Engine Mechanical - 8.1L: Removal & Installation Chevrolet Silverado Classic 1500

Removal Procedure

1. Install a breaker bar with hex-head socket to the drive belt tensioner bolt.
2. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt.
3. Remove the belt from the pulleys and the drive belt tensioner.
4. Slowly release the tension on the drive belt tensioner.
5. Remove the breaker bar and socket and from the drive belt tensioner bolt.
6. Clean and inspect the belt surfaces of all the pulleys.

Installation Procedure

1. Route the drive belt around all the pulleys except the idler pulley.
2. Install the breaker bar with hex-head socket to the belt tensioner bolt.
3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner.
4. Install the drive belt under the idler pulley.
5. Slowly release the tension on the belt tensioner.
6. Remove the breaker bar and socket from the belt tensioner bolt.
7. Inspect the drive belt for proper installation and alignment.

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .
2. Install a breaker bar into the air conditioning (A/C) belt tensioner adapter opening.
3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
4. Remove the A/C belt from the pulleys.
5. Slowly release the tension on the A/C belt tensioner.
6. Remove the breaker bar from the A/C belt tensioner.
7. Clean and inspect the belt surfaces of all the pulleys.

1. Install the A/C belt around the crankshaft balancer.
2. Install the breaker bar into the A/C drive belt tensioner adapter opening
3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner.
4. Install the A/C belt over the idler pulley.
5. Install the A/C belt around the A/C compressor pulley.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the breaker bar from the A/C belt tensioner.
8. Inspect the A/C belt for proper installation and alignment.
9. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .
2. Remove the drive belt tensioner bolts.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolts. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) .
3. Tighten the drive belt tensioner bolts. Tighten: Tighten the accessory drive belt tensioner bolts to 50 N.m (37 lb ft).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .

1. Remove the air conditioning (A/C) drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-277941-S06661750352008012100000) .
2. Remove the A/C belt tensioner bolts.
3. Remove the A/C belt tensioner.

1. Install the A/C belt tensioner.
2. Install the A/C belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-277941-S06661750352008012100000) .

1. Loosen the drive belt idler pulley bolt.
2. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .
3. Remove the drive belt idler pulley.

1. Install the drive belt idler pulley and bolt to the generator bracket. Snug the bolt finger tight.
2. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) . Tighten: Tighten the drive belt idler pulley bolt to 50 N.m (37 lb ft).

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

1. If vehicle is a 2-wheel drive (2WD), raise the vehicle to a height to work through the front wheelhouse opening.
2. If vehicle is a 4-wheel drive (4WD), raise the vehicle in order to remove the front tires and wheels.
3. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
4. Remove the wheelhouse inner panel push pin retainers (2).
5. Remove the wheelhouse inner panel (1).
6. Working through the wheelhouse opening, remove the engine mount heat shield bolts.
7. Remove the engine mount heat shield.
8. Remove the engine mount-to-engine mount bracket bolt.
9. If equipped, remove the oil pan skid plate bolts and plate.
10. Remove the engine shield bolts and shield.
11. Raise the engine with a suitable jack in order to remove the engine mount and bracket.
12. Remove the engine mount-to-engine bolts.
13. Remove the engine mount.
14. Remove the engine mount bracket through bolts.
15. Remove the engine mount bracket.

1. Install the engine mount bracket onto the frame.
2. Perform the following procedure prior to installing the engine mount bracket bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker to the bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
3. Loosely install the engine mount bracket through bolts.
4. Position the engine mount to engine.
5. Loosely install the engine mount-to-engine bolts.
6. Tighten the engine mount bracket through bolts and engine mount-to-engine bolts. Tighten: Tighten the engine mount bracket through bolts to 75 N.m (55 lb ft). Tighten the engine mount-to-engine bolts to 50 N.m (37 lb ft).
7. Install the engine shield and bolts. Tighten: Tighten the engine shield bolts to 20 N.m (15 lb ft).
8. Lower the engine.
9. If equipped, install the oil pan skid plate and bolts. Tighten: Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
10. Install the engine mount heat shield.
11. Install the engine mount-to-engine mount bracket bolts. Tighten: Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).
12. Install the wheelhouse inner panel (1).
13. Install the wheelhouse inner panel push pin retainers (2).
14. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
15. Lower the vehicle.

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

1. If vehicle is a 2-wheel drive (2WD), raise the vehicle to a height to work through the front wheelhouse opening.
2. If vehicle is a 4-wheel drive (4WD), raise the vehicle in order to remove the front tires and wheels.
3. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
4. Remove the wheelhouse inner panel push pin retainers (2).
5. Remove the wheelhouse inner panel (1).
6. Working through the wheelhouse opening, remove the engine mount heat shield bolts (left side shown, right side similar).
7. Remove the engine mount heat shield.
8. Remove the engine mount-to-engine mount bracket bolt (left side shown, right side similar).
9. Remove the oil pan skid plate bolts and plate, if equipped.
10. Remove the engine shield bolts and shield.
11. Raise the engine with a suitable jack in order to remove the engine mount and bracket.
12. Remove the engine mount-to-engine bolts (left side shown, right side similar).
13. Remove the engine mount.
14. Remove the engine mount bracket through bolts.
15. Remove the engine mount bracket.

1. Install the engine mount bracket onto the frame.
2. Perform the following procedure prior to installing the engine mount bracket bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker to the bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
3. Loosely install the engine mount bracket through bolts.
4. Position the engine mount to engine (left side shown, right side similar).
5. Loosely install the engine mount-to-engine bolts.
6. Tighten the engine mount bracket through bolts and engine mount-to-engine bolts. Tighten: Tighten the engine mount bracket through bolts to 75 N.m (55 lb ft). Tighten the engine mount-to-engine bolts to 50 N.m (37 lb ft).
7. Install the engine shield and bolts. Tighten: Tighten the engine shield bolts to 20 N.m (15 lb ft).
8. Lower the engine.
9. If equipped, install the oil pan skid plate and bolts. Tighten: Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
10. Install the engine mount heat shield (left side shown, right side similar).
11. Install the engine mount-to-engine mount bracket bolts (left side shown, right side similar). Tighten: Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).
12. Install the wheelhouse inner panel (1).
13. Install the wheelhouse inner panel push pin retainers (2).
14. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
15. Lower the vehicle.

1. Unsnap the intake manifold sight shield from the stud.
2. Remove the sight shield from the sight shield bracket.
3. Remove the sight shield bracket retainer nuts (1), if necessary.
4. Remove the sight shield bracket from the studs (2), if necessary.

1. Install the sight shield bracket to the studs (2), if necessary.
2. Install the sight shield bracket nuts (1), if necessary. Tighten: Tighten the nuts to 5 N.m (44 lb in).
3. Install the intake manifold sight shield to the bracket.
4. Snap the intake manifold sight shield onto the stud.

1. Loosen the clamps at the throttle body and air cleaner.
2. Remove the air cleaner outlet duct.
3. Unsnap the intake manifold sight shield from the stud.
4. Remove the sight shield from the bracket.
5. Remove the sight shield bracket nuts (1) and bracket, if necessary.
6. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-277873-S40865068532008012100000) or «Fuel Pressure Relief (Without CH 48027)»(ref-277873-S04692472202008012100000) .
7. Disconnect the fuel feed and return pipes. Refer to «Metal Collar Quick Connect Fitting Service»(ref-277872-S10623181322008012100000) .
8. Disconnect the engine harness clips from the studs on the front of dash.
9. Disconnect the engine harness clip from the wheelhouse splash shield.
10. Disconnect the following electrical connectors: Pressure cycling switch (1) Surge tank switch (2) Mass airflow (MAF) sensor (3)
11. Reposition the engine harness branch to top of engine.
12. Remove the connector position assurance (CPA) retainer at the ignition coil harness.
13. Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Ignition coil harness (2) Engine coolant temperature (ECT) sensor (3)
14. Remove the engine harness bolt and studs
15. Remove the CPA retainer at the ignition coil harness.
16. Disconnect the following electrical connectors: Generator (2) Injector harness (3) Ignition coil harness (4) Electronic throttle control (ETC) (5) Purge valve solenoid (1)
17. Reposition the engine harness to the drivers side of the engine compartment.
18. Remove the bypass valve vacuum hose (1) from the intake manifold.
19. Disconnect the evaporative emission (EVAP) tube from the purge solenoid.
20. Unclip the EVAP tube from the fuel rail.
21. Disconnect the EVAP tube from the vent pipe at the rear of the engine.
22. Remove the EVAP tube.
23. If replacing the intake manifold, remove the fuel rail studs.
24. Remove the fuel rail.
25. Remove the intake manifold bolts.
26. Remove the intake manifold.
27. Remove and discard the intake manifold side gaskets.
28. Remove and discard the intake manifold end seals.
29. Remove the splash shield.
30. If replacing the intake manifold, refer to «Intake Manifold Disassemble»(ref-277941-S25796564512008012100000) .
31. Clean and inspect the intake manifold. Refer to «Intake Manifold Cleaning and Inspection»(ref-277941-S36905182882008012100000) .

