Engine Mechanical - 3.5L: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the oil fill cap (2).
2. Remove the oil fill neck (1).
3. Remove the injector sight shield (3).

Installation Procedure

1. Install the injector sight shield (3).
2. Install the oil fill neck (1).
3. Install the oil fill cap (2).

1. Rotate the drive belt tensioner counterclockwise to release the spring tension.
2. Remove the drive belt.

1. Install the drive belt to all of the pulleys except the generator pulley.
2. Rotate the drive belt tensioner counterclockwise to release the spring tension.
3. Install the drive belt. over the generator pulley.
4. Ensure that the drive belt is properly routed.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Removal»(ref-241709-S35096531032006081100000) .

1. Install the drive belt tensioner. «Drive Belt Tensioner Installation»(ref-241709-S17153466422006081100000) .
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .

1. Remove the right engine mount strut. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) .
2. Install the J 45057 to the right engine mount strut bracket (1). See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Install the J 45057 to the left side engine lift bracket. See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Install the J 45057 to the right rear engine lift bracket. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Open and secure the hood in a 90 degree position.
6. Install a J 28467-B and retention pin to each end of the J 28467-500 beam (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
7. Position the J 28467-B to the left and right side inner fender rails in order to install the J 28467-500 . See «Special Tools»(ref-241709-S09370669702006081100000) .
8. Assemble the following to create 2 lift hook assemblies as shown: J 28467-34 . See «Special Tools»(ref-241709-S09370669702006081100000) . J 28467-6A . See «Special Tools»(ref-241709-S09370669702006081100000) . J 28467-7A . See «Special Tools»(ref-241709-S09370669702006081100000) .
9. Install the 2 lift hook assemblies (1) to the J 45057-2 (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
10. Install the right side lift hook assembly to the right side hole in the J 45057 (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
11. Install the left side lift hook assembly to the left side hole in the J 45057 (2). See «Special Tools»(ref-241709-S09370669702006081100000) .
12. Gently tighten the J 28467-34 lift hook wing nuts. See «Special Tools»(ref-241709-S09370669702006081100000) .
13. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
14. Remove the lower air baffle. Refer to «Radiator Air Baffle Assemblies and Deflectors»(ref-241700-S36931602902006081100000) in Engine Cooling.
15. Remove the engine mount left bolt.
16. Install the J 45057-2 to the radiator core support. See «Special Tools»(ref-241709-S09370669702006081100000) .
17. Use the engine mount bolt to install the J 45057-2 to the engine. See «Special Tools»(ref-241709-S09370669702006081100000) .
18. Ensure that the J 45057-2 is assembled properly and hand tighten the fasteners. See «Special Tools»(ref-241709-S09370669702006081100000) .

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
4. Remove the catalytic converter from the engine exhaust manifold. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) in Engine Exhaust.
5. Remove the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
6. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
7. Remove the engine mount lower nuts.
8. Use a utility stand and a block of wood in order to raise the engine.
9. Remove the engine mount bracket-to-oil pan bolts.
10. Remove the engine mount and the engine mount bracket.
11. Remove the engine mount from the engine mount bracket.

1. Install the engine mount to the engine mount bracket.
2. Install the engine mount bracket with the engine mount to the oil pan.
3. Install the engine mount bracket-to-oil pan bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
4. Use the utility stand in order to lower the engine.
5. Install the engine mount lower nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
6. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
7. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
8. Connect the catalytic converter pipe to the engine exhaust manifold. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) in Engine Exhaust.
9. Lower the vehicle.
10. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
11. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.

1. Remove the bolt and the nut from the engine mount strut at the left engine mount strut bracket on the engine.
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper radiator support.
3. Remove the engine mount strut.
4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut.
2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the upper radiator support. Tighten: Tighten the engine mount strut bolt to 48 N.m (36 lb ft).
3. Install the bolt and the nut to the engine mount strut at the left engine mount strut bracket on the engine. Tighten: Tighten the engine mount strut nut to 48 N.m (36 lb ft).

1. Remove the bolt and the nut from the engine mount strut at the right engine mount strut bracket on the engine.
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper radiator support.
3. Remove the engine mount strut.
4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut.
2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the upper radiator support. Tighten: Tighten the engine mount strut bolt to 48 N.m (36 lb ft).
3. Install the bolt and the nut to the engine mount strut at the right engine mount strut bracket on the engine. Tighten: Tighten the engine mount strut nut to 48 N.m (36 lb ft).

1. Remove the left engine mount strut from the left engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) .
2. Remove the thermostat housing. Refer to «THERMOSTAT HOUSING REPLACEMENT - LX9 (3.5L)»(ref-241700-S10998962072007022300000) in Engine Cooling.
3. Remove the engine mount strut bracket bolts from the left engine mount strut bracket to the cylinder head.
4. Remove the left engine mount strut bracket.

1. Install the left engine mount strut bracket.
2. Install the engine mount strut bracket bolts through the engine mount strut bracket to the cylinder head. Tighten: Tighten the engine mount strut bracket bolts to 70 N.m (52 lb ft).
3. Install the thermostat housing. Refer to «Water Outlet and Thermostat Installation»(ref-241709-S25508798822006081100000) .
4. Install the left engine mount strut to the left engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) .

