Engine Mechanical - 4.2L: Other Chevrolet TrailBlazer I

Intermittent

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

Front Engine Mount

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

Scheme 1214

1. Install a pole jack underneath the oil pan.
2. Insert a block of wood between the engine oil pan and the pole jack.
3. Raise the jack until the wooden block contacts the engine oil pan.
4. Raise the engine in order to place a slight tension on the rubber cushion. Observe both mounts while raising the engine.
5. Replace the mounts if any of the following conditions exist: Hard rubber surface covered with heat check cracks The rubber cushion separated from the metal plate of the mount The rubber cushion is split through the center The mount is leaking
6. If there is movement between a metal plate of the mount and its attaching points, lower the engine and tighten the bolts or nuts attaching the mount to the engine, the frame or the bracket.

Scheme 1215

Scheme 1216

Scheme 1217

Scheme 1218

Scheme 1219

Scheme 1220

Scheme 1221

1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
2. Remove the cooling fan. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
3. Remove the MAP sensor electrical connector and the retainer (1).
4. Remove the MAP sensor (2).
5. Remove the left shock module (if frame mount is being removed). Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
6. Remove the right and the left upper engine mount nuts.
7. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield mount bolts.
10. Remove the engine protection shield. IMPORTANT: When placing jack onto the oil pan, pay close attention to not damage the oil level sender.
11. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
12. Raise the engine with the jack just enough to clear the engine mount studs.
13. Remove the left engine mount from the bracket.
14. Remove the left engine mount bracket bolts.
15. Remove the left engine mount bracket.
16. Remove the left frame engine mount bracket bolts, if required.
17. Remove the left frame engine mount bracket, if required.

Scheme 1222

Scheme 1223

Scheme 1224

Scheme 1225

Scheme 1226

Scheme 1227

Scheme 1228

Scheme 1229

1. Install the left frame engine mount bracket, if removed. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the left frame engine mount bracket bolts, if removed. Tighten Tighten the mount bracket bolts to 110 N.m (81 lb ft).
3. Install the left engine mount bracket and secure the bracket with the bolts (1). Tighten Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the left engine mount onto the bracket.
5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts. Tighten Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the jack from under the vehicle.
8. Install the engine protection shield and secure the shield with the bolts. Tighten Tighten the engine protection shield bolts to 25 N.m (18 lb ft).
9. Install the right and the left lower engine mount nuts. Tighten Torque the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the left shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
16. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.

Scheme 1230

Scheme 1231

Scheme 1232

Scheme 1233

Scheme 1234

Scheme 1235

Scheme 1236

1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
2. Remove the cooling fan. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
3. Remove the MAP sensor electrical connector and retainer (1).
4. Remove the MAP sensor (2).
5. Remove the right shock module, if frame engine mount is being removed. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
6. Remove the right and the left upper engine mount nuts.
7. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield mounting bolts.
10. Remove the engine protection shield. IMPORTANT: When placing jack onto the oil pan, pay close attention to not damaging the oil level sender.
11. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
12. Raise the engine with the jack just enough to clear the engine mount studs.
13. Remove the right engine mount from the bracket.
14. Remove the right engine mount bracket bolts.
15. Remove the right engine mount bracket.
16. Remove the right frame engine mount bracket bolts, if required.
17. Remove the right frame engine mount bracket, if required.

Scheme 1237

Scheme 1238

Scheme 1239

Scheme 1240

Scheme 1241

Scheme 1242

Scheme 1243

1. Install the right frame engine mount bracket, if removed.
2. Install the right frame engine mount bracket bolts, if removed. Tighten Tighten the mount bracket bolts to 110 N.m (81 lb ft).
3. Install the right engine mount bracket and secure with the bolts (1). Tighten Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the right engine mount.
5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts. Tighten Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the floor jack from under the vehicle.
8. Install the engine protection shield and secure with the bolts. Tighten Tighten the engine protection shield bolts to 25 N.m (18 lb ft).
9. Install the right and the left lower engine mount nuts. Tighten Tighten the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the right shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
16. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.

