover spacer bolt to 10 N.m (89 lb in).
2. Install J 44219 .
3. Remove 2 bolts from the engine front cover in the location of the alignment pins.
4. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 (Canadian P/N 88901148) to the block sealing surface (1).
5. Align the oil pump to the crankshaft sprocket splines.
6. Install the engine front cover and bolts.
7. Remove J 44219 .
8. Install the 2 remaining engine front cover bolts. Tighten: Tighten the engine front cover bolts to 10 N.m (89 lb in). Tighten the small center bolt (1) last to 8 N.m (71 lb in).

J 45951 Front Seal Installer

1. Apply engine oil to the outside diameter of the crankshaft front oil seal.
2. Use J 45951 to install a new crankshaft front oil seal.
3. Remove J 45951 .

J 41240 Fan Clutch Remover and Installer

1. Install the NEW water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts.
6. Install J 41240 to hold pulley.
7. Tighten the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
8. Remove J 41240 .

J 44219 Cover Alignment Pins

1. Apply a 3 mm (0.12 in) bead of GM P/N 12378521 (Canadian P/N 88901148) to the rear sealing surface of the block (1).
2. Install J 44219 into the block.
3. Slide the crankshaft rear oil seal housing and bolts over the J 44219 and crankshaft, except the 2 in place of the guide pins.
4. Remove J 44219 .
5. Snug the crankshaft rear oil seal housing bolts.
6. Install the remaining two crankshaft rear oil seal housing bolts. Tighten: Tighten the crankshaft rear oil seal housing bolts to 10 N.m (89 lb in).
7. Wipe off any excess material from the bottom of the oil pan sealing area (1).

Oil Pump Suction Pipe and Screen Assembly Installation

1. Install a new oil pump pipe gasket.
2. Install the oil pump pipe and screen assembly.
3. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil pump pipe bolt threads.
4. Install the oil pump pipe and screen assembly bolts. Tighten: Tighten the oil pump pipe and screen assembly bolts to 10 N.m (89 lb in).

Oil Pan Installation

1. Apply a 5.5 mm (0.22 in) bead of sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent, to the oil pan in areas marked (1).
2. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 (Canadian P/N 88901148) to the oil pan area marked (2).
3. Install the oil pan.
4. Install the oil pan bolts.
5. Check the oil pan alignment. Use a straight edge on the back of the block and oil pan (transmission mounting surface).
6. Tighten the oil pan bolts. Tighten: Tighten the (side) oil pan bolts to 25 N.m (18 lb ft). Tighten the (end) oil pan bolts to 10 N.m (89 lb in).

Crankshaft Balancer Installation

Special Tools

1. EN-48034 Crankshaft Balancer Installer
2. J 45059 Angle Meter

1. Install the friction washer on the back side of the crankshaft balancer.
2. Install the crankshaft balancer using EN-48034 .
3. Remove EN-48034 .
4. Hold the flywheel or back of the crankshaft. The crankshaft balancer does not have a keyway so the crankshaft could turn when tightening, causing an improper torque.
5. Install the crankshaft balancer washer and new bolt. Tighten: Tighten the new crankshaft balancer bolt while holding the back to 150 N.m (110 lb ft). Use J 45059 to tighten the crankshaft balancer bolt an additional 180 degrees.

Fuel Rail and Injectors Installation

1. Lubricate the lower injector O-rings with mineral oil GM P/N 9981704.
2. Install the fuel injector rail.
3. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Intake Manifold Installation

1. Install a new intake manifold gasket.
2. Install the intake manifold and bolts. Tighten: Tighten the intake manifold bolts from the inside out to 10 N.m (89 lb in).
3. Install a new throttle control module gasket.
4. Install the throttle control module.
5. Add threadlock GM P/N 12346004 (Canadian P/N 10953480) to the throttle control module bolt threads.
6. Install the throttle control module bolts. Tighten: Tighten the throttle control module bolts to 10 N.m (89 lb in).