1. If replacing the intake manifold, refer to «Intake Manifold Assemble»(ref-277941-S11578174882008012100000) .
2. Install the splash shield.
3. Ensure the splash shield (2) snap fits between the cylinder heads (1).
4. Apply a 5 mm (0.2 in) bead of sealer to the intake manifold. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
5. Install the NEW intake manifold end seals.
6. Apply a 5 mm (0.2 in) bead of sealer (1) onto the end seals. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
7. Install the NEW intake manifold side gaskets.
8. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
9. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
10. Install the intake manifold.
11. Install NEW intake manifold bolts.
12. Tighten the intake manifold bolts in the sequence shown, using 4 passes. Tighten: Tighten the bolts a first pass to 5 N.m (44 lb in). Tighten the bolts a second pass to 8 N.m (71 lb in). Tighten the bolts a third pass to 12 N.m (106 lb in). Tighten the bolts a final pass to 15 N.m (11 lb ft).
13. If replacing the intake manifold, install the fuel rail.
14. Install the fuel rail studs. Tighten: Tighten the studs to 12 N.m (106 lb in).
15. Install the EVAP tube.
16. Connect the EVAP tube to the vent pipe at the rear of the engine.
17. Clip the EVAP tube to the fuel rail.
18. Connect the EVAP tube to the purge solenoid.
19. Install the bypass valve vacuum hose (1) to the intake manifold.
20. Position the engine harness over the engine compartment.
21. Connect the following electrical connectors: Generator (2) Injector harness (3) Ignition coil harness (4) ETC (5) Purge valve solenoid (1)
22. Install the CPA retainer at the ignition coil harness.
23. Install the engine harness bolt and studs. Tighten: Tighten the bolt to 16 N.m (12 lb ft). Tighten the studs to 10 N.m (89 lb in).
24. Connect the following electrical connectors: MAP sensor (1) Ignition coil harness (2) ECT sensor (3)
25. Install the CPA retainer at the ignition coil harness.
26. Position engine harness branch over the top of engine.
27. Connect the following electrical connectors: Pressure cycling switch (1) Surge tank switch (2) MAF sensor (3)
28. Connect the engine harness clip to the wheelhouse splash shield.
29. Connect the engine harness clips to the studs on the front of dash.
30. Connect the fuel feed and return pipes.
31. Install the sight shield bracket and nuts (1). Tighten: Tighten the nuts to 5 N.m (44 lb in).
32. Install the sight shield to the bracket.
33. Snap the intake manifold sight shield to the stud.
34. Install the air cleaner outlet duct.
35. Tighten the clamps at the throttle body and air cleaner. Tighten: Tighten the clamps to 4 N.m (35 lb in).

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .
2. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
3. Disconnect the ignition coil harness electrical connector (4).
4. Remove the spark plug wires from the spark plugs and ignition coils.
5. Remove the valve rocker arm cover bolts.
6. Remove the valve rocker arm cover. IMPORTANT: Valve rocker arm cover gaskets are reusable. Replace the gasket only if damaged.
7. Inspect the valve rocker arm cover gasket for cuts or damage.
8. Clean and inspect the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-277941-S04221948222008012100000) .

1. Install a new valve rocker arm cover gasket if the gasket was removed from the rocker arm cover.
2. Install the valve rocker arm cover.
3. Install the valve rocker arm cover bolts.
4. Tighten the valve rocker arm cover bolts in the sequence shown, using 2 passes as shown. Tighten: Tighten the bolts a first pass to 6 N.m (53 lb in). Tighten the bolts a final pass to 12 N.m (106 lb in).
5. Install the spark plug wires to the spark plugs and ignition coils.
6. Connect the ignition coil harness electrical connector (4).
7. Install the CPA retainer to the ignition coil electrical connector.
8. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .
2. Loosen the clamps at the throttle body and air cleaner.
3. Remove the air cleaner outlet duct.
4. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector (2).
5. Disconnect the ignition coil harness electrical connector (2).
6. Disconnect the engine coolant temperature (ECT) sensor electrical connector (3).
7. Remove the spark plug wires from the ignition coils.
8. Loosen the valve rocker arm cover bolts.
9. Remove the valve rocker arm cover. IMPORTANT: The valve rocker arm cover gasket may be reused if not removed from the valve rocker arm cover.
10. Replace the valve rocker arm cover gasket if it is cut or damaged.
11. Clean and inspect the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-277941-S04221948222008012100000) .

1. Install a NEW valve rocker arm cover gasket, if necessary.
2. Install the valve rocker arm cover.
3. Tighten the valve rocker arm cover bolts in sequence using 2 passes as shown. Tighten: Tighten the bolts a first pass to 6 N.m (53 lb in). Tighten the bolts a final pass to 12 N.m (106 lb in).
4. Install the spark plug wires to the ignition coils.
5. Connect the ECT sensor electrical connector (3).
6. Connect the ignition coil harness electrical connector (2).
7. Install the CPA retainer to the ignition coil electrical connector (2).
8. Install the air cleaner outlet duct.
9. Tighten the clamps at the throttle body and air cleaner. Tighten: Tighten the clamps to 4 N.m (35 lb in).
10. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-277941-S20523656522008012100000) and/or «Valve Rocker Arm Cover Replacement - Right Side»(ref-277941-S37623539302008012100000) .
2. Remove the valve rocker arm nuts, the valve rocker arm balls, and valve rocker arms.
3. Remove the valve pushrods.
4. Remove the valve rocker arm studs and pushrod guides.
5. Clean and inspect the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(ref-277941-S38325425542008012100000) .

1. Apply sealant to the valve rocker arm stud-to-cylinder head threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
2. Install the pushrod guides and valve rocker arm studs. Tighten: Tighten the studs to 50 N.m (37 lb ft).
3. Install the valve pushrods.
4. Coat the valve rocker arm and valve rocker arm ball bearing surfaces with lubricant. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
5. Install the valve rocker arms, the valve rocker arm balls, and the valve rocker arm nuts. Tighten: Tighten the nuts slowly to 35 N.m (26 lb ft) while guiding the tips of the rocker arms over the tips of the valves.
6. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-277941-S20523656522008012100000) or «Valve Rocker Arm Cover Replacement - Right Side»(ref-277941-S37623539302008012100000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 5892-D Valve Spring Compressor
2. J 22794 Spark Plug Port Adapter
3. J 43105 Valve Stem Seal Installer. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
2. Rotate the crankshaft until both valves are closed before installing the compressed air into the cylinder.
3. Remove the spark plug from the cylinder being serviced. Refer to «Spark Plug Replacement»(ref-277874-S39581815162008012100000) .
4. Remove the valve stem keys as followed: Install the J 22794 into the spark plug hole. Apply compressed air into the cylinder in order to hold the valves closed. Lightly tap the valve spring cap to loosen the valve stem keys. Install the J 5892-D to the cylinder head. Install the valve rocker arm nut. IMPORTANT: Tighten the valve rocker arm nut enough to hold J 5892-D in place. Using J 5892-D compress the valve spring.
5. Remove the valve stem keys (1).
6. Slowly release the J 5892-D .
7. Remove the J 5892-D from the cylinder head.
8. Remove the valve spring cap (2) and valve spring (3).
9. Remove the valve stem oil seal (4).

1. Lubricate the valve stem and outside diameter of the valve guide seal with clean engine oil.
2. Lubricate the rotators with clean engine oil. IMPORTANT: When installing valve seals, J 43105 must be used to achieve correct installation. See «Special Tools»(ref-277941-S08724385302008012100000) . Failure to use J 43105 may cause excessive oil consumption. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. Install the valve stem oil seal (2) over the valve tip and onto the valve guide using J 43105 . See «Special Tools»(ref-277941-S08724385302008012100000) . Tap the valve stem seal onto the valve guide until the J 43105 fully seats the seal. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Install the valve spring cap and the spring.
5. Install the valve spring (3).
6. Install the valve spring cap (2).
7. Using J 5892-D compress the valve spring.
8. Install the valve stem keys as follows: Apply a small amount of clean grease to hold the valve stem keys in place. Carefully release the J 5892-D . Make sure the valve stem keys do not move. Remove the J 5892-D from the valve assembly. Remove the compressed air from the cylinder being worked on.
9. Install the spark plug. Refer to «Spark Plug Replacement»(ref-277874-S39581815162008012100000) .
10. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
3. Remove the valve lifter guide retainer bolts and retainer.
4. Remove the valve lifter guides.
5. Remove the valve lifters.
6. Some valve lifter may be stuck in their bore due to gum or varnish deposits, These lifters can be removed using J 3049-A .
7. Clean and inspect the valve lifters. Refer to «Valve Lifters and Guides Cleaning and Inspection»(ref-277941-S40885690762008012100000) .

1. Coat the valve lifter rollers with lubricant. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
2. Install the valve lifters.
3. Install the valve lifter guides over the flats on the valve lifters, making sure the rollers of the valve lifters are properly aligned with the camshaft lobes.
4. Install the valve lifter guide retainer.
5. Install the valve lifter guide retainer bolts. Tighten: Tighten the valve lifter guide retainer bolts to 25 N.m (18 lb ft).
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) . Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .

1. Remove the oil level indicator from the indicator tube.
2. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
3. Remove the ECT sensor connector from the indicator tube.
4. Remove the indicator tube bolt.
5. Remove the indicator tube bracket.
6. Remove the O-ring seal from the indicator tube.

1. Install a NEW O-ring seal onto the indicator tube.
2. Install the indicator tube into the oil pan.
3. Align the indicator tube bracket with the bolt hole in the block. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) .
4. Install the indicator tube bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the ECT sensor connector to the indicator tube.
6. Connect the ECT sensor electrical connector.
7. Install the oil level indicator to the indicator tube.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .
2. Remove the water crossover. Refer to «Engine Coolant Crossover Pipe Replacement (8.1L)»(ref-277850-S04632606012008012100000) .
3. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
4. Remove the engine harness ground bolts.
5. Reposition the engine harness grounds (1 and 5) and ground strap (4) from the cylinder head.
6. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (8.1L Engine)»(ref-277937-S00414399822008012100000) .
7. Remove and discard the cylinder head bolts (1, 2, 3).
8. Remove the cylinder head.
9. Remove and discard the cylinder head gasket.
10. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-277941-S27761562922008012100000) .

1. Place a NEW cylinder head gasket into position.
2. Install the cylinder head.
3. If not pre-applied to the NEW cylinder head bolts, apply sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
4. Install the cylinder head bolts (1, 2, 3).
5. Tighten the cylinder head bolts. Tighten: Tighten the bolts a first pass in sequence to 30 N.m (22 lb ft) Tighten the bolts a second pass in sequence to 30 N.m (22 lb ft) then an additional 120 degrees using J 45059 . Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17) an additional 60 degrees, bolts (15, and 18) an additional 45 degrees, and bolts (4, 5, 12, and 13) an additional 30 degrees a final pass in sequence using J 45059 .
6. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (8.1L Engine)»(ref-277937-S00414399822008012100000) .
7. Install the water crossover. Refer to «Engine Coolant Crossover Pipe Replacement (8.1L)»(ref-277850-S04632606012008012100000) .
8. Position the engine harness grounds (1, 5) and ground strap (4) to the cylinder head.
9. Install the engine harness ground bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
10. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
11. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
2. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .
3. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
4. Remove the engine coolant temperature (ECT) sensor clip from the bracket.
5. Remove the ECT sensor from the cylinder head.
6. Remove the indicator tube bolt.
7. Remove the indicator tube bracket.
8. Remove the O-ring seal from the indicator tube.
9. Remove the heater inlet and outlet hoses from the hose bracket.
10. Remove the heater hose bracket bolts and bracket from the cylinder head.
11. Remove the water crossover. Refer to «Engine Coolant Crossover Pipe Replacement (8.1L)»(ref-277850-S04632606012008012100000) .
12. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (8.1L Engine)»(ref-277937-S00297025632008012100000) .
13. Remove and discard the cylinder head bolts (1, 2, 3).
14. Remove the cylinder head.
15. Remove and discard the cylinder head gasket.
16. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-277941-S27761562922008012100000) .

