Engine Mechanical - 5.3L: Removal & Installation Chevrolet TrailBlazer I

Installation Procedure

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the engine mount bracket spacer if it has been replaced. Tighten Torque the engine mount bracket spacer bolts to 50 N.m (37 lb ft). IMPORTANT: Make sure that the cut out side of the engine mount shield is positioned away from the engine.
2. Install the engine mount to the upper engine mount bracket. Tighten Tighten the engine mount nuts to 50 N.m (37 lb ft)
3. Install the engine mount to engine. Tighten Torque the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts.
6. Install the left side engine mount frame bracket.
7. Install the left side engine mount frame bracket retaining bolts. Tighten Torque the engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
8. Lower the engine, making sure to align engine mount studs with holes in frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten Torque the engine mount nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
12. Install the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) in Frame and Underbody.
13. Install the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
3. Remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) in Frame and Underbody.
4. Remove the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
5. Remove the left side wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
6. Remove the front differential carrier. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts from the upper engine mount bracket to engine block bracket.
9. Remove the 3 frame engine mount bracket retaining bolts.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 2 1/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Remove the engine mount frame bracket from the frame.
14. Remove the engine mount with upper engine mount bracket as an assembly.
15. Separate the engine mount from the upper engine mount bracket.
16. Remove the engine mount bracket spacer if damaged.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the engine mount bracket spacer if it has been replaced. Tighten Torque the engine mount bracket spacer bolts to 50 N.m (37 lb ft). IMPORTANT: Make sure that the cut out side of the engine mount shield is positioned away from the engine.
2. Install the engine mount to the upper engine mount bracket. Tighten Tighten the engine mount nuts to 50 N.m (37 lb ft)
3. Install the engine mount to engine. Tighten Torque the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten Torque the engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
6. Install the left side engine mount frame bracket.
7. Install the left side engine mount frame bracket retaining bolts. Tighten Torque the left side engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
8. Lower the engine, making sure to align engine mount studs with holes in frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten Torque the engine mount nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
12. Install the front differential carrier. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
13. Install the left side wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
14. Install the Engine Protection Shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) in Frame and Underbody.
15. Install the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
2. Remove the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
3. Remove the engine protection shield. Refer to ENGINE PROTECTION SHIELD REPLACEMENT in Frame and Underbody.
4. Remove the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
5. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
6. Remove the 3 mounting bolts from the upper engine mount bracket to engine block bracket.
7. Remove the 3 frame engine mount bracket retaining bolts.
8. Install a pole jack underneath the oil pan.
9. Insert a block of wood between the oil pan and the pole jack.
10. Raise the engine 2 1/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
11. Shift the engine towards the left side of the frame.
12. Remove the engine mount frame bracket from the frame.
13. Remove the engine mount with upper engine mount bracket as an assembly.
14. Separate the engine mount from the upper engine mount bracket.
15. Remove the engine mount bracket spacer if damaged.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the engine mount bracket spacer if it has been replaced. Tighten Torque the engine mount bracket spacer bolts to 50 N.m (37 lb ft). IMPORTANT: Make sure that the cut out side of the engine mount shield is positioned away from the engine.
2. Install the engine mount to the upper engine mount bracket. Tighten Tighten the engine mount nuts to 50 N.m (37 lb ft)
3. Install the engine mount to engine. Tighten Torque the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten Torque the engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
6. Shift engine back to the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the left side engine mount frame bracket retaining bolts. Tighten Torque the left side engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
9. Lower the engine, making sure to align engine mount studs with holes in frame bracket.
10. Remove the pole jack and block of wood.
11. Tighten the engine mount nuts. Tighten Torque the engine mount nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
13. Install the Engine Protection Shield. Refer to ENGINE PROTECTION SHIELD REPLACEMENT in Frame and Underbody.
14. Install the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
15. Lower the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.

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1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
2. Remove the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
3. Remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) in Frame and Underbody.
4. Remove the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
5. Remove the left side wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
6. Remove the front differential carrier. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts from the upper engine mount bracket to engine block bracket.
9. Remove the 3 frame engine mount bracket retaining bolts.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 2 1/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Shift the engine towards the left side of the frame.
14. Remove the engine mount frame bracket from the frame.
15. Remove the engine mount with upper engine mount bracket as an assembly.
16. Separate the engine mount from the upper engine mount bracket.
17. Remove the engine mount bracket spacer if damaged.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the engine mount bracket spacer if it has been replaced. Tighten Torque the engine mount spacer bolts to 50 N.m (37 lb ft). IMPORTANT: Make sure that the cut out side of the engine mount shield is positioned away from the engine.
2. Install the engine mount to the upper engine mount bracket. Tighten Tighten the engine mount nuts to 50 N.m (37 lb ft)
3. Install the engine mount to engine. Tighten Torque the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten Torque the engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
6. Shift the engine back towards the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the left side engine mount frame bracket retaining bolts. Tighten Torque the left side engine mount frame bracket retaining bolts to 100 N.m (74 lb ft).
9. Lower the engine, making sure to align engine mount studs with holes in frame bracket.
10. Remove the pole jack and block of wood.
11. Tighten the engine mount nuts. Tighten Torque the engine mount nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to SHOCK MODULE REPLACEMENT in Front Suspension.
13. Install the front differential carrier. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
14. Install the left side wheel drive shaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
15. Install the Engine Protection Shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) in Frame and Underbody.
16. Install the front tire and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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1. Remove the positive crankcase ventilation (PCV) tube (1) from the rocker arm cover.
2. Remove the PCV valve (2) from the PCV tube (1).

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1. Install a new PCV valve (2) to the PCV tube (1).
2. Install the PCV tube (1) to the rocker arm cover.

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1. Remove the positive crankcase ventilation (PCV) tube (1) and valve (2) from the intake manifold and valve rocker arm cover.
2. Remove the PCV valve (2) from the PCV tube (1).
3. Remove the vent hose from the throttle body and the valve rocker arm cover.
4. Replace the hose/tube as necessary.

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1. Install the hose/tube as necessary.
2. Install the vent hose to the throttle body and the valve rocker arm cover.
3. Install the PCV valve (2) to the tube (1).
4. Install the PCV tube (1) and valve (2) to the intake manifold and valve rocker arm cover.

Removal Procedure

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1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER RESONATOR OUTLET DUCT»(ref-159085-S05754353602003111400000) .
2. Relieve the fuel system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-159085-S07303999702003111100000) .
3. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
4. Remove the harness clip from the cylinder head.
5. Disconnect the MAF/IAT sensor electrical connector (1).
6. Remove the harness clips from the fuel rail.
7. Disconnect the following electrical connectors: Main coil (1) Electronic throttle control (ETC) (2) Fuel injectors (3)
8. Perform the following steps in order to disconnect the fuel injector electrical connector. 8.1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 8.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. 8.3. Push the tab (1) on the connector in. 8.4. Disconnect the fuel injector electrical connector. 8.5. Repeat the steps for each injector electrical connector.
9. Disconnect the generator electrical connector.
10. Disconnect the following electrical connectors: Evaporative emission (EVAP) purge solenoid (1) Knock sensor (2) Manifold absolute pressure (MAP) sensor (3) Main coil (4) Fuel injectors (5)
11. Remove the electrical harness clips from the fuel rail.
12. Remove the knock sensor harness electrical connector from the intake manifold.
13. Remove the positive crankcase ventilation (PCV) hose (with valve).
14. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
15. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following: 15.1. Remove the EVAP tube end from the solenoid. 15.2. Squeeze the EVAP pipe quick connect fitting retainer together 15.3. Remove the EVAP tube end from the vapor pipe.
16. Remove the vacuum brake booster hose from the rear of the intake manifold.
17. Remove the upper engine wire harness retainer nut (1).
18. Reposition the upper engine wire harness aside.
19. Remove the intake manifold bolts.
20. Remove the intake manifold.
21. Remove the intake manifold gaskets (1) from the intake manifold.
22. Discard the old intake manifold gaskets.
23. If necessary, clean and inspect the intake manifold. Refer to «INTAKE MANIFOLD CLEANING AND INSPECTION»(ref-188498-S15421211522005090700000) .

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1. Install NEW intake manifold gaskets (1) to the intake manifold.
2. Install the intake manifold.
3. Apply a 5 mm (0.20 in) bead of threadlock GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the intake manifold bolts. Tighten 4.1. Tighten the bolts a first pass in sequence to 5 N.m (44 lb in). 4.2. Tighten the bolts a final pass in sequence to 10 N.m (89 lb in).
5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1). Tighten Tighten the nut to 10 N.m (89 lb in).
7. Install the vacuum brake booster hose to the rear of the intake manifold.
8. Install the EVAP purge solenoid vent tube.
9. Install the heater water shutoff valve actuator inlet hose to the intake manifold.
10. Install the PCV hose (with valve).
11. Install the knock sensor harness electrical connector to the intake manifold.
12. Connect the following electrical connectors: EVAP purge solenoid (1) Knock sensor (2) (MAP sensor (3) Main coil (4) Fuel injectors (5)
13. Perform the following steps in order to connect the fuel injector electrical connectors. 13.1. Install the connectors to their corresponding injectors to ensure correct reassembly. 13.2. Connect the fuel injector electrical connector. 13.3. Push the CPA retainer (2) on the connector in 1 click. 13.4. Repeat the steps for each injector electrical connector.
14. Install the harness clips to the fuel rail.
15. Connect the generator electrical connector.
16. Connect the following electrical connectors: Main coil (1) ETC (2) Fuel injectors (3)
17. Install the electrical harness clips to the fuel rail.
18. Connect the A/C compressor pressure switch electrical connector (2).
19. Install the harness clip to the cylinder head.
20. Connect the MAF/IAT sensor electrical connector (1).
21. Install the air cleaner outlet duct. Refer to «AIR CLEANER RESONATOR OUTLET DUCT»(ref-159085-S05754353602003111400000) .
22. Install the fuel fill cap.
23. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, wit the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks.

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1. Remove the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188498-S18786914042005090700000) .
2. Gently pry up the rubber covers.
3. Disconnect the knock sensor electrical connectors.
4. Remove the knock sensors.
5. Remove the engine valley cover bolts.
6. Remove the engine valley cover and gasket.
7. Discard the old gasket.
8. Remove the knock sensor oil seals (1) from the cover (2).
9. Clean and inspect the engine valley cover. Refer to «ENGINE VALLEY COVER CLEANING AND INSPECTION»(ref-188498-S25509485282005090700000) .

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1. Lubricate the NEW knock sensor seals (1) with clean engine oil.
2. Install the knock sensor oil seals (1) into the engine valley cover (2).
3. Install the engine valley cover and a NEW gasket onto the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the engine valley cover bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
5. Install the knock sensors. Tighten Tighten the sensors to 20 N.m (15 lb ft).
6. Connect the knock sensor electrical connectors.
7. Push down on the rubber covers.
8. Install the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188498-S18786914042005090700000) .

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1. Remove the connector position assurance (CPA) lock.
2. Disconnect the main electrical connector (5) to the ignition coil wire harness.
3. Remove the harness clips.
4. Reposition the engine harness, if necessary.
5. Remove the spark plug wires from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
6. If necessary, remove the ignition coil bracket studs from the rocker arm cover.
7. If necessary, remove the ignition coils and bracket from the rocker arm cover.
8. Remove the positive crankcase ventilation (PCV) hose from the rocker arm cover.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.
11. Remove the gasket (1) from the rocker cover.
12. Discard the OLD gasket.