1. Remove the right engine mount strut from the right engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
2. Remove the engine oil cooler coolant line bracket bolt, if equipped.
3. Remove the engine wiring harness bracket bolt.
4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
5. Remove the air conditioning compressor mounting bolts.
6. Remove and set the air conditioning compressor aside.
7. Remove the vertical engine mount strut bracket bolt from the right engine mount strut bracket.
8. Remove the lower engine mount strut bracket bolt from the right engine mount strut bracket.
9. Remove the right engine mount strut bracket.

1. Position the right engine mount strut bracket over the pin locator.
2. Install the lower engine mount strut bracket bolt through the right engine mount strut bracket into the cylinder block. Tighten: Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
3. Install the vertical engine mount strut bracket bolt through the right engine mount strut bracket to the cylinder head. Tighten: Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
4. Install the air conditioning compressor. Refer to «Compressor Replacement»(ref-241728-S12265162712006081100000) in HVAC Systems - Manual.
5. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
6. Install the engine wiring harness bracket bolt. Tighten: Tighten the engine wiring harness bracket bolt to 13 N.m (110 lb in).
7. Install the engine oil cooler coolant line bracket bolt, if equipped.
8. Install the right engine mount strut to the right engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
3. Remove the oil filter bypass hole plug.
4. Remove the oil filter fitting, if necessary.
5. Insert a flat bladed tool into the oil filter bypass hole and remove the bypass valve.

1. Install the oil filter bypass valve.
2. Install the oil filter fitting, if necessary. Tighten: Tighten the oil filter fitting to 39 N.m (29 lb ft).
3. Install the oil filter bypass valve plug. Apply sealer GM P/N 12345739 (Canadian P/N 10953541) or the equivalent to the threads. Tighten: Tighten the oil filter bypass valve plug to 19 N.m (14 lb ft).
4. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) . Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
5. Lower the vehicle.
6. Check and fill the crankcase as necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the oil level indicator.
3. Remove the oil level indicator tube bracket bolt.
4. Remove the oil level indicator tube.

1. Clean the oil level indicator tube.
2. Apply sealant around the oil level indicator tube 12.7 mm (0.50 in) below the bead. Use sealant GM P/N 12346286 (Canadian P/N 10953472) or the equivalent.
3. Install the oil level indicator tube into the engine block.
4. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator.
6. Install the spark plug wire to the number 6 cylinder spark plug.

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .
2. Remove the vacuum hoses from the following: Evaporative emissions (EVAP) canister purge valve Brake booster
3. Disconnect the electrical connectors from the following: Exhaust gas recirculation (EGR) valve Mass air flow (MAF) sensor Electronic throttle control EVAP canister purge valve
4. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) .
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
6. Remove the left side spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) .
7. Remove the following wiring harnesses from the retainers: Camshaft position (CMP) sensor wiring harness Left side spark plug wire harness Engine wiring harness
8. Remove the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(ref-241686-S35343301302006081100000) .
9. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-241686-S17026797382006081100000) .
10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-241686-S05170885732006081100000) .
11. Remove the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-241686-S32798936942006081100000) .
12. Remove the upper intake manifold bolts and the stud.
13. Remove the generator bracket.
14. Remove the upper intake manifold.
15. Remove the upper intake manifold gaskets.
16. If replacing the upper intake manifold, remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-241686-S02376021132006081100000) .
17. Clean the upper intake gasket mating surfaces.

1. If removed, install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-241686-S02376021132006081100000) .
2. Install the upper intake manifold gaskets.
3. Install the upper intake manifold.
4. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the upper intake manifold bolt threads.
5. Install the upper intake manifold bolts and the stud. Tighten: Tighten the bolts and the stud to 25 N.m (18 lb ft).
6. Install the generator bracket.
7. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-241686-S32798936942006081100000) .
8. Install the MAP sensor bracket and the sensor. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-241686-S05170885732006081100000) .
9. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-241686-S17026797382006081100000) .
10. Install the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(ref-241686-S35343301302006081100000) .
11. Install the following wiring harnesses to the retainers: Engine wiring harness Left side spark plug wire harness CMP sensor wiring harness
12. Install the left side spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) .
13. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) .
14. Connect the electrical connectors to the following: EVAP canister purge valve Electronic throttle control MAF sensor EGR valve
15. Install the vacuum hoses to the following: Brake booster EVAP canister purge valve
16. Connect the negative battery cable.
17. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .

1. Disconnect the battery ground negative cable. See Engine Electrical.
2. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241709-S09647536442006081100000) .
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) .
4. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-241709-S28721542742006081100000) .
5. Disconnect the engine coolant temperature (ECT) wiring harness.
6. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness.
7. Remove the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(ref-241686-S29661060582006081100000) in Engine Controls - 3.5L.
8. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
9. Disconnect the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) in Engine Cooling.
10. Remove the water outlet.
11. Remove the thermostat.
12. Remove the lower intake manifold bolts.
13. Remove the lower intake manifold.
14. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
15. Remove the lower intake manifold gaskets and seals.
16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
17. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
18. Remove all the loose room temperature vulcanizing sealer (RTV) (1).