1. Place a NEW cylinder head gasket into position.
2. Install the cylinder head.
3. If not pre-applied to the new cylinder heads bolts, apply sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
4. Install the cylinder head bolts (1, 2, 3).
5. Tighten the cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). Tighten the cylinder head bolts a second pass in sequence to 30 N.m (22 lb ft) then an additional 120 degrees using J 45059 . Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, and 17) an additional 60 degrees, bolts (15, and 18) an additional 45 degrees, and bolts (4, 5, 12, and 13) an additional 30 degrees a final pass using J 45059 .
6. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (8.1L Engine)»(ref-277937-S00297025632008012100000) .
7. Install the water crossover. Refer to «Engine Coolant Crossover Pipe Replacement (8.1L)»(ref-277850-S04632606012008012100000) .
8. Install the heater hose bracket and bolts to the cylinder head. Tighten: Tighten the heater hose bracket bolts to 50 N.m (37 lb ft).
9. Install the heater inlet and outlet hoses to the hose bracket.
10. Install a NEW O-ring seal onto the indicator tube.
11. Install the indicator tube into the oil pan.
12. Align the indicator tube bracket with the bolt hole in the block.
13. Install the indicator tube bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
14. Apply sealant to the threads of the ECT sensor. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
15. Install the ECT sensor to the cylinder head. Tighten: Tighten the ECT sensor to 50 N.m (37 lb ft).
16. Install the ECT sensor clip to the bracket.
17. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-277941-S15498365622008012100000) .
18. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .
19. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .

Crankshaft Balancer Replacement

Tools Required

1. J 38416-B Harmonic Balancer Remover. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. J 42845 Crankshaft Balancer Installer. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. J 42846 Crankshaft Balancer Protector Button. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. J 42847 Flywheel Holding Tool. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Remove the air conditioning (A/C) belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-277941-S06661750352008012100000) .
2. Remove the fan. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
3. Remove the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
4. Install the J 42847 to the starter bolt holes. See «Special Tools»(ref-277941-S08724385302008012100000) . Tighten: Tighten the J 42847 bolts to 50 N.m (37 lb ft).
5. Remove the crankshaft balancer bolt and washer.
6. Install the J 42846 onto the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
7. Install the J 38416-B (2) onto the J 42846 (1) in order to remove the crankshaft balancer. See «Special Tools»(ref-277941-S08724385302008012100000) . Place the legs of the J 38416-B into the recesses cast into the backside of the balancer inner hub. See «Special Tools»(ref-277941-S08724385302008012100000) .
8. Tighten the center screw of the J 38416-B until the crankshaft balancer is clear of the crankshaft nose. See «Special Tools»(ref-277941-S08724385302008012100000) .
9. Remove the crankshaft balancer.
10. Remove the J 42846 from the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Install the balancer onto the end of the crankshaft.
2. Install J 42845 to the crankshaft balancer. See «Special Tools»(ref-277941-S08724385302008012100000) . IMPORTANT: Apply the lubricant that comes with J 42845 each time the tool is used. See «Special Tools»(ref-277941-S08724385302008012100000) . Failure to lubricate the J 42845 may prevent the balancer from installing completely. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. Using J 42845 install the balancer. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Tighten the J 42845 until the crankshaft balancer is completely seated against the crankshaft sprocket. See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Remove the J 42845 from the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
6. Install the crankshaft bolt and washer to the crankshaft. Tighten: Tighten the crankshaft balancer bolt to 255 N.m (189 lb ft).
7. Remove the J 42847 . See «Special Tools»(ref-277941-S08724385302008012100000) .
8. Install the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
9. Install the fan. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
10. Install the A/C belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-277941-S06661750352008012100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277941-S11180440222008012100000) .
2. Remove the crankshaft front cover oil seal.

1. Coat the crankshaft front cover oil seal with clean engine oil.
2. Using J 42851 install the oil seal. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. Remove the J 42851 . See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277941-S11180440222008012100000) .

1. Remove the water pump. Refer to «Water Pump Replacement (8.1L)»(ref-277850-S32082901052008012100000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277941-S11180440222008012100000) .
3. Disconnect the camshaft position (CMP) sensor electrical connector (1).
4. Remove the engine harness clips from the battery cable channel.
5. Remove the CMP sensor bolt.
6. Remove the CMP sensor.
7. Remove the battery cable channel bolt.
8. Remove and reposition the battery cable channel.
9. Remove the engine front cover bolts (2).
10. Remove the engine front cover (1). IMPORTANT: The engine front cover gasket is reusable.
11. Remove the engine front cover gasket.
12. Remove the crankshaft front oil seal from the front cover.

1. Install a NEW crankshaft front oil seal using J 42851 . See «Special Tools»(ref-277941-S08724385302008012100000) .
2. Lubricate the sealing surface of the crankshaft front oil seal with clean engine oil. IMPORTANT: The engine front cover must be installed and the fasteners tightened while the sealant is still wet to the touch.
3. Apply sealant in 2 places (1) on the engine block where the front cover meets the oil pan. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
4. Install the engine front cover gasket into the front cover.
5. Install the front cover and gasket. Hold the front cover (1) up to the crankshaft (2). Lift the front cover (1) while sliding the cover over the crankshaft (2). Slide the front cover towards the engine block (5) while keeping the cover raised. Lower the cover down over the dowel pin (4), allowing the front cover to rest on the sealant (3).
6. Install the engine front cover bolts.
7. Tighten the engine front cover bolts. Tighten: Tighten the engine front cover bolts in sequence a first pass to 6 N.m (53 lb in). Tighten the engine front cover bolts in sequence a final pass to 12 N.m (106 lb in).
8. Position the battery cable channel into place.
9. Install the battery cable channel bolt. Tighten: Tighten the battery cable channel bolt to 9 N.m (80 lb in).
10. Inspect the CMP sensor O-ring for cuts, cracks, tears or damage. Replace as needed.
11. Apply a light film of clean engine oil to the CMP sensor O-ring.
12. Install the CMP sensor. Install the CMP sensor bolt. Tighten: Tighten the CMP sensor bolt to 12 N.m (106 lb in).
13. Install the engine harness clips to the battery cable channel.
14. Connect the CMP sensor electrical connector (1).
15. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277941-S11180440222008012100000) .
16. Install the water pump. Refer to «Water Pump Replacement (8.1L)»(ref-277850-S32082901052008012100000) .

Timing Chain and Sprockets Replacement

Tools Required

1. J 22102 Crankshaft Sprocket Installer. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. J 42846 Crankshaft Protector Button. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-277941-S03424076992008012100000) .
2. Aligned the timing marks on the camshaft and crankshaft sprockets.
3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and timing chain.
5. Install the J 42846 (1) into the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
6. Remove the crankshaft sprocket using a suitable three jaw puller.
7. Clean and inspect the timing chain and sprockets. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-277941-S22020598652008012100000) .

1. Use the J 22102 in order to install the crankshaft sprocket. Align the keyway of the crankshaft sprocket with the crankshaft pin.
2. Remove the J 22102 .
3. Rotate the crankshaft until the crankshaft sprocket alignment mark is in the 12 o'clock position.
4. Install the camshaft sprocket and timing chain.
5. Ensure that the crankshaft sprocket is aligned at the 12 o'clock position and the camshaft sprocket is aligned at the 6 o'clock position.
6. Install the camshaft sprocket bolts. Tighten: Tighten the bolts a to 30 N.m (22 lb ft).
7. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-277941-S03424076992008012100000) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .
2. Remove the oil pump drive bolt.
3. Remove the oil pump drive.
4. Clean and inspect the oil pump drive. Refer to «Oil Pump Drive Cleaning and Inspection»(ref-277941-S12694905392008012100000) .

1. Apply grease to the oil pump drive gear for ease of assembly.
2. Line up the oil pump drive, making sure that the oil pump is fully seated in the engine block.
3. Install the oil pump, making sure that the oil pump drive is fully seated in the engine block. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-277941-S08896737422008012100000) .

1. Remove the grille. Refer to «Grille Replacement (Chevrolet)»(ref-277848-S20641943312008012100000) or «Grille Replacement (GMC)»(ref-277848-S39643988622008012100000) .
2. Remove the air conditioning (A/C) condenser. Refer to «Condenser Replacement»(ref-277853-S35551967062008012100000) .
3. Remove the valve lifters. Refer to «Valve Lifter Replacement»(ref-277941-S04750383562008012100000) .
4. Remove the timing chain and sprocket. Refer to «Timing Chain and Sprockets Replacement»(ref-277941-S07785659682008012100000) .
5. Remove the camshaft retainer bolts.
6. Remove the camshaft retainer.
7. Install three 8 - 1.25 x 100 mm bolts into the camshaft front bolt holes.
8. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block.
9. Remove the bolts from the front of the camshaft.
10. Clean and inspect the camshaft. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-277941-S38946241282008012100000) .

1. Apply lubricant to the following components: The camshaft lobes The camshaft bearing journals The camshaft bearings Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
2. Install three 8 - 1.25 x 100 mm bolts into the camshaft threaded bolt holes.
3. Using the bolts as a handle, carefully install the camshaft.
4. Remove the bolts from the front of the camshaft.
5. Install the camshaft retainer and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
6. Install the timing chain and sprocket. Refer to «Timing Chain and Sprockets Replacement»(ref-277941-S07785659682008012100000) .
7. Install the valve lifters. Refer to «Valve Lifter Replacement»(ref-277941-S04750383562008012100000) .
8. Install the A/C condenser. Refer to «Condenser Replacement»(ref-277853-S35551967062008012100000) .
9. Install the grille. Refer to «Grille Replacement (Chevrolet)»(ref-277848-S20641943312008012100000) or «Grille Replacement (GMC)»(ref-277848-S39643988622008012100000) .