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1. Install a NEW rocker cover gasket (1) into the groove of the valve rocker arm cover.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the rocker arm cover bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
5. Install the PCV hose to the rocker arm cover.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
7. If necessary, install the ignition coils and bracket to the rocker arm cover.
8. If necessary, install the ignition coil bracket studs to the rocker arm cover. Tighten Tighten the studs to 12 N.m (106 lb in).
9. Install the spark plug wires to the ignition coils.
10. Position the engine harness, if necessary.
11. Install the harness clips.
12. Connect the main electrical connector (5) to the ignition coil wire harness.
13. Install the CPA lock.

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1. Remove the air conditioning (A/C) compressor hose. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) or COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 6) in Heating, Ventilation, and Air Conditioning.
2. Remove the connector position assurance (CPA) lock.
3. Disconnect the main electrical connector (1) to the ignition coil wire harness.
4. Remove the harness clips.
5. Reposition the engine harness, if necessary.
6. Remove the spark plug wires from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
7. If necessary, remove the ignition coil bracket studs from the rocker arm cover.
8. If necessary, remove the ignition coils and bracket from the rocker cover.
9. Remove the vent hose from the throttle body and valve rocker arm cover.
10. Remove the valve rocker arm cover bolts.
11. Remove the valve rocker arm cover.
12. Remove the gasket (1) from the rocker cover.
13. Discard the OLD gasket.
14. Remove the oil fill cap from the oil fill tube.
15. Remove the oil fill tube from the rocker cover, if required.
16. Discard the oil fill tube.

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1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position.
4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover.
5. Install the valve rocker arm cover onto the cylinder head.
6. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the rocker arm cover bolts and grommets. Tighten Tighten the bolts to 12 N.m (106 lb in).
8. Install the vent hose to the throttle body and valve rocker arm cover.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
10. If necessary, install the ignition coils and bracket to the rocker arm cover.
11. If necessary, install the ignition coil bracket studs to the rocker cover. Tighten Tighten the studs to 12 N.m (106 lb in).
12. Install the spark plug wires to the ignition coils.
13. Position the engine harness, if necessary.
14. Install the harness clips.
15. Connect the main electrical connector (1) feeding the ignition coils.
16. Install the CPA lock.
17. Install the A/C compressor hose. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) or COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 6) in Heating, Ventilation, and Air Conditioning.

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1. Remove the valve rocker arm cover. Refer to «VALVE ROCKER ARM COVER REPLACEMENT - LEFT»(ref-188498-S02664204742005090700000) or «VALVE ROCKER ARM COVER REPLACEMENT - RIGHT»(ref-188498-S40885564832005090700000) . IMPORTANT: Place the valve rocker arms, pushrods, and pivot support, in a rack so that the can be installed in the same location from which they were removed.
2. Remove the valve rocker arm bolts.
3. Remove the valve rocker arms.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrods.
6. Clean and inspect the valve rocker arms and pushrods. Refer to «VALVE ROCKER ARM AND PUSH RODS CLEANING AND INSPECTION»(ref-188498-S26256206212005090700000) .

Valve lash is net build, no valve adjustment is required.

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1. Lubricate the valve rocker arms and pushrods with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support. IMPORTANT: Make sure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods. IMPORTANT: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to «VALVE ROCKER ARM COVER REPLACEMENT - LEFT»(ref-188498-S02664204742005090700000) or «VALVE ROCKER ARM COVER REPLACEMENT - RIGHT»(ref-188498-S40885564832005090700000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter
2. J 38606 Valve Spring Compressor

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1. Remove the valve rocker arm. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .
2. Disconnect the spark plug wire at the spark plug. Twist each plug wire boot 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug. IMPORTANT: Remove the spark plugs from the cylinder head with the engine at room temperature.
3. Loosen the spark plug 1 or 2 turns.
4. Brush or air blast away any dirt or debris from around the spark plug.
5. Remove the spark plug.
6. Install J 22794 into the spark plug hole.
7. Attach an air hose to J 22794.
8. Apply compressed air to J 22794 in order to hold the valves in place.
9. Use J 38606 in order to compress the valve spring.
10. Remove the valve stem keys (2).
11. Carefully release the valve spring tension.
12. Remove the J 38606.
13. Remove the valve spring cap (3).
14. Remove the valve spring (4).
15. Remove the valve stem oil seal and shim (1, 5).

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1. Clean the cylinder head valve spring seat and/or shim area.
2. Lubricate the valve guide and valve stem oil seal with clean engine oil.
3. Install the valve stem oil seal and shim (1, 5).
4. Install the valve spring (4).
5. Install the valve spring cap (3).
6. Compress the valve spring using the J 38606.
7. Install the valve keys. 7.1. Use grease in order to hold the valve keys in place. 7.2. Make sure the keys seat properly in the groove of the valve stem. 7.3. Carefully release the valve spring pressure, making sure the valve keys stay in place. 7.4. Remove the J 38606. 7.5. Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary).
8. Remove J 22794 from the spark plug port. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Hand start the spark plug. Tighten Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the spark plug wires at the ignition coil.
11. Install the spark plug wire to the spark plug.
12. Inspect the wires for proper installation: Push sideways on each boot in order to check for proper installation. Reinstall any loose boot.
13. Install the valve rocker arm. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .

Scheme 243

1. Remove the cylinder number 2 spark plug and wire. Refer to «SPARK PLUGS»(ref-159085-S02952502512003111400000) .
2. Remove the oil level indicator from the tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube from the engine block. IMPORTANT: The O-ring seal may be reused if not cut or damaged.
5. Inspect the O-ring seal for cuts or damage.
6. Remove the O-ring seal from the tube (if required).

Scheme 244

1. Lubricate the O-ring seal with clean engine oil.
2. Install the O-ring seal onto the oil level indicator tube.
3. Install the oil level indicator tube behind the exhaust manifold.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Install the oil level indicator tube into the block. The tube must be installed with the collar flush to the block.
6. Lower the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the oil level indicator tube bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
8. Install the oil level indicator to the tube.
9. Install the cylinder number 2 spark plug and wire. Refer to «SPARK PLUGS»(ref-159085-S02952502512003111400000) .

Cylinder Head Replacement - Left

Tools Required

1. J 36660-A Torque Angle Meter
2. J 42385-200 Thread Repair Kit

Scheme 245

Scheme 246

Scheme 247

Scheme 248

1. Remove the generator bracket. Refer to GENERATOR BRACKET REPLACEMENT (5.3L ENGINE) in Engine Electrical.
2. Remove the coolant air bleed pipe. Refer to COOLANT AIR BLEED PIPE ASSEMBLY REPLACEMENT (5.3L ENGINE) in Engine Cooling.
3. Remove the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (5.3L ENGINE) in Engine Exhaust.
4. Remove the pushrods. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .
5. If equipped, remove the auxiliary air conditioning (A/C) bracket bolt (5). IMPORTANT: The cylinder head bolts are NOT reusable.
6. Remove and discard the cylinder head bolts (1, 2, 3). NOTE: After removal, place the cylinder head on two wood blocks to prevent damage.
7. Remove the cylinder head.
8. Remove and discard the cylinder head gasket.
9. Clean and inspect the cylinder head. Refer to «CYLINDER HEAD CLEANING AND INSPECTION»(ref-188498-S38284877562005090700000) .

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107, found in J 42385-200 may be used to clean the threads of old threadlock material.
2. Use spray cleaner GM P/N 12346139, or GM P/N 12377981 (Canadian P/N 10953463), or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Check the cylinder head locating pins for proper installation, location (a) 8.3 mm (0.327 in).
5. When properly installed, with FRONT on the left side, the tab on the cylinder head gasket should be located left of center or closer to the front of the engine.
6. Install the NEW cylinder head gasket.
7. Install the cylinder head.
8. Install NEW cylinder head bolts (1, 2, 3). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Tighten the cylinder head bolts. Tighten 9.1. Tighten the M11 bolts a first pass in sequence to 30 N.m (22 lb ft). 9.2. Tighten the M11 bolts a second pass in sequence to 90 degrees using J 36660-A . 9.3. Tighten the M11 bolts (1, 2, 3, 4, 5, 6, 7, 8) to 90 degrees and the M11 bolts (9 and 10) to 50 degrees a final pass in sequence using J 36660-A . 9.4. Tighten the M8 bolts (11, 12, 13, 14, 15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
10. If equipped, install the auxiliary A/C bracket bolt (5). Tighten Tighten the bolt to 20 N.m (15 lb ft).
11. Install the pushrods. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .
12. Install the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (5.3L ENGINE) in Engine Exhaust.
13. Install the coolant air bleed pipe. Refer to COOLANT AIR BLEED PIPE ASSEMBLY REPLACEMENT (5.3L ENGINE) in Engine Cooling.
14. Install the generator bracket. Refer to GENERATOR BRACKET REPLACEMENT (5.3L ENGINE) in Engine Electrical.

Cylinder Head Replacement - Right

Tools Required

1. J 36660-A Torque Angle Meter
2. J 42385-200 Thread Repair Kit

Scheme 256

Scheme 257

Scheme 258

Scheme 259

1. Remove the oil level indicator. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-188498-S40231935672005090700000) .
2. Remove the coolant air bleed pipe. Refer to COOLANT AIR BLEED PIPE ASSEMBLY REPLACEMENT (5.3L ENGINE) in Engine Cooling.
3. Remove the right exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (5.3L ENGINE) in Engine Exhaust.
4. Remove the pushrods. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .
5. If equipped, remove the auxiliary air conditioning (A/C) bracket nut (2). IMPORTANT: The cylinder head bolts are NOT reusable.
6. Remove and discard the cylinder head bolts (1, 2, 3). NOTE: After removal, place the cylinder head on two wood blocks to prevent damage.
7. Remove the cylinder head.
8. Remove and discard the cylinder head gasket.
9. Clean and inspect the cylinder head. Refer to «CYLINDER HEAD CLEANING AND INSPECTION»(ref-188498-S38284877562005090700000) .

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107, found in J 42385-200 may be used to clean the threads of old threadlock material.
2. Use spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463), or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Check the cylinder head locating pins for proper installation, location (a) 8.3 mm (0.327 in).
5. When properly installed, with FRONT on the right side, the tab on the cylinder head gasket should be located right center or closer.
6. Install the NEW cylinder head gasket.
7. Install the cylinder head.
8. Install the NEW cylinder head bolts (1, 2, 3). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Tighten the cylinder head bolts. Tighten 9.1. Tighten the M11 bolts a first pass in sequence to 30 N.m (22 lb ft). 9.2. Tighten the M11 bolts a second pass in sequence to 90 degrees using J 36660-A . 9.3. Tighten the M11 bolts (1,2,3,4,5,6,7,8) to 90 degrees and the M11 bolts (9 and 10) to 50 degrees a final pass in sequence using J 36660-A . 9.4. Tighten the M8 bolts (11,12,13,14,15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
10. If equipped, install the auxiliary air conditioning (A/C) bracket nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
11. Install the pushrods. Refer to «VALVE ROCKER ARM AND PUSH ROD REPLACEMENT»(ref-188498-S18094683602005090700000) .
12. Install the right exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (5.3L ENGINE) in Engine Exhaust.
13. Install the coolant air bleed pipe. Refer to COOLANT AIR BLEED PIPE ASSEMBLY REPLACEMENT (5.3L ENGINE) in Engine Cooling.
14. Install the oil level indicator. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-188498-S40231935672005090700000) .

