Engine Mechanical - 2.4L: Removal & Installation Chevrolet HHR I

Removal Procedure

1. Remove the engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .
2. Install the J 44811 to the drive belt tensioner.
3. Using the J 44811 , rotate the drive belt tensioner counter clockwise in order to release the spring tension.
4. Remove the drive belt from under the drive belt tensioner.
5. Remove the drive belt from around the accessory drive pulleys.
6. Remove the drive belt.
7. Using the J 44811 , rotate the drive belt tensioner clockwise in order to release the spring tension.

Installation Procedure

1. Position the drive belt around all the accessory drive pulleys, except for the drive belt tensioner.
2. Using the J 44811 , rotate the drive belt tensioner counter clockwise in order to release the spring tension.
3. Position the drive belt under the drive belt tensioner.
4. Using the J 44811 , rotate the drive belt tensioner clockwise in order to release the spring tension.
5. Remove the J 44811 from the drive belt tensioner.
6. Ensure that the drive belt is properly aligned on the accessory drive pulleys.
7. Install the engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
2. Insert a pry bar between the engine and the cradle, and raise the engine slightly until a socket with an extension can be installed onto the drive belt tensioner bolt.
3. Remove the drive belt tensioner bolt.
4. Remove the drive belt tensioner.

1. Position the drive belt tensioner.
2. Insert a pry bar between the engine and the cradle, and raise the engine slightly until the drive belt tensioner bolt can be installed.
3. Tighten the drive belt tensioner bolt. Tighten: Tighten the bolt to 45 N.m (33 lb ft).
4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .

1. Remove the starter. Refer to «Starter Motor Replacement»(ref-299586-S14036750712008092400000) .
2. Disconnect the oil pressure sensor electrical connector (5).
3. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the oil pressure sensor electrical connector (5).
3. Install the starter. Refer to «Starter Motor Replacement»(ref-299586-S14036750712008092400000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-299589-S15949141872008092400000) .
2. Remove the engine mount bracket to engine bolts.
3. Remove the engine mount bracket.

1. Position the engine mount bracket to the engine.
2. Install the engine mount bracket bolts in the following locations: The long bolts in the forward and lower rear holes The short bolt in the upper rear hole
3. Tighten the engine mount bracket bolts in the following sequence. Upper rear Lower rear Forward Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(ref-299589-S15949141872008092400000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
2. Remove the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
3. Support the engine with a hydraulic floor jack. Use a piece of wood between the floor jack and the oil pan.
4. Remove the engine mount to bracket bolts.
5. Remove the engine mount to side rail nuts.
6. Remove the engine mount from the engine compartment.

1. Place the engine mount onto the side rail studs.
2. Install the engine mount to side rail nuts. Tighten: Tighten the nuts to 100 N.m (74 lb ft).
3. Install the engine mount to bracket bolts.
4. Tighten the engine mount to bracket bolts in the following sequence. Middle Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Remove the hydraulic floor jack from under the oil pan.
6. Install the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
2. Install the J 41602 (1) to the fender pinch welds as far forward as possible.
3. From the J 28467-B , place the J 28467-4A (2) across the engine compartment on top of the J 41602 (1).
4. From the J 28467-B , install the J 28467-8A hook to the J 28467-6A bracket, and install the J 28467-34 wing nut and washer.
5. Repeat the previous step in order to assemble two lift hooks and brackets.
6. Place the hook on J 28467-8A (1) through the engine lift bracket on the engine, and set the J 28467-6A (3) onto the J 28467-4A (4)
7. Place the J 36462-A (1) onto the J 28467-4A.
8. Place the J 28467-4A (2) in the corner of the core support.
9. Install the J 28467-1A bracket (3) where the J 36462-A (1) and the J 28467-4A intersect.
10. Hand tighten the J 28467-1A bracket wing nuts.
11. Install the second hook and bracket assembly to the J 36462-A (1) and install the hook to the engine lift bracket.
12. Prior to lifting and/or supporting the engine, ensure that the lift hooks do not interfere with any adjacent components.

1. Remove the hook from the engine lift bracket and remove the hook and bracket assembly from the J 36462-A (1).
2. Loosen the J 28467-1A bracket wing nuts.
3. Remove the J 28467-1A bracket (3) from where the J 36462-A (1) and the J 28467-4A intersect.
4. Remove the J 36462-A (1).
5. Remove the hook on J 28467-8A (1) from the engine lift bracket on the engine, and remove the J 28467-6A (3) from the J 28467-4A (4)
6. Remove the J 28467-34 wing nut and washer, and remove the J 28467-8A hook from the J 28467-6A bracket.
7. Repeat the previous step in order to disassemble the two lift hooks and brackets.
8. Remove the J 28467-4A (2) from across the engine compartment.
9. Remove the J 41602 (1) from the fender pinch welds.
10. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
2. Remove the oil level indicator.
3. Remove the engine harness clip (1) from the oil level indicator tube bracket.
4. Remove the air conditioning (A/C) compressor and condenser hose clip (1) from the oil level indicator tube bracket.
5. Remove the oil level indicator tube bolt (2).
6. Remove the oil level indicator tube (1).
7. Remove the oil level indicator tube O-ring seals, if necessary.

1. Install NEW oil level indicator tube O-ring seals, if necessary.
2. Install the oil level indicator tube (1).
3. Install the oil level indicator tube bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the A/C compressor and condenser hose clip (1) to the oil level indicator tube bracket.
5. Install the engine harness clip (1) to the oil level indicator tube bracket.
6. Install the oil level indicator.
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp at the camshaft cover.
3. Remove the PCV hose from the camshaft cover.

1. Install the PCV hose to the camshaft cover.
2. Position the PCV hose clamp at the camshaft cover.
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-299615-S02888143092008092400000) .
2. Disconnect the fuel injector electrical connector (2).
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
4. Disconnect the engine harness clips (2 and 4) from the intake manifold.
5. Lower the vehicle.
6. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-299589-S12792928692008092400000) .
7. Disconnect the fuel injector electrical connector clip (3) from the intake manifold.
8. Reposition the vacuum brake booster hose clamp at the intake manifold.
9. Remove the vacuum brake booster hose from the intake manifold.
10. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-299615-S24605884712008092400000) .
11. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-299615-S17082866842008092400000) .
12. Remove the intake manifold lower bolts.
13. Remove the intake manifold upper bolt and nuts.
14. Remove the intake manifold.
15. Inspect the intake manifold O-ring seals.

1. Install NEW intake manifold O-ring seals if necessary.
2. Install the intake manifold.
3. Install the intake manifold upper bolt and nuts.
4. Install the intake manifold lower bolts. Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
5. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-299615-S17082866842008092400000) .
6. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-299615-S24605884712008092400000) .
7. Install the vacuum brake booster hose to the intake manifold.
8. Position the vacuum brake booster hose clamp at the intake manifold.
9. Connect the fuel injector electrical connector clip (3) to the intake manifold.
10. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-299589-S12792928692008092400000) .
11. Raise and support the vehicle.
12. Connect the engine harness clips (2 and 4) to the intake manifold.
13. Lower the vehicle.
14. Connect the fuel injector electrical connector (2).
15. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-299615-S02888143092008092400000) .