1. Remove the engine oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .
2. Loosen the oil filter fitting using a hex wrench.
3. Remove the oil filter fitting.
4. Remove the oil filter bypass valves. Unstake the tangs on the oil bypass valves and remove with long nose pliers.
5. Discard the oil bypass valves.

1. Install NEW oil bypass valves. Stake the tangs on the new oil bypass valves.
2. Inspect the oil filter fitting, replace as necessary.
3. Install the oil filter fitting. Tighten: Tighten the oil filter fitting to 66 N.m (49 lb ft).
4. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .

1. Remove the front differential, if equipped with 4-wheel drive (4WD). Refer to «Differential Carrier Assembly Replacement»(ref-277880-S42731471152008012100000) .
2. Remove the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
3. Remove the oil pan skid plate bolts.
4. Remove the oil pan skid plate.
5. If equipped with 2-wheel drive (2WD), remove the crossbar bolts.
6. Remove the crossbar.
7. If equipped with 4WD, remove the crossbar bolts.
8. Remove the crossbar.
9. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .
10. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-277941-S38626898542008012100000) .
11. Disconnect the oil level sensor electrical connector (4).
12. Remove the engine harness clip from the oil pan.
13. Remove the oil level sensor from the oil pan.
14. Remove the battery cable channel bolt.
15. Remove and reposition the battery cable channel.
16. Remove the oil pan bolts.
17. Remove the oil pan and gasket.

1. Apply sealant to the sides of the front (2) and rear (1) crankshaft bearing caps, on both the left and right sides (4 locations total). Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
2. Install a NEW oil pan gasket into the oil pan groove, if required.
3. Install the oil pan.
4. Install the oil pan bolts.
5. Tighten the oil pan bolts. Tighten: Tighten the bolts a first pass in sequence to 10 N.m (89 lb in). Tighten the bolts a final pass in sequence to 25 N.m (18 lb ft).
6. Position the battery cable channel into place.
7. Install the battery cable channel bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
8. Install the oil level sensor to the oil pan. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
9. Install the engine harness clip to the oil pan.
10. Connect the oil level sensor electrical connector (4).
11. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-277941-S38626898542008012100000) .
12. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .
13. If equipped with 4WD, install the crossbar.
14. Install the crossbar bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
15. If equipped with 2WD, install the crossbar.
16. Install the crossbar bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
17. Install the oil pan skid plate.
18. Install the oil pan skid plate bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
19. Install the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
20. Install the front differential, if equipped with 4WD. Refer to «Differential Carrier Assembly Replacement»(ref-277880-S42731471152008012100000) .

1. Remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .
2. Disconnect the oil pressure sensor electrical connector (2).
3. Using J 41712 or equivalent, remove the oil pressure sensor.

1. Apply sealant to the threads of the oil pressure sensor. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) for the correct part number.
2. Using J 41712 or equivalent, install the oil pressure sensor. Tighten: Tighten the sensor to 30 N.m (22 lb ft).
3. Connect the oil pressure sensor electrical connector (2).
4. Install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-277941-S19833915252008012100000) .

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .
2. Disconnect the oil level sensor electrical connector (4).
3. Remove the oil level sensor from the oil pan.

1. Install the oil level sensor to the oil pan. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
2. Connect the oil level sensor electrical connector (4).
3. Fill the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-277941-S22915240782008012100000) .

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-277941-S39545141672008012100000) .
2. Remove the oil pump bolt.
3. Remove and separate the oil pump, retainer, and driveshaft.
4. Discard the driveshaft retainer.
5. Remove the crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.
7. Clean and inspect the oil pump. Refer to «Oil Pump Cleaning and Inspection»(ref-277941-S11616193562008012100000) .

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Assemble the oil pump, driveshaft and a NEW retainer.
4. Install the oil pump assembly. Position the oil pump onto the locating pins.
5. Install the oil pump bolt. Tighten: Tighten the bolts to 75 N.m (56 lb ft).
6. Install the oil pan. Refer to «Oil Pan Replacement»(ref-277941-S39545141672008012100000) .

Crankshaft Rear Oil Seal Replacement

Tools Required

1. J 43320 Crankshaft Rear Seal Puller. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. J 42849 Crankshaft Rear Seal Installer. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-277941-S37373169152008012100000) .
2. Install the guide pins from J 43320 into the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. Install the J 43320 over the guide pins. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Using a suitable drill, insert eight of the self-drilling sheet metal screws into the rear crankshaft seal, using a criss-cross pattern. The self-tapping screws are included with the J 43320 . See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Thread the center bolt of J 43320 into the crankshaft to remove the seal. See «Special Tools»(ref-277941-S08724385302008012100000) .
6. Remove the guide pins from the crankshaft.

1. Make sure the crankshaft is free of grit, loose rust, and burrs. Correct as needed.
2. Apply a very light film of oil onto the crankshaft sealing surface. DO NOT apply oil to the sealing surface of the engine block.
3. Install the seal onto J 42849 . See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Position the J 42849 against the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) . Thread the attaching screws into the tapped holes in the crankshaft.
5. Tighten the screws securely with a screwdriver in order to ensure that the seal is installed squarely over the crankshaft.
6. Rotate the center nut until the J 42849 bottoms. See «Special Tools»(ref-277941-S08724385302008012100000) .
7. Remove the J 42849 . See «Special Tools»(ref-277941-S08724385302008012100000) .
8. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-277941-S37373169152008012100000) .

1. If equipped with a automatic transmission, remove the transmission. Refer to «Transmission Replacement (8.1L)»(ref-277908-S34452206862008012100000) for the Allison transmission.
2. Remove the engine flywheel bolts.
3. Remove the engine flywheel.
4. If equipped with a manual transmission, remove the clutch assembly. Refer to «Clutch Assembly Replacement»(ref-277945-S32449211492008012100000) .
5. Remove the engine flywheel bolts.
6. Remove the engine flywheel.
7. Clean and inspect the engine flywheel. Refer to «Engine Flywheel Cleaning and Inspection (Automatic Transmission)»(ref-277941-S23904348442008012100000) or «Engine Flywheel Cleaning and Inspection (Manual Transmission)»(ref-277941-S32297592822008012100000) .

1. If equipped with a manual transmission, Install the engine flywheel.
2. If equipped with a automatic transmission, install the engine flywheel.
3. Install the engine flywheel bolts. Tighten: Tighten the bolts a first pass to 40 N.m (30 lb ft). Tighten the bolts a second pass to 80 N.m (59 lb ft). Tighten the bolts a final pass to 100 N.m (74 lb ft).
4. If equipped with a manual transmission, install the clutch assembly. Refer to «Clutch Assembly Replacement»(ref-277945-S32449211492008012100000) .
5. If equipped with a automatic transmission, install the transmission. Refer to «Transmission Replacement (8.1L)»(ref-277908-S34452206862008012100000) for the Allison transmission.

1. Open the hood.
2. Place fender covers over both fenders.
3. Raise the hood to the service position, perform the following: Remove the hood hinge bolts (1). Raise the hood until vertical. Install the hood hinge bolts until snug in the service position (2).
4. Loosen the clamps at the throttle body and air cleaner.
5. Remove the air cleaner outlet duct.
6. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
7. Disconnect the positive battery cable.
8. Remove the ignition coils. Refer to «Ignition Coil Replacement»(ref-277874-S38269318082008012100000) .
9. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027)»(ref-277873-S40865068532008012100000) or «Fuel Pressure Relief (Without CH 48027)»(ref-277873-S04692472202008012100000) .
10. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-277872-S10623181322008012100000) .
11. Remove the air conditioning (A/C) compressor. Refer to «Compressor Replacement (8.1L)»(ref-277853-S21358349192008012100000) .
12. Remove the radiator. Refer to «Radiator Replacement (8.1L)»(ref-277850-S41515550482008012100000) .
13. Disconnect the throttle actuator control (TAC) module electrical connector (1).
14. Remove the vacuum lines from the engine, as required.
15. Remove the ground cable bolt at the engine block.
16. Remove the generator. Refer to «Generator Replacement (8.1L Engine)»(ref-277854-S23534712002008012100000) .
17. Remove the engine electrical harness and tie out of the way.
18. Raise and suitably support the vehicle safety stands. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
19. Remove the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
20. Remove the hoses from the power steering pump. Refer to «Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion)»(ref-277902-S42118680232008012100000) or «Power Steering Cooler Pipe/Hose Replacement (With Hydroboost)»(ref-277902-S28745871352008012100000) or «Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost)»(ref-277902-S34819257922008012100000) .
21. Remove the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L & 8.1L)»(ref-277937-S09592906872008012100000) .
22. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (6.0L & 8.1L)»(ref-277937-S37138818212008012100000) .
23. Remove the torque converter bolts, if equipped.
24. Remove the clutch pressure plate bolts, if equipped.
25. Remove the bolts from the transmission to the engine. For the automatic transmission, refer to «Transmission Replacement (8.1L)»(ref-277908-S34452206862008012100000) for the Allison transmission. For the manual transmission, refer to «Transmission Replacement»(ref-277844-S23599795752008012100000) for the NV 4500 transmission.
26. Remove the engine oil cooler lines from the engine block. Refer to «Engine Oil Cooler Hose/Pipe Replacement (2WD)»(ref-277850-S33087270862008012100000) or «Engine Oil Cooler Hose/Pipe Replacement (4WD)»(ref-277850-S03425979082008012100000) .
27. Attach J 36857 to the rear of the right cylinder head and to the front of the left cylinder head.
28. Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963. Tighten: Tighten the lift bracket bolts to 40 N.m (30 lb ft).
29. Remove the engine mount heat shield bolts and shields.
30. Remove the engine mount to engine mount bracket bolts.
31. Remove the engine using a suitable lifting devise.
32. Install the engine onto a suitable engine stand.
33. Remove the generator mounting bracket. Refer to «Generator Bracket Replacement (8.1L Engine)»(ref-277854-S13092536382008012100000) .
34. Remove the A/C compressor/power steering pump bracket from the cylinder head.
35. Remove the lift brackets from the cylinder head.