Valve Lifter Replacement

Tools Required

J 3049-A Valve Lifter Remover

Scheme 267

Scheme 268

Scheme 269

1. Remove the cylinder head and gasket. Refer to «CYLINDER HEAD REPLACEMENT - LEFT»(ref-188498-S04139425352005090700000) or «CYLINDER HEAD REPLACEMENT - RIGHT»(ref-188498-S19077050772005090700000) .
2. Remove the valve lifter guide bolts.
3. Remove the valve lifters and guide. IMPORTANT: Some valve lifters may be stuck in their bores because of gum or varnish deposits.
4. Use J 3049-A or equivalent in order to remove the valve lifters (if required).
5. Remove the valve lifters from the guide.
6. Organize or mark the components so that they can be installed in the same location from which they were removed.
7. Clean and inspect the valve lifters. Refer to «VALVE LIFTERS AND GUIDES CLEANING AND INSPECTION»(ref-188498-S39261013052005090700000) .

Scheme 270

Scheme 271

Scheme 272

1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore.
3. Install the valve lifters and guide to the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the valve lifter guide bolt. Tighten Tighten the bolt to 12 N.m (106 lb in).
5. Install the cylinder head and gasket. Refer to «CYLINDER HEAD REPLACEMENT - LEFT»(ref-188498-S04139425352005090700000) or «CYLINDER HEAD REPLACEMENT - RIGHT»(ref-188498-S19077050772005090700000) .

Crankshaft Balancer Replacement

Tools Required

1. J 41816 Crankshaft Balancer Remover
2. J 41816-2 Crankshaft End Protector
3. J 42386-A Flywheel Holding Tool
4. J 41665 Crankshaft Balancer and Sprocket Installer
5. J 36660-A Torque Angle Meter

Scheme 273

Scheme 274

Scheme 275

1. Remove the air conditioning (A/C) drive belt, if equipped. Refer to «DRIVE BELT REPLACEMENT - AIR CONDITIONING»(ref-188498-S07121034902005090700000) .
2. Remove the accessory drive belt, if not equipped with A/C. Refer to «DRIVE BELT TENSIONER REPLACEMENT - AIR CONDITIONING»(ref-188498-S36388622452005090700000) .
3. Remove the fan shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
4. Remove the starter motor. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical. IMPORTANT: Make sure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the J 42386-A and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten Tighten the J 42386-A bolts to 50 N.m (37 lb ft).
6. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
7. Use the J 41816 and J 41816-2 in order to remove the crankshaft balancer.
8. Remove the J 41816 and the J 41816-2 from the crankshaft balancer.
9. Clean and inspect the crankshaft balancer. Refer to «CRANKSHAFT BALANCER CLEANING AND INSPECTION»(ref-188498-S33882103142005090700000) .

Scheme 276

Scheme 277

1. Install the crankshaft balancer onto the end of the crankshaft.
2. Use the J 41665 in order to install the crankshaft balancer. 2.1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2.2. Use a wrench and hold the hex end of the threaded rod. 2.3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 2.4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 2.5. Use a wrench and hold the hex end of the threaded rod. 2.6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 2.7. Remove the balancer installation tool.
3. Install the used crankshaft balancer bolt. Tighten Tighten the USED bolt to 330 N.m (240 lb ft).
4. Remove the used crankshaft balancer bolt. IMPORTANT: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure.
6. Install a NEW crankshaft balancer bolt. Tighten 6.1. Tighten the bolt a first pass to 50 N.m (37 lb ft). 6.2. Tighten the bolt a final pass to 140 degrees using J 36660-A .
7. Remove the J 42386-A and bolts.
8. Install the starter motor. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical.
9. Install the fan shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
10. Install the accessory drive belt (if not equipped with A/C). Refer to «DRIVE BELT REPLACEMENT - ACCESSORY»(ref-188498-S29906989872005090700000) .
11. Install the A/C drive belt (if equipped). Refer to «DRIVE BELT REPLACEMENT - AIR CONDITIONING»(ref-188498-S07121034902005090700000) .
12. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-159085-S15986821592003111100000) .

Crankshaft Front Oil Seal Replacement

Tools Required

J 41478 Crankshaft Front Oil Seal Installer

Scheme 278

1. Remove the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
2. Remove the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188498-S23376675342005090700000) .
3. Remove the crankshaft oil seal (1) from the front cover.

Scheme 279

Scheme 280

1. Lubricate the outer edge of the oil seal (1) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal onto the J 41478 guide.
4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft.
5. Use the J 41478 in order to install the oil seal into the cover bore. 5.1. Use a wrench and hold the hex on the installer bolt. 5.2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 5.3. Remove the J 41478 . 5.4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.
6. Install the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188498-S23376675342005090700000) .
7. Install the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.

Engine Front Cover Replacement

Tools Required

J 41476 Front and Rear Cover Alignment Tool (at crankshaft seal area)

Scheme 281

1. Remove the air conditioning (A/C) compressor and bracket. Refer to COMPRESSOR REPLACEMENT (BODY TYPE VIN 3) or COMPRESSOR REPLACEMENT (BODY TYPE VIN 6) in Heating, Ventilation, and Air Conditioning.
2. Remove the water pump. Refer to WATER PUMP REPLACEMENT (5.3L ENGINE) in Engine Cooling.
3. Remove the crankshaft balancer. Refer to «CRANKSHAFT BALANCER REPLACEMENT»(ref-188498-S23376675342005090700000) .
4. Remove the oil pan-to-front cover bolts.
5. Remove the front cover bolts.
6. Remove the front cover and gasket.
7. Discard the front cover gasket.
8. Clean and inspect the engine front cover. Refer to «ENGINE FRONT COVER CLEANING AND INSPECTION»(ref-188498-S09455153122005090700000) .

Scheme 282

Scheme 283

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction.
2. Install the front cover gasket and cover.
3. Install the front cover bolts until snug. Do not overtighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.
5. Install J 41476 to the front cover.
6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the crankshaft balancer bolt until snug. Do not overtighten. Tighten 7.1. Tighten the oil pan to front cover bolts to 25 N.m (18 lb ft). 7.2. Tighten the engine front cover bolts to 25 N.m (18 lb ft).
8. Remove the J 41476 .
9. Install a NEW crankshaft front oil seal. Refer to «CRANKSHAFT FRONT OIL SEAL REPLACEMENT»(ref-188498-S37606438262005090700000) .
10. Install the water pump. Refer to WATER PUMP REPLACEMENT (5.3L ENGINE) in Engine Cooling.
11. Install the A/C compressor and bracket. Refer to COMPRESSOR REPLACEMENT (BODY TYPE VIN 3) or COMPRESSOR REPLACEMENT (BODY TYPE VIN 6) in Heating, Ventilation, and Air Conditioning.

Crankshaft Rear Oil Seal Replacement

Tools Required

J 41479 Crankshaft Rear Oil Seal Installer

Scheme 284

1. Remove the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188498-S30477815642005090700000) .
2. Remove the crankshaft rear oil seal (1) from the rear cover.

Scheme 285

Scheme 286

1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft.
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal.
7. Align the oil seal into the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore.
9. Remove the J 41479 .
10. Install the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188498-S30477815642005090700000) .

Engine Rear Cover Replacement

Tools Required

J 41476 Front and Rear Cover Alignment Tool (at crankshaft seal area)

Scheme 287

Scheme 288

1. Remove the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188498-S30477815642005090700000) .
2. Remove the oil pan-to-rear cover bolts (1).
3. Remove the rear cover bolts.
4. Remove the rear cover and gasket.
5. Discard the rear cover gasket.
6. Clean and inspect the rear cover. Refer to «ENGINE REAR COVER CLEANING AND INSPECTION»(ref-188498-S19619084892005090700000) .

Scheme 289

Scheme 290

Scheme 291

Scheme 292

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction.
2. Install the rear cover gasket and cover.
3. Install the rear cover bolts until snug. Do not overtighten.
4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten.
5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the crankshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Tighten the J 41476 mounting bolts until snug. Do not overtighten. Tighten 7.1. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). 7.2. Tighten the engine rear cover bolts to 25 N.m (18 lb ft).
8. Remove the J 41476 .
9. Install a NEW crankshaft rear oil seal. Refer to «CRANKSHAFT REAR OIL SEAL REPLACEMENT»(ref-188498-S35748905402005090700000) .
10. Install the engine flywheel. Refer to «ENGINE FLYWHEEL REPLACEMENT»(ref-188498-S30477815642005090700000) .

Scheme 293

Scheme 294

1. Drain the engine oil.
2. Remove the oil filter.
3. Remove the oil filter adapter (1).

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 295

Scheme 296

1. Install the oil filter adapter (1). Tighten Tighten the adapter to 55 N.m (40 lb ft).
2. Install the oil filter.
3. Refill the engine oil. Refer to Capacities - Approximate Fluid and/or Fluid and Lubricant Recommendations in Maintenance and Lubrication.

Scheme 297

Scheme 298

1. Drain the engine oil.
2. Remove the oil filter.
3. Remove the oil filter adapter (1).
4. Remove the oil filter bypass valve (2).

Scheme 299

Scheme 300

1. Install the oil filter bypass valve (2). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil filter adapter (1). Tighten Tighten the adapter to 55 N.m (40 lb ft).
3. Install the oil filter. Tighten Tighten the filter to 30 N.m (22 lb ft).
4. Refill the engine oil. Refer to Capacities - Approximate Fluid and/or Fluid and Lubricant Recommendations in Maintenance and Lubrication.

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
2. Remove the oil level indicator tube. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-188498-S40231935672005090700000) .
3. Remove the front shock upper retaining nuts.
4. Remove the tires and wheels. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the engine shield bolts and shield.
6. Drain the engine oil.
7. Drain the differential oil.
8. Remove the steering gear. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
9. Remove the left and right antilock brake system (ABS) wiring harnesses from the retainers.
10. Disconnect the wheel speed sensor electrical connectors.
11. Remove the brake hose retaining bolts from the frame.
12. Disconnect the sway bar link pins from the lower control arm on both sides.
13. Place an adjustable jack stand under the lower control arm.
14. Remove the upper ball joint pinch bolt and nut.
15. Disconnect the upper control arm from the upper ball joint.
16. Lower and remove the adjustable jack stand allowing the suspension to hang.
17. Remove the left wheel driveshaft. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
18. Remove the right wheel driveshaft from the intermediate shaft bearing assembly only. It is not necessary to remove the drive shaft from the steering knuckle. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) . Position the drive shaft to the side out of the way.
19. Using mechanic's wire or metal hooks, secure the front shock modules to the frame. DO NOT let the shock modules and steering knuckle hang without supporting them.
20. Reference mark the relationship of the propeller shaft to the front axle pinion yoke.
21. Remove the yoke retainer bolts and yoke retainers from the front axle pinion yoke.
22. Disconnect the propeller shaft from the front axle pinion yoke. Wrap the bearing caps with tape in order to prevent the loss or the bearing rollers. Secure the propeller shaft to the frame.
23. Remove the transmission oil cooler lines from the retainer.
24. Remove the transmission oil cooler line retaining bracket bolt and bracket.
25. Remove the inner axle shaft. Refer to INNER AXLE SHAFT REPLACEMENT - FRONT DRIVE AXLE in Front Drive Axle.
26. Remove the starter. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical.
27. Remove the Flywheel inspection cover from the left side of the transmission.
28. Remove the battery cable channel bolt from the front of the oil pan.
29. Remove the battery cable channel from the oil pan.
30. Loosen the 2 upper air conditioning (A/C) compressor bracket bolts.
31. Remove the 2 lower A/C compressor bracket bolts.
32. Remove the front differential attachment bolts.
33. Secure the front differential to the frame.
34. Remove the 2 lower bellhousing bolts.
35. Remove the oil pan bolts.
36. Remove the oil pan by tilting the rear of the oil pan down to clear the transmission, pull the oil pan rearward past the front wire harness, then lower the oil pan clear of the vehicle. IMPORTANT: The oil pan gasket is reusable. It is NOT necessary to remove the oil pan gasket unless damaged. IMPORTANT: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required.
37. Drill out the oil pan gasket retaining rivets (2), if required.
38. Remove the gasket (1) from the pan.
39. Discard the gasket and rivets.
40. Clean and inspect the oil pan. Refer to «OIL PAN CLEANING AND INSPECTION»(ref-188498-S15198836622005090700000) .

