Engine Mechanical - 4.2L: Removal & Installation Chevrolet TrailBlazer I

Installation Procedure

1. Route the drivebelt over all the pulleys except the drivebelt tensioner pulley.
2. Install the 3/8 inch breaker bar on the drivebelt tensioner arm and turn the breaker bar clockwise.
3. Install the drivebelt over the drivebelt tensioner pulley.
4. Slowly release the tension to the drivebelt tensioner arm.
5. Inspect for proper installation of the drivebelt on the pulleys.

Scheme 875

1. Remove the drivebelt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
2. Inspect the drivebelt. Change the drivebelt as necessary.
3. Using a wrench loosen and remove the drivebelt tensioner bolt.
4. Remove the drivebelt tensioner.

Scheme 876

1. Install the drive belt tensioner. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the drive belt tensioner bolt. Tighten Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
3. Install the drive belt «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .

Removal Procedure

1. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
2. Remove the idler pulley bolt from the idler pulley bracket.
3. Remove idler pulley.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

1. Install the idler pulley and secure the pulley with the bolt. Tighten Tighten the idler pulley bolt to 50 N.m (37 lb ft).
2. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .

Valve Rocker Arm and Valve Lash Adjuster Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44222 Camshaft Sprocket Holding Tool

Scheme 877

Scheme 878

Scheme 879

Scheme 880

Scheme 881

1. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Remove the exhaust and the intake sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components.
4. Carefully move the sprockets with the timing chain off of the camshafts. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
5. Remove the camshaft cap bolts.
6. Remove the camshaft caps.
7. Remove the camshafts. IMPORTANT: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations.
8. Remove the valve rocker arms.
9. Remove the valve lash adjusters.

Scheme 882

Scheme 883

Scheme 884

Scheme 885

Scheme 886

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm roller.
4. Install the valve rocker arms in their original locations.
5. Coat the camshaft journals with engine oil.
6. Install the camshafts to their original position NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the camshaft caps onto their original journal. Tighten Tighten the camshaft cap bolts to 12 N.m (106 lb in).
8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 .
9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. Tighten Tighten the intake camshaft sprocket bolt the first pass 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
10. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 38820 Valve Stem Seal Remover and Installer
2. J 44222 Camshaft Sprocket Holding Tool
3. J 44228 Valve Spring Compressor

Scheme 887

Scheme 888

Scheme 889

Scheme 890

Scheme 891

Scheme 892

Scheme 893

1. Remove the cam cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Remove the spark plugs. Refer to «SPARK PLUGS»(ref-159085-S02952502512003111400000) .
3. Remove the exhaust and the intake sprocket bolts.
4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components.
5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension.
6. Carefully move the sprockets with the timing chain, off of the camshafts.
7. Remove the camshaft cap bolts. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
8. Remove the camshaft caps.
9. Remove the camshafts.
10. Using a suitable adapter, apply air pressure to the cylinder.
11. Install the J 44228 and compress the valve springs.
12. Remove the valve keys.
13. Remove the J 44228 .
14. Remove the valve spring retainer and the valve spring.
15. Use the J 38820 and remove the seals.
16. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-188499-S23018537412005090700000) .

Scheme 894

Scheme 895

Scheme 896

Scheme 897

Scheme 898

Scheme 899

Scheme 900

1. Use the J 38820 to install the valve seals. There is only one size seal.
2. Install the valve spring and the valve spring retainer.
3. Use the J 44228 and compress the valve springs.
4. Install the valve keys.
5. Remove the J 44228 .
6. Remove the air pressure to the cylinder.
7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil.
8. Install the camshafts to their original position. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Install the camshaft caps onto their original journal. Tighten Tighten the camshaft cap bolts to 12 N.m (106 lb in).
10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 .
11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. Tighten Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
12. Install the spark plugs. Refer to «SPARK PLUGS»(ref-159085-S02952502512003111400000) .
13. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .

Scheme 901

Scheme 902

1. Remove the A/C line bracket nut.
2. Remove the A/C line bracket from the oil level indicator tube stud.
3. Disconnect the O2 sensor electrical connector from the oil level indicator bracket.
4. Remove the oil level indicator tube stud.
5. Pull the indicator out of the tube.
6. Pull the tube out of the block.

Scheme 903

1. Install the oil level indicator tube into the engine block.
2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the oil level indicator tube stud. Tighten Tighten the oil level indicator tube stud to 10 N.m (89 lb in).
4. Install the A/C line bracket to oil level indicator tube and secure with the nut. Tighten Tighten the A/C line bracket nut to 7 N.m (6 lb in).
5. Connect the O2 sensor electrical connector.
6. Install the oil level indicator into the tube.

Cylinder Head Replacement

Note. General Motors has developed a procedure for removing the cylinder head without the removal of of the front cover. The new procedure can be done in vehicle with the aid of a new special service tool. See INFORMATION ON NEW IN-VEHICLE SERVICE PROCEDURE FOR REMOVAL/INSTALLATION OF LK5 OR L52 CYLINDER HEAD .

Tools Required

J 36660-A Torque Angle Meter

Scheme 904

Scheme 905

Scheme 906

Scheme 907

Scheme 908

Scheme 909

1. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Remove the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT (4.2L ENGINE) .
3. Remove the front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .
4. Remove the cylinder head access hole plugs.
5. Remove the timing chain tensioner shoe bolt.
6. Remove the timing chain tensioner shoe.
7. Remove the timing chain tensioner guide bolts.
8. Remove the timing chain tensioner guide.
9. Remove the timing chain and the sprockets. Refer to «TIMING CHAIN, SPROCKETS, AND/OR TENSIONER REPLACEMENT»(ref-188499-S08155262102005090700000) .
10. Loosen and remove the cylinder head bolts.
11. Remove the cylinder head.
12. Remove the cylinder head gasket.
13. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
14. If replacing cylinder head refer to «Cylinder Head Disassemble»(ref-188499-S33806785752005090700000) .
15. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-188499-S23018537412005090700000) .

Scheme 910

Scheme 911

Scheme 912

Scheme 913

Scheme 914

1. If installing new cylinder head, refer to «Cylinder Head Assemble»(ref-188499-S03568324902005090700000) .
2. Install the dowel pins, cylinder head locator, if necessary.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
5. Install new cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
6. Tighten the new cylinder head bolts in the following sequence: Tighten 6.1. Tighten the cylinder head bolts (1-14) in sequence to 30 N.m (22 lb ft). 6.2. Use J 36660-A to tighten the cylinder head bolts in sequence an additional 155 degrees. 6.3. Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 36660-A to tighten the short cylinder head end bolts an additional 60 degrees. 6.4. Tighten the (1 Long) end bolt to 7 N.m (62 lb in). Use J 36660-A to tighten the long cylinder head end bolt an additional 120 degrees.
7. Install the cylinder head access hole plugs. Tighten Tighten the plugs to 5 N.m (44 lb in).
8. Install the timing chain and sprockets. Refer to «TIMING CHAIN, SPROCKETS, AND/OR TENSIONER REPLACEMENT»(ref-188499-S08155262102005090700000) .
9. Install the front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .
10. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
11. Install the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT (4.2L ENGINE) .