1. Install the lower intake manifold gaskets.
2. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
3. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent, to the 4 corners of the intake manifold to block joints (1).
4. Install the lower intake manifold.
5. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the lower intake manifold bolt threads.
6. Install the new lower intake manifold bolts, if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Install the thermostat.
10. Install the water outlet bolts. Refer to «THERMOSTAT HOUSING REPLACEMENT - LX9 (3.5L)»(ref-241700-S10998962072007022300000) in Engine Cooling.
11. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
12. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
13. Connect the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) in Engine Cooling.
14. Connect the heater inlet pipe and heater hose to the lower intake manifold.
15. Install the power steering pump to the front engine cover.
16. Install the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(ref-241686-S29661060582006081100000) in Engine Controls - 3.5L.
17. Connect the fuel feed pipe to the fuel injector rail.
18. Connect the fuel injector and MAP wiring harness.
19. Connect the ECT wiring harness.
20. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-241709-S28721542742006081100000) .
21. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) .
22. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241709-S09647536442006081100000) .
23. Connect the battery ground negative cable. See Engine Electrical.

1. Disconnect the positive crankcase ventilation (PCV) hose from the intake air duct.
2. Disconnect the crankcase ventilation hose from the right hand engine rocker cover.
3. Remove the crankcase ventilation hose from the engine.

1. Install the crankcase ventilation hose to the engine.
2. Connect the crankcase ventilation hose to the right hand engine rocker cover.
3. Connect the positive crankcase ventilation hose to the intake air duct.

1. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) .
2. Remove the PCV baffle. Remove the screws (1) from the PCV baffle. Clean the PCV valve (3).
3. If the PCV valve is defective or cannot be effectively cleaned the valve cover (4) must be replaced.

1. If the PCV valve was cleaned: Install the PCV baffle (2). Install the PCV baffle screws (1). Tighten: Tighten the screws to 6 N.m (53 lb in).
2. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
2. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
3. Remove the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) .
4. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
5. Remove the valve rocker arm cover bolts.
6. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
7. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints (1).
8. Remove the valve cover gasket.
9. Clean the sealing surface on the cylinder head with degreaser.
10. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-241709-S23826271902006081100000) .

1. Apply sealant at the cylinder head to the lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the valve rocker cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the PCV valve vacuum line.
6. Install the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) .
7. Install the front ignition wire harness.
8. Refill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
3. Remove the generator. Refer to «GENERATOR REPLACEMENT (LX9)»(ref-241706-S40594947222007022100000) in Engine Electrical.
4. Remove the generator bracket. Refer to «GENERATOR BRACKET REPLACEMENT (RPO LX9)»(ref-241706-S33972706722007022100000) in Engine Electrical.
5. Remove the right spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
6. Disconnect the vacuum hoses from the evaporative emission (EVAP) purge valve.
7. Remove the EVAP purge valve.
8. Remove the ignition coil bracket with the coils. Refer to «Ignition Coil(s) Replacement»(ref-241686-S07152379392006081100000) in Engine Controls - 3.5L.
9. Remove the ignition coil bracket studs.
10. Remove the vacuum hose from the grommet in the right valve rocker arm cover.
11. Remove the right valve rocker arm cover bolts.
12. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
13. Trim the valve gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
14. Remove the valve cover gasket.
15. Clean the sealing surface on the cylinder head with degreaser.
16. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-241709-S23826271902006081100000) .

1. Apply sealant at the cylinder head to lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the right valve rocker arm cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the vacuum hose to the grommet in the right valve rocker arm cover.
6. Install the ignition coil bracket studs.
7. Install the ignition coil bracket with coils. Refer to «Ignition Coil(s) Replacement»(ref-241686-S07152379392006081100000) in Engine Controls - 3.5L.
8. Install the EVAP purge valve.
9. Connect the vacuum hoses to the EVAP purge valve.
10. Install the right spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
11. Install the generator bracket. Refer to «GENERATOR BRACKET REPLACEMENT (RPO LX9)»(ref-241706-S33972706722007022100000) in Engine Electrical.
12. Install the generator. Refer to «GENERATOR REPLACEMENT (LX9)»(ref-241706-S40594947222007022100000) in Engine Electrical.
13. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
14. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-241709-S28721542742006081100000) .
2. Remove the rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods.

1. Install the pushrods in the original location. Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter.
2. Install the rocker arms.
3. Install the rocker arm bolts. Tighten: Tighten the rocker arm bolts to 32 N.m (24 lb ft).
4. Install the valve rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241709-S37311869972006081100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-241709-S28721542742006081100000) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
3. Install the J 22794 into the spark plug port. See «Special Tools»(ref-241709-S09370669702006081100000) . Apply compressed air in order to hold the valves in place.
4. Install the J 38606 on the valve spring. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Compress the valve spring with the J 38606 . See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Remove the valve locks.
7. Remove the valve cap.
8. Remove the valve spring.
9. Inspect the valve spring for damage. Refer to «Cylinder Head Cleaning and Inspection»(ref-241709-S36573750802006081100000) .
10. Remove the valve stem oil seal.

1. Install the valve stem oil seal.
2. Install the valve spring.
3. Install the valve cap.
4. Compress the valve spring with the J 38606 .
5. Install the valve locks. If necessary, hold the valve locks in place with grease.
6. Release the valve spring using the J 38606 .
7. Ensure the valve locks are seated.
8. Release the air pressure and remove the J 22794 from the spark plug port. See «Special Tools»(ref-241709-S09370669702006081100000) .
9. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
3. Remove the intake manifold oil splash shield
4. Remove the lifter guide bolts.
5. Remove the valve lifter guides.
6. Remove the valve lifters.
7. Clean all gasket surfaces with degreaser.
8. Clean the valve train parts.
9. Inspect the valve lifters and the cam lobes for wear. Refer to «Valve Lifters Cleaning and Inspection»(ref-241709-S36242958132006081100000) .