Crankshaft Balancer Replacement

Tools Required

1. J 38122-A Harmonic Balancer Holder
2. J 45059 Angle Meter

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt.
3. Remove and discard the crankshaft balancer bolt.
4. Remove the crankshaft balancer.

1. Position the crankshaft balancer.
2. Install a NEW crankshaft balancer bolt.
3. Use the J 38122-A to hold the crankshaft balancer in order to prevent the balancer from rotating while tightening the bolt.
4. Tighten the crankshaft balancer bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 .
5. Install the drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-299589-S12272234912008092400000) .
2. Use a flat-bladed tool to remove the seal from the front cover.

1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-299589-S12272234912008092400000) .

1. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-299589-S39356707702008092400000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-299589-S12272234912008092400000) .
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
4. Remove the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
5. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-299589-S09105512942008092400000) .
6. Remove the engine mount to bracket bolts.
7. Remove the engine mount to side rail nuts.
8. Remove the engine mount from the engine compartment.
9. Remove the engine mount bracket to engine bolts.
10. Remove the engine mount bracket.
11. Remove the engine front cover to water pump bolt.
12. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
13. Remove the engine front cover bolts.
14. Remove the engine front cover.
15. Remove and discard the engine front cover gasket.

1. Install a NEW engine front cover gasket to the dowel pins.
2. Install the engine front cover.
3. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Install the engine front cover to water pump bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Position the engine mount bracket to the engine.
7. Install the engine mount bracket bolts in the following locations. The long bolts in the forward and lower rear holes The short bolt in the upper rear hole
8. Tighten the engine mount bracket bolts in the following sequence. Upper rear Lower rear Forward Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Install the engine mount to the engine compartment.
10. Install the engine mount to side rail nuts. Tighten: Tighten the nuts to 100 N.m (74 lb ft).
11. Install the engine mount to bracket bolts.
12. Tighten the engine mount to bracket bolts in the following sequence. Middle Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-299589-S09105512942008092400000) .
14. Install the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
15. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
16. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-299589-S12272234912008092400000) .
17. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-299589-S39356707702008092400000) .

Camshaft Timing Chain, Sprocket, and Tensioner Replacement

Special Tools

1. J 45027 Tensioner Tool
2. J 45059 Angle Meter

1. Remove the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-299615-S29960280702008092400000) .
2. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
3. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-299589-S33115286152008092400000) .
5. Remove the upper timing chain guide bolts and guide.
6. Remove the timing chain tensioner.
7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
8. Remove and discard the exhaust camshaft actuator bolt (2).
9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
10. Remove the timing chain tensioner guide bolt and guide.
11. Remove the fixed timing chain guide access plug.
12. Remove the fixed timing chain guide bolts and guide.
13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
14. Remove and discard the intake camshaft actuator bolt (2).
15. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head.
16. Remove the timing chain crankshaft sprocket.
17. If replacing the balance shaft timing chain and sprocket, perform the following steps, if not proceed to step 10 in the installation procedure.
18. Remove the balance shaft drive chain tensioner bolts and tensioner.
19. Remove the adjustable balance shaft chain guide bolt and guide.
20. Remove the small balance shaft drive chain guide bolts and guide.
21. Remove the upper balance shaft drive chain guide bolts and guide.
22. Remove the balance shaft drive chain (7).
23. Remove the balance shaft drive sprocket.

1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10.
2. Install the balance shaft drive sprocket.
3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and 1 is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
4. Install the upper balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
5. Install the small balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
6. Install the adjustable balance shaft chain guide and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
8. Install the balance shaft drive chain tensioner and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.
10. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
11. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
12. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
13. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
14. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
15. Hand tighten the new intake camshaft actuator bolt.
16. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
17. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
18. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
19. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
20. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
21. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
22. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
23. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
24. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
25. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
26. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
27. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
28. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
29. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
30. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
31. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 .
32. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 .
33. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
34. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
35. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).
36. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-299589-S33115286152008092400000) .
37. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
38. Install the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-299615-S29960280702008092400000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp.
3. Remove the PCV hose from the cover.
4. Disconnect the intake (2) and exhaust (1) camshaft position actuator solenoid valve electrical connectors.
5. Remove the ignition coils. Refer to «Ignition Coil Replacement»(ref-299615-S42473825782008092400000) .
6. Remove the engine harness clips (1, 2) from the cover.
7. Remove the camshaft cover bolts.
8. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Install the ignition coils. Refer to «Ignition Coil Replacement»(ref-299615-S42473825782008092400000) .
3. Install the engine harness clips (1, 2) to the cover.
4. Connect the intake (2) and exhaust (1) camshaft position actuator solenoid valve electrical connectors.
5. Install the PCV hose to the cover.
6. Position the PCV hose clamp.
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-299586-S01592789752008092400000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-299586-S01592789752008092400000) .

1. Remove the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-299589-S07808301132008092400000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the intake camshaft (1).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers with GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the intake camshaft (1). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-299589-S07808301132008092400000) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-299589-S07853141312008092400000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the exhaust camshaft (3).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Apply lubricate GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the exhaust camshaft (3). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-299589-S07853141312008092400000) .

Camshaft Position Intake Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool
2. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
2. Remove the upper timing chain guide bolts and guide.
3. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
4. Loosen, but DO NOT remove the intake camshaft actuator bolt.
5. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
6. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
7. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
8. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
9. Remove and discard the intake camshaft actuator bolt (2).
10. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW intake camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 .
8. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .

Camshaft Position Exhaust Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool
2. J 45027 Tensioner Tool
3. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .
2. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
3. Remove the upper timing chain guide bolts and guide.
4. Remove the timing chain tensioner.
5. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
6. Loosen, but DO NOT remove the exhaust camshaft actuator bolt.
7. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
8. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
9. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
10. Remove and discard the exhaust camshaft actuator bolt (2).
11. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 .
8. Remove the old oil from the timing chain tensioner.
9. Inspect the timing chain tensioner for scoring or free movement.
10. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
11. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 in) from end to end (a).
12. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
13. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
14. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
15. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1- 8.4.
16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.
19. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
20. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-299589-S25855727012008092400000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor
2. J 36017 Valve Guide Seal Remover

1. Remove the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-299589-S04482854082008092400000) or «Exhaust Camshaft and Valve Lifter Replacement»(ref-299589-S26041817192008092400000) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-299615-S29960280702008092400000) .
3. Remove the camshaft roller followers.
4. Install the front section of the J 43649 to the second camshaft cover bolt hole.
5. Install the remaining parts of the J 43649 to the cylinder head.
6. Install an air hose adapter into the spark plug hole.
7. Attach an air hose to the adapter
8. Using the compressed air, pressurize the cylinder to 690 kPa (100 psi).
9. Compress the valve spring using the J 43649 .
10. Remove the valve spring keepers.
11. Remove the valve spring retainer.
12. Remove the valve spring.
13. Using the J 36017 remove the valve seal.