Crankshaft Balancer Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 41478 Crankshaft Front Oil Seal Replacement
3. J 41816-2 Crankshaft End Protector
4. J 44226 Crankshaft Balancer Remover/Holder

Scheme 915

Scheme 916

1. Remove the radiator intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
2. Remove the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Exterior Trim. IMPORTANT: When removing the diagonal brace, only remove the one bolt from the battery tray brace that is bolted to the radiator brace.
3. Remove the radiator support diagonal brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
4. Remove the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
5. Remove the cooling fan and shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
6. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
7. Carefully loosen and remove the balancer bolt.
8. Install J 41816-2 into the end of the crankshaft. IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
9. Using the J 44226 remove the balancer.
10. Remove J 44226 and J 41816-2 .
11. Remove the crankshaft balancer shim from the crankshaft snout.
12. Clean and inspect the crankshaft balancer. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-188499-S35837244272005090700000) .

Scheme 917

Scheme 918

1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
2. Remove the torque converter access plug in the dry part of the oil pan.
3. Use the torque converter holding tool from the J 44226 kit and secure the torque converter while tightening the crankshaft balancer.
4. Install a new crankshaft balancer shim GM P/N 12573950 over the crankshaft snout, against the crankshaft gear.
5. Using the J 41478 install and seat the crankshaft balancer.
6. Remove the J 41478 . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. While still holding the flywheel, install the balancer washer and the bolt. Tighten Tighten the crankshaft balancer bolt to 150 N.m (110 lb ft). Use the J 36660-A in order to tighten the balancer bolt an additional 180 degrees.
8. Remove the torque converter holding tool.
9. Install the torque converter access plug into the oil pan.
10. Lower the vehicle.
11. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
12. Install the cooling fan and shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
13. Install the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
14. Install the radiator diagonal brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
15. Install the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Exterior Trim.
16. Install the radiator air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.

Crankshaft Front Oil Seal Replacement

Tools Required

J 44218 Seal Installer

Scheme 919

1. Remove the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188499-S03822332922005090700000) .
2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal.

Scheme 920

Scheme 921

1. Apply the engine oil to the outside diameter of the crankshaft front oil seal.
2. Use the J 44218 to install the front oil seal.
3. Remove the J 44218 .
4. Install the crank balancer shaft. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188499-S03822332922005090700000) .

Engine Front Cover Replacement

Tools Required

J 44219 Cover Alignment Pins

Scheme 922

1. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.
2. Remove the cooling fan and the shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
3. Remove the drivebelt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
4. Remove the water pump. Refer to WATER PUMP REPLACEMENT (4.2L ENGINE) in Engine Cooling.
5. Remove the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188499-S03822332922005090700000) .
6. Remove the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (4.2L) in Power Steering.
7. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
8. Remove the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-188499-S34196719702005090700000) .
9. Lower the vehicle.
10. Remove the 7 mm center bolt (1).
11. Loosen and remove the remaining engine front cover bolts.
12. Place two of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to release the front cover from the engine.
13. Remove the two bolts from the front cover.
14. Remove the oil pump. Refer to «Oil Pump Replacement»(ref-188499-S12715144742005090700000) .
15. Clean and Inspect the front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-188499-S37465612882005090700000) .

Scheme 923

Scheme 924

Scheme 925

1. Install the J 44219 , onto the engine. IMPORTANT: The engine front cover must be installed within 10 minutes from when the sealer was applied.
2. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 to the trace grooves on back side of the engine front cover (1).
3. Also apply sealant on the inside three bolt hole bosses on the cover.
4. Align the oil pump to the crankshaft sprocket splines.
5. Install the front cover. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
6. Install the front cover bolts, tightening the center bolt last (1). Tighten Tighten the front cover bolts to 10 N.m (89 lb in).
7. Remove the J 44219 .
8. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
9. Install the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-188499-S34196719702005090700000) .
10. Lower the vehicle.
11. Install the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (4.2L) or in Power Steering System.
12. Install the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188499-S03822332922005090700000) .
13. Install the water pump. Refer to WATER PUMP REPLACEMENT (4.2L ENGINE) in Engine Cooling.
14. Install the drivebelt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
15. Install the cooling fan and shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
16. Fill the engine with coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.

Exhaust Camshaft Position Actuator Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44217 Timing Chain Retention Tool

Scheme 926

Scheme 927

Scheme 928

1. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with the cylinder head to cam cover mating surface.
3. Remove the top chain guide bolts.
4. Remove the top chain guide.
5. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link across from it.
6. Install the J-44217 . 6.1. Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. 6.2. Tighten the wingnuts. 6.3. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on the edge of the head.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.

Scheme 929

Scheme 930

Scheme 931

1. Install the exhaust camshaft actuator into the timing chain.
2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator sprocket (1). IMPORTANT: Ensure the alignment pin is engaged between the camshaft and the exhaust camshaft position actuator.
3. Install the exhaust camshaft actuator onto the exhaust camshaft. IMPORTANT: Insure the camshaft actuator is rotated clockwise relative to the camshaft prior to tightening the bolt. Do not force the camshaft actuator to rotate clockwise. If it doesn't move easily, it is already fully advanced. New camshaft actuators are already packaged in the fully advanced (clockwise) position.
4. Use the 25 mm (1 in) hex between the cam lobes to rotate the exhaust camshaft counter-clockwise until it stops (as seen from the front of the vehicle), this will place the camshaft actuator in the fully advanced (clockwise) position. NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the exhaust camshaft actuator bolt. Tighten Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
6. Remove the J-44217 .
7. Install the top chain guide.
8. Add threadlock GM P/N 12345493 (Canadian P/N 10953488) to the top chain guide bolt threads.
9. Install the top chain guide bolts. Tighten Tighten the top chain guide bolts to 10 N.m (89 lb in).
10. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44221 Camshaft Holding Tool

Scheme 932

Scheme 933

Scheme 934

Scheme 935

Scheme 936

Scheme 937

Scheme 938

Scheme 939

Scheme 940

1. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Remove the engine front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .
3. Release the tension on the timing chain by moving the tensioner shoe in.
4. Place the tee into the tensioner to hold the shoe in place.
5. Remove the top chain guide bolts.
6. Remove the top chain guide.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.
9. Remove the intake camshaft sprocket bolt.
10. Remove the intake camshaft sprocket.
11. Remove the timing chain.
12. Remove the crankshaft sprocket.
13. Remove the cylinder head access hole plugs.
14. Remove the timing chain tensioner shoe bolt.
15. Remove the timing chain tensioner shoe.
16. Remove the timing chain tensioner guide bolts.
17. Remove the timing chain tensioner guide.
18. Remove the timing chain tensioner bolts.
19. Remove the timing chain tensioner.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 941