1. Coat the valve lifters with prelube GM P/N 1052367 (Canadian P/N 992869) or equivalent.
2. Install the valve lifters to the same location from which they were removed.
3. Install the valve lifter guides.
4. Install the valve lifter guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the intake manifold oil splash shield
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
7. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
3. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
4. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
5. Install the jack stands to the frame.
6. Loosen the left frame bolts and remove the right side frame bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
7. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
8. Remove the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) in Automatic Transaxle - 4T65-E.
9. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(ref-241709-S09370669702006081100000) .
10. Remove the crankshaft balancer bolt and the washer.
11. Remove the crankshaft balancer. Use the J 41816 . See «Special Tools»(ref-241709-S09370669702006081100000) .

1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or the equivalent, to the keyway of the balancer.
2. Install the crankshaft balancer. Use the J 29113 . See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Remove the J 29113 . See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Install the crankshaft balancer washer and the bolt. Tighten: Tighten the bolt to 160 N.m (118 lb ft).
6. Remove the J 37096 from the flywheel. See «Special Tools»(ref-241709-S09370669702006081100000) .
7. Install the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) in Automatic Transaxle - 4T65-E.
8. Raise the frame to the original position.
9. Install and tighten the frame bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
10. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
11. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
12. Lower the vehicle.
13. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
4. Drain the crankcase.
5. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
6. Remove the right front splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
7. Remove the wheel speed sensor harness from the right suspension support.
8. Remove the right front ball joint, bolt and nut. Separate the ball joint from the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-241710-S06348524922006081100000) in Front Suspension.
9. Remove lower closeout panel.
10. Remove the air conditioning (A/C) compressor bolts and position the compressor aside.
11. Remove the braces that support the engine to the transmission.
12. Remove the starter. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) in Engine Electrical.
13. Disconnect the oil level sensor.
14. Remove the retainers that secure the brake line to the frame.
15. Remove the right side engine mount nuts and bolts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) .
16. Loosen the left side cradle bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
17. Remove the frame bolts from the right front and the right rear.
18. Remove the oil pan side bolts.
19. Remove the oil pan bolts.
20. Remove the oil pan.
21. Remove the oil pan gasket.
22. Clean the following items: The oil pan flanges The oil pan rail The front cover The rear main bearing cap The threaded holes

1. Install a new gasket. If you are installing the rear main bearing cap, place sealant on the oil pan gasket tabs. Place the sealer on the tabs that insert into the gasket groove on the outer surface of the main bearing cap. Use GM P/N 1052080 (Canadian P/N 10953480) or the equivalent.
2. Install the oil pan.
3. Install the oil pan bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the oil pan side bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the starter. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) in Engine Electrical.
6. Install the flywheel inspection cover.
7. Install the A/C compressor to the engine. Refer to «Compressor Replacement»(ref-241728-S12265162712006081100000) in Heating, Ventilation and Air Conditioning.
8. Install the frame bolts on the right side. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
9. Install engine mount bolts and nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) .
10. Install the right side ball joint to the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-241710-S06348524922006081100000) in Front Suspension.
11. Connect the right front antilock brake system (ABS) wheel speed sensor harness.
12. Install the retainers that support the brake line to the frame.
13. Install the braces that support the engine to the transmission.
14. Install the right front splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
15. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
16. Install the lower closeout panel.
17. Lower the vehicle.
18. Remove the engine support fixture.
19. Fill the crankcase with engine oil.
20. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.

1. Disconnect the battery negative cable from the battery. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .
2. Remove the electrical connector from the engine oil pressure sensor.
3. Remove the engine oil pressure switch.

1. Install the engine oil pressure switch. Tighten: Tighten the switch to 16 N.m (12 lb ft).
2. Install the electrical connector to the engine oil pressure switch.
3. Connect the battery negative cable to the battery. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241709-S24492468042006081100000) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.
4. Inspect the oil pump drive shaft and the oil pump. Refer to «Oil Pump Cleaning and Inspection»(ref-241709-S18483782722006081100000) .

1. Install the oil pump drive shaft and the oil pump.
2. Install the oil pump bolt. Tighten: Tighten the bolt to 41 N.m (30 lb ft).
3. Install the oil pan. Refer to «Oil Pan Replacement»(ref-241709-S24492468042006081100000) .

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241709-S09647536442006081100000) .
2. Remove the oil pump drive bolt.
3. Remove the oil pump drive clamp.
4. Remove the oil pump drive.
5. Remove the oil pump drive seal.

1. Install the oil pump drive seal. Coat the seal or bore in the engine block with engine oil.
2. Coat the drive gear on the oil pump drive with prelube GM P/N 1052367 (Canadian P/N 992869) or the equivalent.
3. Install the oil pump drive.
4. Install the oil pump drive clamp.
5. Install the oil pump drive bolt. Tighten: Tighten the bolt to 36 N.m (27 lb ft).
6. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241709-S09647536442006081100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241709-S06347827882006081100000) .
2. Remove the crankshaft key from the keyway.
3. Pry out the oil seal using a large screwdriver or the equivalent.
4. Inspect the following items for scratches: The front cover The crankshaft

1. Lubricate the oil seal using clean engine oil.
2. Insert the oil seal into the front cover with the lip facing the engine. Use the J 35468 . See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Install the crankshaft key into the keyway.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241709-S06347827882006081100000) .