Scheme 1244

Scheme 1245

Scheme 1246

Scheme 1247

1. Disconnect the crankcase dirty air hose from the intake manifold.
2. Disconnect the crankcase dirty air hose from the PCV orifice tube.
3. Loosen the throttle body clamps (2).
4. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator.
5. Remove the 2 resonator to engine bolts (4) from the air cleaner outlet resonator (5).
6. Lift up the front of the air cleaner outlet resonator (2).
7. Disconnect the crankcase clean air hose from the valve cover port.
8. Disconnect the crankcase clean air hose from the air cleaner outlet resonator (2).

Scheme 1248

Scheme 1249

Scheme 1250

Scheme 1251

1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2).
2. Connect the crankcase clean air hose to the valve cover port. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5). Tighten Tighten the bolts to 6 N.m (53 lb in).
4. Tighten the throttle body clamps (2). Tighten Tighten the clamps to 4 N.m (35 lb in).
5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator.
6. Connect the crankcase dirty air hose to the intake manifold.
7. Connect the crankcase dirty air hose to the PCV orifice tube.

Scheme 1252

Scheme 1253

Scheme 1254

Scheme 1255

1. Remove the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .
2. Remove the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
3. Disconnect all harnesses from the engine harness bracket.
4. Remove the front differential vent hose from the bracket clip.
5. Remove the engine harness bracket bolt and remove the bracket.
6. Disconnect the MAP sensor electrical connector.
7. Disconnect the crankcase ventilation hose.
8. Disconnect the brake hose at the booster.
9. Remove the generator. Refer to GENERATOR REPLACEMENT (4.2L ENGINE) in Engine Electrical.
10. Loosen and remove the intake manifold bolts.
11. Remove the intake manifold.

Scheme 1256

Scheme 1257

Scheme 1258

Scheme 1259

1. Install a new intake manifold gasket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the intake manifold onto the engine and secure the manifold with the bolts. Tighten Tighten the intake manifold bolts to 10 N.m (89 lb in).
3. Install the generator. Refer to GENERATOR REPLACEMENT (4.2L ENGINE) or in Engine Electrical.
4. Install the brake hose to the booster.
5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent.
6. Install the crankcase ventilation hose.
7. Install the MAP sensor electrical connector.
8. Install the engine harness bracket. Secure the bracket with the bolt. Tighten Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
9. Install the front differential vent hose to the engine harness bracket clip.
10. Install all harnesses to the original location onto the engine harness bracket.
11. Install the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
12. Install the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .

Scheme 1260

Scheme 1261

Scheme 1262

Scheme 1263

Scheme 1264

Scheme 1265

Scheme 1266

1. Remove the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188499-S37928601202005090700000) .
2. Discharge the A/C. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
3. Remove the A/C line at the oil level indicator tube bracket nut.
4. Remove the A/C line from the accumulator.
5. Remove the A/C bracket bolt from the engine lift hook.
6. Remove the engine lift bracket.
7. Disconnect the ignition control module electrical connectors.
8. Loosen and remove the ignition control module bolts.
9. Remove the ignition control module.
10. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage the clips that hold the housing in place.
11. Disconnect the fuel injection harness electrical connector.
12. Loosen and remove the camshaft cover bolts.
13. Remove the camshaft cover.
14. Clean and inspect the camshaft cover. Refer to «Camshaft Cover Cleaning and Inspection»(ref-188499-S17561042992005090700000) .

Scheme 1267

Scheme 1268

Scheme 1269

Scheme 1270

Scheme 1271

1. Install a new camshaft cover seal.
2. Install new rubber ignition control module seals. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the camshaft cover and secure with the cam cover bolts. Tighten Tighten the camshaft cover bolts to 10 N.m (89 lb in).
4. Install the ignition control modules and secure the modules with bolts. Tighten Tighten the ignition coil bolts to 10 N.m (89 lb in).
5. Connect the ignition control module electrical connectors.
6. Install the fuel injector electrical connectors.
7. Install the engine electrical harness housing (1).
8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. Tighten Tighten the A/C line bracket nut to 7 N.m (62 lb in).
9. Install the engine lift bracket and secure the lift hook with the bolts. Tighten Tighten the lift bracket bolts to 50 N.m (37 lb ft).
10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten Tighten the A/C bracket bolt to 10 N.m (89 lb in).
11. Install the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188499-S37928601202005090700000) .
12. Recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.