Scheme 316

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Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.
2. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.
3. Pre-assemble the oil pan gasket and bolts to the pan. Install the gasket onto the pan. Install the oil pan bolts to the pan and through the gasket.
4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly.
5. Hand thread the oil pan bolts into the engine block until snug. Do not tighten at this time. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
6. Install the 2 lower bellhousing bolts. Tighten 6.1. Tighten the lower bellhousing bolts to 50 N.m (37 lb ft). 6.2. Tighten the 2 rear oil pan to rear cover bolts to 12 N.m (106 lb in). 6.3. Tighten the remaining oil pan bolts to 25 N.m (18 lb ft).
7. Release the differential from the frame and install to the oil pan.
8. Install the differential bolts. Tighten Tighten the bolts to 85 N.m (63 lb ft).
9. Install the 2 lower A/C compressor bracket bolts.
10. Tighten the 2 upper A/C compressor bracket bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
11. Install the battery cable channel to the oil pan.
12. Install the battery cable channel bolt to the oil pan. Tighten Tighten the bolt to 12 N.m (106 lb in).
13. Install the Flywheel inspection cover to the left side of the transmission.
14. Install the starter. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical.
15. Install the inner axle shaft. Refer to INNER AXLE SHAFT REPLACEMENT - FRONT DRIVE AXLE in Front Drive Axle.
16. Install the transmission oil cooler line retaining bracket and bolt. Tighten Tighten the bolt to 9 N.m (80 lb in).
17. Install the transmission oil cooler lines to the retainer.
18. Unsecure the right wheel driveshaft from the frame.
19. Install the left and right wheel driveshafts. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
20. Unsecure the front shock modules from the frame.
21. Place an adjustable jack stand under the lower control arm.
22. Using the adjustable jack stand raise the lower control arm and knuckle assembly in order to connect the upper ball joint to the upper control arm.
23. Install the upper ball joint pinch nut and bolt. Tighten Tighten the nut to 40 N.m (30 lb ft).
24. Remove the jack stand from under the lower control arm.
25. Connect the sway bar link pins to the lower control arm on both sides.
26. Install the steering gear. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
27. Unsecure the propeller shaft from the frame.
28. Align the reference marks on the propeller shaft to the marks on the front axle pinion yoke.
29. Connect the propeller shaft to the front axle pinion yoke.
30. Install the yoke retainers and yoke retainer bolts to the front axle pinion yoke. Tighten Tighten the bolts to 20 N.m (15 lb ft).
31. Install the brake hose retaining bolts to the frame. Tighten Tighten the bolts to 25 N.m (18 lb ft).
32. Connect the wheel speed sensor electrical connectors.
33. Install the left and right ABS wiring harnesses to the retainers.
34. Fill the differential with oil.
35. Install the engine shield and bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
36. Install the tires and wheels. Refer to Lifting and Jacking the Vehicle in General Information.
37. Fill the engine with oil.
38. Fill the Power Steering System with fluid.
39. Install the front shock upper retaining nuts. Tighten Tighten the nuts to 100 N.m (74 lb ft).
40. Install the oil level indicator tube. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-188498-S40231935672005090700000) .
41. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.

Engine Oil Pressure Sensor and/or Switch Replacement

Tools Required

J 41712 Oil Pressure Switch Socket

Scheme 332

Scheme 333

1. Disconnect the oil pressure sensor electrical connector (1).
2. Using J 41712 or equivalent, remove the oil pressure sensor.

Scheme 334

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the oil pressure sensor. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Using J 41712 or equivalent, install the oil pressure sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the oil pressure sensor electrical connector (1).

Scheme 335

Scheme 336

Scheme 337

1. Remove the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-188498-S25995403672005090700000) .
2. Remove the engine front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188498-S09178884252005090700000) .
3. Remove the oil pump screen bolt and nuts.
4. Remove the oil pump screen with O-ring seal.
5. Remove the O-ring seal from the pump screen.
6. Discard the O-ring seal.
7. Remove the remaining crankshaft oil deflector nuts.
8. Remove the crankshaft oil deflector.
9. Remove the oil pump bolts. IMPORTANT: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary.
10. Remove the oil pump.
11. Clean and inspect the oil pump. Refer to «OIL PUMP CLEANING AND INSPECTION»(ref-188498-S15314593702005090700000)

Scheme 338

Scheme 339

Scheme 340

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump.
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the oil pump bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector and nuts until snug.
5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump.
7. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs.
8. Install the oil pump screen.
9. Install the oil pump screen bolt and nuts. Tighten 9.1. Tighten the bolt to 12 N.m (106 lb in). 9.2. Tighten the nuts to 25 N.m (18 lb ft).
10. Install the engine front cover. Refer to «ENGINE FRONT COVER REPLACEMENT»(ref-188498-S09178884252005090700000) .
11. Install the oil pan. Refer to «OIL PAN REPLACEMENT»(ref-188498-S25995403672005090700000) .

Timing Chain and Sprockets Replacement

Tools Required

1. J 8433 Pulley Puller
2. J 41816-2 Crankshaft End Protector
3. J 41558 Crankshaft Sprocket Remover
4. J 41665 Crankshaft Balancer and Sprocket Installer

Scheme 341

Scheme 342

Scheme 343

Scheme 344

1. Remove the oil pump. Refer to «OIL PUMP, PUMP SCREEN AND DEFLECTOR REPLACEMENT»(ref-188498-S37508123682005090700000) .
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and timing chain.
5. Use the J 8433 , the J 41816-2 and the J 41558 in order to remove the crankshaft sprocket.
6. Remove the crankshaft sprocket.
7. Remove the crankshaft sprocket key, if required.
8. Clean and inspect the timing chain and sprockets. Refer to «TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION»(ref-188498-S40943342992005090700000) .

Scheme 345

Scheme 346

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Scheme 350

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.
7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
8. Install the camshaft sprocket bolts. Tighten Tighten the bolts to 35 N.m (26 lb ft).
9. Install the oil pump. Refer to «OIL PUMP, PUMP SCREEN AND DEFLECTOR REPLACEMENT»(ref-188498-S37508123682005090700000) .

Scheme 351

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Scheme 355

1. Remove the condenser. Refer to CONDENSER REPLACEMENT in Heating, Ventilation and Air Conditioning.
2. Remove the valve lifters from both cylinder heads. Refer to «VALVE LIFTER REPLACEMENT»(ref-188498-S31493571512005090700000) .
3. Remove the camshaft sensor bolt and sensor.
4. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned.
5. Remove the camshaft sprocket bolts. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
6. Remove the camshaft sprocket and reposition the timing chain.
7. Remove the camshaft retainer bolts and retainer. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
8. Remove the camshaft. 8.1. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft. 8.2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 8.3. Remove the three bolts from the camshaft.
9. Clean and inspect the camshaft and bearings. Refer to «CAMSHAFT AND BEARINGS CLEANING AND INSPECTION»(ref-188498-S23739674162005090700000) .

Scheme 356

Scheme 357

Scheme 358

Scheme 359

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the three bolts from the front of the camshaft. IMPORTANT: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the camshaft retainer and bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position.
6. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
7. Install the camshaft sprocket and the timing chain.
8. Install the camshaft sprocket bolts. Tighten Tighten the bolts to 35 N.m (26 lb ft).
9. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused.
10. Lubricate the O-ring seal with clean engine oil.
11. Install the camshaft sensor and bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
12. Install the valve lifters. Refer to «VALVE LIFTER REPLACEMENT»(ref-188498-S31493571512005090700000) .
13. Install the condenser. Refer to CONDENSER REPLACEMENT in Heating, Ventilation and Air Conditioning.

Scheme 360

1. Remove the transmission. Refer to Transmission Replacement (LM4) in Automatic Transmission - 4L60-E. IMPORTANT: Note the position and direction of the engine flywheel before removal.
2. Remove the engine flywheel bolts.
3. Remove the engine flywheel.
4. Clean and inspect the engine flywheel. Refer to «ENGINE FLYWHEEL CLEANING AND INSPECTION»(ref-188498-S19289295952005090700000) .

Scheme 361

Scheme 362

1. Install the engine flywheel to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the engine flywheel bolts. Tighten 3.1. Tighten the bolts a first pass in sequence to 20 N.m (15 lb ft). 3.2. Tighten the bolts a second pass in sequence to 50 N.m (37 lb ft). 3.3. Tighten the bolts a final pass in sequence to 100 N.m (74 lb ft).
4. Install the transmission. Refer to Transmission Replacement (LM4) in Automatic Transmission - 4L60-E.