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

1. Install the timing chain tensioner and secure the tensioner with the bolts. Tighten Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
2. Install the timing chain tensioner guide and secure the guide with the bolts. Tighten Tighten the timing chain tensioner guide to 10 N.m (89 lb in).
3. Install the timing chain tensioner shoe and secure the shoe with the bolt. Tighten Tighten the timing chain tensioner shoe bolt to 26 N.m (19 lb ft).
4. Install the cylinder head access hole plugs. Tighten Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).
5. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. Crank pin will be at 12 o'clock position when number 1 piston is at top dead center.
6. Install the crankshaft sprocket (1).
7. Install the intake camshaft sprocket into the timing chain.
8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1).
9. Feed the timing chain down through the opening in the head.
10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing mark on to the crankshaft sprocket. IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket.
11. Install the intake camshaft sprocket onto the intake camshaft.
12. Install the intake camshaft sprocket washer and bolt.
13. Install the exhaust camshaft actuator into the timing chain.
14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1). IMPORTANT: It may be necessary to remove the J 44221 to rotate and hold the camshaft hex to align the pin to the camshaft sprocket.
15. Install the exhaust camshaft actuator onto the exhaust camshaft. IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.
16. Rotate the camshaft actuator clockwise until it stops (as seen from the front of the vehicle). NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced.
17. Install the exhaust camshaft actuator bolt. Tighten Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
18. Install the intake camshaft sprocket bolt. Tighten Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 ft lb). Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
19. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
20. Remove the J 44221 .
21. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown.
22. Install the top chain guide.
23. Add threadlock GM P/N 12345496 on the top chain guide bolt threads.
24. Install the top chain guide bolts. Tighten Tighten the top chain guide bolts to 10 N.m (89 lb ft).
25. Install the engine front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .
26. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .

Camshaft Replacement

Tools Required

1. J 44221 Camshaft Holding Tool
2. J 44222 Camshaft Sprocket Holding Tool
3. J 36660-A Torque/Angle Meter

Scheme 952

Scheme 953

Scheme 954

1. Remove the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .
2. Remove the intake and the exhaust camshaft sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components.
4. Carefully move the sprockets with the timing chain, off of the camshafts.
5. Remove the camshaft cap bolts. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
6. Remove the camshaft caps and store.
7. Remove the camshafts.

Scheme 955

Scheme 956

Scheme 957

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the intake and exhaust camshafts to their original positions.
3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Install the camshaft caps onto their original locations. The camshaft caps are pin stamped for direction and numerical order.
4. Install the camshaft caps and bolts. Tighten Tighten the camshaft cap bolts to 12 N.m (106 lb in).
5. Remove the J 44221
6. Carefully move the sprockets back onto the camshafts and remove the J 44222 .
7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt. Tighten Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
8. Install the camshaft cover. Refer to «CAMSHAFT COVER REPLACEMENT»(ref-188499-S26958180152005090700000) .

Scheme 958

Scheme 959

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-188499-S18492055032005090700000) .
2. Remove the oil filter adapter.
3. Remove the oil filter bypass valve.

Scheme 960

Scheme 961

1. Install the oil filter bypass valve. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil filter adapter. Tighten Tighten the oil filter adapter to 30 N.m (22 lb ft).
3. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-188499-S18492055032005090700000) .

Scheme 962

Scheme 963

Scheme 964

Scheme 965

1. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3).
2. Remove the oil level indicator and tube. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-188499-S20331899772005090700000) .
3. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
4. Remove left and right front tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
5. Remove the engine protection shield mounting bolts.
6. Remove the engine protection shield.
7. Remove the steering gear crossmember, front.
8. Remove the left and right wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
9. Remove the front drive axle clutch fork assembly. Refer to INTERMEDIATE SHAFT BEARING ASSEMBLY REPLACEMENT - FRONT DRIVE AXLE (S4WD) or INTERMEDIATE SHAFT BEARING ASSEMBLY REPLACEMENT - FRONT DRIVE AXLE (A4WD) in Front Drive Axle.
10. Disconnect the prop shaft from the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Prop Shaft.
11. Remove the oil pan drain plug and drain the oil.
12. Unclip the transmission cooler lines from the engine block.
13. Remove the front differential bolts and set aside the front differential.
14. Remove 4 transmission bell housing bolts that are attached to the oil pan.
15. Remove the remaining oil pan bolts.
16. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine.
17. Clean and inspect the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-188499-S01770131362005090700000) .

Scheme 966

Scheme 967

Scheme 968

Scheme 969

Scheme 970

Scheme 971

1. Apply a 3 mm (0.12 in) bead of sealer GM PN 12378521 to the block, rather than the oil pan. IMPORTANT: When you install the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block.
2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly.
3. Install the oil pan bolts.
4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission mounting surface. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the oil pan bolts. Tighten Tighten the oil pan side bolts to 25 N.m (18 lb ft). Tighten the oil pan end bolts to 10 N.m (89 lb in).
6. Install the 4 transmission bell housing bolts that attach to the oil pan. Tighten Tighten bolts to 47 N.m (35 lb ft).
7. Install the A/C compressor 2 bottom bolts (4). Tighten Tighten all 4 bolts to 50 N.m (37 lb ft).
8. Install the front differential bolts. Tighten Tighten the front differential bolts to 85 N.m (63 lb ft.)
9. Install the front drive axle, clutch fork assembly. Refer to INTERMEDIATE SHAFT BEARING ASSEMBLY REPLACEMENT - FRONT DRIVE AXLE (S4WD) or INTERMEDIATE SHAFT BEARING ASSEMBLY REPLACEMENT - FRONT DRIVE AXLE (A4WD) in Front Drive Axle.
10. Clip transmission cooler lines to block.
11. Connect prop shaft to front differential.
12. Install the steering gear crossmember.
13. Install the left and right wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
14. Install the oil pan drain plug. Tighten Torque the oil pan drain plug to 26 N.m (19 lb ft).
15. Install the engine protection shield and secure with the bolts. Tighten Tighten the engine protection shield bolts to 25 N.m (18 lb ft).
16. Install the left and the right front tires. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
17. Lower the vehicle. IMPORTANT: Inspect the engine for oil leaks in order to ensure all sealing surfaces are sealed.
18. Service the engine with oil.