1. Using the J 36017 install the NEW valve seal. Fully seat the seal onto the valve guide.
2. Install the valve spring.
3. Install the valve spring retainer.
4. Compress the valve spring using the J 43649 .
5. Install the valve spring keepers.
6. Disconnect the air hose from the adapter.
7. Remove the air hose adapter from the spark plug hole.
8. Remove the J 43649 from the cylinder head.
9. Install the camshaft roller followers.
10. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-299615-S29960280702008092400000) .
11. Install the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-299589-S04482854082008092400000) or «Exhaust Camshaft and Valve Lifter Replacement»(ref-299589-S26041817192008092400000) .

Cylinder Head Replacement

Tools Required

1. J 38185 Hose Clamp Pliers
2. J 45059 Angle Meter

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (L61/LE5)»(ref-299637-S34274091382008092400000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-299589-S36957704562008092400000) .
4. Reposition the radiator surge tank air bleed hose clamp.
5. Remove the radiator surge tank air bleed hose from the cylinder head.
6. Reposition the radiator inlet hose clamp using the J 38185 .
7. Remove the radiator inlet hose from the cylinder head.
8. Remove the timing chain. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-299589-S32575040162008092400000) .
9. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
10. Remove the cylinder head.
11. Remove the cylinder head gasket.
12. Clean all of the gasket surfaces.
13. Use the following steps when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface. IMPORTANT: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket. Hold the razor blade as parallel to the gasket surface as possible.
14. Clean the old sealer/lube and any dirt from around the bolt holes.
15. Clean the bolts holes with a nylon bristle brush.
16. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Install NEW cylinder head bolts.
4. Install and tighten the cylinder head bolts in the sequence shown. Tighten: Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059 .
5. Install the NEW front cylinder head bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
6. Install the timing chain. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-299589-S32575040162008092400000) .
7. Install the radiator inlet hose to the cylinder head.
8. Position the radiator inlet hose clamp using the J 38185 .
9. Install the radiator surge tank air bleed hose to the cylinder head.
10. Position the radiator surge tank air bleed hose clamp.
11. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (L61/LE5)»(ref-299637-S34274091382008092400000) .
12. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-299589-S36957704562008092400000) .
13. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
2. Place a drain pan under the oil pan drain plug.
3. Remove the oil pan drain plug.
4. Drain the engine oil.
5. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
6. Remove the lower AC compressor bolt.
7. Remove the 4 oil pan to transaxle bolts (1).
8. Remove the oil pan bolts.
9. Remove the oil pan
10. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-299639-S13806737202008092400000) for the correct part number.
3. Install the oil pan.
4. Install the oil pan bolts.
5. Install the 4 oil pan to transaxle bolts (1). Tighten: Tighten the bolts to 75 N.m (55 lb ft).
6. Tighten the oil pan bolts in the sequence shown. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the lower AC compressor bolt.
8. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
9. Lower the vehicle.
10. Fill the engine oil to the proper level.

1. Remove the engine from the vehicle. Refer to «Engine Replacement»(ref-299589-S02901230362008092400000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Removal»(ref-299589-S15534835782008092400000) .
3. Remove the front cover. Refer to «Camshaft Cover Removal»(ref-299589-S02339989472008092400000) .
4. Remove the engine oil pan. Refer to «Oil Pan Removal»(ref-299639-S18289532112008092400000) .
5. Remove the crankshaft position sensor.
6. Remove the 3 perimeter bolts.
7. Remove and discard the crankshaft bearing bolts.
8. Using the pry points and an appropriate prying tool, gently separate the upper and lower crankcase.
9. Clean the sealing material from the engine block and lower the crankcase.

1. Apply oil to the crankshaft bearing surfaces.
2. Apply a 2-5 mm (0.08-0.20 in) bead (a) of sealer GM P/N 12378521 (Canadian P/N 88901148) to the surface of the engine block-to-lower crankcase mating surface.
3. Install the lower crankcase. Tap gently into place with a suitable tool, if necessary. Ensure it is aligned properly on the dowels.
4. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . Tighten: Tighten the crankshaft bearing bolts to 70 degrees using the J 45059 .
5. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).
6. Install the crankcase position sensor.
7. Install the front cover. Refer to «Engine Front Cover and Oil Pump Installation»(ref-299588-S08654541762008092400000) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Installation»(ref-299588-S16517551962008092400000) .
9. Install the engine oil pan. Refer to «Oil Pan Installation»(ref-299588-S30986902482008092400000) .
10. Install the engine. Refer to «Engine Replacement»(ref-299589-S02901230362008092400000) .

Piston, Connecting Rod, and Bearing Replacement

Tools Required

1. EN-47836 Piston Ring Compressor
2. J-43966-1 Connecting Rod Guides
3. J 45059 Angle Meter

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-299589-S29473151292008092400000) .
2. Remove the cylinder head. Refer to «Cylinder Head Replacement»(ref-299589-S27697175282008092400000) .
3. If a ring ridge is present, remove the ring ridge as follows: Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use a ridge reamer to remove the ring ridge. Turn the crankshaft so the piston is at top of the stroke. Remove the cloth and cutting debris.
4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts.
5. Remove the connecting rod and the piston out of the top of the engine block using the J-43966-1 .
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

1. Coat the following parts with engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the piston into its original bore using the J-43966-1 .
3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the EN-47836 firmly against the engine block until all the piston rings have entered the cylinder bore.
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.
8. Install the new connecting rod bolts and nuts. Tighten: On the first pass, tighten the nuts evenly to 25 N.m (18 lb ft). On the final pass, use the J 45059 in order to tighten the nuts an additional 100 degrees.
9. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-299589-S27697175282008092400000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-299589-S29473151292008092400000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-299588-S05026227092008092400000) .
2. Pry out the crankshaft rear oil seal using a flat-bladed tool.

1. Using the J 42067 , install a NEW crankshaft real oil seal.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-299588-S05026227092008092400000) .

Engine Flywheel Replacement

Tools Required

1. J 38122-A Crankshaft Balancer Holder
2. J 45059 Angle Meter

1. If equipped with a automatic transaxle, remove the transaxle. Refer to «Transmission Replacement»(ref-299570-S16389573042008092400000) .
2. If equipped with a manual transaxle, remove the clutch. Refer to «Clutch Pressure and Driven Plate Replacement»(ref-299638-S21368655432008092400000) .
3. Using the J 38122-A , hold the crankshaft balancer.
4. Remove and discard the automatic transaxle flywheel bolts, if equipped.
5. Remove the automatic transaxle flywheel, if equipped.
6. Remove and discard the manual transaxle flywheel bolts, if equipped.
7. Remove the manual transaxle flywheel, if equipped.
8. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Install the manual transaxle flywheel, if equipped.
2. Install the NEW manual transaxle flywheel bolts, if equipped. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 .
3. Install the automatic transaxle flywheel, if equipped.
4. Install the NEW automatic transaxle flywheel bolts, if equipped. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 .
5. Remove the J 38122-A .
6. If equipped with a manual transaxle, install the clutch. Refer to «Clutch Pressure and Driven Plate Replacement»(ref-299638-S21368655432008092400000) .
7. If equipped with a automatic transaxle, install the transaxle. Refer to «Transmission Replacement»(ref-299570-S16389573042008092400000) .