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-241709-S23416389032006081100000) .
4. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
5. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241709-S24492468042006081100000) .
6. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241709-S06347827882006081100000) .
7. Remove the thermostat bypass pipe from the engine front cover. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
8. Remove the radiator outlet hose from the engine front cover. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) in Engine Cooling.
9. Remove the water pump from the engine front cover. Refer to «WATER PUMP REPLACEMENT - LX9 (3.5L)»(ref-241700-S04638981472007022300000) in Engine Cooling.
10. Remove the power steering pump from the engine. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) in Power Steering System.
11. Remove the engine front cover bolts.
12. Remove the engine front cover.
13. Remove the engine front cover gasket.
14. Clean and inspect the engine front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-241709-S02147759152006081100000) .
15. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
16. If replacing the engine front cover remove the water pump. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.

1. Apply sealant to both sides of the engine front cover gasket with GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Apply the sealer no less than 5.0 mm (0.20 in) wide.
2. Install the engine front cover gasket.
3. Install the engine front cover.
4. Install the engine front cover bolts (1, 2 and 3). Tighten: Tighten the small engine front cover bolts (1) to 27 N.m (20 lb ft). Tighten the large engine front cover bolts (2, 3) to 55 N.m (41 lb ft).
5. Install the power steering pump to the engine. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) in Power Steering System.
6. Install the water pump. Refer to «WATER PUMP REPLACEMENT - LX9 (3.5L)»(ref-241700-S04638981472007022300000) in Engine Cooling.
7. Install the radiator outlet hose to the engine front cover. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) in Engine Cooling.
8. Install the thermostat bypass pipe to the engine front cover. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
9. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241709-S06347827882006081100000) .
10. Install the oil pan. Refer to «Oil Pan Replacement»(ref-241709-S24492468042006081100000) .
11. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-241709-S23416389032006081100000) .
12. Fill the crankcase with new engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
13. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
14. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-241709-S03468831292006081100000) .
2. Rotate the crankshaft until the timing marks in the following locations are aligned: The camshaft alignment pin (4). The timing chain dampener (1) to the crankshaft sprocket (2).
3. Remove the camshaft sprocket bolt.
4. Remove the camshaft sprocket with the timing chain.
5. Remove the crankshaft sprocket.
6. Remove the timing chain dampener bolts.
7. Remove the timing chain dampener.
8. If necessary, remove the camshaft thrust plate bolts.
9. Remove the camshaft thrust plate.
10. Clean and inspect the timing chain and the gears. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-241709-S29606657042006081100000) .

1. If removed, install the camshaft thrust plate.
2. Install the camshaft thrust plate bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the crankshaft sprocket.
4. Apply engine oil supplement (EOS) GM P/N 1052367 (Canadian P/N 992869) or equivalent, to the sprocket thrust surface.
5. Install the timing chain dampener.
6. Install the timing chain dampener bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
7. Install the timing chain onto the camshaft gear.
8. Hold the camshaft sprocket with the chain hanging down and install the chain to the crankshaft gear.
9. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
10. Align the timing mark on the camshaft gear, center line of the locator hole (4), with the timing mark on the top of the chain dampener (3).
11. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket (1).
12. Install the camshaft sprocket bolt. Tighten: Tighten the bolt to 140 N.m (103 lb ft).
13. Coat the crankshaft and camshaft sprocket with engine oil.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-241709-S03468831292006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .
6. Remove the valve rocker arms and the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
7. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) in Engine Exhaust.
8. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-241709-S07348297302006081100000) .
9. Remove the left spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
10. Remove the left spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.
11. Remove the left exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (3.5L)»(ref-241745-S34448678412007022700000) in Engine Exhaust.
12. Remove the left cylinder head bolts and discard.
13. Remove the left cylinder head.
14. Remove the left cylinder head gasket.
15. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(ref-241709-S05416635312006081100000) and «Cylinder Head Cleaning and Inspection»(ref-241709-S36573750802006081100000) .

1. Install a new left cylinder head gasket.
2. Install the left cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 45059 to rotate the bolts in sequence an additional 95 degrees. See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Install the left exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (3.5L)»(ref-241745-S34448678412007022700000) in Engine Exhaust.
5. Install the left spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.
6. Install the left spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
7. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-241709-S07348297302006081100000) .
8. Install the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) in Engine Exhaust.
9. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
10. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .
11. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
13. Inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .
6. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
7. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) .
8. Remove the right spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
9. Remove the right spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.
10. Remove the generator. Refer to «GENERATOR REPLACEMENT (LX9)»(ref-241706-S40594947222007022100000) in Engine Electrical.
11. Remove the right exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.5L)»(ref-241745-S18302164752007022700000) in Engine Exhaust.
12. Remove the right cylinder head bolts and discard.
13. Remove the right cylinder head.
14. Remove the right cylinder head gasket.
15. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(ref-241709-S05416635312006081100000) and «Cylinder Head Cleaning and Inspection»(ref-241709-S36573750802006081100000) .

1. Install a new right cylinder head gasket.
2. Install the right cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 45059 to rotate the bolts in sequence an additional 95 degrees. See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Install the right exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.5L)»(ref-241745-S18302164752007022700000) .
5. Install the generator. Refer to «GENERATOR REPLACEMENT (LX9)»(ref-241706-S40594947222007022100000) in Engine Electrical.
6. Install the right spark plugs. Refer to «Spark Plug Replacement»(ref-241686-S36085824072006081100000) in Engine Controls - 3.5L.
7. Install the right spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
8. Install the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) .
9. Install the pushrods and valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241709-S23046807992006081100000) .
10. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241709-S09336426802006081100000) .
11. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
13. Inspect for leaks.