Scheme 972

1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
2. Remove the engine shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000)
3. Remove the electrical connector from the oil pressure switch.
4. Remove the oil pressure switch.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 973

1. Install the oil pressure switch. Tighten Tighten the oil pressure switch to 20 N.m (15 lb ft).
2. Install the electrical connector to the oil pressure switch.
3. Install the engine shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000)
4. Lower the vehicle.

Scheme 974

Scheme 975

Scheme 976

1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
2. Remove the engine oil pan drain plug and drain the engine oil.
3. Remove the engine protection shield mounting bolts.
4. Remove the engine protection shield.
5. Disconnect the electrical connector from the engine oil level sensor.
6. Remove the engine oil level sensor mounting bolt.
7. Remove the engine oil level sensor.

Scheme 977

Scheme 978

Scheme 979

1. Install the engine oil level sensor. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the engine oil level sensor mounting bolt. Tighten Tighten the engine oil level sensor mounting bolt to 10 N.m (89 lb in).
3. Connect the electrical connector to the engine oil level sensor.
4. Install the engine protection shield.
5. Install the engine protection shield mounting bolts. Tighten Tighten the engine protection shield mounting bolts to 25 N.m (18 lb ft).
6. Install the engine oil drain plug. Tighten Tighten the engine oil drain plug bolt to 26 N.m (19 lb ft).
7. Lower the vehicle.
8. Fill the crankcase with the proper quantity of engine oil.

Scheme 980

1. Remove the engine front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .
2. Remove the oil pump cover bolts.
3. Remove the oil pump cover.
4. Mark the inner and the outer gears in relation to the oil pump housing.
5. Remove the inner and the outer oil pump gears.
6. Remove the oil pump pressure relief valve plug.
7. Remove the oil pump pressure relief valve and the spring.

Scheme 981

1. Install the oil pump pressure relief valve and the spring. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil pump pressure relief valve plug. Tighten Tighten the oil pump pressure relief valve to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten Tighten the oil pump cover bolts to 10 N.m (89 lb in).
6. Install the front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188499-S12821675792005090700000) .

Crankshaft Rear Oil Seal and Housing Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44219 Cover Alignment Pins
3. J 44227 Rear Seal Installer

Scheme 982

Scheme 983

1. Remove the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) .
2. Remove the fly wheel bolts and remove the fly wheel.
3. Remove the crankshaft rear oil seal housing bolts.
4. Install two bolts into the jackscrew holes (1) to release the cover from the block.
5. Remove the crankshaft and rear oil seal housing.
6. Remove the oil seal from the crankshaft snout.

Scheme 984

Scheme 985

Scheme 986

Scheme 987

1. Use the J 44227 to install the crankshaft rear oil seal.
2. Remove the J 44227 .
3. Apply a 3 mm (0.12 in) bead of GM P/N 12378521 to the rear oil seal housing (1).
4. Install the J 44219 guide pins into the block. IMPORTANT: When installing a new seal, use the plastic installation sleeve supplied with the new seal. The seal installation sleeve should come off after the seal is installed. Disregard the sleeve.
5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft.
6. Install the crankshaft rear oil seal housing bolts, except the two in place of the guide pins.
7. Remove the J 44219 guide pins. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
8. Install the remaining two crankshaft rear oil seal housing bolts. Tighten Tighten all the oil seal housing bolts to 10 N.m (89 lb in).
9. Wipe off any excess material from the bottom of the oil pan sealing area (1).
10. Install the fly wheel and secure with the bolts. Tighten Tighten the fly wheel bolts in sequence to 25 N.m (18 lb ft).
11. Use the J 36660-A to tighten the bolts an additional 50 degrees.
12. Install the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) .

Crankshaft Rear Oil Seal Replacement

Tools Required

J 44227 Rear Seal Installer

Scheme 988

1. Remove the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) .
2. Remove the flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188499-S42657172162005090700000) . IMPORTANT: Do not damage the crankshaft or seal bore.
3. Pry the crankshaft rear oil seal out of the rear oil seal housing using a suitable tool.

1. Use J 44227 install the crankshaft rear oil seal.
2. Remove the J 44227 .
3. Remove the seal installation sleeve after the seal is installed. Discard the sleeve.
4. Install the flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188499-S42657172162005090700000) .
5. Install the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) .

Engine Flywheel Replacement

Tools Required

J 36660-A Torque Angle Meter

Scheme 989

1. Remove the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) . IMPORTANT: Note the position and the direction of the engine flywheel before removal.
2. Remove the flywheel bolts.
3. Remove the flywheel.
4. Clean and Inspect the flywheel. Refer to «ENGINE FLYWHEEL CLEANING AND INSPECTION»(ref-188499-S01227614532005090700000) .

Scheme 990

1. Add threadlock GM P/N 12345493 (Canadian P/N 10953488) to the new flywheel bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the flywheel and secure the flywheel with the new bolts. Tighten 2.1. Tighten the bolts in sequence to 25 N.m (18 lb ft). 2.2. Use the J 36660-A in order to tighten the bolts an additional 50 degrees.
3. Install the transmission. Refer to «TRANSMISSION»(ref-154685-S22910359782003052000000) .