1. Remove the piston and connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement»(ref-299589-S04517001102008092400000) .
2. Inspect the condition of the piston. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection»(ref-299589-S07942874842008092400000) .
3. 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.
4. Install the EN 45680-882 cylinder bore sleeve puller (1) through the cylinder bore.
5. Align the shoe (1) of the EN 45680-882 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2).
6. Hold the threaded shaft of the EN 45680-882 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
7. Install the EN 456850-881 fixture (4) onto the threaded shaft of the EN 456850-882 cylinder bore sleeve puller and the engine block.
8. Install the bearing (3) and the nut (1).
9. Tighten the nut (1) to the bearing (3).
10. 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).
11. Rotate the nut clockwise in order to remove the cylinder bore liner.
12. Remove EN 45680-881 fixture, EN 45680-882 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block.
13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.

1. Place the NEW cylinder bore sleeve onto the cylinder block.
2. Install EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
3. Insert the 4 attachment bolts into the legs of the EN 45680-881 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
6. Align the pusher block (2) of EN 45680-883 cylinder bore sleeve installer into the groove of EN 45680-881 fixture (1).
7. Using a ratchet, rotate the threaded shaft of EN 45680-88 fixture and EN 45680-883 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block.
8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1.60 mm (1/16 inch) of the cylinder bore sleeve above the surface of the cylinder block.
9. Using a torque wrench, tighten the threaded shaft of the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer 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 liner flange will protrude above the block deck surface.
10. Remove the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly (1) from the cylinder block (2).

Scheme 59

1. EN 45680-885 Debris Collector (3)
2. EN 45680-881 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. 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 60

1. Trim Tool Preloader (1)
2. EN 45680-882 Set Gage Ring (2)
3. EN 45680-883 Metal Shavings Catch Plug (3)
4. EN 45680-886 Drive Adapter (4)
5. EN 45680-884 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 the EN 45680-883 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-883 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional EN 45680-883 metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the EN 45680-883 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the EN 45680-882 set gage ring (1) should be positioned upward on a flat surface.
6. Carefully position EN 45680-881 trim tool assembly onto the EN 45680-882 set gage ring.
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 the EN 45680-881 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
11. Install the EN 45680-884 4 bolts into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten the drive adapter EN 45680-886 into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-881 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place the EN 45680-886 drive adapter and the drill assembly vertically onto the EN 45680-881 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove the EN 45680-886 drive adapter (1) and the drill assembly from the EN 45680-881 trim tool assembly.
16. Turn OFF the compressed air valve.
17. Remove the EN 45680-881 trim tool assembly from the engine block.
18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-883 metal shaving catch plug.
19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
20. Using a light, illuminate the backside of the straight edge.
21. Looking at the front of the straight edge, inspect 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 of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
22. Looking at the front of the straight edge, inspect 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.
23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary.
24. Install the piston and the connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement»(ref-299589-S04517001102008092400000) .

Engine Replacement

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller
2. J 45341 Rear Wheel Drive Shaft Removal Tool
3. J-2619-A Slide Hammer
4. J 44394 Axle Seal Protector
5. J 45059 Angle Meter