1. Remove the automatic transaxle. Refer to «Transmission Replacement (M15)»(ref-241713-S36188207002006081100000) or «Transmission Replacement (M76)»(ref-241713-S39803377572006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Loosen the 6 flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft rotation.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel retainer and the flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Install the flywheel and the flywheel retainer.
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Install the engine flywheel bolts. Tighten: Tighten the bolts to 71 N.m (52 lb ft).
4. Measure the flywheel runout: Install a dial indicator on the engine block and inspect the engine flywheel runout at 3 attaching bosses. Refer to «Engine Mechanical Specifications»(ref-241709-S33342289312006081100000) . If the condition cannot be corrected, replace the engine flywheel.
5. Install the automatic transaxle. Refer to «Transmission Replacement (M15)»(ref-241713-S36188207002006081100000) or «Transmission Replacement (M76)»(ref-241713-S39803377572006081100000) in Automatic Transaxle - 4T40-E/4T45-E.

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .
2. Remove the crankshaft rear oil seal. Insert a flat-bladed tool or similar tool through the dust lip at an angle. Pry the crankshaft rear oil seal out by moving the handle of the tool towards the end of the crankshaft. Repeat, as necessary, around the crankshaft rear oil seal.

1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal into the J 34686 by sliding the crankshaft rear oil seal over the mandrel using a twisting motion until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Install the J 34686 onto the rear of the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) . Hand tighten the screws in order to ensure the seal will be installed squarely over the crankshaft.
4. Install the crankshaft rear oil seal to the crankshaft.
5. Tighten the wing nut on the J 34686 until it bottoms. See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Remove the J 34686 from the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) .
7. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer GM P/N 12377901 (Canadian P/N 10953504) or equivalent.
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
2. Loosen the 2 intake air duct clamps (1) from air cleaner housing (2) and the throttle body.
3. Remove the air cleaner intake duct from the air cleaner housing and throttle body.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
5. Remove the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) in Engine Cooling.
6. Remove the radiator outlet hose from the engine. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) in Engine Cooling.
7. Remove the heater outlet and inlet hoses from the engine. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) in Heating Ventilation and Air Conditioning.
8. Remove the vacuum hoses from the upper intake manifold.
9. Remove the brake booster vacuum hose from the upper intake manifold.
10. Remove the fuel lines from the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-241686-S29661060582006081100000) in Engine Controls - 3.5L.
11. Disconnect the following electrical connectors: The knock sensor (KS) The camshaft position (CMP) sensor The crankshaft position (CKP) sensor The heated oxygen sensor (HO2S) The manifold absolute pressure (MAP) sensor The exhaust gas recirculation (EGR) valve The evaporative emission (EVAP) canister purge solenoid The electronic throttle control The ignition coil The body wiring harness-to-engine harness The engine wiring harness from transmission
12. Remove the engine wiring harness grounds from the transaxle.
13. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
14. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
15. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
16. Remove rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft. (AWD Only)
17. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) in Engine Exhaust.
18. Remove the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
19. Remove the lower radiator air baffle assembly. Refer to «Radiator Air Baffle Assemblies and Deflectors»(ref-241700-S36931602902006081100000) in Engine Cooling.
20. Remove the engine splash shields. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
21. Remove the stabilizer shaft links from the lower control arms. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
22. Remove the tie rod ends from the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
23. Remove the lower ball joints from the knuckles. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) in Front Suspension.
24. Remove the A/C compressor bolts and position compressor aside. DO NOT discharge the A/C system. Support the compressor. Refer to «Compressor Replacement»(ref-241728-S12265162712006081100000) in Heating, Ventilation and Air Conditioning.
25. Disconnect the drive axles from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
26. Secure the drive axles to the steering knuckle/struts.
27. Remove the intermediate shaft pinch bolt from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
28. Lower the vehicle until the frame contacts the transaxle table.
29. Remove the frame bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
30. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
31. Remove the starter motor. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) in Engine Electrical.
32. Remove the torque converter covers. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
33. Remove the torque converter bolts. Refer to «Flywheel to Torque Converter Bolt Replacement»(ref-241713-S03548337862006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
34. Remove the engine mount lower nuts.
35. Remove the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) or «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
36. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) in Engine Exhaust.
37. Install engine hoist to engine.
38. Remove the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2).
39. Support the transaxle.
40. Separate and remove the engine from the transaxle/frame.
41. Install the engine to the engine stand.
42. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .
43. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .

1. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) .
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-241709-S40516593592006081100000) .
3. Remove the engine from the engine stand.
4. Install and align the engine to the transaxle/frame.
5. Install the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2). Tighten: Tighten the bolts (3, 4, 5, 6) and the studs (1, 2) to 75 N.m (55 lb ft).
6. Remove the engine hoist from the engine.
7. Install the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-241745-S33460791922007022700000) in Engine Exhaust.
8. Install the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) or «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
9. Install the engine mount lower nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
10. Install the torque converter bolts. Refer to «Flywheel to Torque Converter Bolt Replacement»(ref-241713-S03548337862006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
11. Install the torque converter covers. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) in Automatic Transaxle - 4T40-E/4T45-E.
12. Install the starter motor. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) in Engine Electrical.
13. Position the transaxle table with the powertrain/frame under the vehicle.
14. Lower the vehicle until the frame contacts the transaxle table.
15. Install the new frame bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
16. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
17. Remove the transaxle table.
18. Install the intermediate shaft pinch bolt to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
19. Connect the drive axles to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
20. Position compressor to the engine and Install the A/C compressor bolts. Refer to «Compressor Replacement»(ref-241728-S12265162712006081100000) in Heating, Ventilation and Air Conditioning.
21. Install the lower ball joints to the knuckles. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) in Front Suspension.
22. Install the tie rod ends to the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
23. Install the stabilizer shaft links to the lower control arms. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
24. Install the engine splash shields. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
25. Install the lower radiator air baffle assembly. Refer to «Radiator Air Baffle Assemblies and Deflectors»(ref-241700-S36931602902006081100000) in Engine Cooling.
26. Install the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
27. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) in Engine Exhaust.
28. Install rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft. (AWD Only)
29. Lower the vehicle.
30. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241709-S08230253372006081100000) .
31. Install the engine mount strut. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
32. Connect the following electrical connectors: The KS The CMP sensor The CKP sensor The HO2S The MAP sensor The EGR valve The EVAP canister purge solenoid The electronic throttle control The ignition coil The body wiring harness-to-engine harness The engine wiring harness from transmission
33. Install the engine wiring harness ground nut to the transaxle stud. Tighten: Tighten the nut to 35 N.m (26 lb ft).
34. Install the fuel lines to the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-241686-S29661060582006081100000) in Engine Controls - 3.5L.
35. Install the brake booster vacuum hose to the upper intake manifold.
36. Install the vacuum hoses to the upper intake manifold.
37. Install the heater outlet and inlet hoses to the engine. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) in Heating Ventilation and Air Conditioning.
38. Install the radiator outlet hose to the engine. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) in Engine Cooling.
39. Install the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) in Engine Cooling.
40. Install the air cleaner intake duct to the air cleaner housing (2) and the throttle body.
41. Tighten the 2 intake air duct clamps (1). Tighten: Tighten the clamps to 2 N.m (18 lb in).
42. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
43. Fill cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) in Engine Cooling.
44. Perform a CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-241686-S36031987732006081100000) in Engine Controls - 3.5L.
45. Inspect for leaks.

1. Remove the negative battery cable.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
3. Remove the oil pan drain plug.
4. Remove the oil filter.

1. Lubricate the oil filter gasket with clean engine oil and install the oil filter. Tighten the filter to one turn after gasket contact.
2. Install the oil pan drain bolt. Tighten: Tighten the oil pan drain bolt to 26 N.m (19 lb ft).
3. Lower the vehicle.
4. Fill the engine with oil to the appropriate mark.
5. Start engine and inspect for leaks.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the coolant drain plug from the left side.
5. Remove the coolant drain plug from the right side.
6. Drain the coolant.

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816-A along with EN 46359 or equivalent. See «Special Tools»(ref-241709-S09370669702006081100000) .

Engine Flywheel Removal

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

Drive Belt Tensioner Removal

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

Engine Lift Bracket and Generator Bracket Removal

1. Remove the generator bracket assembly bolts (230, 231, 232).
2. Remove the generator assembly bracket.
3. Remove the front engine lift hook.

Engine Mount Strut and Air Conditioning Compressor Bracket Removal

1. Remove the engine mount strut and A/C compressor bracket bolts.
2. Remove the engine mount strut and A/C compressor bracket.

Engine Mount Strut and Engine Lift Bracket Removal

1. Remove the engine mount strut and lift bracket bolts.
2. Remove the engine mount strut and lift bracket.

Oil Level Indicator and Tube Removal

1. Remove the thermostat bypass pipe hose from the thermostat bypass pipe.
2. Remove the 16 pin connector.
3. Remove the spark plug wires from the spark plugs and set aside.
4. Remove the spark plug wire clip from the pipe.
5. Remove the heated oxygen sensor connector from pipe.
6. Remove the thermostat bypass pipe to throttle body nuts.
7. Remove the thermostat bypass pipe to throttle body bolt.
8. Remove the thermostat bypass pipe to engine front cover bolt.
9. Remove the thermostat bypass pipe.
10. Remove the oil level indicator tube bolt.
11. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter bypass hole plug.
2. Remove the oil filter fitting, if necessary.
3. Remove the oil filter bypass valve, by prying out with a suitable tool.

Oil Cooler Removal

1. Disconnect the upper oil cooler outlet hose from the thermostat bypass pipe.
2. Disconnect the lower oil cooler outlet hose from the oil cooler.
3. Remove the oil cooler outlet hoses and pipe.
4. Remove the oil cooler connector.
5. Remove the oil cooler inlet hose clamp and oil cooler.
6. Remove the oil cooler inlet hose and oil cooler inlet hose clamp from the oil cooler hose fitting.
7. Remove the oil cooler hose fitting.

Exhaust Crossover Pipe Removal

1. Remove the exhaust crossover pipe nuts (2).
2. Remove the exhaust crossover pipe (3).
3. Remove the exhaust crossover pipe studs if necessary (1).