Engine Replacement

Tools Required

J 44220 Engine Lift Bracket

Scheme 991

Scheme 992

Scheme 993

Scheme 994

Scheme 995

Scheme 996

Scheme 997

Scheme 998

Scheme 999

Scheme 1000

Scheme 1001

Scheme 1002

Scheme 1003

Scheme 1004

Scheme 1005

1. Remove the hood. Refer to HOOD REPLACEMENT in Body Front End.
2. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
3. Drain engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.
4. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning. IMPORTANT: Keep drain plug removed during engine removal and installation.
5. Remove the oil pan drain plug and drain the oil.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
7. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY»(ref-159085-S37652319732003111400000) .
8. Remove the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .
9. Remove the map sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-159085-S17062346442003111100000) .
10. Remove the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-188870-S21358678172005090500000) in Wipers/Washer Systems.
11. Remove the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
12. Remove the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Body Exterior.
13. Remove the headlamp housing. Refer to HEADLAMP HOUSING PANEL REPLACEMENT (OLDSMOBILE) or HEADLAMP HOUSING PANEL REPLACEMENT (CHEVROLET, GMC) in Body Front End.
14. Remove the radiator support brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
15. Remove the hood latch. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
16. Disconnect A/C lines at the condenser.
17. Disconnect the transmission cooler lines at the engine, not the radiator.
18. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
19. Remove the radiator with condenser and transmission cooler lines. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
20. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
21. Remove the power steering pump bolts and lay the pump aside.
22. Ensure the heater hoses at the heater core are disconnected.
23. Disconnect the transmission filler tube bracket nut from the AIR adapter.
24. Remove the AIR adapter.
25. Install the lift hook J 44220 to the AIR adapter.
26. Disconnect the oxygen sensor electrical connector.
27. Disconnect the A/C line at the accumulator.
28. Disconnect the front axle actuator electrical connector.
29. Disconnect the camshaft phaser actuator valve electrical connector.
30. Unclip the transmission cooler lines from right side of the engine block.
31. Disconnect the ignition coil harness connectors.
32. Carefully disconnect harness retainer at clips (1) and remove.
33. Remove power brake hose at booster.
34. Remove the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
35. Disconnect the fuel lines at the fuel pressure regulator and cap lines. Refer to «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
36. Remove all harnesses from the engine harness bracket.
37. Disconnect the front differential vent hose from the engine harness bracket.
38. Remove the engine harness bracket bolt and remove bracket.
39. Disconnect starter electrical connections (1).
40. Disconnect the A/C pressure sensor and clutch electrical connector.
41. Disconnect generator electrical connector and battery lead.
42. Disconnect the knock sensor electrical connector.
43. Disconnect the crankshaft sensor electrical connector.
44. Disconnect the camshaft sensor electrical connector.
45. Remove 4 grounds on the left side of the block (1).
46. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
47. Remove the wheel drive shafts, left and right. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
48. Remove the propeller shaft from the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
49. Remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000)
50. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
51. Remove the fuel tank shield, if equipped.
52. Remove the torque converter bolt access cover.
53. Remove the torque converter bolts.
54. Place a jack on the transmission oil pan for support.
55. Remove the transmission support. Refer to «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000) .
56. Lower the transmission enough to reach the top bell housing bolts.
57. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
58. Raise the transmission.
59. Reinstall the transmission support using only 2 through bolts.
60. Remove the remaining bell housing bolts, for a total of 11 bolts.
61. Remove the left and right engine lower mount nuts.
62. Disconnect the oil lever sensor electrical connector.
63. Disconnect the oil pressure switch electrical connector.
64. Lower the vehicle.
65. Remove the left upper engine mount nut.
66. Remove the right upper engine mount nut.
67. Install the engine hoist.
68. Raise the engine out of the compartment slowly keeping the transmission supported.
69. Remove both engine mount for clearance.
70. Continue raising the engine out of the vehicle.
71. Install the engine to the engine stand.

Scheme 1006

Scheme 1007

Scheme 1008

Scheme 1009

Scheme 1010

Scheme 1011

Scheme 1012

Scheme 1013

Scheme 1014

Scheme 1015

Scheme 1016

Scheme 1017

Scheme 1018

1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Lower the engine onto the mounts and install the upper engine mount nuts. Tighten Tighten the nuts to 70 N.m (51 lb ft).
5. Remove the engine hoist.
6. Lay the radiator into the radiator support, but do not install the radiator completely.
7. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
8. Install all of the lower bell housing bolts, excluding the top four.
9. Remove the two through bolts securing the transmission support.
10. Lower the transmission.
11. Install the top four bell housing bolts. Tighten Tighten all eleven bell housing bolts to 50 N.m (37 lb ft).
12. Raise the transmission.
13. Install the transmission support. Refer to «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000) .
14. Install the 3 torque converter bolts. Tighten Tighten the torque converter bolts to 60 N.m (44 lb ft).
15. Install the torque converter bolt cover.
16. Install the fuel tank shield, if removed.
17. Install the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) .
18. Install the propeller shaft to the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
19. Connect the exhaust pipe to the manifold and secure the pipe with the bolts. Tighten Tighten the exhaust pipe bolts to 50 N.m (37 lb ft).
20. Connect the oil level switch electrical connector.
21. Connect the oil pressure sensor electrical connector.
22. Install the oil pan drain plug. Tighten Tighten the plug to 26 N.m (19 lb ft).
23. Install the lower radiator hose (1).
24. Install the left and right wheel drive shafts. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
25. Lower the vehicle.
26. Install the 4 grounds on the left side of the block (1).
27. Install the camshaft sensor electrical connectors.
28. Install the crankshaft sensor electrical connector.
29. Install the knock sensor electrical connector.
30. Install the generator electrical connector and battery lead (1). Tighten Tighten the generator battery lead nut to 9 N.m (80 lb in).
31. Install the A/C pressure sensor and clutch electrical connector.
32. Install starter electrical connectors and battery lead (1). Tighten Tighten the starter battery lead to 9 N.m (80 lb in).
33. Install the fuel lines at the fuel pressure regulator. Refer to «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
34. Install the engine harness bracket and bolt. Tighten Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
35. Install the front differential vent hose, to the engine harness bracket.
36. Install all the harnesses to the engine harness bracket.
37. Install the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
38. Install the power brake hose at booster
39. Install the harness retainer to the original location.
40. Install the ignition coil harness electrical connectors.
41. Clip the transmission cooler lines to the right side of the engine block.
42. Connect the camshaft phaser actuator valve electrical connector.
43. Connect the front axle actuator electrical connector.
44. Connect the A/C line at the accumulator.
45. Install the oxygen sensor electrical connector.
46. Remove the lift hook J 44220 .
47. Install the AIR adapter and secure the adapter with the studs. Tighten Tighten the AIR adapter studs to 25 N.m (18 lb ft).
48. Install the transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut. Tighten Tighten the nut to 10 N.m (89 lb in).
49. Install the heater hoses to the heater core. Refer to HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 3) or HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 6) and HEATER HOSE REPLACEMENT - OUTLET (LL8) in Heating, Ventilation, and Air Conditioning.
50. Install the power steering pump.
51. Install the power steering pump bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
52. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
55. Install transmission cooler lines together.
56. Install map Sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-159085-S17062346442003111100000) .
57. Install the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .
58. Install the hood latch. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
59. Install the head lamp housing. Refer to HEADLAMP HOUSING PANEL REPLACEMENT (OLDSMOBILE) or HEADLAMP HOUSING PANEL REPLACEMENT (CHEVROLET, GMC) in Body Front End.
60. Install the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Exterior Trim.
61. Install the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Engine Controls - 4.2L.
62. Install the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-188870-S21358678172005090500000) in Wipers/Washer Systems.
63. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY»(ref-159085-S37652319732003111400000) .
64. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
65. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
66. Service the engine oil.
67. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.
68. Recharge the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
69. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-159085-S15986821592003111100000) . IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle. Disable the ignition system. Crank the engine several times. Listen for unusual noises or evidence that parts are binding. Enable the ignition system. 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. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature. Listen for a sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Perform a final inspection for the proper engine oil and coolant levels.
70. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.

Scheme 1019

1. Remove the oil fill cap.
2. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
3. Remove the oil pan drain plug and drain the oil into a suitable container. IMPORTANT: Check the old oil filter to ensure the filter seal is not left on the engine block.
4. Remove the oil filter using a suitable wrench.
5. Wipe the excess oil from the oil filter housing.