1. Attach J 36857 to the rear of the right cylinder head and to the front of the left cylinder head.
2. Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963. Tighten: Tighten the lift bracket bolts to 40 N.m (30 lb ft).
3. Install the air compressor/power steering mounting bracket to the engine block. Tighten: Tighten the power steering pump bracket bolts and nut to 50 N.m (37 lb ft).
4. Install the generator bracket. Refer to «Generator Bracket Replacement (8.1L Engine)»(ref-277854-S13092536382008012100000) .
5. Remove the engine using a suitable lifting devise.
6. Install the engine into the vehicle.
7. Install the engine mount to engine mount bracket bolts.
8. Install the engine mount heat shield and bolts.
9. Remove the engine lift hooks from the cylinder heads.
10. Raise the vehicle and support with safety stands.
11. Install the engine oil cooler lines to the engine block. Refer to «Engine Oil Cooler Hose/Pipe Replacement (2WD)»(ref-277850-S33087270862008012100000) or «Engine Oil Cooler Hose/Pipe Replacement (4WD)»(ref-277850-S03425979082008012100000) .
12. Install the bolts from the transmission to the engine. For the automatic transmission, refer to «Transmission Replacement (8.1L)»(ref-277908-S34452206862008012100000) for the Allison transmission. For the manual transmission, refer to «Transmission Replacement»(ref-277844-S23599795752008012100000) for the NV 4500 transmission.
13. Install the clutch pressure plate bolts, if equipped.
14. Install the torque converter bolts, if equipped.
15. Install the catalytic converter. Refer to «Catalytic Converter Replacement (6.0L & 8.1L)»(ref-277937-S37138818212008012100000) .
16. Install the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L & 8.1L)»(ref-277937-S09592906872008012100000) .
17. Install the hoses to the power steering pump. Refer to «Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion)»(ref-277902-S42118680232008012100000) or «Power Steering Cooler Pipe/Hose Replacement (With Hydroboost)»(ref-277902-S28745871352008012100000) or «Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost)»(ref-277902-S34819257922008012100000) .
18. Install the starter motor. Refer to «Starter Motor Replacement (8.1L Engine)»(ref-277854-S33008003962008012100000) .
19. Lower the vehicle.
20. Route the engine electrical harness.
21. Install the generator. Refer to «Generator Replacement (8.1L Engine)»(ref-277854-S23534712002008012100000) .
22. Install the ground cable bolt at the engine block. Tighten: Tighten the engine wiring harness bolt to 16 N.m (12 lb ft).
23. Install the vacuum lines to the engine.
24. Connect the TAC module electrical connector (1).
25. Install the radiator. Refer to «Radiator Replacement (8.1L)»(ref-277850-S41515550482008012100000) .
26. Install the A/C compressor. Refer to «Compressor Replacement (8.1L)»(ref-277853-S21358349192008012100000) .
27. Connect the fuel feed pipe (1) to the fuel rail.
28. Install the ignition coils. Refer to «Ignition Coil Replacement»(ref-277874-S38269318082008012100000) .
29. Connect the positive battery cable.
30. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
31. Install the air cleaner outlet duct.
32. Tighten the clamps at the throttle body and air cleaner. Tighten: Tighten the clamps to 4 N.m (35 lb in).
33. Remove fender covers from both fenders.
34. Remove the hood hinge bolts from the service position (2).
35. Lower the hood to the normal position.
36. Install the hood hinge bolts. Tighten: Tighten the hood hinge bolts to 25 N.m (18 lb ft).
37. Before starting a new engine or one that has been repaired, complete the following procedure. Prelube the engine. Refer to «Engine Prelubing»(ref-277941-S30090275652008012100000) . Remove the fuel pump fuse and disconnect the coil harness connectors, then crank the engine until oil pressure is present. Crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding. Install the fuel pump fuse and connect the coil harness connectors and start the engine and listen for unusual noises. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. If necessary install an oil pressure gage and measure the oil pressure. Run the engine at about 1000 RPM until the engine has reached normal operating temperature. Inspect for oil and or coolant leaks while the engine is running. Stop the engine and perform a final inspection for the proper engine oil and coolant levels. The final step is to perform the crankshaft position (CKP) sensor variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-277874-S33090055312008012100000) .

1. Raise and suitably support the vehicle with safety stands. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
2. Remove the oil pan drain plug and allow the engine oil to drain completely.
3. Clean the oil pan drain plug surface.
4. Remove the oil filter (2) from the engine block and allow the engine oil to drain completely.
5. Clean the oil filter surface.

1. Install a new oil filter (2) to the engine block. Tighten the oil filter per the oil filter manufacturers instruction printed on the oil filter box.
2. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 28 N.m (21 lb ft).
3. Lower the vehicle.
4. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(ref-277950-S15933951552008012100000) .

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug (401).
2. Drain the engine oil.
3. Remove the oil filter (435).
4. Remove the left side engine block coolant drain hole plug (131) and the right side engine block coolant drain hole plug.
5. Drain the engine coolant.

Crankshaft Balancer Removal

Tools Required

1. J 38416-B Harmonic Balancer Remover. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. J 42846 Crankshaft Protector Button. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. J 42847 Flywheel Holding Tool. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Install the J 42847 (1) to the starter bolt holes. See «Special Tools»(ref-277941-S08724385302008012100000) . Tighten: Tighten the J 42847 bolts to 50 N.m (37 lb ft).
2. Remove the crankshaft balancer bolt and washer.
3. Install the J 42846 onto the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Install the J 38416-B (2) in order to remove the crankshaft balancer. See «Special Tools»(ref-277941-S08724385302008012100000) . Place the legs of the J 38416-B into the recesses cast into the backside of the balancer inner hub. See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Tighten the center screw of the J 38416-B until the crankshaft balancer is removed from the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
6. Remove the J 38416-B . See «Special Tools»(ref-277941-S08724385302008012100000) .
7. Remove the crankshaft balancer.
8. Remove the J 42846 from the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
9. Remove the J 42847 (1). See «Special Tools»(ref-277941-S08724385302008012100000) .

Engine Flywheel Removal (Automatic Transmission)

1. Remove the bolts.
2. Remove the flexplate.

Engine Flywheel Removal (Manual Transmission)

1. Remove the engine flywheel bolts.
2. Remove the engine flywheel.

Crankshaft Rear Oil Seal Removal

1. Install the J 43320 guide pins into the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. Install the J 43320 over the guide pins. See «Special Tools»(ref-277941-S08724385302008012100000) .
3. Using a suitable drill, insert eight of the self-drilling sheet metal screws (1-8) into the rear crankshaft seal, using a criss-cross pattern. The self-drilling screws are included with the J 43320 . See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Thread the center bolt of J 43320 into the crankshaft to remove the seal. See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Remove the J 43320 guide pins from the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .

Clutch Pilot Bearing Removal

1. Using the J 43276 , remove the clutch pilot bearing. Install the J 43276-1 tool body into the clutch pilot bearing. Using a wrench, secure the J 43276-1 tool body. Insert the J 43276-2 forcing screw into the J 43276-1 tool body. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft. Rotate the J 43276-2 forcing screw counterclockwise in order to remove the J 43276-2 forcing screw from the J 43276-1 tool body. Remove the J 43276-1 tool body from the clutch pilot bearing.
2. Discard the clutch pilot bearing.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator from the oil level indicator tube.
2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube from the oil pan.
4. Remove the O-ring seal from the oil level indicator tube.

Exhaust Manifold Removal - Left Side

1. Remove the spark plug wires from the spark plugs and ignition coils.
2. Remove the exhaust manifold heat shield bolts and nuts.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold nuts and center bolt.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Remove the spark plugs, if required.
8. Remove the exhaust manifold studs, if required.

Exhaust Manifold Removal - Right Side

1. Remove the spark plug wires from the spark plugs and ignition coils.
2. Remove the exhaust manifold heat shield bolts and nuts.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold nuts and center bolt.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Remove the spark plugs, if required.
8. Remove the exhaust manifold studs, if required.

Water Crossover Removal

1. Remove the drive belt tensioner bolts.
2. Remove the drive belt tensioner.
3. Remove the thermostat bypass hose and clamps.
4. Remove the engine coolant crossover bolts.
5. Remove the engine coolant crossover.
6. Remove the crossover gaskets.
7. Remove the water outlet bolts/studs (310).
8. Remove the water outlet (311).
9. Remove the thermostat (312) from the coolant crossover (308).

Intake Manifold Removal

1. Remove the vacuum plug (513), if required.
2. Remove the throttle body nuts (503).
3. Remove the throttle body (502) and gasket (501).
4. Remove the studs (504), if required.
5. Remove the fuel injection fuel rail bolts/studs.
6. Remove the fuel injection fuel rail with injectors.
7. Remove the intake manifold bolts.
8. Remove the intake manifold.
9. Remove and discard the intake manifold side gaskets.
10. Remove and discard the intake manifold end seals.
11. Remove the splash shield.

Valve Rocker Arm Cover Removal - Left Side

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.
3. Replace the valve rocker arm cover gasket if it is cut or damaged.

Valve Rocker Arm Cover Removal - Right Side

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.
3. Replace the valve rocker arm cover gasket if it is cut or damaged.

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm nuts, the valve rocker arm balls and the valve rocker arms.
2. Remove the valve push rods.
3. Remove the valve rocker arm studs and push rod guides.

Cylinder Head Removal - Left Side

1. Remove and discard the cylinder head bolts (227, 228, 229).
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Discard the cylinder head gasket.

Cylinder Head Removal - Right Side

1. Remove and discard the cylinder head bolts (227, 228, 229).
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Discard the cylinder head gasket.

Valve Lifter Removal

1. Remove the valve lifter guide retainer bolts and retainer.
2. Remove the valve lifter guides.
3. Remove the valve lifters.
4. Some valve lifters may be stuck in their bore due to gum or varnish deposits. These valve lifters can be removed using J 3049-A .

Oil Pump Drive Removal

1. Remove the oil pump drive bolt.
2. Remove the oil pump drive.

Oil Pan Removal

1. Remove the oil level sensor from the oil pan.
2. Remove the oil pan bolts.
3. Remove the oil pan (400) and the oil pan gasket (404).