Engine Coolant Thermostat Housing Installation

1. Install the thermostat housing.
2. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).

Heater Inlet Pipe Installation

1. Install the heater inlet pipe.
2. Install the heater inlet pipe bolt. Tighten: Tighten the heater inlet pipe bolt to 10 N.m (89 lb in).

Heater Outlet Hose Fitting Installation

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads.
2. Install the heater outlet hose fitting. Tighten: Tighten the heater outlet hose fitting to 45 N.m (33 lb ft).

Water Outlet Installation

1. Install the water outlet.
2. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 10 N.m (89 lb in).

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter adapter. Tighten: Tighten the oil filter adapter to 30 N.m (22 lb ft).

Exhaust Manifold Installation

1. Install the NEW exhaust manifold gasket.
2. Install the exhaust manifold.
3. Add threadlock GM P/N 89021297 (Canadian P/N 10953488) to the exhaust manifold bolt threads.
4. Install the exhaust manifold bolts.
5. Tighten the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts a first pass in sequence to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts a second pass in sequence to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts a final pass in sequence to 20 N.m (15 lb ft).
6. Install the exhaust manifold heat shield studs (if required). Tighten: Tighten the exhaust manifold heat shield studs to 10 N.m (89 lb in).
7. Install the exhaust manifold heat shield.
8. Add anti-seize GM P/N 12371386 (Canadian P/N 993128) to the exhaust manifold heat shield nuts.
9. Install the exhaust manifold heat shield nuts. Tighten: Tighten the exhaust manifold heat shield nuts to 10 N.m (89 lb in).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.
2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads.
3. Install the oil level indicator tube stud. Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in).
4. Install the oil level indicator.

Power Steering Pump Bracket Installation

1. Install the power steering pump bracket.
2. Install the power steering pump bracket bolts. Tighten: Tighten the power steering pump bracket bolts to 50 N.m (37 lb ft).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Drive Belt Idler Pulley Installation

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolts. Tighten: Tighten the drive belt idler pulley bolts to 50 N.m (37 lb ft).

J 44215 Rear Seal Installer

1. Use the plastic installation sleeve supplied with the new seal when installing a new seal. Use J 44215 to install the crankshaft rear oil seal.
2. Remove J 44215 .

J 45059 Angle Meter

1. Install the flywheel.
2. Install new flywheel bolts. Tighten: Tighten the new flywheel bolts to 40 N.m (30 lb ft). Use J 45059 to tighten the flywheel bolts an additional 45 degrees.

J 45059 Angle Meter

1. Install the flywheel.
2. Install new flywheel bolts. Tighten: Tighten the new flywheel bolts to 40 N.m (30 lb ft). Use J 45059 to tighten the flywheel bolts an additional 45 degrees.

J 45299 Engine Preluber

Prelube

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Remove the engine block oil gallery plug (1).
3. Install the M16 x 1.5 adapter P/N 509375.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the oil pressure sensor. Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft).
8. Top-off the engine oil to the proper level.

Scheme 118

A crankcase ventilation system is used to consume crankcase vapors created during the combustion process instead of venting them to the atmosphere.

Fresh air is supplied through a filter to the crankcase, the crankcase mixes the fresh air with the blow-by gases and then passed through a positive crankcase ventilation (PCV) orificed tube (5) into the intake manifold (3).

The PCV orificed tube (5) restricts the flow rate of the blow-by gases using a 2.5 mm (0.098 in) orifice located in the camshaft cover tube (5). If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow-by gases to back flow through the crankcase ventilation fresh air tube (6) into the air cleaner resonator (1) in order to be consumed by normal combustion.

Drive Belt System Description

The drive belt system consists of the following components

1. The drive belt
2. The drive belt tensioner
3. The drive belt idler pulley
4. The crankshaft balancer pulley
5. The accessory drive component mounting brackets
6. The accessory drive components The power steering pump, if belt driven The generator The A/C compressor, if equipped The engine cooling fan, if belt driven The water pump, if belt driven The vacuum pump, if equipped The air compressor, if equipped

The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.

Engine Block

The lost foam all aluminum engine block utilizes a deep skirt design for increased rigidity. The cylinders are positioned in a straight in-line orientation. The crankshaft bearing caps have a bearing beam or "ladder" for enhanced structural rigidity and vibration reduction.