1. Raise the hood.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-299586-S01592789752008092400000) .
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
4. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-299613-S31788787272008092400000) or «Fuel Pressure Relief (Without CH 48027)»(ref-299613-S29866935032008092400000) .
5. Disconnect the fuel feed line from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-299615-S09500084542008092400000) .
6. Disconnect the evaporative emission (EVAP) line from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-299615-S24605884712008092400000) .
7. Remove the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
8. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) .
9. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
10. Remove the left side engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .
11. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LE5/L61)»(ref-299637-S08552234042008092400000) .
12. Disconnect the cooling fan electrical connector.
13. Lower the vehicle.
14. Remove the engine control module (ECM)/transaxle control module (TCM) cover.
15. Disconnect the body harness electrical connector (1) from the ECM.
16. Disconnect the engine harness electrical connectors (1, 2) from the ECM.
17. Open the junction block terminal cover.
18. Remove the junction block terminal nut (1).
19. Remove the positive/negative battery cable terminal (2) from the stud.
20. Remove the positive battery cable terminal (1) from the junction block stud.
21. Reposition the engine harness as necessary to access the ECM bracket lower bolts.
22. Remove the ECM bracket nuts (1) and bolts (2).
23. Lift the ECM bracket off of the studs and secure the bracket out of the way.
24. Reposition the radiator inlet hose clamp at the engine.
25. Remove the radiator inlet hose from the engine.
26. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
27. Remove the engine harness clip (1) from the EVAP purge solenoid bracket.
28. If the vehicle is equipped with a engine oil cooler perform the following steps, reposition the radiator outlet hose clamp (1) at the water outlet.
29. Reposition the radiator outlet hose clamp (2) at the oil cooler.
30. Remove the radiator outlet hose from the water outlet.
31. Remove the radiator outlet hose from the oil cooler
32. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the engine.
33. Remove the radiator outlet hose from the engine.
34. Disconnect the intake (2) and exhaust (1) camshaft position (CMP) sensor electrical connectors.
35. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
36. Remove the heater inlet and outlet hoses from the thermostat housing.
37. Disconnect the engine coolant heater cord, if necessary.
38. Remove the engine coolant heater cord straps from the engine harness, if equipped.
39. Reposition the engine coolant heater cord out of the way, if equipped.
40. Reposition the brake booster vacuum hose clamp at the intake manifold.
41. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.
42. Disconnect the following electrical connectors: Throttle actuator control (TAC) (1) Manifold absolute pressure (MAP) sensor Fuel injector harness (2) Generator (3)
43. Disconnect the ignition coils electrical connectors (3).
44. Disconnect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.
45. Remove the engine harness clips (1, 2) from the camshaft cover.
46. Remove the engine harness clip nut (2).
47. Remove the engine harness clip (1) from the transaxle stud.
48. Remove the engine harness clip (1) from the oil level indicator tube bracket.
49. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
50. Remove the engine harness clips (2, 4) from the intake manifold.
51. Remove the starter. Refer to «Starter Motor Replacement»(ref-299586-S14036750712008092400000) .
52. If equipped with a automatic transaxle perform the following steps, remove the positive/negative battery cable ground nut (1).
53. Remove the positive/negative cable (2) terminal from the stud.
54. Remove the engine harness ground terminal (3) from the stud.
55. Disconnect the following electrical connectors: Crankshaft position (CKP) sensor (4) Oil pressure sensor (5) Knock sensor (6)
56. If equipped with a manual transaxle perform the following steps, remove the positive/negative battery cable ground nut (2).
57. Remove the positive/negative cable (3) terminal from the stud.
58. Remove the engine harness ground terminal (4) from the stud.
59. Disconnect the following electrical connectors: Crankshaft position (CKP) sensor (1) Oil pressure sensor (5) Knock sensor (6)
60. Disconnect the air conditioning (A/C) pressure switch electrical connector (1).
61. Disconnect the A/C compressor electrical connector (2).
62. Unbolt and reposition the AC compressor aside. Secure the compressor with tie straps or mechanics wire.
63. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-299588-S10317292742008092400000) .
64. Remove the engine harness ground bolt (7).
65. Remove the engine harness ground (8) from the engine block.
66. Lower the vehicle.
67. Remove the generator nut (2).
68. Remove the engine harness lead terminal (1) from the generator.
69. If equipped with a automatic transaxle perform the following steps, remove the engine harness clip nut (2) from the engine stud.
70. Remove the engine harness clip (1) from the stud.
71. Disconnect the vehicle speed sensor (VSS) electrical connector (4).
72. Remove the engine harness clip (3) from the speed sensor.
73. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.
74. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
75. Remove the connector position assurance (CPA) retainer (2).
76. Disconnect the engine harness electrical connector (3) from the heater oxygen sensor (HO2S).
77. If equipped with a manual transaxle, perform the following steps, disconnect the ECT sensor electrical connector (1).
78. Remove the CPA retainer (2).
79. Disconnect the engine harness electrical connector (3) from the HO2S.
80. If equipped with a automatic transaxle, perform the following steps, remove the CPA retainer (5).
81. Disconnect the engine harness electrical connector (6) from the park neutral position switch.
82. Remove the engine harness clip (1) from the transaxle stud.
83. Remove the CPA retainer (2).
84. Remove the engine harness electrical connector clip (4) from the transaxle rear mount bracket.
85. Disconnect the engine harness electrical connector (3) from the HO2S.
86. If equipped with a manual transaxle, disconnect the engine harness electrical connector (1) from the VSS.
87. Remove the engine harness clip (2) from the transaxle.
88. Remove the CPA retainer (3).
89. Remove the engine harness electrical connector clip (5) from the transaxle rear mount bracket.
90. Disconnect the engine harness electrical connector (4) from the HO2S.
91. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
92. Remove the engine harness clip (6) from the transaxle.
93. Gather all engine harness branches are reposition the harness off to the side, out of the way.
94. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
95. Remove the range selector lever cable from the transaxle bracket.
96. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
97. Remove the range selector and shift lever cables from the transaxle bracket.
98. If equipped with a automatic transaxle, remove the oil cooler line nut.
99. Remove the oil cooler lines from the transaxle.
100. Remove the left and right stabilizer link to strut nuts.
101. Separate the stabilizer links from the struts. (left side shown, right side similar).
102. Remove the left and right steering gear outer tie rod to knuckle nuts. Discard the nuts.
103. Using the J 24319-B , separate the outer tie rods from the steering knuckles. (left side shown, right side similar).
104. Remove the left and right ball joint to steering knuckle bolts and nuts.
105. Separate the lower ball joints from the steering knuckles. (left side shown, right side similar).
106. Assemble the J 45341 and the J-2619-A .
107. Using the J 45341 and the J-2619-A , separate the right wheel drive shaft from the transaxle. Repeat for the left side.
108. Secure the wheel drive shafts out of the way.
109. Remove the lower radiator support bolts.
110. Secure the radiator assembly to the radiator core support with bungee cords.
111. Lower the vehicle to about 3 feet off the ground.
112. Position a engine lift table under the frame.
113. Place wood blocks on top of the lift table between the table and the frame.
114. Lower the vehicle until the frame is resting on the blocks of wood.
115. Remove the engine mount bracket bolts.
116. Remove the transaxle mount to transaxle bolts.
117. Remove the frame bolts using the following sequence: Remove the front frame bolts. Remove the rear frame bolts.
118. Slowly raise the vehicle up away from the powertrain assembly.
119. Slide the lift table out from under the vehicle.
120. Attach an engine lift hoist to the engine lift hooks.
121. If equipped with a automatic transaxle, remove the torque converter housing access plug.
122. If equipped with a automatic transaxle, remove the torque converter bolts.
123. If equipped with a automatic transaxle, remove the transaxle brace bolts and brace.
124. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.
125. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
126. Separate the engine from the transaxle.
127. If equipped with a manual transaxle, remove the clutch pressure plate and disc. Refer to «Clutch Pressure and Driven Plate Replacement»(ref-299638-S21368655432008092400000) .
128. Remove the following components: The engine mount bracket The engine block heater, if equipped The generator
129. Using the engine hoist, install the engine to a suitable engine stand.