Scheme 1020

1. Lubricate the oil filter seal with clean engine oil. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the new oil filter. Tighten Tighten the oil filter to 17 N.m (22 lb ft) plus 150 degrees.
3. Install the oil pan drain plug. Tighten Tighten the oil pan drain plug to 26 N.m (19 lb ft).
4. Lower the vehicle.
5. Fill the crankcase with the proper quantity of engine oil.
6. Remove the oil level indicator.
7. Wipe the indicator with a clean cloth.
8. Install the oil level indicator.
9. Remove the oil level indicator and check the oil level.
10. Add oil if necessary.
11. Check for any oil leaks.

Scheme 1021

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

Scheme 1022

Scheme 1023

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

Scheme 1024

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

Scheme 1025

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

Scheme 1026

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

Scheme 1027

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

Scheme 1028

Scheme 1029

Scheme 1030

Scheme 1031

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

Scheme 1032

Scheme 1033

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

Heater Inlet Hose Fitting Removal

Remove the heater inlet hose fitting.

Scheme 1034

Heater Outlet Hose Fitting Removal

Remove the heater outlet hose fitting.

Scheme 1035

Scheme 1036

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

Water Pump Removal

Tool Required

J 41240 Fan Clutch Remover and Installer

Scheme 1037

Scheme 1038

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

Scheme 1039

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

Scheme 1040

Scheme 1041

Scheme 1042

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

Scheme 1043

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

Scheme 1044

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

Scheme 1045

Scheme 1046

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

Oil Pan Removal

Note. Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first.

Scheme 1047

1. Remove the oil level sensor.
2. Remove the oil pan bolts and nuts.
3. Install two of the oil pan bolts into the threaded holes (jack bolts) to break the seal of oil pan (1).
4. Remove the oil pan.

Scheme 1048

1. Remove the oil pump pipe bolts.
2. Remove the oil pump pipe.

Crankshaft Balancer Removal

Tools Required

J 41816-2 Crankshaft End Protector

Scheme 1049

Scheme 1050

1. Remove the crankshaft balancer bolt.
2. Install J 41816-2 into the end of the crankshaft. IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
3. Use a three jaw puller to remove the crankshaft balancer.
4. Remove J 41816-2.

Crankshaft Front Oil Seal Removal

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

Scheme 1051

Scheme 1052

Scheme 1053

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

Scheme 1054

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

Scheme 1055

Scheme 1056

Scheme 1057

1. Remove the top chain guide bolts.
2. Remove the top chain guide.
3. Remove the exhaust camshaft position actuator bolt.
4. Remove the exhaust camshaft position actuator.
5. Remove the intake camshaft sprocket bolt.
6. Remove the intake camshaft sprocket.
7. Remove the timing chain.
8. Remove the crankshaft sprocket.

Scheme 1058

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

Crankshaft Rear Oil Seal Removal

Remove the crankshaft rear oil seal.

Scheme 1059

Scheme 1060

Scheme 1061

Scheme 1062

Scheme 1063

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

Scheme 1064

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

Scheme 1065

Scheme 1066

1. Remove the camshaft cap bolts. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
2. Remove the camshaft caps.
3. Remove the camshafts.

Valve Rocker Arm and Valve Lash Adjuster Removal

Scheme 1067

Scheme 1068

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

Cylinder Head Removal

Scheme 1069

Scheme 1070

Scheme 1071

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

Piston, Connecting Rod, and Bearing Removal

Tools Required

J 41556 Connecting Rod Guides

Scheme 1072

Scheme 1073

Scheme 1074

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

Crankshaft and Bearings Removal

Scheme 1075

Scheme 1076

Scheme 1077

Scheme 1078

Scheme 1079

1. Remove the crankshaft main bearing cap bolts.
2. Remove the crankshaft main bearing cap stiffener.
3. Remove the crankshaft main bearing caps and lower bearings.
4. Remove the crankshaft.
5. Remove the upper crankshaft main bearing halves.

Scheme 1080

Scheme 1081

Scheme 1082

Scheme 1083

Scheme 1084

Scheme 1085

1. Remove the engine block oil gallery plugs.
2. Remove the engine block oil gallery plug from rear of block.
3. Remove the crankshaft position sensor.
4. Remove the knock sensors.
5. Remove the EVAP solenoid.
6. Remove the coolant temperature sensor.

Crankshaft and Bearings Installation

Tools Required

J 36660-A Torque Angle Meter

Scheme 1086

Scheme 1087

Scheme 1088

Scheme 1089

Scheme 1090

Scheme 1091

1. Install the upper crankshaft main bearings into the block.
2. Lubricate the upper crankshaft main bearing surface with clean engine oil.
3. Install the crankshaft. IMPORTANT: Refer to the pin stamp on the crankshaft main bearing caps for sequence and direction of installation. The pin stamp arrow points to the front of the engine.
4. Install the lower crankshaft main bearings into the main bearing caps.
5. Lubricate the lower crankshaft main bearing surface with clean engine oil.
6. Install the crankshaft main bearing caps. IMPORTANT: The crankshaft main bearing cap stiffener is directional. The end marked front goes to the front.
7. Install the crankshaft main bearing cap stiffener.
8. Install new crankshaft main bearing bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the block surface. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Tighten the crankshaft main bearing cap bolts in equal increments. Tighten 9.1. Tighten the crankshaft main bearing cap bolts to 25 N.m (18 lb ft) in sequence. 9.2. Use J 36660-A to tighten the crankshaft main bearing cap bolts an additional 180 degrees.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 36660-A Torque Angle Meter
2. J 8037 Piston Ring Compressor
3. J 41556 Connecting Rod Guide

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

Scheme 1096

Scheme 1097

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at Bottom Dead Center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Install J 8037 onto the piston and ring assembly to compress the rings.
6. Install the connecting rod bearings into the connecting rods and caps (1).
7. Lubricate the connecting rod bearing contact surfaces with engine oil (2).
8. Install the J 41556 into the connecting rod. IMPORTANT: The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and connecting rod assembly into the proper cylinder bore. The piston alignment mark MUST face the front of the engine block (1) or the flat casting boss (2).
9. Install the connecting rod and piston into the proper cylinder bore.
10. Hold the J 8037 firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore
11. Guide the connecting rod end onto the crankshaft journal. Use J 41556 to pull the connecting rod into place.
12. Install the connecting rod bearing, cap, and bolts. Tighten 12.1. Tighten the connecting rod bearing cap bolts on the first pass to 25 N.m (18 lb ft). 12.2. Use J 36660-A to tighten the connecting rod bearing cap bolts on the second pass an additional 110 degrees.
13. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankshaft.
14. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be between 0.05-0.35 mm (0.0019-0.0137 in).