Honing Procedure

Scheme 1272

1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. DO NOT hone to a final grade with a coarse or medium-grade stone. Leave sufficient metal so that all the stone marks will be removed with the fine grade stones. Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45-65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore. Repeatedly check the cylinder bore fit with the selected piston. All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
5. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. 5.1. Scrub the cylinder bores with a stiff bristle brush. 5.2. Rinse the cylinder bores thoroughly with clean hot water. 5.3. Dry the cylinder bores with a clean rag. 5.4. Do not allow any abrasive material to remain in the cylinder bores. Abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
6. Perform final measurements of the piston and the cylinder bore.
7. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Boring Procedure

Scheme 1273

1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline.
2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar.
3. Follow the instructions furnished by the manufacturer regarding use of the boring equipment.
4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction.
5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly.
6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings, and the cylinder bores.

Thread Repair

Tools Required

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

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

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

Scheme 1274

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

Scheme 1275

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

Scheme 1276

Recessed Thread Repair

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

Scheme 1277

Scheme 1278

Scheme 1279

Scheme 1280

Scheme 1281

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Scheme 1284

Scheme 1285

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Scheme 1291

Scheme 1292

1. Install a stop collar (2) on the counterbore drill (1), if required. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Drill the hole until the stop collar contacts the surface of the base material.
2. Drill out the threads of the damaged hole. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
3. Using compressed air, clean out any chips. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
4. Using a suitable tapping wrench, tap the threads of the drilled hole. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
5. Using compressed air, clean out any chips.
6. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
7. Using compressed air, clean out any chips. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
12. Install the insert until the flange (2) of the insert contacts the counterbored surface. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
13. Continue to rotate the driver installation tool (1) through the insert (2).
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Tapered Pipe Thread Repair

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

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

Scheme 1293

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Scheme 1300

Scheme 1301

Scheme 1302

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Scheme 1307

Scheme 1308

1. Drill out the threads of the damaged hole. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
2. Using compressed air, clean out any chips. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
3. Using a suitable tapping wrench, tap the threads of the drilled hole.
4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
5. Using compressed air, clean out any chips.
6. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
7. Using compressed air, clean out any chips. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole. IMPORTANT: If the insert will not thread down until the flange contacts the surface of the base material remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
12. Install the insert until the flange (2) of the insert contacts the surface of the base material. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3).
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Cylinder Head Bolt Hole Thread Repair

The cylinder head bolt hole required tools consist of the following

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

Scheme 1309

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

Scheme 1310

Scheme 1311

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Scheme 1320

Scheme 1321

Scheme 1322

Scheme 1323

1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
6. Drill out the threads of the damaged hole. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
7. Using compressed air, clean out any chips. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
8. Using a suitable tapping wrench, tap the threads of the drilled hole.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt hole until the first mark (1) on the tap aligns with the top of the drill bushing (3). IMPORTANT: Remove the fixture plate prior to installing the insert with the installer tool.
10. Remove the fixture plate bolts (2).
11. Remove the fixture plate (3) and bushing (1). IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
12. Using compressed air, clean out any chips.
13. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
14. Using compressed air, clean out any chips. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
15. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
16. Install the insert (2) onto the driver installation tool (1).
17. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2).
18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
20. Install the insert until the flange of the insert contacts the counterbored surface. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the tapped hole.

Crankshaft Main Bolt Hole Thread Repair

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

Scheme 1324

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

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

Scheme 1325

Scheme 1326

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Scheme 1330

Scheme 1331

Scheme 1332

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Scheme 1338

Scheme 1339

1. Position the fixture plate (3) with the bushing (2), installed over the crankshaft main cap bolt hole to be repaired.
2. Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.
3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).
6. Drill out the threads of the damaged hole. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
7. Using compressed air, clean out any chips. IMPORTANT: Do not remove the fixture plate, ensure the fixture plate is installed during the machining and installation processes of the insert. During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
8. Using a suitable tapping wrench, tap the threads of the drilled hole.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2). IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
10. Using compressed air, clean out any chips.
11. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
12. Using compressed air, clean out any chips. IMPORTANT: Do not remove the fixture plate, ensure the fixture plate is installed during the installation process of the insert. Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
13. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
14. Install the insert (2) onto the driver installation tool (1).
15. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
16. Install the insert and installation driver (1) into the tapped hole.
17. Start the insert into the threaded hole. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
18. Install the insert until the flange of the insert contacts the counterbored surface. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
19. Continue to rotate the driver installation tool through the insert.
20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
21. Inspect the insert for proper installation into the tapped hole.
22. Remove the fixture plate bolts (1).
23. Remove the fixture plate (3) and bushing (2).