1. Using a engine hoist, remove the engine from the engine stand.
2. Install the following components: The engine mount bracket The engine block heater, if equipped The generator
3. If equipped with a manual transaxle, install the clutch pressure plate and disc. Refer to «Clutch Pressure and Driven Plate Replacement»(ref-299638-S21368655432008092400000) .
4. Install the engine to the transaxle.
5. If equipped with a automatic transaxle, install the transaxle to engine bolts/stud. Tighten: Tighten the bolt/stud to 75 N.m (55 lb ft).
6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud. Tighten: Tighten the bolt/stud to 75 N.m (55 lb ft).
7. If equipped with a automatic transaxle, install the transaxle brace and bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. If equipped with a automatic transaxle, install the torque converter bolts. Tighten: Tighten the bolts to 62 N.m (46 lb ft).
9. If equipped with a automatic transaxle, install the torque converter housing access plug.
10. Remove the engine lift hoist from the engine lift hooks.
11. Slide the lift table under the vehicle.
12. Slowly lower the vehicle until the frame bolts align with the holes in the body.
13. Install the frame bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft) plus an additional 180 degrees using the J 45059 .
14. Install the transaxle mount to transaxle bolts.
15. Tighten the transaxle mount to transaxle bolts in the following sequence: Rear Middle Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
16. Install the engine mount bracket bolts.
17. Tighten the engine mount to bracket bolts in the following sequence: Middle Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
18. Raise the vehicle until the lift table can be removed from under the vehicle.
19. Remove the lift table.
20. Unsecure the radiator assembly from the radiator core support.
21. Install the lower radiator support bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
22. Unsecure the wheel drive shaft.
23. Install the J 44394 into the right transaxle output shaft seal.
24. Install the right wheel drive shaft into the transaxle until the drive shaft splines are past the seal, remove the J 44394 , then fully install the drive shaft.
25. Verify that the wheel drive shaft is properly engaged: Grasp the inner tripot housing and pull the inner housing outward. Do NOT pull on the wheel drive shaft. The wheel drive shaft will remain firmly in place when properly engaged.
26. Repeat steps 22 through 25 for the left side.
27. Install the left and right lower ball joints to the steering knuckles.
28. Install the ball joint to steering knuckle bolts and nuts. Tighten: Tighten the nut a first pass to 50 N.m (37 lb ft), then loosen the nut 3/4 of a turn. Tighten the nut a final pass to 50 N.m (37 lb ft) plus an additional 30 degrees using the J 45059 .
29. Install the left and right outer tie rods to the steering knuckles.
30. Install the NEW left and right steering gear outer tie rod to knuckle nuts. Tighten: Tighten the nut to 25 N.m (18 lb ft) plus an additional 90 degrees using the J 45059 .
31. Install the left and right stabilizer links to the struts.
32. Install the stabilizer link to strut nuts. Tighten: Tighten the nut to 65 N.m (48 lb ft).
33. Lower the vehicle.
34. If equipped with a automatic transaxle, install the oil cooler lines to the transaxle.
35. Install the oil cooler line nut. Tighten: Tighten the nut to 7 N.m (62 lb in).
36. If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket.
37. Install the range selector and shift lever cables to the transaxle levers.
38. If equipped with a automatic transaxle, install the range selector lever cable to the transaxle bracket.
39. Connect the range selector lever cable to the transaxle lever.
40. Gather all engine harness branches and position the harness over the engine.
41. If equipped with a manual transaxle perform the following steps, install the engine harness clip (6) to the transaxle.
42. Connect the engine harness electrical connector (7) to the back up lamp switch.
43. Connect the engine harness electrical connector (4) to the HO2S.
44. Install the engine harness electrical connector clip (5) to the transaxle rear mount bracket.
45. Install the engine harness clip (2) to the transaxle.
46. Install the CPA retainer (3).
47. Connect the engine harness electrical connector (1) to the VSS.
48. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
49. Install the CPA retainer (2).
50. Install the engine harness electrical connector clip (4) to the transaxle rear mount bracket.
51. Install the engine harness clip (1) to the transaxle stud.
52. Connect the engine harness electrical connector (6) to the park neutral position switch.
53. Install the CPA retainer (5).
54. If equipped with a manual transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
55. Install the CPA retainer (2).
56. Connect the ECT sensor electrical connector (1).
57. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
58. Install the CPA retainer (2).
59. Connect the ECT sensor electrical connector (1).
60. If equipped with a automatic transaxle, connect the engine harness to the transaxle.
61. If equipped with a automatic transaxle, install the engine harness clip (3) to the speed sensor.
62. Connect the VSS electrical connector (4).
63. Install the engine harness clip (1) to the stud.
64. Install the engine harness clip nut (2) to the engine stud. Tighten: Tighten the nut to 10 N.m (89 lb in).
65. Install the engine harness lead terminal (1) to the generator.
66. Install the generator nut (2). Tighten: Tighten the nut to 20 N.m (14 lb ft).
67. Raise and support the vehicle.
68. Install the engine harness ground (8) to the engine block.
69. Install the engine harness ground bolt (7). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
70. Unsecure the A/C compressor and position to the engine block. Install the A/C compressor bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
71. Connect the A/C compressor electrical connector (2).
72. Connect the A/C pressure switch electrical connector (1).
73. Raise and support the vehicle.
74. If equipped with a manual transaxle perform the following steps, install the engine harness ground terminal (4) to the stud.
75. Install the positive/negative cable (3) terminal to the stud.
76. Install the positive/negative battery cable ground nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
77. Connect the following electrical connectors: CKP sensor (1) Oil pressure sensor (5) Knock sensor (6)
78. If equipped with a automatic transaxle perform the following steps, install the engine harness ground terminal (3) to the stud.
79. Install the positive/negative cable (2) terminal to the stud.
80. Install the positive/negative battery cable ground nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
81. Connect the following electrical connectors: CKP sensor (4) Oil pressure sensor (5) Knock sensor (6)
82. Install the starter. Refer to «Starter Motor Replacement»(ref-299586-S14036750712008092400000) .
83. Install the engine harness clips (2, 4) to the intake manifold.
84. Lower the vehicle.
85. Install the engine harness clip (1) to the oil level indicator tube bracket.
86. Install the engine harness clip (1) to the transaxle stud.
87. Install the engine harness clip nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
88. Install the engine harness clips (1, 2) to the camshaft cover.
89. Connect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.
90. Connect the ignition coils electrical connectors (3).
91. Connect the following electrical connectors: TAC (1) MAP sensor Fuel injector harness (2) Generator (3)
92. Install the brake booster vacuum hose to the intake manifold.
93. Position the brake booster vacuum hose clamp at the intake manifold.
94. Position the engine coolant heater cord, if equipped.
95. Install the engine coolant heater cord straps to the engine harness, if equipped.
96. Connect the engine coolant heater cord, if equipped.
97. If the vehicle is not equipped with a engine oil cooler, install the radiator outlet hose to the engine.
98. Position the radiator outlet hose clamp at the engine.
99. If the vehicle is equipped with a engine oil cooler perform the following steps, install the radiator outlet hose to the oil cooler.
100. Install the radiator outlet hose to the water outlet.
101. Position the radiator outlet hose clamp (2) at the oil cooler.
102. Position the radiator outlet hose clamp (1) at the water outlet.
103. Install the heater inlet and outlet hoses to the thermostat housing.
104. Position the heater inlet and outlet hose clamps at the thermostat housing.
105. Connect the intake (2) and exhaust (1) CMP sensor electrical connectors.
106. Install the engine harness clip (1) to the EVAP purge solenoid bracket.
107. Connect the EVAP purge solenoid electrical connector (1).
108. Install the radiator inlet hose to the engine.
109. Position the radiator inlet hose clamp at the engine.
110. Position and install the ECM bracket to the studs.
111. Install the ECM bracket nuts (1) and bolts (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft). Tighten the nuts to 10 N.m (89 lb in).
112. Install the positive battery cable terminal (1) to the junction block stud.
113. Install the positive/negative battery cable terminal (2) to the stud.
114. Install the junction block terminal nut (1). Tighten: Tighten the nut to 15 N.m (11 lb ft).
115. Close the junction block terminal cover.
116. Connect the engine harness electrical connectors (1, 2) to the ECM.
117. Connect the body harness electrical connector (1) to the ECM.
118. Install the ECM/TCM cover.
119. Raise the vehicle.
120. Connect the cooling fan electrical connector.
121. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LE5/L61)»(ref-299637-S08552234042008092400000) .
122. Install the left side engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .
123. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-299589-S11926140382008092400000) .
124. Install the windshield washer solvent reservoir. Refer to «Windshield Washer Solvent Container Replacement»(ref-299563-S38953142922008092400000) .
125. Connect the EVAP line to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-299615-S24605884712008092400000) .
126. Connect the fuel feed line to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-299615-S09500084542008092400000) .
127. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-299586-S01592789752008092400000) .
128. Perform the engine prelubing procedure. Refer to «Engine Prelubing»(ref-299639-S02042658992008092400000) .
129. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) .
130. Check the automatic transaxle fluid, if equipped, add as needed. Refer to «Transmission Fluid Check»(ref-299570-S42118884552008092400000) .
131. Check the manual transaxle fluid, if equipped, add as needed. Refer to «Transmission Fluid Check»(ref-299571-S09228952132008092400000) .
132. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) .
133. Close the hood.
134. Check the front alignment. Refer to «Wheel Alignment Measurement»(ref-299592-S18617489842008092400000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Allow the oil to drain completely.
5. Install the oil pan drain plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
6. Lower the vehicle.
7. Use a 32 mm (1 1/4 in) socket on the hex on top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap.
8. Remove the oil filter cap and filter.
9. Remove the filter from the cap.