Engine Replacement

Tools Required

1. J 41798 Engine Lifting Brackets
2. J 21366 Converter Holding Strap
3. J 38185 Hose Clamp Pliers

Scheme 363

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Scheme 382

1. Remove the hood. Refer to HOOD REPLACEMENT in Body Front End.
2. Place fender covers over both fenders.
3. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
4. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation, and Air Conditioning.
5. Remove the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
6. Remove the radiator support brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
7. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD). Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
8. Remove the wheel drive shafts. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
9. Remove the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188498-S18786914042005090700000) .
10. Disconnect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
11. Remove the air conditioning (A/C) compressor hose. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) or COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 6) in Heating, Ventilation, and Air Conditioning.
12. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
13. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
14. Tie the pipe assembly out of the way.
15. Disconnect the engine coolant temperature (ECT) sensor (1).
16. Remove the ground terminal bolt (2).
17. Remove the retaining clips from the brackets.
18. Disconnect the A/C pressure switch electrical connector (2).
19. Remove the retaining clip (1) from the cylinder head.
20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
21. Remove the ground terminal bolts (2, 4).
22. Remove the starter. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical.
23. Remove the battery cable channel bolt.
24. Remove the battery cable channel from the oil pan.
25. Disconnect the A/C compressor electrical connector.
26. Lower the vehicle.
27. Gather all branches of the engine wiring harness and reposition the harness off to the side.
28. Remove the generator cable from the generator, perform the following: Slide the boot down revealing the terminal stud. Remove the generator cable nut from the terminal stud. Remove the generator cable.
29. Remove the generator bracket bolts.
30. Position the bracket with generator aside.
31. Using J 38185 , reposition the inlet hose clamp.
32. Remove the inlet hose from the water outlet.
33. Using J 38185 , reposition the inlet hose clamp.
34. Remove the outlet hose from the water outlet.
35. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.
36. Using J 38185 , reposition the auxiliary heater inlet and outlet hose clamps.
37. Remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.
38. Remove the ignition coil(s) (as required) for the proper fit of the J 41798 before lifting the engine. Refer to «IGNITION COILS»(ref-159085-S05803187002003111100000) in Engine Controls - 4.8L, 5.3L, and 6.0L. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
39. Install the J 41798 to the cylinder heads. Tighten Tighten the M8 bolts to 25 N.m (18 lb ft). Tighten the M10 bolts to 50 N.m (37 lb ft).
40. Raise the vehicle.
41. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (5.3L ENGINE) in Engine Exhaust.
42. Remove the 3 frame engine mount bracket bolts from both the right and left sides.
43. Remove the torque converter bolts.
44. Remove the transmission oil level indicator tube nut.
45. Remove the transmission oil level indicator tube.
46. Remove the transmission bolt and stud on the right side.
47. Remove the lower transmission bolt/studs.
48. Lower the vehicle.
49. Remove the 3 upper transmission bolts/studs.
50. Install an engine hoist to the J 41798 .
51. Install a floor jack under the transmission for support.
52. Separate the engine from the transmission.
53. Remove the engine.
54. Install the engine to an engine stand.
55. Install J 21366 to the transmission in order to hold the torque converter.

Scheme 383

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Scheme 402

1. Remove the J 21366 from the transmission.
2. Install an engine hoist to the J 41798 .
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the 3 upper transmission bolts/studs. Tighten Tighten the bolts/studs to 50 N.m (37 lb ft).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs. Tighten Tighten the bolts/studs to 50 N.m (37 lb ft).
10. Install the transmission bolt and stud on the right side. Tighten Tighten the bolts/studs to 50 N.m (37 lb ft).
11. Install the transmission oil level indicator tube.
12. Install the transmission oil level indicator tube nut. Tighten Tighten the nut to 10 N.m (89 lb ft).
13. Install the torque converter bolts. Tighten Tighten the bolts to 60 N.m (44 lb ft).
14. Install the 3 frame engine mount bracket bolts to both the right and left sides. Tighten Tighten the bolts to 50 N.m (37 lb ft).
15. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (5.3L ENGINE) in Engine Exhaust.
16. Lower the vehicle.
17. Remove the J 41798 from the cylinder heads.
18. Install the ignition coil(s) (as required). Tighten Tighten the bolts to 8 N.m (71 lb in).
19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump.
20. Using J 38185 , reposition the auxiliary heater inlet and outlet hose clamps.
21. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.
22. Install the outlet hose to the water outlet.
23. Using J 38185 , reposition the inlet hose clamp.
24. Install the inlet hose to the water outlet.
25. Using J 38185 , reposition the inlet hose clamp.
26. Position the bracket with generator to the engine.
27. Install the generator bracket bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
28. Install the generator cable to the generator, perform the following: Install the generator cable. Install the generator cable nut to the terminal stud. Tighten Tighten the nut to 9 N.m (80 lb in). Slide the boot down covering the terminal stud.
29. Gather all branches of the engine wiring harness and position the harness over the engine.
30. Raise the vehicle.
31. Connect the A/C compressor electrical connector.
32. Install the battery cable channel to the oil pan.
33. Install the battery cable channel bolt. Tighten Tighten the bolt to 12 N.m (106 lb in).
34. Install the starter. Refer to STARTER MOTOR REPLACEMENT (5.3L ENGINE) in Engine Electrical.
35. Install the ground terminal bolts (2, 4). Tighten Tighten the bolt to 25 N.m (18 lb ft).
36. Lower the vehicle.
37. Install the retaining clip (1) to the cylinder head.
38. Connect the A/C pressure switch electrical connector (2).
39. Install the retaining clips to the brackets.
40. Install the ground terminal bolt (2). Tighten Tighten the bolt to 25 N.m (18 lb ft).
41. Connect the ECT sensor (1).
42. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5). Tighten Tighten the nut/bolt to 20 N.m (15 lb ft).
43. Connect the rear auxiliary A/C compressor pipe fitting (7). Tighten Tighten the nut to 16 N.m (12 lb ft).
44. Install the A/C compressor hose. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) or COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 6) in Heating, Ventilation, and Air Conditioning.
45. Connect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
46. Install the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-188498-S18786914042005090700000) .
47. Install the wheel drive shafts. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
48. Install the front differential drive axle, if equipped with 4WD. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
49. Install the radiator support brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
50. Install the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
51. Recharge the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation, and Air Conditioning.
52. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
53. Remove the fender covers from both fenders.
54. Prelube the engine. Refer to «ENGINE PRELUBING»(ref-188498-S13223186462005090700000) .
55. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-159085-S15986821592003111100000) .
56. Install the hood. Refer to HOOD REPLACEMENT in Body Front End. IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
57. Test the vehicle using the following procedure: Disable the ignition system. Crank the engine several times. Listen for any 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 gauge 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 sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Close the hood.

Scheme 403

Scheme 404

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Place a oil drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug.
6. Drain the engine oil.
7. Wipe the excess oil from the drain plug hole and plug.
8. Remove the oil filter from the engine block. IMPORTANT: Check the old oil filter to ensure that the filter seal is not left on the engine block.
9. Wipe the excess oil from the oil filter mounting.

Scheme 405

Scheme 406

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 oil filter to the engine block. Tighten Tighten the filter to 30 N.m (22 lb ft).
3. Install the oil drain plug to the engine block. Tighten Tighten the oil pan drain plug to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to «CAPACITIES»(ref-151520-S41602694542002123000000) and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
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 in order to check the level.
10. Add oil if necessary.
11. Close the hood.

Draining Fluids and Oil Filter Removal

Tools Required

J 41712 Oil Pressure Switch Socket

Scheme 407

Scheme 408

Scheme 409

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Scheme 411

Scheme 412

1. Remove the oil pan drain plug and allow the oil to drain.
2. Remove the engine oil filter.
3. Remove the right rear engine block coolant drain plug and allow the coolant to drain.
4. Remove the left rear engine block coolant drain plug, if applicable, and allow the coolant to drain.
5. Remove the engine block coolant heater, if applicable, and allow the coolant to drain.
6. Use the J 41712 or equivalent in order to remove the oil pressure sensor, if required.

Crankshaft Balancer Removal

Tools Required

1. J 41816 Crankshaft Balancer Remover
2. J 41816-2 Crankshaft End Protector
3. J 42386-A Flywheel Holding Tool

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 413

Scheme 414

Scheme 415

1. Install the J 42386-A and bolts. Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten Tighten the J 42386-A bolts to 50 N.m (37 lb ft).
2. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
3. Use the J 41816 and the J 41816-2 in order to remove the crankshaft balancer.
4. Remove the J 42386-A and bolts.

Engine Flywheel Removal

Scheme 416

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

Scheme 417

1. Remove the oil level indicator from the tube.
2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube from the engine block. IMPORTANT: Inspect the O-ring seal for cuts or damage. The O-ring seal may be used again if it is not cut or damaged.
4. Remove the O-ring seal from the tube, if required.

Scheme 418

Scheme 419

1. Remove the spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (2) and bolts (3) from the manifold (1), if required.

Scheme 420

Scheme 421

1. Remove the spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (2) and bolts (3) from the manifold (1), if required.

Scheme 422

1. Remove the water pump bolts.
2. Remove the water pump and gaskets.
3. Discard the water pump gaskets.

Throttle Body Removal

Scheme 423

Scheme 424

1. Remove the electrical wire harness connectors from the throttle body.
2. Remove the engine coolant air bleed hose and clamp.
3. Remove the throttle body nuts.
4. Remove the throttle body.
5. Remove the throttle body gasket (1).
6. Discard the gasket.
7. Remove the throttle body studs, if required.

Fuel Rail and Injectors Removal

Note. Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

Scheme 425

Scheme 426

1. Remove the fuel rail stop bracket and bolt, if required.
2. Remove the vacuum hose from the fuel pressure regulator.
3. Loosen the crossover tube-to-right fuel rail retaining bolt.
4. Remove the fuel rail bolts. IMPORTANT: Do not separate the fuel injectors from the fuel rail unless component service is required. Use cleanliness and care when handling the fuel system components. Do not allow dirt or debris to enter the fuel injectors or fuel rail components, cap ends as necessary.
5. Remove the fuel rail, with injectors, lifting evenly from both sides of the fuel rail until all the injectors have left their bores.

Intake Manifold Removal

DO NOT use the intake manifold-to-cylinder head gaskets again.

Scheme 427

Scheme 428

Scheme 429

Scheme 430

Scheme 431

1. Remove the positive crankcase ventilation (PCV) hose (1) and valve (2).
2. Remove the manifold absolute pressure (MAP) sensor (1), if required.
3. Remove the engine coolant air bleed clamp and hose from the throttle body.
4. Remove the evaporative emission (EVAP) solenoid (3), bolt (2), and isolator (1).
5. Remove the intake manifold bolts.
6. Remove the intake manifold with gaskets.
7. Separate the intake manifold-to-cylinder head gaskets (1) from the manifold.
8. Discard the intake manifold gaskets.

Scheme 432

Scheme 433

Scheme 434

Scheme 435

1. Remove the engine coolant air bleed pipe bolts (1).
2. Remove the pipe (2) and gaskets (3).
3. Remove the engine coolant air bleed pipe cover bolts (1) and covers (2).
4. Remove the gaskets from the pipe and covers.
5. Discard the gaskets.
6. Remove the hose (1) from the pipe (2).

Scheme 436

Scheme 437

Scheme 438

Scheme 439

1. Remove the knock sensor wire harness.
2. Remove the knock sensors.
3. Remove the valley cover bolts.
4. Remove the valley cover and gasket.
5. Discard the valley cover gasket.
6. Remove the knock sensor oil seals (1) from the cover (2).

Valve Rocker Arm Cover Removal - Left

Do not remove the positive crankcase ventilation (PCV) valve grommet from the cover unless service is required.

Scheme 440

Scheme 441

Scheme 442

1. Remove the ignition coil bracket bolts from the rocker arm cover, if required.
2. Remove the ignition coil and bracket assembly from the cover.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Remove the gasket (1) from the cover.
6. Discard the gasket. The bolt grommets may be used again if not damaged.

Valve Rocker Arm Cover Removal - Right

Do not remove the oil fill tube from the cover unless service is required.

If the oil fill tube has been removed from the cover, install a NEW tube during assembly.

Scheme 443

Scheme 444

Scheme 445

Scheme 446

1. Remove the ignition coil bracket bolts from the rocker arm cover, if required.
2. Remove the ignition coil and bracket assembly from the cover.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Remove the gasket (1) from the cover.
6. Discard the gasket. The bolt grommets may be used again if not damaged.
7. Remove the oil fill cap from the oil fill tube.
8. Remove the oil fill tube, if required.
9. Discard the oil fill tube.

Valve Rocker Arm and Push Rod Removal

Scheme 447

Scheme 448

Scheme 449

1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the valve rocker arm pivot support.
4. Remove the pushrods.