Oil Pan

A single piece cast aluminum oil pan contributes to crankshaft and block rigidity while reducing overall weight. The oil pan bolts to the bell housing as well as the block. This eliminates points of vibration and makes the complete powertrain act as a single casting. Jack screws are used to remove the oil pan.

Crankshaft

The crankshaft is a nodular iron design.

Connecting Rods

The connecting rods are forged powdered metal. The connecting rods and caps are of a fractured split design to improve durability and reduce internal friction. Care must be taken to ensure the mating surfaces are not damaged during service procedures.

Pistons

The pistons are a full-floating design. The piston pins are a slip fit in the bronze bushed connecting rod and are retained in the piston by round wire retainers. There are 2 compression rings and 1 oil control ring.

Cylinder Head

The cylinder head is also made of the lost foam aluminum for lighter weight and rapid heat dissipation. There are 4 valves per cylinder and the ports are of a high swirl design for improved combustion. The cylinder head gasket consists of a steel laminated construction.

Valve Train

The engine utilizes dual overhead camshafts and roller followers for reduced friction, which results in improved gas mileage.

Fuel System

A new electronic throttle control system is used on the engine. A throttle actuator control or TAC system eliminates cable linkage from the pedal to the throttle control module. All throttle movements are controlled by the powertrain control module (PCM).

Oil Pump

The oil pump is gear driven directly from the crankshaft. The oil pump drive gear is a slip fit to the crankshaft.

Engine Covers

There is a front engine cover and a rear engine cover, both are made of aluminum. The front engine cover and rear engine cover have "T" sealing joints and need to be removed after the oil pan. The front and rear covers need to be installed before the oil pan. Jack screws are used to remove the covers. Guide pins are used to aid in the installation of both covers.

Exhaust Camshaft Position Actuator Description

The camshaft position actuator is bolted to the front of the exhaust camshaft and is integral with the sprocket. The actuator and sprocket can only be replaced as one unit. The total range of actuator rotation is 0 to 25 camshaft degrees. At idle, the exhaust camshaft position actuator is at full advance or 0 degrees.

New Product Information

The purpose of New Product Information is to highlight or indicate important new features for the service community.

Changes may include one or more of the following items

1. Torque values and/or fastener tightening strategies
2. Engine specifications
3. New sealants and/or adhesives
4. Disassembly and assembly procedure revisions
5. Engine mechanical diagnostic procedure revisions
6. Special tools required

New Sealants and/or Adhesives

1. U.S. and Canadian SPO part numbers
2. 3-Bond sealant P/N 12378521

Engine Features

1. Powder metal connecting rods with oil squirter hole
2. Full floating piston pins
3. Lost foam casted aluminum block and head
4. Aluminum camshaft cover
5. Electronic Throttle Control - ETC
6. Composite intake manifold
7. Bridge/bearing beam - stiffener ladder
8. Stainless steel fuel rail
9. Coil-on-plug ignition system
10. Inlet side thermostat
11. No EGR

Scheme 119

The engine lubrication system is of the force-feed type. The oil is supplied under full pressure to the crankshaft, connecting rods, valve lash adjusters, and cam phasing system. A controlled volume of oil is supplied to the camshaft and valve rocker arms. Gravity flow or splash lubricates all other parts. The engine oil is stored in the oil pan, which is filled through a fill cap in the camshaft cover. A removable oil level indicator, on the right side of the engine block, is provided to check the oil level. The oil pump is located in the engine front cover and is driven by the crankshaft. It is a gerotor-style pump, which is a combination of a gear, and a rotor pump. It is connected by a passage in the cylinder block to an oil screen and pipe assembly. The screen is submerged in the oil supply and has ample volume for all operating conditions. Oil is drawn into the pump through the screen and pipe assembly, and a passage in the crankcase, connecting to the passages in the engine front cover. Oil is discarged from the oil pump to the oil filter. The oil pressure relief valve limits the oil pressure. The oil filter bypass valve opens when the oil filter is restricted to approximately 68.95 kPa (10 psi) of pressure difference between the oil filter inlet and discharge. The oil will then bypass the oil filter and channel unfiltered oil directly to the main oil galleries of the engine. A full-flow oil filter is mounted to the oil filter adapter on the lower right front side of the engine. The main oil galleries run the full length of the engine block and cut into the valve lash adjuster holes to supply oil at full pressure to the valve lash adjusters. Holes are drilled from the crankshaft bearings to the main oil gallery. Oil is transferred from the crankshaft bearings to the connecting rod bearings through holes drilled in the crankshaft. Pistons, piston pins, and cylinder walls are lubricated by oil splash from the crankshaft and connecting rods. The camshafts and valve rocker arms are supplied with oil from the oil passages drilled into the camshaft mounting areas.