1. Install the NEW oil filter to the cap.
2. Install the oil filter cap and filter.
3. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap. Tighten: Tighten the oil filter cap until fully seated. DO NOT exceed 25 N.m (18 lb ft).
4. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(ref-299612-S40895838632008092400000) .

Draining Fluids and Oil Filter Removal

Tools Required

J 44887 Oil Filter Wrench

1. Use J 44887 to remove the oil filter cap. Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

1. Remove the balancer retaining bolt and washer. Discard the bolt.
2. Remove the balancer using a universal removal tool.

Engine Flywheel Removal

Tools Required

J 38122-A Crankshaft Balancer Holder

1. Remove the flywheel attaching bolt. Use the J 38122-A to prevent crankshaft rotation.
2. Remove the flywheel retainer.
3. Remove the flywheel.
4. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

1. Remove knock sensor connector from the oil level indicator tube.
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator and the oil level indicator tube from the oil pan.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield.
2. Remove the block heater if equipped.
3. Remove the oxygen sensor.
4. Remove and discard the exhaust manifold to cylinder head retaining nuts.
5. Remove the exhaust manifold.
6. Clean all of the sealing surfaces.
7. If the exhaust manifold is being replaced, transfer the following parts: The exhaust manifold heat shield The oxygen sensor

Intake Manifold Removal

1. Remove the evaporative emission (EVAP) canister valve tube (1).
2. Remove the EVAP canister valve (2).
3. Remove the throttle body bolts.
4. Remove the throttle body.
5. Remove fuel pipes and clip. Remove the fuel rail assembly.
6. Remove the fuel injector tip insulators and discard.
7. Remove the intake manifold retaining nuts and bolts.
8. Remove the intake manifold.
9. Remove the intake manifold gasket, if necessary. The gasket can be used again if it is not damaged.
10. If the intake manifold needs to be replaced, transfer the throttle body to the new intake manifold.

Camshaft Cover Removal

1. Remove the bolt and coil.
2. Remove the camshaft position actuator solenoid valve bolts.
3. Remove the camshaft position actuator solenoid valves.
4. Remove the camshaft cover assembly.

Engine Front Cover and Oil Pump Removal

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

Timing Chain and Tensioner Removal

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide.
3. Remove the timing chain tensioner plunger.
4. Locate hex on the exhaust camshaft and hold with a wrench.
5. Remove the exhaust camshaft bolt and the exhaust camshaft actuator. Discard the bolt.
6. Remove the adjustable timing chain guide bolt.
7. Remove the adjustable timing chain guide.
8. Remove the plug to gain access to the fixed timing chain guide bolt.
9. Remove the fixed timing chain guide bolts.
10. Remove the fixed timing chain guide.
11. Locate hex on the intake camshaft and hold with a wrench.
12. Remove the intake camshaft actuator bolt, the intake camshaft actuator and the timing chain through the top of the cylinder head. Discard the bolt.
13. Remove the crankshaft sprocket.
14. Remove the timing chain oil nozzle bolt.
15. Remove the timing chain oil nozzle.

Intake Camshaft, Bearing Cap, and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the intake camshaft cap bolts.
3. Remove the camshaft caps.
4. Remove the intake camshaft.
5. Remove the intake camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Exhaust Camshaft, Bearing Cap, and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the exhaust camshaft cap bolts.
3. Remove the camshaft caps ensuring they are marked and refitted in same position on assembly.
4. Remove the exhaust camshaft.
5. Remove the exhaust camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Water Pump and Balance Shaft Chain and Tensioner Removal

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

Balance Shaft Removal

Tools Required

J 43650 Balancer Shaft Bearing Remover and Installer

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

Water Pump Removal

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

Cylinder Head Removal

Tools Required

J 38188 Cylinder Head Broken Bolt Extractor Kit

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

Oil Pan Removal

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

Piston, Connecting Rod, and Bearing Removal

Tools Required

J-43966-1 Connecting Rod Guides

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

Lower Crankcase Removal

1. Remove the crankshaft position sensor.
2. Inspect the crankshaft position sensor for damage and replace, if necessary.
3. Remove the bedplate perimeter bolts.
4. Remove and discard the crankshaft bearing bolts.
5. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase.

Crankshaft and Bearing Removal

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

Cylinder Sleeve Removal

Special Tools

1. EN 45680-850 Cylinder Sleeve Removal and Installation Kit
2. EN-45680-880 Cylinder Sleeve Removal and Installation Kit. See «Special Tools»(ref-299589-S39492348912008092400000) .

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-45680-882 (1) from EN-45680-880 through the cylinder bore. See «Special Tools»(ref-299589-S39492348912008092400000) .
3. Align the shoe (1) of the cylinder bore sleeve puller EN-45680-882 to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller EN-45680-882 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN-456850-851 (4) from EN 45680-850 onto the threaded shaft of the cylinder bore sleeve puller EN-456850-882 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-45680-851, cylinder bore sleeve puller EN-45680-882, 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»(ref-299589-S07942874842008092400000) .

Cylinder Sleeve Installation

Special Tools

1. EN 45680-850 Cylinder Sleeve Removal and Installation Kit
2. EN-45680-880 Cylinder Sleeve Removal and Installation Kit. See «Special Tools»(ref-299589-S39492348912008092400000) .

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture EN-45680-851 (1) from EN 45680-850 with the cylinder bore sleeve installer EN-45680-883 from EN-45680-880 over the cylinder bore sleeve (117) and onto the cylinder block. See «Special Tools»(ref-299589-S39492348912008092400000) . Do not apply downward pressure to the cylinder bore sleeve (117).
3. Insert the 4 attachment bolts into the legs of the fixture EN-45680-851 (1).
4. Tighten the 4 attachment bolts. 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 of the cylinder bore sleeve installer EN-45680-883 (1) from EN-45680-880 onto the top of the cylinder bore sleeve (117). See «Special Tools»(ref-299589-S39492348912008092400000) .
7. Align the pusher block of the cylinder bore sleeve installer EN-45680-883 (2) into the groove of fixture EN-45680-851 (1).
8. Using a ratchet, rotate the threaded shaft of the cylinder bore sleeve installer EN-45680-883 (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 to 102 N.m (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the fixture assembly EN-4680-851 with the cylinder bore sleeve installer EN-45680-883 (1) from the cylinder block (100).