Oil Pump, Screen and Crankshaft Oil Deflector Removal

1. Remove the bolt that attaches the oil pump to the crankshaft rear bearing cap.
2. Remove the oil pump, driveshaft and retainer from the crankshaft rear bearing cap.
3. Separate the oil pump (422), driveshaft (420) and retainer (424).
4. Discard the driveshaft retainer (424).
5. Remove the crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.

Engine Front Cover Removal

1. Remove the camshaft position (CMP) sensor bolt.
2. Remove the CMP sensor.
3. Inspect the CMP sensor O-ring for cuts, cracks, tears, or damage.
4. Replace the O-ring, as required.
5. Remove the engine front cover bolts (521).
6. Remove the engine front cover (522).
7. Remove the engine front cover gasket (523).
8. Remove the crankshaft front oil seal (125) from the engine front cover.

Timing Chain and Sprockets Removal

1. Measure the camshaft timing chain free play. If the chain can be moved back and forth in excess of 16 mm (0.625 in), replace the chain and sprockets.
2. Remove the camshaft sprocket bolts.
3. Remove the camshaft sprocket and the timing chain.
4. Install the J 42846 (1) into the end of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Remove the crankshaft sprocket using a three jaw puller (2).

Camshaft Removal

1. Remove the camshaft retainer bolts.
2. Remove the camshaft retainer.
3. Install three 8-1.25 x 100 mm bolts in the camshaft front bolt holes.
4. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block.
5. Remove the bolts from the front of the camshaft.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer
2. J 42846 Crankshaft Protector Button. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Install the J 42846 onto the front of the crankshaft in order to rotate the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. Rotate the crankshaft until the piston is at the bottom of the stroke (BDC).
3. Remove the cylinder bore ridge as necessary. Place a cloth on top of the piston. Perform the cutting operation with a J 24270 . Refer to the manufacturer's instructions before using the J 24270 . Remove the J 24270 . Rotate the crankshaft until the piston is at top dead center (TDC). Remove the cloth and the cuttings. Repeat the procedure for each piston.
4. Remove the connecting rod nuts.
5. Remove the connecting rod cap and the connecting rod lower bearing.
6. Install rubber fuel line (1) onto the connecting rod bolts to prevent contact with the crankshaft journal.
7. Remove the piston, connecting rod, and connecting rod bearing.
8. Remove the rubber fuel line (1) from the connecting rod bolts.
9. Remove the remaining piston and the connecting rod assemblies.
10. Remove the J 42846 from the front of the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .

Crankshaft and Bearings Removal

1. Remove the CKP sensor bolt.
2. Apply penetrating oil to the CKP sensor-to-engine block mating surface. Allow the penetrating oil to soak for several minutes, to help loosen the O-ring from the engine block.
3. Twist the sensor to loosen the O-ring seal. When removing the sensor, pull the sensor straight out of the engine block at the same angle the sensor was installed.
4. Inspect both CKP sensor O-rings for cuts, cracks, tears, or damage. Replace the O-rings, as needed.
5. Remove the crankshaft bearing cap bolts and studs.
6. Remove the crankshaft bearing caps.
7. Remove the crankshaft bearings from the crankshaft bearing caps.
8. Remove the crankshaft.
9. Remove the crankshaft bearings from the engine block.

Oil Filter Adapter Removal

1. Using a hex wrench, loosen the oil filter fitting.
2. Remove the oil filter fitting.
3. Inspect the oil filter fitting.
4. Replace the oil filter fitting, if necessary.
5. Remove the oil bypass valves, if required. Unstake the tangs on the oil bypass valves and remove with long nose pliers.
6. Discard the oil bypass valves, if removed.

Engine Block Plug Removal

1. Remove the oil pressure sensor using J 41712 (1).
2. Remove the camshaft rear bearing hole plug: Obtain a suitable self-threading screw. Drill a hole into the plug. Install the self-threading screw. Pull on the screw until the plug is removed from the bore. IMPORTANT: Use care not to damage the camshaft bearings. An alternate method to remove the plug would be to insert a long shaft or bar through the front of the engine and drive the plug from the bore.
3. Remove the left side knock sensor heat shield bolts.
4. Remove the left side knock sensor heat shield.
5. Remove the left side knock sensor.
6. Remove the right side knock sensor heat shield (720) and bolts (721).
7. Remove the right side knock sensor (719).
8. Remove the engine block oil cooler hose fittings.
9. Remove the rear oil gallery plugs.
10. Remove the front oil gallery plugs.
11. Remove the left side oil gallery plug.
12. Remove the top oil gallery plugs.
13. Remove the engine block coolant drain hole plug.
14. Remove the engine block coolant heater, if equipped.

Camshaft Bearing Removal

1. Remove the camshaft rear bearing hole plug, if not previously removed. Insert a long bar through the front of the engine and drive the plug out of the bore.
2. Prior to bearing removal, inspect the camshaft bearings (1-5) for loose fit in the engine block.
3. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 .
4. Assemble the J 33049 .
5. Insert the J 33049 through the front of the engine block and into the bearing.
6. Tighten the expander assembly nut until snug.
7. Push the guide cone into the front camshaft bearing in position 1 to align the J 33049 .
8. Drive the inner bearings from positions 2, 3, and 4.
9. Assemble the J 33049 handle, expanding driver, and washer.
10. Insert the J 33049 into the outer camshaft bearings.
11. Drive the outer bearings from the bore.

Valve Installation

1. Lubricate the valve stems (232) with clean engine oil.
2. Insert the valves into their proper locations.
3. Install the necessary valve spring shims onto the cylinder head, if applicable.
4. Lubricate the rotators (216) with clean engine oil.
5. Install the rotators over the guide and on top of the cylinder head or valve spring shims, if applicable.
6. Lubricate the valve stem seal and the outside diameter (OD) of the valve guide with clean engine oil.
7. Install the valve stem oil seals (217) over the valve tip and onto the valve guides, using the J 43105 (1). See «Special Tools»(ref-277941-S08724385302008012100000) . Tap the valve stem seal onto the valve guide until the J 43105 fully seats the seal. See «Special Tools»(ref-277941-S08724385302008012100000) .
8. Install the valve springs (218).
9. Install the valve spring caps (219).
10. Use the J 8062 in order to compress the valve spring. Compress the spring enough to clearly see the valve stem key grooves of the valve.
11. Install the valve stem keys. Use grease to hold the keys in place. Ensure that the keys seat properly in the upper groove of the valve stem.
12. Release and remove the J 8062 .
13. Lightly tap the end of the valve stem with a plastic-face hammer in order to seat the keys.
14. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the engine coolant temperature (ECT) sensor.
15. Install the ECT sensor into the right cylinder head. Tighten: Tighten the ECT sensor to 50 N.m (37 lb ft).
16. Install the ECT sensor bracket and bolt. Tighten: Tighten the ECT sensor bracket bolt to 50 N.m (37 lb ft).
17. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the cylinder head coolant hole plug.
18. Install the cylinder head coolant hole plug into the left cylinder head. Tighten: Tighten the cylinder head coolant hole plug to 50 N.m (37 lb ft).

Engine Block Plug Installation

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the engine coolant drain hole plug threads.
2. Install the engine coolant drain hole plug into the block. Tighten: Tighten the engine coolant drain hole plug to 60 N.m (40 lb ft).
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the engine block coolant heater threads, if applicable.
4. Install the engine block coolant heater into the block. Tighten: Tighten the engine block coolant heater to 50 N.m (37 lb ft).
5. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the oil gallery plugs.
6. Install the engine block top oil gallery plugs. Tighten: Tighten the top oil gallery plugs to 20 N.m (15 lb ft).
7. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the left side oil gallery plug threads.
8. Install the engine block left side oil gallery plug. Tighten: Tighten the left side oil gallery plug to 30 N.m (22 lb ft).
9. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the front oil gallery plug threads.
10. Install the front oil gallery plugs. Tighten: Tighten the front oil gallery plugs to 30 N.m (22 lb ft).
11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the rear oil gallery plug threads.
12. Install the rear oil gallery plugs. Tighten: Tighten the rear oil gallery plugs to 20 N.m (15 lb ft).
13. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the engine block oil cooler hose fitting threads.
14. Install the engine block oil cooler hose fittings. Tighten: Tighten the engine block oil cooler hose fittings to 23 N.m (17 lb ft).
15. Install the left knock sensor to the engine block. Tighten: Tighten the left knock sensor to 20 N.m (15 lb ft).
16. Install the left side knock sensor heat shield.
17. Install the left side knock sensor heat shield bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
18. Install the right knock sensor (719) to the engine block. Tighten: Tighten the right side knock sensor to 20 N.m (15 lb ft).
19. Install the right side knock sensor heat shield (720) and bolts (721). Tighten: Tighten the bolts to 12 N.m (106 lb in).
20. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the engine block coolant drain hole plug threads.
21. Install the engine block coolant drain hole plugs. Tighten: Tighten the coolant drain hole plugs to 30 N.m (22 lb ft).
22. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) to the outside diameter (OD) of the new camshaft rear bearing hole plug.
23. Install the NEW camshaft rear bearing hole plug to the proper depth of 6.2-7.6 mm (0.244-0.299 in) (a).
24. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the oil pressure sensor threads.
25. Install the oil pressure sensor. Tighten: Using the J 41712 (1), tighten the oil pressure sensor to 30 N.m (22 lb ft).

Oil Filter Adapter Installation

1. If removed, install the new oil filter bypass valves. Stake the tangs on the oil filter bypass valves.
2. Install the oil filter fitting. Tighten: Tighten the oil filter fitting to 66 N.m (49 lb ft).