Cleanliness and Care

An automobile engine is a combination of many of the following surfaces

1. Machined
2. Honed
3. Polished
4. Lapped

The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice proper cleaning and protection procedures to the machined surfaces and to the friction areas.

Note. Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.

Whenever you remove the valve train components, keep the components in order. Follow this procedure in order to install the components in the same locations and with the same mating surfaces as when removed.

Disconnect the negative battery cables before you perform any major work on the engine.

Separating Parts

The components of an internal combustion engine develop wear patterns with their mating components. During disassembly of the engine, parts should be separated and kept in order so they may be reinstalled in the same location from which they were removed.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use jack screws to separate components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Sealant Types

The following 2 major types of sealant are commonly used in engines

1. Aerobic sealant (Room Temperature Vulcanizing (RTV))
2. Anaerobic sealant, which include the following: Gasket eliminator Pipe Threadlock

Aerobic Type Room Temperature Vulcanizing (RTV) Sealant

Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is used where 2 components (such as the intake manifold and the engine block) are assembled together.

Use the following information when using RTV sealant

1. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Any other surfaces where a different type of sealant is specified in the service procedure
2. Always follow all the safety recommendations and the directions that are on the RTV sealant container.
3. Use a plastic or wood scraper in order to remove all the RTV sealant from the components.
4. The surfaces to be sealed must be clean and dry.
5. Use a RTV sealant bead size as specified in the service procedure.
6. Apply the RTV sealant bead to the inside of any bolt holes areas.
7. Assemble the components while the RTV sealant is still wet to the touch. Do not wait for the RTV sealant to skin over.
8. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Anaerobic Type Threadlock Sealant

Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for threadlocking and sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when confined between 2 close fitting metal surfaces.

Use the following information when using threadlock sealant

1. Always follow all safety recommendations and directions that are on the threadlock sealant container.
2. The threaded surfaces to be sealed must be clean and dry.
3. Apply the threadlock sealant as specified on the threadlock sealant container.
4. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Anaerobic Type Pipe Sealant

Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is used where 2 parts are assembled together and require a leak proof joint.

Use the following information when using pipe sealant

1. Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Surfaces where a different sealant is specified
2. Always follow all the safety recommendations and the directions that are on the pipe sealant container.
3. The surfaces to be sealed must be clean and dry.
4. Use a pipe sealant bead of the size or quantity as specified in the service procedure.
5. Apply the pipe sealant bead to the inside of any bolt hole areas.
6. Apply a continuous bead of pipe sealant to 1 sealing surface.
7. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Tools and Equipment

Work in a clean and well-lit area. Have the following components available before you begin to work

1. A suitable parts cleaning tank
2. A compressed air supply
3. Trays, in order to keep the parts and the fasteners organized
4. An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly of various parts.