Crankshaft and Bearing Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gage
2. J 45059 Angle Meter

Scheme 61

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

1. Tighten the bedplate to specification using the J 45059 .
2. Measure the bearing bore for taper and out-of-round using the J 8087 .
3. No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2 methods to measure bearing clearance. Method A gives more reliable results and is preferred. Method A yields measurement from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
2. To measure bearing clearance using Method A, use the following procedure: Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements. Measure the crankshaft bearing journal taper and runout. Install the lower crankcase and tighten the bearing cap bolts to specification. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing ID measurement to determine clearance. Determine whether clearance is within specification. If out of specification, choose different inserts. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer.
3. To measure bearing clearance using Method B, use the following procedure: Clean the used bearing inserts. Install the used bearing inserts. Place a piece of gaging plastic across the entire bearing width. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Install the bearing cap bolts to specification. IMPORTANT: Do not rotate the crankshaft. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package. Remove the gaging plastic.

Lower Crankcase Installation

Tools Required

J 45059 Angle Meter

1. Install the upper crankshaft bearings and lubricate bearing surfaces with engine oil.
2. Install the crankshaft on the journals.
3. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) to the surfaces of the engine block to bedplate mating surfaces.
5. Install the lower crankcase. Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . Tighten: Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
7. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Installation

Tools Required

J 42067 Rear Main Seal Installer

1. Remove excess sealer from seal recess.
2. Using the J 42067 , press the new crankshaft seal into the housing. The J 42067 also establishes the depth of the seal in the crankshaft seal bore.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. EN-47836 Piston Ring Compressor
2. J 45059 Angle Meter
3. J-43966-1 Connecting Rod Guides

1. Install the connecting rod bearings. Use NEW bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install EN-47836 , piston, and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-47836 against the engine block until all the rings have entered the cylinder bore. Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use new bolts. Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft), plus 100 degrees using the J 45059 .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.07-0.37 mm (0.0027-0.0145 in).

Cylinder Head Installation

Tools Required

J 45059 Angle Meter

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence. Use the J 45059 .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).

Intake Camshaft, Bearing Cap, and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Lubricate the valve tips.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Set the intake camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
6. Install the camshaft caps and hand start the camshaft cap bolts.
7. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

Exhaust Camshaft, Bearing Cap, and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Lubricate the valve tips with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Position the roller followers on the tip of the valve stem and on the lash adjuster. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
4. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the camshaft caps and hand start the camshaft cap bolts.
6. Tighten the camshaft cap bolts in increments of 3 turns until they are seated, lubricate. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

Balance Shaft Installation

Tools Required

J 43650 Balance Shaft Bushing Remover/Installer

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

Water Pump Installation

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

1. Install the water pump assembly.
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
5. Install the water pump drain plug, if necessary. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
6. Install the water feed tube.
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing to block bolts and stud. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the engine coolant temperature sensor by hand.
11. Tighten the engine coolant temperature sensor. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

Water Pump and Balance Shaft Chain and Tensioner Installation

1. Install the upper balance shaft chain guide and bolts. Tighten: Tighten the upper balance shaft chain guide bolts to 15 N.m (11 lb ft).
2. Install the small balance shaft chain guide.
3. Install the balance shaft chain guide bolts. Tighten: Tighten the chain guide bolts to 15 N.m (11 lb ft).
4. Install the adjustable balance shaft drive chain guide.
5. Install the adjustable balance shaft drive chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
6. Reset the timing chain tensioner by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts. Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Camshaft Timing Chain, Sprocket, and Tensioner Installation

Tools Required

1. J 45027 Tensioner Tool
2. J 45059 Angle Meter

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
3. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
4. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
5. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
6. Hand tighten the new intake camshaft actuator bolt.
7. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
8. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
9. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
10. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
11. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
12. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
13. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
14. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
15. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
16. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
17. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
18. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
19. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
20. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
21. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
22. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 .
23. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 .
24. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
25. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
26. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

Crankshaft Front Oil Seal Installation

Tools Required

J 35268-A Camshaft/Front Main Seal Installer

1. Install the seal into the front cover using the J 35268-A .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

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

Camshaft Cover Installation

1. Assemble the camshaft cover and gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
2. Install the cover on the cylinder head and hand start the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install the front lift bracket.
4. Install the front lift bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the rear lift bracket.
6. Install the rear lift bracket bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
8. Install the ignition coil. Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
9. Install the camshaft position actuator solenoid valves.
10. Install the camshaft position actuator solenoid valve bolts.

Oil Pan Installation

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 3.5 mm bead of GM P/N 12378521 (Canadian P/N 88901148) or equivalent around the perimeter of the oil pan and the oil suction port opening.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

Crankshaft Balancer Installation

Special Tools

1. EN-48585 Crankshaft Balancer Guide
2. J 38122-A Crankshaft Balancer Holder
3. J 45059 Angle Meter

1. Install the EN-48585 into the end of the crankshaft.
2. Install the balancer onto the EN-48585 . Use care to properly align the keyway and flats on the balancer with the oil pump drive.
3. Install the J 38122-A .
4. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar to prevent the crankshaft from rotating when tightening the bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 .

Oil Filter Adapter Installation

Tools Required

J 44887 Oil Filter Wrench

1. Install a new oil filter on the oil filter cap.
2. Lubricate the O-ring on the oil filter cap with 5W30 engine oil.
3. Use J 44887 to install the oil filter adapter. Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 6 N.m (53 lb in).
2. Install a new intake manifold gasket on the intake manifold.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate NEW fuel injector tip insulators with engine oil.
6. Install NEW fuel injector tip insulators.
7. Lubricate the fuel injector oil rings with engine oil.
8. Install the fuel rail assembly.
9. Install the fuel rail stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
10. Install a new throttle body gasket.
11. Install the throttle body.
12. Install the throttle body bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
13. Install the EVAP canister valve (2). Tighten: Tighten the EVAP canister valve to 22 N.m (16 lb ft).
14. Install the EVAP canister valve tube (1).

Exhaust Manifold Installation

1. Install new exhaust manifold studs. Tighten: Tighten the studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten: Tighten the nuts a second time to 14 N.m (124 lb in).
6. Coat the threads of the oxygen sensor with antiseize GM P/N 12397953 or equivalent.
7. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 42 N.m (31 lb ft).
8. Install the exhaust manifold heat shield.
9. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).

Oil Level Indicator and Tube Installation

1. Lubricate the oil level indicator tube O-ring with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the oil level indicator and the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the intake manifold bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the electrical wiring harness to the oil level indicator tube.
5. Install the knock sensor wiring clip into the oil level indicator tube.

Engine Flywheel Installation

Tools Required

1. J 38122-A Crankshaft Balancer Holder
2. J 45059 Angle Meter

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft balancer with J 38122-A , tighten the bolts evenly. Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 .