Crankshaft and Bearings Installation

Tools Required

1. J 8001 Dial Indicator Set
2. J 45059 Angle Meter

1. Install the crankshaft upper bearings into the block. Apply clean engine oil to the bearing surfaces.
2. Install the crankshaft lower bearings into the crankshaft bearing caps. Apply clean engine oil to the bearing surfaces.
3. Install the crankshaft.
4. Apply a 13 mm (0.5 in) (a) light film of sealant GM P/N 1052942, (Canadian P/N 10953466), or equivalent, to the rear bearing cap sealing face or to the rear bearing cap channel of the engine block. Apply the sealant to the bearing cap mating surface and bearing cap channel from the rear seal bore to the oil pan surface.
5. Install the crankshaft bearing caps in the location the caps were marked and originally removed from.
6. Install the bearing cap bolts and studs. Tighten: Tighten the bearing cap 1-4 bolts a first pass to 30 N.m (22 lb ft). Tighten the bearing cap 1-4 studs a first pass to 30 N.m (22 lb ft). Tighten the bearing cap 1-4 bolts a final pass an additional 90 degrees, using the J 45059 . Tighten the bearing cap 1-4 studs a final pass an additional 80 degrees, using the J 45059 . Tighten the bearing cap 5 bolts and studs to 30 N.m (22 lb ft). Loosen the bearing cap 5 bolts and studs. Tighten the bearing cap 5 bolts and studs to 5 N.m (44 lb in).
7. Thrust the crankshaft firmly rearward.
8. Thrust the crankshaft firmly forward. Tighten: Tighten the bearing cap 5 bolts a first pass to 30 N.m (22 lb ft). Tighten the bearing cap 5 studs a first pass to 30 N.m (22 lb ft). Tighten the bearing cap 5 bolts a final pass an additional 90 degrees, using the J 45059 . Tighten the bearing cap 5 bolts a final pass an additional 80 degrees, using the J 45059 .
9. Measure the crankshaft end play as follows: Install the J 8001 , or equivalent, to the cylinder block, with the dial indicator plunger against one of the counterweights of the crankshaft. Firmly thrust the end of the crankshaft first rearward then forward. This lines up the rear crankshaft bearing and the crankshaft thrust surfaces. With the crankshaft pushed forward, zero the dial indicator. Move the crankshaft rearward, and read the end play measurement on the dial indicator. An optional method is to insert a feeler gage between the crankshaft and the bearing surface and measure the clearance. Refer to «Engine Mechanical Specifications»(ref-277941-S07562565932008012100000) . If the correct end play cannot be obtained, inspect for the following conditions: Verify that the correct size crankshaft bearing has been installed. Refer to «Engine Mechanical Specifications»(ref-277941-S07562565932008012100000) . Inspect the crankshaft thrust wall surface or surfaces for wear and/or excessive runout. Refer to «Engine Mechanical Specifications»(ref-277941-S07562565932008012100000) . Turn the crankshaft in order to inspect for binding. If the crankshaft does not turn freely, loosen the crankshaft bearing bolts and studs, 1 cap at a time, until the tight bearing is located. The following conditions could cause a lack of clearance at the bearing: Burrs on the crankshaft bearing cap Foreign material between the bearing and the block Foreign material between the bearing and the bearing cap A faulty crankshaft bearing Improper bearing size
10. Inspect the CKP sensor O-ring for cuts, cracks, tears, or damage. Replace the O-ring, as needed. Lubricate the CKP sensor O-ring with clean engine oil.
11. Install the CKP sensor into the block. There may be a slight resistance as the O-ring seats into the engine block.
12. Apply thread adhesive GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the CKP sensor bolt.
13. Install the CKP sensor bolt. Tighten: Tighten the CKP sensor bolt to 12 N.m (106 lb in).

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor
2. J 8087 Cylinder Bore Gage
3. J 45059 Angle Meter

Piston Installation

1. Coat the following components with clean engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install rubber fuel lines (1) onto the connecting rod bolts.
3. Position the right bank piston and connecting rod assemblies for proper installation. The arrow (1) on the top of the piston should be facing the front of the engine and the master or larger flange (2) of the connecting rod facing rear of engine.
4. Position the left bank piston and connecting rod assemblies for proper installation. The arrow (1) on the top of the piston should be facing the front of the engine and the master or larger flange (2) of the connecting rod facing front of engine.
5. Install the piston, connecting rod, and upper connecting rod bearing through the top of the engine block.
6. Install the J 8037 onto the piston and compress the piston rings.
7. Use the J 8037 and lightly tap the top of the piston with a wooden hammer handle.
8. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.
9. Use the rubber fuel lines (1) in order to guide the connecting rod onto the crankshaft journal.
10. Remove the rubber fuel lines.
11. Install the connecting rod cap and lower connecting rod bearing.
12. Install the NEW connecting rod nuts. Tighten: Tighten the connecting rod nuts a first pass to 30 N.m (22 lb ft). Tighten the connecting rod nuts a final pass an additional 90 degrees, using the J 45059 .
13. Once the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to ensure they have side clearance.
14. Use a feeler gage or a dial indicator in order to measure the side clearance between the connecting rod caps. The rod side clearance should be 0.384-0.686 mm (0.0151-0.0270 in).

Camshaft Installation

1. Lubricate the following components with clean engine oil: The camshaft lobes The camshaft bearing journals The camshaft bearings
2. Install the 3 8-1.25 x 100 mm bolts in the camshaft front bolt holes.
3. Using the bolts as a handle, install the camshaft.
4. Remove the 3 bolts from the front of the camshaft.
5. Install the camshaft retainer.
6. Install the camshaft retainer bolts. Tighten: Tighten the camshaft retainer bolts to 12 N.m (106 lb in).

Timing Chain and Sprockets Installation

1. Use the J 22102 in order to install the crankshaft sprocket. See «Special Tools»(ref-277941-S08724385302008012100000) . Align the keyway of the crankshaft sprocket with the crankshaft pin.
2. Inspect the sprocket pin for proper installation. Refer to «Crankshaft and Bearings Cleaning and Inspection»(ref-277941-S34536460262008012100000) .
3. Rotate the crankshaft until the crankshaft sprocket alignment mark is in the 12 o'clock position.
4. Install the camshaft sprocket and timing chain.
5. Ensure the crankshaft sprocket is aligned to the 12 o'clock position and the camshaft sprocket is aligned to the 6 o'clock position.
6. Install camshaft sprocket bolts. Tighten: Tighten the camshaft sprocket bolts to 30 N.m (22 lb ft).

Engine Front Cover Installation

1. Lubricate the outer sealing surface of the crankshaft front oil seal lightly with clean engine oil. DO NOT lubricate the inner portion of the seal.
2. Position the NEW crankshaft front oil seal in the engine front cover so the mark (1) on the rear of the seal is in the 12 o'clock position. Second design oil seals do not have an alignment mark on the rear face. The seal may be installed in any position.
3. Using the J 42851 , install the crankshaft front oil seal (1). See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Install the front cover locating pins (129), if required.
5. Apply a 3-4 mm (0.12-0.16 in) bead of sealant GM P/N 12346141 (Canadian P/N 10953433), or equivalent, in 2 sealant points (1) on the engine block where the front cover meets the oil pan.
6. Apply a 3-4 mm (0.12-0.16 in) bead of sealant GM P/N 12346141 (Canadian P/N 10953433), or equivalent, in 2 sealant points (1) across the flange where the gasket ends at the bottom of the front cover.
7. Install the engine front cover gasket into the front cover.
8. Install the engine front cover. Hold the front cover (1) up to the crankshaft (2). Lift the front cover (1) while sliding the cover over the crankshaft (2). Slide the front cover towards the engine block (5) while keeping the cover raised. Lower the cover down over the dowel pin (4), allowing the front cover to rest on the sealant (3).
9. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts (1-6) in sequence a first pass to 6 N.m (53 lb in). Tighten the engine front cover bolts (1-6) in sequence a final pass to 12 N.m (106 lb in).
10. Inspect the camshaft position (CMP) sensor O-ring for cuts, cracks, tears, or damage. Replace the O-ring, as needed.
11. Apply a light film of clean engine oil to the CMP sensor O-ring.
12. Install the CMP sensor.
13. Install the CMP sensor bolt. Tighten: Tighten the CMP sensor bolt to 12 N.m (106 lb in).

Oil Pump, Screen and Crankshaft Oil Deflector Installation

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 50 N.m (37 lb ft).
3. Apply clean engine oil into the oil pump through the outlet oil hole. Rotate the pump in both directions in order to prime and lubricate the pump.
4. Assemble the oil pump, driveshaft, and a NEW retainer.
5. Install the oil pump assembly. Position the oil pump onto the locating pins.
6. Install the bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 75 N.m (56 lb ft).
7. Pour clean engine oil into the oil pump pick-up screen.

Oil Pan Installation

1. Apply sealant GM P/N 12346141 (Canadian P/N 10953433) to the side of the front cover (1) and rear crankshaft bearing cap (2), on both the left and right sides, 4 locations total.
2. Install the new oil pan gasket (404) into the oil pan groove.
3. Install the oil pan (400).
4. Install the oil pan bolts (1-12).
5. Tighten the oil pan bolts in sequence. Tighten: Tighten the oil pan bolts (1-12) a first pass in sequence to 10 N.m (89 lb in). Tighten the oil pan bolts (1-12) a final pass in sequence to 25 N.m (18 lb ft).
6. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 28 N.m (21 lb ft).
7. Lubricate the oil level sensor O-ring with engine oil.
8. Install the oil level sensor. Tighten: Tighten the oil level sensor to 20 N.m (15 lb ft).

Oil Pump Drive Installation

1. Apply grease to the oil pump drive gear for ease of assembly.
2. Line up the oil pump drive gear with the oil pump driveshaft.
3. Install the oil pump drive. Ensure the oil pump drive is fully seated in the engine block.
4. Install the oil pump drive bolt. Tighten: Tighten the oil pump drive bolt to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Apply clean engine oil to the valve lifter rollers.
2. Install the valve lifters.
3. Install the valve lifter guides over the flats on the valve lifters. Ensure the rollers of the valve lifters are properly aligned with the camshaft lobes.
4. Install the valve lifter guide retainer.
5. Install the valve lifter guide retainer bolts. Tighten: Tighten the valve lifter guide retainer bolts to 25 N.m (18 lb ft).

Cylinder Head Installation - Left Side

1. Place the cylinder head gasket in position over the cylinder head locating pins.
2. Install the cylinder head to the block.
3. If not pre-applied to the new cylinder head bolts (227, 228, 229), apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the cylinder head bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) .
4. Install the cylinder head bolts. Tighten: Tighten the bolts (1-18) a first pass in sequence to 30 N.m (22 lb ft). Tighten the bolts (1-18) a second pass in sequence to 30 N.m (22 lb ft), then an additional 120 degrees, using the J 45059 . Tighten the bolts, 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17, an additional 60 degrees, bolts 15 and 18 an additional 45 degrees, and bolts, 4, 5, 12, 13, an additional 30 degrees a final pass in sequence, using the J 45059 .