Scheme 450

Scheme 451

1. Remove the spark plugs from the cylinder head. IMPORTANT: The cylinder head bolts can NOT be used again. Install NEW cylinder head bolts during assembly.
2. Remove the cylinder head bolts. NOTE: After removal, place the cylinder head on two wood blocks to prevent damage.
3. Remove the cylinder head.
4. Remove the gasket.
5. Discard the gasket.
6. Discard the cylinder head bolts.

Scheme 452

Scheme 453

1. Remove the spark plugs from the cylinder head. IMPORTANT: The cylinder head bolts can NOT be used again. Install NEW cylinder head bolts during assembly.
2. Remove the cylinder head bolts. NOTE: After removal, place the cylinder head on two wood blocks to prevent damage.
3. Remove the cylinder head.
4. Remove the gasket.
5. Discard the gasket.
6. Discard the cylinder head bolts.

Valve Lifter Removal

Tools Required

J 3049-A Valve Lifter Remover

Scheme 454

Scheme 455

Scheme 456

1. Remove the valve lifter guide bolts (1).
2. Remove the valve lifters and guide. IMPORTANT: Some valve lifters may be stuck in their bores because of gum or varnish deposits.
3. Use the J 3049-A or equivalent in order to remove the valve lifters, if required.
4. Remove the valve lifters from the guide.
5. Organize or mark the components so that they can be installed in the same location from which they were removed. Refer to «SEPARATING PARTS»(ref-188498-S17158006432005090700000) .

Scheme 457

Scheme 458

1. Remove the oil filter.
2. Remove the oil filter fitting (1) and bypass valve (2), if required.

Oil Pan Removal

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

1. Remove the left closeout cover and bolt.
2. Remove the right closeout cover and bolt.
3. Remove the oil pan bolts.
4. Remove the oil pan. IMPORTANT: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. Use care not to gouge, score, or damage the oil pan sealing surface.
5. Drill (3) out the oil pan gasket retaining rivets (2), if required.
6. Remove the gasket (1) from the pan.
7. Discard the gasket and rivets.
8. Remove the transfer tube, baffle and other components, if required. Refer to «OIL PAN CLEANING AND INSPECTION»(ref-188498-S15198836622005090700000) .

Scheme 464

Scheme 465

1. Remove the front cover bolts.
2. Remove the front cover and gasket.
3. Discard the front cover gasket.
4. Remove the crankshaft front oil seal (1) from the cover.

Scheme 466

Scheme 467

1. Remove the rear cover bolts.
2. Remove the rear cover and gasket.
3. Discard the rear cover gasket.
4. Remove the crankshaft rear oil seal (1) from the cover.

Scheme 468

Scheme 469

Scheme 470

1. Remove the oil pump screen bolt (3) and nuts (2).
2. Remove the oil pump screen (1) with O-ring seal (3).
3. Remove the O-ring seal from the pump screen.
4. Discard the O-ring seal.
5. Remove the remaining crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.
7. Remove the oil pump bolts. IMPORTANT: Do not allow dirt or debris to enter the oil pump assembly, cap ends as necessary.
8. Remove the oil pump.

Timing Chain and Sprockets Removal

Tools Required

1. J 8433-1 Two Jaw Puller
2. J 41558 Crankshaft Sprocket Remover
3. J 41816-2 Crankshaft End Protector

Note. Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.

Scheme 471

Scheme 472

Scheme 473

Scheme 474

1. Remove the camshaft sprocket bolts.
2. Remove the camshaft sprocket and timing chain.
3. Use the J 8433-1 , the J 41816-2 , and the J 41558 in order to remove the crankshaft sprocket.
4. Remove the crankshaft sprocket.
5. Remove the crankshaft sprocket key, if required.

Scheme 475

Scheme 476

Scheme 477

1. Remove the camshaft sensor bolt and the sensor.
2. Remove the camshaft retainer bolts and the retainer. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
3. Remove the camshaft. 3.1. Install the 3 M8-1.25 x 100 mm bolts in the camshaft front bolt holes. 3.2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 3.3. Remove the bolts from the front of the camshaft.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer
2. J 41556 Connecting Rod Guide

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

1. Use the J 24270 in order to remove the cylinder bore ring ridge, if required. 1.1 Turn the crankshaft until the piston is at the bottom of the stroke. 1.2 Place a cloth on top of the piston. 1.3 Use the J 24270 or equivalent in order to remove a cylinder ring ridge. 1.4 Turn the crankshaft so the piston is at the top of the stroke. 1.5 Remove the cloth. 1.6 Remove the cutting debris from the cylinder and piston. IMPORTANT: Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction. A stamping mark on the side of the connecting rod at the crank journal may effect component geometry. Mark the top of the piston to the specific cylinder bore.
2. Remove the connecting rod bolts. IMPORTANT: Mark, sort, or organize the connecting rod bearings so they may be installed to their original position and location.
3. Remove the connecting rod cap. Refer to «SEPARATING PARTS»(ref-188498-S17158006432005090700000) .
4. Install the J 41556 to the connecting rod.
5. Use a hammer and tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore.
6. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolts onto the matching connecting rod.

Crankshaft and Bearings Removal

Tools Required

1. J 6125-1B Slide Hammer
2. J 41818 Crankshaft Bearing Cap Remover

Do not use the bearing cap M8 side bolts again.

Remove the bearing cap M8 side bolts prior to cap removal.

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the crankshaft bearing cap M8 side bolts.
4. Remove the bearing cap M10 bolts and bolt/studs. Note the M10 bolt/stud locations. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the J 41818 . Tighten Tighten the J 41818 bolts to 11 N.m (100 lb in).
6. Install the J 6125-1B to the J 41818 in order to remove the crankshaft bearing caps.
7. Remove the bearing caps.
8. Remove the crankshaft. IMPORTANT: Use care when handling the crankshaft. Avoid damage to the crankshaft position sensor reluctor ring teeth. Nicks, burrs or other damage to the teeth may effect On-Board Diagnostics (OBD) II system performance.
9. Lay the crankshaft onto two wooden V blocks or other protective surface.
10. Remove the crankshaft bearings from the bearing caps and the engine block.
11. Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location. Refer to «SEPARATING PARTS»(ref-188498-S17158006432005090700000) .

Engine Block Plug Removal

Tools Required

J 41712 Oil Pressure Switch Socket

If the front oil gallery plug is removed for service, a NEW oil gallery plug must be installed.

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

1. Remove the oil pressure sensor, if not previously removed, using the J 41712 or equivalent.
2. Remove the engine block right rear coolant plug.
3. Remove the engine block coolant heater, if applicable.
4. Remove the engine block left rear coolant plug, if applicable.
5. Remove the engine block left front oil gallery plug.
6. Remove the engine block left rear oil gallery plug.
7. Inspect the block plug sealing washers. If the block plug and heater sealing washers are not damaged, they may be used during assembly.
8. Remove the engine block rear oil gallery plug.
9. Inspect the O-ring seal of the rear oil gallery plug. If the O-ring seal is not cut or damaged, the plug and O-ring seal may be used during assembly. IMPORTANT: Remove the front oil gallery plug only if service is required. If the front oil gallery plug is removed, a NEW oil gallery plug must be installed.
10. Remove the engine block front oil gallery plug.

Camshaft Bearing Removal

Tools Required

J 33049 Camshaft Bearing Service Set

Scheme 498

Scheme 499

Scheme 500

1. Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores. Refer to «CAMSHAFT AND BEARINGS CLEANING AND INSPECTION»(ref-188498-S23739674162005090700000) .
2. Repair or replace the components as required.
3. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 .
4. Assemble the tool.
5. Insert the tool through the front of the engine block and into the bearing.
6. Tighten the expander assembly (15) nut until snug.
7. Push the guide cone (1) into the front camshaft bearing to align the tool.
8. Drive the bearing from the block bore. IMPORTANT: To remove the front camshaft bearing, operate the tool from the rear of the block using the guide cone in the rear camshaft bearing bore.
9. Repeat the above procedures to remove the remaining bearings.

Scheme 501

1. The tool consists of a guide cone (1), driving washers (2 or 3), expander bearing drivers (4-8), driver bars (9 or 10), expander jaws (11), expander sleeve (12), expander cone (13), expander shaft (14), and expander assembly (15).
2. Expander bearing driver number one inside diameter is 28.575-37.465 mm (1.125-1.475 in) and is used with the expander assembly and the small washer.
3. Expander bearing driver number two inside diameter is 37.465-43.18 mm (1.475-1.7 in) and is used with number one expanding driver and the small washer.
4. Expander bearing driver number three inside diameter is 43.18-48.895 mm (1.7-1.925 in) and is used with number two expanding driver and the large washer.
5. Expander bearing driver number four inside diameter is 48.895-54.61 mm (1.925-2.15 in) and is used with number three expanding driver and the large washer.
6. Expander bearing driver number five inside diameter is 54.61-60.325 mm (2.150-2.375 in) and is used with number four expanding driver and the large washer.
7. Expander bearing driver number six inside diameter is 60.325-68.326 mm (2.375-2.69 in) and is used with number five expanding driver and the large washer.

Scheme 502

Scheme 503

1. Select the proper expanding driver and washer from the expanding driver and washer information. IMPORTANT: To install or remove the expanding driver, always push on or pull from the ends. Pressure on the outside diameter may cause a bind against the rubber expanding sleeve.
2. Place the expanding driver onto the expander assembly.
3. Check to insure that the separation lines between the segments of the expanding driver align with the separation lines of the expander assembly.
4. Place the guide cone over the driving bar, with the small end of the cone facing the driver assembly.
5. Place the driving washer over the threaded portion of the expander assembly.
6. Screw the expander assembly, with driving washer, onto the driving bar. It may be necessary to install the driver bar extension for removal of the inner bearings.
7. Insert the tool into a inner camshaft bearing and tighten until snug. Operate the tool from the front or rear of the engine block. On some engine blocks the nut on the expander assembly is inaccessible except from either end. In this case you must use a socket and extension to enlarge and reduce the expander assembly.
8. Slide the nylon cone into the front or rear camshaft bearing. This will properly align the tool.
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner bearings.
11. For the two end bearings, front and rear, remove the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.

Camshaft Bearing Installation

Tools Required

J 33049 Camshaft Bearing Service Set

Scheme 504

Scheme 505

Scheme 506

1. Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores.
2. Repair or replace the components as required.
3. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 . Refer to «CAMSHAFT BEARING REMOVAL»(ref-188498-S16917673712005090700000) .
4. Assemble the tool.
5. Insert the tool through the front of the engine block and into the bearing.
6. Tighten the expander assembly nut until snug.
7. Push the guide cone into the front camshaft bearing to align the tool.
8. Drive the bearing from the block bore. IMPORTANT: To remove the front camshaft bearing, operate the tool from the rear of the block using the guide cone in the rear camshaft bearing bore.
9. Repeat the above procedures to remove the remaining bearings.

Scheme 507

Scheme 508

Scheme 509

1. Clean the components with cleaning solvent. CAUTION: Refer to «SAFETY GLASSES CAUTION»(ref-175132-S23208358672005041500000) in Cautions and Notices.
2. Dry the components with compressed air.
3. Inspect the timing chain for binding or wear.
4. Inspect the camshaft and crankshaft sprockets for: Worn teeth (1) Damaged teeth (2) Chipped teeth (3) Worn valleys between the sprocket teeth
5. Inspect the crankshaft sprocket keyway for wear.
6. Inspect the crankshaft sprocket oil pump drive splines for wear.