Engine Prelubing

Tools Required

J 45299 Engine Preluber

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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

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1. Add sealer GM P/N United States 12346004, GM P/N Canada 10953480 to the plug threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the engine block oil gallery plug to rear of block. Tighten Tighten the engine block oil gallery plug to 80 N.m (40 lb ft).
3. Add sealer GM P/N United States 12346004, GM P/N Canada 10953480 to the plug threads.
4. Install the engine block oil gallery plugs to front and left of block. Tighten Tighten the side engine block oil gallery plugs to 35 N.m (26 lb ft). Tighten the front (1) engine block oil gallery plug to 80 N.m (40 lb ft).
5. Add sealer GM P/N United States 12346004, GM P/N Canada 10953480 to the coolant temperature sensor threads.
6. Install the coolant temperature sensor. Tighten Tighten the coolant temperature sensor to 20 N.m (15 lb ft).
7. Add sealer GM P/N United States 12346004, GM P/N Canada 10953480 to the EVAP solenoid bolt threads. Tighten Tighten the EVAP solenoid bolt to 10 N.m (89 lb in).
8. Install the knock sensors. Tighten Tighten the knock sensors to 25 N.m (18 lb ft).
9. Add sealer GM P/N United States 12346004, GM P/N Canada 10953480 to the crankshaft position sensor bolt.
10. Install the crankshaft position sensor and bolt. Tighten Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).

Engine Block

The lost foam all aluminum engine block utilizes a deep skirt design for increased rigidity. The cylinders are positioned in a straight in-line 6 cylinder orientation. The crankshaft bearing caps have a bearing beam or "ladder" for enhanced structural rigidity and vibration reduction.

Oil Pan

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

Crankshaft

The crankshaft is a nodular iron design with seven main bearings.

Connecting Rods

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

Pistons

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

Cylinder Head

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

Valve Train

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

Fuel System

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

Oil Pump

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

Engine Covers

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

New Product Information

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

Changes may include one or more of the following items

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

New Sealants and/or Adhesives

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

New Features on the LL8 Engine

1. Pan-axle design oil pan
2. Exhaust camshaft position actuator
3. Exhaust camshaft position actuator valve
4. Jack bolts on the front cover, rear cover, and oil pan

Engine Features

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

Cleanliness and Care

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

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

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

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

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

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to Battery in Electrical.

Separating Parts

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

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use jack screws to separate components. IMPORTANT: Do not use any other method or technique in order to remove the gasket material from a components. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand paper Power tools These methods of cleaning may damage the component. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces. IMPORTANT: Do not allow the sealant to enter any blind threaded holes. The sealant may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Sealant Types

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

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

Aerobic Type Room Temperature Vulcanizing (TRV) Sealant

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

Use the following information when using RTV sealant

1. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Any other surfaces where a different type of sealant is specified in the service procedure
2. Always follow all the safety recommendations and the directions that are on the RTV sealant container.
3. Use a plastic or wood scraper in order to remove all the RTV sealant from the components.

1. The surfaces to be sealed must be clean and dry.
2. Use a RTV sealant bead size as specified in the service procedure.
3. Apply the RTV sealant bead to the inside of any bolt holes areas.
4. Assemble the components while the RTV sealant is still wet to the touch. Do not wait for the RTV sealant to skin over.
5. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Anaerobic Type Threadlock Sealant

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

Use the following information when using threadlock sealant

1. Always follow all safety recommendations and directions that are on the threadlock sealant container.
2. The threaded surfaces to be sealed must be clean and dry.
3. Apply the threadlock sealant as specified on the threadlock sealant container.

1. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Anaerobic Type Pipe Sealant

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

Use the following information when using pipe sealant

1. Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Surfaces where a different sealant is specified
2. Always follow all the safety recommendations and the directions that are on the pipe sealant container.
3. The surfaces to be sealed must be clean and dry.
4. Use a pipe sealant bead of the size or quantity as specified in the service procedure.

1. Apply the pipe sealant bead to the inside of any bolt hole areas.
2. Apply a continuous bead of pipe sealant to 1 sealing surface.
3. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Tools and Equipment

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

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

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

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