Cylinder Head Installation

Tools Required

J 36660-A Torque Angle Meter

Scheme 1098

Scheme 1099

Scheme 1100

Scheme 1101

1. Install the dowel pins (cylinder head locator) (if necessary).
2. Install a new cylinder head gasket.
3. Install the cylinder head.
4. Install new cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Tighten the new cylinder head bolts in the following sequence: Tighten 5.1. Tighten the (14) long cylinder head bolts in sequence to 30 N.m (22 lb ft). 5.2. Use J 36660-A to tighten the cylinder head bolts in sequence an additional 155 degrees. 5.3. Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 36660-A to tighten the short cylinder head end bolts an additional 60 degrees. 5.4. Tighten the (1 Long) end bolt to 7 N.m (82 lb in). Use J 36660-A to tighten the long cylinder-head end bolt an additional 120 degrees.

Scheme 1102

Scheme 1103

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm roller, needle bearings, valve pallet, and lash adjuster pocket.
4. Install the valve rocker arms in their original locations.

Camshaft Installation

Tools Required

J 44221 Camshaft Holding Tool

Scheme 1104

Scheme 1105

Scheme 1106

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the exhaust camshaft
3. Install the intake camshaft.
4. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. IMPORTANT: Install the same camshaft cap onto the same camshaft journal from which it was removed. The camshaft caps are pin stamped for direction and numerical order.
5. Install the exhaust camshaft caps.
6. Install the intake camshaft caps. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the camshaft cap bolts. Tighten Tighten the camshaft cap bolts to 12 N.m (106 lb in).
8. Remove J 44221 .

Scheme 1107

1. Install the engine lift bracket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the engine lift bracket bolts in sequence. Tighten Tighten the engine lift bracket bolts in sequence to 50 N.m (37 lb ft)

Scheme 1108

Scheme 1109

Scheme 1110

Scheme 1111

1. Install the timing chain tensioner. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the timing chain tensioner bolts. Tighten Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
3. Install the timing chain tensioner guide.
4. Install the timing chain tensioner guide bolts. Tighten Tighten the timing chain tensioner guide bolts to 14 N.m (124 lb in).
5. Install the timing chain tensioner shoe.
6. Install the timing chain tensioner shoe bolt. Tighten Tighten the timing chain tension shoe bolt to 25 N.m (18 lb ft).
7. Install the cylinder head access hole plugs. Tighten Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).

Timing Chain and Sprockets Installation

Tools Required

1. J 44221 Camshaft Holding Tool
2. J 36660-A Torque/Angle Meter

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

1. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center.
2. Compress the tensioner and lock in place.
3. Install the crankshaft sprocket.
4. Install the intake camshaft sprocket into the timing chain.
5. Align the (dark) link of the timing chain with the timing mark on the intake camshaft sprocket (1).
6. Feed the timing chain down through the opening in the head.
7. Install the timing chain onto the crankshaft sprocket. Align the (dark) link of the timing chain with the timing mark on the crankshaft sprocket (2). IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket.
8. Install the intake camshaft sprocket onto the intake camshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Install the intake camshaft sprocket washer and new bolt. Tighten Tighten the new intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
10. Install the exhaust camshaft actuator into the timing chain.
11. Align the (dark) link of the timing chain with the timing mark on the exhaust camshaft actuator (1). IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket.
12. Install the exhaust camshaft actuator onto the exhaust camshaft. NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced.
13. Install the new exhaust camshaft actuator bolt. Tighten Tighten the new exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
14. Unlock the tensioner.
15. Remove J 44221 . IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.
16. Rotate the camshaft actuator clockwise (as seen from the front of the vehicle).
17. The dark links (1) on the chain should be aligned with marks on sprockets as shown.
18. Install the top chain guide.
19. Add threadlock GM P/N United States 12345498, GM P/N Canada 10953488 to the top chain guide bolt threads.
20. Install the top chain guide bolts. Tighten Tighten the top chain guide bolts to 10 N.m (89 lb in).

Scheme 1119

Scheme 1120

1. Install a new camshaft cover seal. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the camshaft cover and bolts. Tighten Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install new ignition control module seals.
4. Install the ignition control modules and bolts. Tighten Tighten the ignition control module bolts to 10 N.m (89 lb in).

Scheme 1121

1. Apply clean engine oil to the camshaft position actuator valve hole.
2. Install the camshaft position actuator valve.
3. Add sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the camshaft position actuator valve bolt threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the camshaft position actuator valve bolt. Tighten Tighten the camshaft position actuator valve bolt to 10 N.m (89 lb in).

Scheme 1122

1. Install the oil pump pressure relief valve and spring. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil pump pressure relief valve plug. Tighten Tighten the oil pump pressure relief valve plug to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten Tighten the oil pump cover bolts to 10 N.m (89 lb in).

Engine Front Cover Installation

Tools Required

J 44219 Engine Cover Alignment Pins

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 1123

Scheme 1124

Scheme 1125

Scheme 1126

1. Install the engine front cover spacer bolt. Tighten Tighten the engine front cover spacer bolt to 10 N.m (89 lb in).
2. Install the crankshaft balancer friction washer GM P/N 12573950 over the crankshaft snout, up against the crankshaft gear.
3. Install J 44219 . IMPORTANT: The engine front cover must be installed within 10 minutes from when the sealer was applied
4. Apply a 3 mm (0.12 in) bead of sealer GM P/N United States 12378521, GM P/N Canada 88901148 to the back side of the engine front cover (1).
5. Align the oil pump to the crankshaft sprocket splines.
6. Install the engine front cover.
7. Remove J 44219 .
8. Install the engine front cover bolts. Tighten 8.1. Tighten the engine front cover bolts to 10 N.m (89 lb in) 8.2. Tighten the small center bolt (1) last to 10 N.m (89 lb in).

Crankshaft Front Oil Seal Installation

Tools Required

J 44218 Seal Installer

Scheme 1127

1. Apply engine oil to the outside diameter of the crankshaft front oil seal.
2. Use J 44218 to install the crankshaft front oil seal.
3. Remove J 44218 .

Water Pump Installation

Tool Required

J 41240 Fan Clutch Remover and Installer

Scheme 1128

Scheme 1129

1. Install the water pump gasket.
2. Install the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the water pump bolts. Tighten Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts.
6. Install J 41240 to hold pulley.
7. Tighten the water pump pulley bolts. Tighten Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
8. Remove J 41240 .