Cylinder Head Installation - Right Side

1. Place the cylinder head gasket in position over the cylinder head locating pins.
2. Install the cylinder head to the block.
3. If not pre-applied to the new cylinder head bolts (227, 228, 229), apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the cylinder head bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-277941-S29090895732008012100000) .
4. Install the cylinder head bolts. Tighten: Tighten the bolts (1-18) a first pass in sequence to 30 N.m (22 lb ft). Tighten the bolts (1-18) a second pass in sequence to 30 N.m (22 lb ft), then an additional 120 degrees, using the J 45059 . Tighten the bolts, 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17, an additional 60 degrees, bolts 15 and 18 an additional 45 degrees, and bolts, 4, 5, 12, 13, an additional 30 degrees a final pass in sequence, using the J 45059 .

Valve Rocker Arm and Push Rod Installation

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the valve rocker arm stud-to-cylinder head threads. Apply the sealer to a minimum of 6 threads.
2. Install the push rod guides and valve rocker arm studs onto the cylinder head. Tighten: Tighten the valve rocker arm studs to 50 N.m (37 lb ft).
3. Install the valve push rods.
4. Apply grease or clean engine oil to the valve rocker arm and valve rocker arm ball bearing surface.
5. Install the valve rocker arms, the valve rocker arm balls, and the valve rocker arm nuts. Tighten: Tighten the valve rocker arm nuts slowly to 35 N.m (26 lb ft), while guiding the tips of the rocker arms over the tips of the valves.

Intake Manifold Installation

1. Install the splash shield.
2. Ensure the splash shield (2) snap fits between the cylinder heads (1).
3. Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) to the 4 engine block/cylinder head locations.
4. Install the new intake manifold end seals.
5. Apply a 5 mm (0.2 in) bead of GM P/N 12346141 (Canadian P/N 10953433) sealer (1) onto the end seals at the 4 engine block/cylinder head locations.
6. Install the new intake manifold side gaskets onto the cylinder heads.
7. Ensure the intake manifold gasket tabs align with the hole in the head gasket.
8. Ensure the intake manifold gasket tabs align with the slot in the intake manifold end seals.
9. Install the intake manifold onto the engine block.
10. Install the NEW intake manifold bolts.
11. Tighten the intake manifold bolts (1-10) in sequence, using 4 passes. Tighten: Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in). Tighten the intake manifold bolts a second pass in sequence to 8 N.m (71 lb in). Inspect the intake manifold joints for signs of intake manifold shifting. Correct, as required. Tighten the intake manifold bolts a third pass in sequence to 12 N.m (106 lb in). Tighten the intake manifold bolts a final pass in sequence to 15 N.m (11 lb ft).
12. Install the fuel injection fuel rail with injectors.
13. Install the fuel injection fuel rail bolts/studs. Tighten: Tighten the fuel injection fuel rail bolts/studs to 12 N.m (106 lb in).
14. Install the throttle body gasket (501) and throttle body (502).
15. Install the throttle body nuts (503). Tighten: Tighten the throttle body nuts to 10 N.m (89 lb in).
16. Install the vacuum plug (513).

Valve Rocker Arm Cover Installation - Left Side

1. Install a new valve rocker arm cover gasket if the gasket was removed from the valve rocker arm cover.
2. Install the valve rocker arm cover.
3. Install the valve rocker arm cover bolts.
4. Tighten the valve rocker arm cover bolts (1-7) in sequence, using 2 passes. Tighten: Tighten the valve rocker arm cover bolts (1-7) a first pass to 6 N.m (54 lb in). Tighten the valve rocker arm cover bolts (1-7) a final pass to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right Side

1. Install a new valve rocker arm cover gasket if the gasket was removed from the valve rocker arm cover.
2. Install the valve rocker arm cover.
3. Install the valve rocker arm cover bolts.
4. Tighten the valve rocker arm cover bolts (1-7) in sequence, using 2 passes. Tighten: Tighten the valve rocker arm cover bolts (1-7) a first pass to 6 N.m (54 lb in). Tighten the valve rocker arm cover bolts (1-7) a final pass to 12 N.m (106 lb in).

Water Pump Installation

1. Install the water pump and gaskets.
2. Install the water pump bolts. Tighten: Tighten the water pump bolts (1-4) a first pass in sequence to 25 N.m (18 lb ft). Tighten the water pump bolts (1-4) a final pass in sequence to 50 N.m (37 lb ft).
3. Install the water pump pulley (303) and bolts (302).
4. Use the J 41240 in order to retain the water pump pulley. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).

Water Crossover Installation

1. Install the thermostat (312) with the seal into the engine coolant crossover (308).
2. Install the water outlet (311).
3. Install the water outlet bolts (310). Tighten: Tighten the bolts to 30 N.m (22 lb ft).
4. Install the gaskets and the engine coolant crossover.
5. Install the bolts. Tighten: Tighten the engine coolant crossover bolts to 50 N.m (37 lb ft).
6. Install the thermostat bypass hose and clamps.
7. Install the drive belt tensioner.
8. Install the drive belt tensioner bolts. Tighten: Tighten the drive belt tensioner bolts to 50 N.m (37 lb ft).

Exhaust Manifold Installation - Left Side

1. Install the exhaust manifold studs into the cylinder head, if necessary. Tighten: Tighten the exhaust manifold studs to 20 N.m (15 lb ft).
2. Install the NEW left exhaust manifold gasket.
3. Install the left exhaust manifold.
4. Install the left exhaust manifold nuts and center bolt. Tighten: Tighten the left exhaust manifold center bolt to 35 N.m (26 lb ft). Tighten the left exhaust manifold nuts to 16 N.m (12 lb ft).
5. Install the left exhaust manifold heat shield.
6. Install the left exhaust manifold heat shield bolts and nuts. Tighten: Tighten the left exhaust manifold heat shield bolts and nuts to 25 N.m (18 lb ft).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 30 N.m (22 lb ft).
8. Install the spark plug wires to the spark plugs and ignition coils.

Exhaust Manifold Installation - Right Side

1. Install the exhaust manifold studs into the cylinder head, if necessary. Tighten: Tighten the exhaust manifold studs to 20 N.m (15 lb ft).
2. Install the NEW right exhaust manifold gasket.
3. Install the right exhaust manifold.
4. Install the right exhaust manifold nuts and center bolt. Tighten: Tighten the right exhaust manifold center bolt to 35 N.m (26 lb ft). Tighten the right exhaust manifold nuts to 16 N.m (12 lb ft).
5. Install the right exhaust manifold heat shield.
6. Install the right exhaust manifold heat shield bolts and nuts. Tighten: Tighten the right exhaust manifold heat shield bolts and nuts to 25 N.m (18 lb ft).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 30 N.m (22 lb ft).
8. Install the spark plug wires to the spark plugs and ignition coils.

Oil Level Indicator and Tube Installation

1. Install a NEW O-ring seal onto the oil level indicator tube.
2. Install the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the exhaust manifold stud.
4. Install the oil level indicator tube bracket bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator into the oil level indicator tube.

Clutch Pilot Bearing Installation

1. Install the NEW clutch pilot bearing.
2. Measure to ensure the proper installation depth is obtained. The bearing (138) should be 14.650-15.650 mm (0.577-0.616 in) (a) from the lip of the crankshaft or 6.400-7.400 mm (0.252-0.291 in) (b) from the crankshaft flange.

Crankshaft Rear Oil Seal Installation

1. Make sure the crankshaft rear chamfer is free of grit, loose rust, and burrs. Correct as needed.
2. Apply a very light film of oil onto the crankshaft sealing surface. DO NOT apply oil to the sealing surface of the engine block.
3. Install the seal on the J 42849 . See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Position J 42849 against the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) . Thread the attaching screws into the tapped holes in the crankshaft.
5. Tighten the screws securely with a screwdriver in order to ensure that the seal is installed squarely over the crankshaft.
6. Rotate the center nut until the J 42849 bottoms. See «Special Tools»(ref-277941-S08724385302008012100000) .
7. Remove the J 42849 . See «Special Tools»(ref-277941-S08724385302008012100000) .

Engine Flywheel Installation (Automatic Transmission)

1. Install the engine flex plate.
2. Install the engine flex plate bolts. Tighten the bolts following a criss-cross pattern. Tighten: Tighten the engine flex plate bolts a first pass to 40 N.m (30 lb ft). Tighten the engine flex plate bolts a second pass to 80 N.m (59 lb ft). Tighten the engine flex plate bolts a final pass to 100 N.m (74 lb ft).

Engine Flywheel Installation (Manual Transmission)

1. Install the engine flywheel.
2. Install the engine flywheel bolts. Tighten the bolts following a criss-cross pattern. Tighten: Tighten the engine flywheel bolts a first pass to 40 N.m (30 lb ft). Tighten the engine flywheel bolts a second pass to 80 N.m (59 lb ft). Tighten the engine flywheel bolts a final pass to 100 N.m (74 lb ft).

Crankshaft Balancer Installation

Tools Required

1. J 42845 Crankshaft Balancer Installer. See «Special Tools»(ref-277941-S08724385302008012100000) .
2. J 42847 Flywheel Holding Tool. See «Special Tools»(ref-277941-S08724385302008012100000) .

1. Install the J 42847 (1) to the starter bolt holes. See «Special Tools»(ref-277941-S08724385302008012100000) . Tighten: Tighten the J 42847 bolts to 50 N.m (37 lb ft).
2. Install the balancer onto the end of the crankshaft.
3. Use the J 42845 (1) in order to install the balancer. See «Special Tools»(ref-277941-S08724385302008012100000) .
4. Tighten the J 42845 until the crankshaft balancer is completely seated against the crankshaft sprocket. See «Special Tools»(ref-277941-S08724385302008012100000) .
5. Remove the J 42845 from the crankshaft. See «Special Tools»(ref-277941-S08724385302008012100000) .
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt to 255 N.m (189 lb ft).
7. Remove the J 42847 (1). See «Special Tools»(ref-277941-S08724385302008012100000) .