Engine Block Plug Installation

Tools Required

J 41712 Oil Pressure Switch Socket or equivalent

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

1. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block coolant heater sealing washer, if applicable. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the engine block coolant heater to the engine block, if applicable. Tighten Tighten the block coolant heater to 40 N.m (30 lb ft).
3. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block left rear coolant drain plug sealing washer, if applicable.
4. Install the engine block left rear coolant drain plug, if applicable. Tighten Tighten the block left rear coolant drain plug to 60 N.m (44 lb ft).
5. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block right rear coolant drain plug sealing washer.
6. Install the engine block right rear coolant drain plug. Tighten Tighten the block right rear coolant drain plug to 60 N.m (44 lb ft).
7. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block left front oil gallery plug sealing washer.
8. Install the engine block left front oil gallery plug. Tighten Tighten the block left front oil gallery right plug to 60 N.m (44 lb ft).
9. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the engine block left rear oil gallery plug sealing washer.
10. Install the engine block left rear oil gallery plug. Tighten Tighten the block left rear oil gallery plug to 60 N.m (44 lb ft).
11. Inspect the engine block rear oil gallery plug and O-ring seal. If the O-ring seal on the plug is not cut or damaged, the rear oil gallery plug may be used again.
12. Lubricate the O-ring seal with clean engine oil.
13. Install the block rear oil gallery plug into the oil gallery bore. A properly installed block plug will protrude 0.8-1.4 mm (0.0315-0.055 in) beyond the rear face of the block. IMPORTANT: The engine block front oil gallery plug should not be removed unless service is required.
14. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the sides of the NEW front oil gallery plug.
15. Install a NEW engine block front oil gallery plug, if required. Install the front oil gallery plug into the oil gallery bore 2.2-2.8 mm (0.0086-0.011 in) below flush.
16. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the oil pressure sensor.
17. Use the J 41712 or equivalent in order to install the oil pressure sensor. Tighten Tighten the oil pressure sensor to 20 N.m (15 lb ft).

Crankshaft and Bearings Installation

Tools Required

J 36660-A Torque Angle Meter

Scheme 518

Scheme 519

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

1. Install the crankshaft thrust bearings to the engine block and center bearing cap.
2. Install the remaining crankshaft bearings to the engine block and bearing caps.
3. Lubricate the bearing surfaces and crankshaft journals with clean engine oil. NOTE: To maintain proper crankshaft end play, use extreme care during crankshaft installation. Avoid scoring or damaging the thrust bearing.
4. Install the crankshaft. IMPORTANT: The bearing caps must be installed in the proper location and direction.
5. Install the crankshaft bearing caps, with bearings, into the engine block.
6. Start the M10 bolts and bolt/studs.
7. Tap the bearing caps into place with a plastic-faced hammer.
8. Install the NEW M8 bearing cap side bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
9. Tighten the bearing cap bolts and studs. Tighten Tighten the inner M10 bearing cap bolts first pass in sequence to 20 N.m (15 lb ft). IMPORTANT: To properly align the crankshaft thrust bearings, the final thrust of the crankshaft MUST be in the forward direction.
10. Using a plastic faced hammer, tap the crankshaft rearward then forward to align the thrust bearings. Tighten 10.1. Tighten the inner M10 bolts final pass in sequence 80 degrees using the J 36660-A . 10.2. Tighten the outer M10 bolts/studs first pass in sequence to 20 N.m (15 lb ft). 10.3. Tighten the outer M10 bolts/studs final pass in sequence 51 degrees using the J 36660-A . 10.4. Tighten the bearing cap side M8 bolts to 25 N.m (18 lb ft). Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap.
11. Install the crankshaft position sensor. 11.1. Inspect the crankshaft position sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be used. 11.2. Coat the O-ring seal with clean engine oil. 11.3. Install the sensor. Align the notch in the sensor retaining bracket with the bolt hole in the block. 11.4. Install the sensor bolt. Tighten Tighten the crankshaft position sensor bolt to 25 N.m (18 lb ft).
12. Measure the crankshaft end play. 12.1. Thrust the crankshaft forward or rearward. 12.2. Insert a feeler gage between the center crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.04-0.2 mm (0.0015-0.0078 in). 12.3. If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.

Piston, Connecting Rod, and Bearing Installation

Tools Required

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

The piston alignment mark MUST face the front of the engine block.

Scheme 525

Scheme 526

Scheme 527

Scheme 528

Scheme 529

1. Lightly lubricate the following components with clean engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.
3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
4. Install the J 41556 to the connecting rod.
5. Install the J 8037 onto the piston and compress the piston rings. IMPORTANT: The piston alignment mark MUST facing the front of the engine block.
6. Install the piston and connecting rod assembly into the proper cylinder bore. 6.1. Hold the piston ring compressor 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. 6.2. Use the J 41556 to guide the connecting rod end onto the crankshaft journal.
7. Remove the J 41556 . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Position the connecting rod cap onto the connecting rod properly. Align the flat side of the connecting rod cap with the flat side of the connecting rod.
8. Install the bearing, cap, and bolts. Tighten 8.1. Tighten the bolts a first pass evenly to 20 N.m (15 lb ft). 8.2. Tighten the bolts a final pass to 75 degrees using the J 36660-A .
9. Inspect the connecting rods for proper orientation onto the crankshaft journal.
10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using a feeler gage or a dial indicator. Connecting rod side clearance should be within 0.11-0.51 mm (0.0043-0.02 in).

Camshaft Installation

Scheme 530

Scheme 531

Scheme 532

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install 3 M8 - 1.25 x 100 mm (M8 - 1.25 x 4.0 in) bolts into the camshaft front bolt holes. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the 3 bolts from the front of the camshaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt or debris.
5. Install the camshaft retainer and the bolts. Tighten Tighten the camshaft retainer bolts to 25 N.m (18 lb ft).
6. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be used again.
7. Lubricate the O-ring seal with clean engine oil.
8. Install the camshaft sensor and bolt. Tighten Tighten the camshaft sensor bolt to 25 N.m (18 lb ft).

Timing Chain and Sprockets Installation

Tools Required

J 41665 Crankshaft Balancer and Sprocket Installer

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

Scheme 538

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use the J 41665 in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.
7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
8. Install the camshaft sprocket bolts. Tighten Tighten the camshaft sprocket bolts to 35 N.m (26 lb ft).

Oil Pump, Pump Screen and Deflector Installation

Scheme 539

Scheme 540

Scheme 541

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump.
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the oil pump bolts. Tighten Tighten the oil pump bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector.
5. Lubricate a NEW oil pump screen O-ring seal (3) with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs.
7. Install the oil pump screen (1).
8. Install the oil pump screen bolt (3) and the deflector nuts (2). Tighten 8.1. Tighten the oil pump screen bolt (3) to 12 N.m (106 lb in). 8.2. Tighten the crankshaft oil deflector nuts (2) to 25 N.m (18 lb ft).

Engine Rear Cover Installation

Tools Required

1. J 41480 Front/Rear Cover Alignment - Oil Pan Surface
2. J 41476 Front/Rear Cover Alignment - Crankshaft Oil Seal Area

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

1. Inspect the rear oil gallery plug for proper installation.
2. Install the rear cover gasket, rear cover and bolts.
3. Tighten the bolts finger tight. Do not overtighten. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Start the J 41480 tool-to-rear cover bolts. Do not tighten the bolts at this time.
4. Install the J 41480 and bolts. Tighten Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). IMPORTANT: To properly align the rear cover, the J 41476 must be installed onto the rear of the crankshaft with the tool mounting bolts parallel to the oil pan surface.
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the crankshaft. Tighten 6.1. Tighten the tool mounting bolts until snug. Do not overtighten. 6.2. Tighten the J 41480 tool-to-rear cover bolts evenly to 12 N.m (106 lb in). 6.3. Tighten the rear cover bolts to 25 N.m (18 lb ft).
7. Remove the tools.
8. Measure the rear cover-to-engine block oil pan surface for flatness. 8.1. Place a straight edge onto the engine block and rear cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. 8.2. Insert a feeler gage between the rear cover and the straight edge. The cover must be flush with the oil pan or no more than 0.5 mm (0.02 in) below flush.
9. If the rear cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
10. If the correct rear cover-to-engine block alignment at the oil pan surface cannot be obtained, replace the rear cover.

Crankshaft Rear Oil Seal Installation

Tools Required

J 41479 Crankshaft Rear Oil Seal Installer

Scheme 548

Scheme 549

1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft.
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal.
7. Align the oil seal onto the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore.
9. Remove the tool.

Engine Front Cover Installation

Tools Required

1. J 41480 Front/Rear Cover Alignment - Oil Pan Surface
2. J 41476 Front/Rear Cover Alignment - Crankshaft Oil Seal Area

Scheme 550

Scheme 551

Scheme 552

Scheme 553

1. Install the front cover gasket, cover, and bolts onto the engine.
2. Tighten the cover bolts finger tight. Do not overtighten. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. IMPORTANT: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.
3. Install the J 41480 . Tighten Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). IMPORTANT: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
4. Install the J 41476 .
5. Install the crankshaft balancer bolt. Tighten 5.1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. 5.2. Tighten the J 41480 . 5.3. Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block. 7.1. Place a straight edge across the engine block and front cover oil pan sealing surfaces Avoid contact with the portion of the gasket that protrudes into the oil pan surface. 7.2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no more than 0.5 mm (0.02 in) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.

Crankshaft Front Oil Seal Installation

Tools Required

J 41478 Crankshaft Front Oil Seal Installer

Scheme 554

Scheme 555

1. Lubricate the outer edge of the oil seal (1) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal onto the J 41478 guide.
4. Install the J 41478 threaded rod, with nut, washer, guide, and oil seal, into the end of the crankshaft.
5. Use the J 41478 in order to install the oil seal into the cover bore. 5.1. Use a wrench and hold the hex on the installer bolt. 5.2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 5.3. Remove the tool. 5.4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.

Oil Pan Installation

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

1. Install the oil pan baffle and bolts, if previously removed. Tighten Tighten the oil pan baffle bolts to N.m (106 lb in).
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the oil pan oil gallery plugs.
3. Install the oil gallery plugs. Tighten Tighten the oil gallery plugs to 25 N.m (18 lb ft).
4. Install the oil transfer tube (2), gaskets (3) and bolts (1). Tighten Tighten the oil transfer tube bolts to 12 N.m (106 lb in).
5. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) .
6. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface. IMPORTANT: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket.
7. Pre-assemble the oil pan gasket to the pan. 7.1. Install the gasket onto the oil pan. 7.2. Install the oil pan bolts to the pan and through the gasket.
8. Install the oil pan, gasket and bolts to the engine block.
9. Tighten bolts finger tight. Do not overtighten.
10. Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces.
11. Align the oil pan until the rear of engine block and rear of oil pan are flush or even. Tighten 11.1. Tighten the oil pan-to-block and oil pan-to-front cover bolts to 25 N.m (18 lb ft). 11.2. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in).
12. Measure the oil pan-to-engine block alignment. 12.1. Place a straight edge across the rear of the engine block and rear of oil pan at the transmission housing mounting surfaces. IMPORTANT: The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing mounting surfaces. 12.2. Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface, and inspect to ensure there is no more than a 0.25 mm (0.01 in) gap (a) between the pan and straight edge. 12.3. If the oil pan alignment is not within specifications, remove the oil pan and repeat the above procedure.