Crankshaft Rear Oil Seal and Housing Installation

Tools Required

J 44219 Housing Alignment Pins

Scheme 1130

Scheme 1131

Scheme 1132

1. Apply a 3 mm (0.12 in) bead of GM P/N United States 12378521, GM P/N Canada 88901148 to the rear oil seal housing (1).
2. Install J 44219 into the block. IMPORTANT: With the help of the plastic installation aid (supplied with the new seal), be sure the lip of the seal faces inward.
3. Slide the crankshaft rear oil seal housing over the alignment pins (J 44219) and crankshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the crankshaft rear oil seal housing bolts (except the two in place of the guide pins).
5. Remove J 44219 .
6. Install the remaining two crankshaft rear oil seal housing bolts. Tighten Tighten the crankshaft rear oil seal housing bolts to 10 N.m (89 lb in).
7. Wipe off any excess material from the bottom of the oil pan sealing area (1).

Scheme 1133

1. Install a new oil pump pipe O-ring.
2. Install the oil pump pipe and screen assembly.
3. Add sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the oil pump pipe bolt threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the oil pump pipe and screen assembly bolts. Tighten Tighten the oil pump pipe and screen assembly bolts to 10 N.m (89 lb in).

Scheme 1134

Scheme 1135

Scheme 1136

1. Apply a 3 mm (0.12 in) bead of sealer GM P/N United States 12378521, GM P/N Canada 88901148 to the block. IMPORTANT: The oil pan must be installed within 10 minutes from when the sealer was applied.
2. Install the oil pan.
3. Install the oil pan bolts. IMPORTANT: When installing the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block.
4. Check the oil pan alignment. Use a straight edge on the back of the block and oil pan (transmission mounting surface). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Tighten the oil pan bolts. Tighten Tighten the (side) oil pan bolts to 25 N.m (18 lb ft). Tighten the (end) oil pan bolts to 10 N.m (89 lb in).
6. Install the oil level sensor.
7. Install the oil level sensor bolt. Tighten Tighten the oil level sensor bolt to 10 N.m (89 lb in).

Crankshaft Balancer Installation

Tools Required

1. J 36660-A Torque Angle Meter
2. J 41478 Crankshaft Front Oil Seal Installer

Scheme 1137

Scheme 1138

1. Install the crankshaft balancer using J 41478 .
2. Remove J 41478 .
3. Hold the flywheel or back of the crankshaft. The crankshaft balancer does not have a keyway so the crankshaft could turn when tightening, causing an improper torque. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Be sure the crankshaft balancer friction washer, GM P/N 12573950, was installed prior to the engine front cover installation.
4. Install the crankshaft balancer washer and new bolt. Tighten 4.1. Tighten the new crankshaft balancer bolt while holding the back to 150 N.m (110 lb ft). 4.2. Use J 36660-A to tighten the crankshaft balancer bolt an additional 180 degrees.

Scheme 1139

1. Lubricate the lower injector O-rings with mineral oil GM P/N 9981704.
2. Install the fuel injector rail. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the fuel injector rail bolts. Tighten Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Scheme 1140

Scheme 1141

Scheme 1142

1. Install a new intake manifold gasket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the intake manifold and bolts. Tighten Tighten the intake manifold bolts from the inside out to 10 N.m (89 lb in).
3. Lubricate the inner diameter of the ends of PCV hose with GM P/N 12345884, (Canadian P/N 5728223) or equivalent.
4. Install the PCV hose.
5. Install a new throttle control module gasket.
6. Install the throttle control module.
7. Add sealer GM P/N 12346004, (Canadian P/N 10953480) to the throttle control module bolt threads.
8. Install the throttle control module bolts. Tighten Tighten the throttle control module bolts to 10 N.m (89 lb in).

Scheme 1143

1. Install the thermostat housing. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the thermostat housing bolts. Tighten Tighten the thermostat housing bolts to 10 N.m (89 lb in).

Scheme 1144

1. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the heater inlet hose fitting threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the heater inlet hose fitting. Tighten Tighten the heater inlet hose fitting to 45 N.m (33 lb ft).

Scheme 1145

1. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the heater outlet hose fitting threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the heater outlet hose fitting. Tighten Tighten the heater outlet hose fitting to 45 N.m (33 lb ft).

Scheme 1146

1. Install the water outlet NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the water outlet bolts. Tighten Tighten the water outlet bolts to 10 N.m (89 lb in).

Scheme 1147

Scheme 1148

1. Install the oil filter bypass valve. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil filter adapter. Tighten Tighten the oil filter adapter to 50 N.m (37 lb ft).

Scheme 1149

Scheme 1150

Scheme 1151

Scheme 1152

Scheme 1153

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Add threadlock GM P/N United States 12345493, GM P/N Canada 10953488 to the exhaust manifold bolt threads.
4. Install the exhaust manifold bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Tighten the exhaust manifold bolts. Tighten 5.1. Tighten the exhaust manifold bolts a first pass in sequence to 20 N.m (15 lb ft). 5.2. Tighten the exhaust manifold bolts a second pass in sequence to 20 N.m (15 lb ft). 5.3. Tighten the exhaust manifold bolts a final pass in sequence to 20 N.m (15 lb ft).
6. Install the exhaust manifold heat shield studs (if required). Tighten Tighten the exhaust manifold heat shield studs to 10 N.m (89 lb in).
7. Install the exhaust manifold heat shield.
8. Add anti-seize GM P/N United States 12371386, GM P/N Canada 993128 to the exhaust manifold heat shield nuts.
9. Install the exhaust manifold heat shield nuts. Tighten Tighten the exhaust manifold heat shield nuts to 10 N.m (89 lb in).

Scheme 1154

1. Install the oil level indicator tube.
2. Add sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the oil level indicator tube stud threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the oil level indicator tube stud. Tighten Tighten the oil level indicator tube stud to 10 N.m (89 lb in).
4. Install the oil level indicator.

Scheme 1155

1. Install the power steering pump bracket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the power steering pump bracket bolts. Tighten Tighten the power steering pump bracket bolts to 50 N.m (37 lb ft).

Scheme 1156

1. Install the drive belt tensioner. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the drive belt tensioner bolt. Tighten Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Scheme 1157

1. Install the drive belt idler pulley. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the drive belt idler pulley bolts. Tighten Tighten the drive belt idler pulley bolts to 50 N.m (37 lb ft).

Crankshaft Rear Oil Seal Installation

Tools Required

J 44227 Rear Seal Installer

Scheme 1158

1. Use the plastic installation sleeve supplied with the new seal when installing a new seal. Use J 44227 to install the crankshaft rear oil seal
2. Remove J 44227 .

Engine Flywheel Installation

Tools Required

J 36660-A Torque Angle Meter

Scheme 1159

1. Install the flywheel. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install new flywheel bolts. Tighten 2.1. Tighten the new flywheel bolts to 25 N.m (18 lb ft). 2.2. Use J 36660-A to tighten the flywheel bolts an additional 50 degrees.