Special Tools Illustration Tool Number/Description EN 45680-450 Cylinder Sleeve Removal and Installation Kit EN 46119 Off-Vehicle Valve Spring Compressor Adapter EN 46547 Flywheel Holding Tool EN 46745 Piston Pin Retainer Remover and Installer EN 47702 Bolt Extractor Kit EN 48034 Crankshaft Balancer Installer EN 48260 Piston Ring Compressor EN 48268 Main Bearing Cap Remover EN 48464 Lower Timing Gear Tensioner Holding Tool J 6125-1B Slide Hammer with Adapter J 7872 Magnetic Base Indicator Set J 8001 Dial Indicator Set J 8062 Valve Spring Compressor (Head-Off) J 8087 Cylinder Bore Checking Gage J 8092 Driver Handle J 9666 Valve Spring Tester J 21867 Pressure Gage and Hose J 28428-E High Intensity Black Light J 35667-A Cylinder Leakdown Tester J 38185 Hose Clamp Pliers J 38722 Compression Tester J 38820 Valve Stem Seal Remover & Installer J 39313 Spark Plug Port Adapter J 41240 Fan Clutch Wrench J 41556 Connecting Rod Guides J 41816 Crankshaft Balancer Remover J 41816-2 Crankshaft End Protector J 41816-3 Crankshaft Balancer Remover Legs J 42385-400 Thread Repair Kit J 42907 Oil Pressure Tester Adapter J 43059-A Valve Retainer Remover/Installer J 43276 Clutch Pilot Bearing Remover J 43965 Thread Repair Extension Kit J 44215 Rear Seal Installer J 44217 Timing Chain Retention Tool J 44217-45 Timing Chain Retention Tool J 44219 Cover Alignment Pins J 44220-A Engine Lift Bracket J 44221 Camshaft Holding Tool J 44222 Camshaft Sprocket Holding Tool J 44225 Balance Shaft Bearing Remover/Installer J 44228-A Valve Spring Compressor J 45059 Angle Meter J 45299 Engine Pre-Luber J 45849 Bearing Remover J 45949 Pilot Bearing and Flywheel Locator Installer J 45951 Front Seal Installer J 46525 Storage Case

Scheme 120

Scheme 121

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Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

See also:
• Engine Component Description
• Symptoms - Engine Controls
• BATTERY DISCONNECT CAUTION
• Spark Plug Replacement
• Oil Pump Cleaning and Inspection
• Belt Dressing Notice
• Fastener Notice
• Vibration Analysis - Engine
• Water Pump Replacement (LLV,LLR)
• Front Wheelhouse Liner Replacement
• Suction Hose Replacement (LLV, LLR)
• Tire and Wheel Removal and Installation
• Lower Intermediate Steering Shaft Replacement
• Battery Box Replacement
• Lifting and Jacking the Vehicle
• Valve Rocker Arm and Valve Lash Adjuster Cleaning and Inspection
• Fuel Pressure Relief (With CH 48027)
• Fuel Pressure Relief (Without CH 48027)
• Cooling System Draining and Filling (Static Fill)
• Cooling System Draining and Filling (Vac N Fill)
• Windshield Washer Solvent Container Replacement (2nd Design)
• Exhaust Manifold Replacement (LLR)
• DTC P0016 or P0017
• Power Steering Pump Replacement
• Camshaft Holding Tool Caution
• Component Fastener Tightening Notice
• Wheel Drive Shaft Replacement
• Transmission Replacement (RWD)
• Clutch Assembly Replacement
• Hood Replacement
• Fan Replacement (LLV, LLR)
• Manifold Absolute Pressure Sensor Replacement
• Front Propeller Shaft Replacement
• Crankshaft Position System Variation Learn
• Fluid and Lubricant Recommendations
• Approximate Fluid Capacities
• SAFETY GLASSES CAUTION
• Disassembled Views
• Base Engine Misfire without Internal Engine Noises
• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Upper Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Oil Consumption Diagnosis
• Oil Pressure Diagnosis and Testing
• Oil Leak Diagnosis
• Cylinder Head Replacement
• Engine Mechanical Specifications
• Engine Block Plug Installation
• Fastener Tightening Specifications
• Exhaust Camshaft Position Actuator Description
• Camshaft Replacement
• Cylinder Head Disassemble
• Cylinder Head Assemble
• Camshaft Position Actuator Diagnosis
• Camshaft Cover Cleaning and Inspection
• Crankshaft Balancer Replacement
• Adhesives, Fluids, Lubricants, and Sealers
• Crankshaft Rear Oil Seal and Housing Replacement