Scheme 563

Scheme 564

Scheme 565

1. Install a new oil filter bypass valve (2) into the oil pan, if required. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the oil filter fitting (1). Tighten Tighten the oil filter fitting to 55 N.m (40 lb ft).
3. Lubricate the oil filter seal with clean engine oil.
4. Install the oil filter. Tighten Tighten the oil filter to 30 N.m (22 lb ft).
5. Install the oil pan drain plug. Tighten Tighten the oil pan drain plug to 25 N.m (18 lb ft).

Valve Lifter Installation

If camshaft replacement is required, the valve lifters must also be replaced.

Scheme 566

Scheme 567

1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore.
3. Install the valve lifters and guide assembly to the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the valve lifter guide bolt (1). Tighten Tighten the valve lifter guide bolt to 12 N.m (106 lb in).

Cylinder Head Installation - Left

Tools Required

1. J 36660-A Torque Angle Meter
2. J 42385-100 Thread Repair Kit

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Scheme 568

Scheme 569

Scheme 570

Scheme 571

Scheme 572

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlock material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Check the cylinder head locating pins for proper installation. IMPORTANT: When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.
5. Install the NEW left cylinder head gasket onto the locating pins.
6. Install the cylinder head onto the locating pins and the gasket.
7. Install the NEW cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
8. Tighten the cylinder head bolts. Tighten 8.1. Tighten the M11 cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). 8.2. Tighten the M11 cylinder head bolts a second pass in sequence to 90 degrees using the J 36660-A . 8.3. Tighten the M11 cylinder head bolts (1,2,3,4,5,6,7,8) to 90 degrees and the M11 cylinder head bolts (9 and 10) to 50 degrees a final pass in sequence to using the J 36660-A . 8.4. Tighten the M8 cylinder head bolts (11,12,13,14,15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
9. The cylinder head gasket displacement can be verified by markings visible on the top side of the left gasket locating tab. Some 5.3L head gaskets may have 48 or 53 stamped onto the locating tab.

Cylinder Head Installation - Right

Tools Required

1. J 36660-A Torque Angle Meter
2. J 42385-100 Thread Repair Kit

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlock material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Check the cylinder head locating pins for proper installation. IMPORTANT: When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.
5. Install the NEW right cylinder head gasket onto the locating pins.
6. Install the cylinder head onto the locating pins and the gasket.
7. Install the NEW cylinder head bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
8. Tighten the cylinder head bolts. Tighten 8.1. Tighten the M11 cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft). 8.2. Tighten the M11 cylinder head bolts a second pass in sequence to 90 degrees using the J 36660-A . 8.3. Tighten the M11 cylinder head bolts (1,2,3,4,5,6,7,8) to 90 degrees and the M11 cylinder head bolts (9 and 10) to 50 degrees a final pass in sequence to using the J 36660-A . 8.4. Tighten the M8 cylinder head bolts (11,12,13,14,15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
9. The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket locating tab. Some 5.3L head gaskets may have 48 or 53 stamped onto the locating tab.

Valve Rocker Arm and Push Rod Installation

Valve lash is net build, no valve adjustment is required.

Scheme 578

Scheme 579

Scheme 580

Scheme 581

1. Lubricate the valve rocker arms and pushrods with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support. IMPORTANT: Ensure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods. IMPORTANT: Ensure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
6. Rotate the crankshaft until number one piston is at top dead center of compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. If viewing from the rear of the engine, the additional crankshaft pilot hole, non-threaded, will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten Tighten exhaust valve rocker arm bolts 1,2,7, and 8 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 1,3,4, and 5 to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten Tighten exhaust valve rocker arm bolts 3, 4, 5, and 6 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 2, 6, 7, and 8 to 30 N.m (22 lb ft).

Valve Rocker Arm Cover Installation - Left

Scheme 582

Scheme 583

Scheme 584

1. Install a NEW cover gasket (1) into the valve rocker arm cover.
2. Install the valve rocker arm cover onto the cylinder head. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the cover bolts with grommets. Tighten Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
5. Install the ignition coils and bracket assembly and bolts. Tighten Tighten the ignition coil and bracket assembly bolts to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right

Scheme 585

Scheme 586

Scheme 587

Scheme 588

1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
2. Insert the NEW oil fill tube into the rocker arm cover and rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube and rotate clockwise until locked in the proper position.
4. Install a NEW cover gasket (1) into the valve rocker arm cover.
5. Install the valve rocker arm cover onto the cylinder head. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
6. Install the cover bolts with grommets. Tighten Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
8. Install the ignition coil and bracket assembly and bolts. Tighten Tighten the ignition coil and bracket assembly studs to 12 N.m (106 lb in).

Engine Valley Cover Installation

Scheme 589

Scheme 590

Scheme 591

Scheme 592

1. Install NEW knock sensor oil seals (1) into the valley cover (2). Lubricate the seal surfaces with clean engine oil.
2. Install the valley cover and NEW gasket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the valley cover bolts. Tighten Tighten the valley cover bolts to 25 N.m (18 lb ft).
4. Install the knock sensors. Tighten Tighten the knock sensors to 20 N.m (15 lb ft).
5. Install the knock sensor wire harness.

Coolant Air Bleed Pipe Installation

Position the gasket O-ring seal onto the nipple portion of the pipe.

Scheme 593

Scheme 594

Scheme 595

Scheme 596

1. Install the gaskets onto the engine coolant air bleed pipe and covers.
2. Install the pipe (2) and gaskets (3) onto the cylinder heads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the pipe bolts (1). Install the two pipe studs to the front of the engine. Tighten Tighten the pipe bolts to 12 N.m (106 lb in).
4. Install the covers (2), gaskets (3), and bolts (1) onto the rear of the engine. Tighten Tighten the cover bolts to 12 N.m (106 lb in).
5. Install the hose and clamp (1) onto the pipe (2).

Intake Manifold Installation

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

1. (1).
2. Install the intake manifold.
3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the intake manifold bolts. Tighten 4.1. Tighten intake manifold bolts first pass in sequence to 5 N.m (44 lb in). 4.2. Tighten intake manifold bolts final pass in sequence to 10 N.m (89 lb in).
5. Install the manifold absolute pressure (MAP) sensor (1), if previously removed. The electrical connector end of the sensor should be facing the front of the engine.
6. Install the positive crankcase ventilation (PCV) valve (2) and hose (1).
7. Install the engine coolant air bleed hose and clamp onto the throttle body.
8. Install the evaporative emission (EVAP) purge solenoid (3), bolt (2), and isolator (1). Tighten Tighten the solenoid bolt to 10 N.m (89 lb in).

Fuel Rail and Injectors Installation

Scheme 603

Scheme 604

1. Lubricate the NEW fuel injector O-ring seals with clean engine oil.
2. Install the O-ring seals onto the fuel injectors.
3. Install a new O-ring seal to the right side of the crossover tube.
4. Assemble the crossover tube and bolt to the right fuel rail.
5. Install the fuel rail, with fuel injectors, into the intake manifold. Press evenly on both sides of the fuel rail until all of the injectors are seated in their bores.
6. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the fuel rail bolts. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
7. Install the fuel rail bolts. Tighten 7.1. Tighten the fuel rail bolts to 10 N.m (89 lb in). 7.2. Tighten the crossover tube right side retaining bolt to 3.8 N.m (34 lb in).
8. Install the fuel rail stop bracket and bolt. Tighten Tighten the fuel rail stop bracket bolt to 50 N.m (37 lb ft).

Throttle Body Installation

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 605

Scheme 606

1. Install the throttle body studs, if required. Tighten Tighten the throttle body studs to 6 N.m (53 lb in). IMPORTANT: DO NOT use the throttle body gasket again. Install a NEW gasket during assembly.
2. Install the throttle body gasket (1) to the intake manifold.
3. Install the throttle body and nuts. Tighten Tighten the throttle body nuts to 10 N.m (89 lb in).
4. Install the engine coolant air bleed hose and clamp to the throttle body.

Water Pump Installation

Note. DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly.

Scheme 607

1. Install the water pump and NEW gaskets. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the water pump bolts. Tighten 2.1. Tighten the water pump bolts first pass to 15 N.m (11 lb ft). 2.2. Tighten the water pump bolts final pass to 30 N.m (22 lb ft).

Exhaust Manifold Installation - Left

Scheme 608

Scheme 609

1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) .
2. Install the exhaust manifold and NEW exhaust manifold gasket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the exhaust manifold bolts. Tighten 3.1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
5. Install the heat shield (2) and bolts (3). Tighten Tighten the heat shield bolts to 9 N.m (80 lb in).

Exhaust Manifold Installation - Right

Scheme 610

Scheme 611

1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts. Refer to «SEALERS, ADHESIVES, AND LUBRICANTS»(ref-188498-S34876591732005090700000) .
2. Install the exhaust manifold gasket and exhaust manifold. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the exhaust manifold bolts. Tighten 3.1. Tighten the exhaust manifold bolts first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
5. Install the heat shield (2) and bolts (3). Tighten Tighten the heat shield bolts to 9 N.m (80 lb in).

Scheme 612

1. Inspect the O-ring seal for cuts or damage. If the oil level indicator tube O-ring seal is not cut or damaged, it may be used again.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the O-ring seal onto the oil level indicator tube.
4. Install the oil level indicator tube into the engine block and rotate into proper position. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
5. Install the tube bolt. Tighten Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
6. Install the oil level indicator into the tube.

Engine Flywheel Installation

Scheme 613

Scheme 614

1. Install the automatic transmission engine flywheel to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the engine flywheel bolts. Tighten 3.1. Tighten the engine flywheel bolts first pass in sequence to 20 N.m (15 lb ft). 3.2. Tighten the engine flywheel bolts second pass in sequence to N.m (37 lb ft). 3.3. Tighten the engine flywheel bolts final pass in sequence to 100 N.m (74 lb ft).

Crankshaft Balancer Installation

Tools Required

1. J 41665 Crankshaft Balancer and Sprocket Installer
2. J 36660-A Torque Angle Meter
3. J 42386-A Flywheel Holding Tool

Note. Refer to FASTENER NOTICE in Cautions and Notices.

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

1. Install the J 42386-A and bolts. Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten Tighten the J 42386-A bolts to 50 N.m (37 lb ft). IMPORTANT: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation.
2. Install the balancer onto the end of the crankshaft.
3. Use the J 41665 in order to install the balancer. 3.1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 3.2. Use a wrench and hold the hex end of the threaded rod. 3.3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto crankshaft. 3.4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 3.5. Use a wrench and hold the hex end of the threaded rod. 3.6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 3.7. Remove the balancer installation tool.
4. Install the used crankshaft balancer bolt. Tighten Tighten the crankshaft balancer bolt to 330 N.m (240 lb ft).
5. Remove the used crankshaft balancer bolt. IMPORTANT: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore.
6. Measure for a correctly installed balancer.
7. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure.
8. Install the NEW crankshaft balancer bolt. Tighten 7.1. Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). 7.2. Tighten the crankshaft balancer bolt a second pass to 140 degrees using the J 36660-A.
9. Remove the J 42386-A .