Exhaust Manifold Removal - Left

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

Exhaust Manifold Removal - Right

1. Remove the spark plug wires.
2. Remove the spark plugs.
3. Remove the EGR pipe from the exhaust manifold.
4. Remove the heated oxygen sensor.
5. Remove the exhaust manifold heat shield bolts.
6. Remove the exhaust manifold heat shields.
7. Remove the exhaust manifold nuts.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Remove the exhaust studs, if required.

Water Outlet and Thermostat Removal

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

Valve Rocker Arm Cover Removal - Left

1. Remove the positive crankcase ventilation (PCV) tube bolt and clip.
2. Remove the PCV tube.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Trim valve cover gasket and sealant away from lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
6. Remove the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right

1. Remove any remaining spark plug wires from their retainers.
2. Remove the ignition coil assembly bolts and nuts.
3. Remove the ignition coil assembly.
4. Remove the ignition coil assembly studs, if necessary.
5. Remove the positive crankcase ventilation tube from the valve rocker arm cover.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover.
8. Trim valve cover gasket and sealant away from lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
9. Remove the valve rocker arm cover gasket.

Intake Manifold Removal - Upper

1. Remove the connector from manifold absolute pressure (MAP) sensor.
2. Remove the exhaust gas recirculation (EGR) bolts.
3. Remove the EGR.
4. Remove the upper intake manifold bolts or studs.
5. Remove the upper intake manifold and gaskets.

Intake Manifold Removal - Lower

1. Remove the heater inlet pipe nut.
2. Remove the heater inlet pipe.
3. Remove the heater inlet pipe stud, if necessary.
4. Remove the fuel injector rail bolts.
5. Remove the fuel rail assembly.
6. Remove the lower intake manifold bolts and discard.
7. Remove the lower intake manifold.

Valve Rocker Arm and Push Rod Removal

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 144.18 mm (5.68 in). The exhaust push rods measure 152.51 mm (6.0 in).
4. Remove the intake manifold gaskets.

Valve Lifter Removal

1. Remove the valve lifter guide bolts.
2. Remove the valve lifter guides.
3. Remove the valve lifters.

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gasket.

Cylinder Head Removal - Left

1. Remove the cylinder head bolt and discards.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts and discard.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Oil Pan Removal

1. Remove the oil pan support bracket bolts and brackets as needed
2. Remove the oil pan side bolts.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Remove the oil pan gasket.

Oil Pump Removal

1. Remove the oil pump bolt.
2. Remove the oil pump and oil pump drive shaft.
3. Remove the crankshaft oil deflector nuts.
4. Remove the crankshaft oil deflector.

Oil Pump Drive Removal

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

Scheme 4

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

Engine Front Cover Removal

1. Remove the engine front cover bolts (540, 541, 545).
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Timing Chain and Sprockets Removal

1. Remove the camshaft sprocket bolt.
2. Remove the camshaft sprocket and timing chain.
3. Remove the crankshaft sprocket.
4. Remove the timing chain dampener bolts.
5. Remove the timing chain dampener.

Camshaft Removal

1. Remove the camshaft position sensor bolt.
2. Remove the camshaft position sensor.
3. Remove the camshaft thrust plate screws.
4. Remove the camshaft thrust plate.
5. Complete the following steps in order to remove the camshaft. Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate and remove the camshaft from the engine block.

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See «Special Tools»(ref-241709-S09370669702006081100000) . Complete the following steps: Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Remove the connecting rod bearing half.
7. Install J 41556 into the connecting rod. See «Special Tools»(ref-241709-S09370669702006081100000) .
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

Crankshaft Rear Oil Seal Removal

1. Remove the crankshaft rear oil seal.
2. Pry out the crankshaft rear oil seal out using a suitable tool.

Crankshaft and Bearings Removal

1. Remove the crankshaft position sensor heat shield nut and heat shield.
2. Remove the crankshaft position sensor stud.
3. Remove the crankshaft position sensor from the side of the block.
4. Remove the crankshaft main bearing cap bolt and studs.
5. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
6. Remove the crankshaft.
7. Remove the upper crankshaft main bearing halves.

Piston Oil Nozzle Removal

1. Remove the bolt retaining the piston oil nozzle to the engine block.
2. Remove the piston oil nozzle.

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 . See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Drive out the camshaft bearings. Use the J 33049 . See «Special Tools»(ref-241709-S09370669702006081100000) .

1. Install fork insert J 24086-310 into fixture J 24086-10, which are part of J 24086-C . See «Special Tools»(ref-241709-S09370669702006081100000) .
2. Lubricate the piston pin with clean engine oil.
3. Assemble the piston, connecting rod and adapter J 24086-6A and install onto fixture J 24086-10, which are part of J 24086-C . See «Special Tools»(ref-241709-S09370669702006081100000) .
4. Adjust installation pin J 24086-9 to G-4.
5. Insert pin J 24086-9 through fixture J 24086-10, which are part of J 24086-C and to the piston pin. See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Press pin J 24086-9 until it bottoms on fixture J 24086-10.
7. Using piston ring pliers, install the piston rings onto the piston. Install the oil control ring spacer into the bottom groove of the piston. Install the lower oil control ring. The oil control rings do not have a dimple or orientation mark and may be installed in either direction. Install the upper oil control ring. Install the middle compression ring with the dot facing up. Install the top compression ring in either direction. The ring has no orientation markings.

1. Assemble the J 33049 according to the manufacturer's instructions. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. Install the camshaft bearings in the following order: Index the camshaft bearing oil holes with the engine block oil passages. Place the bearing on the J 33049 . See «Special Tools»(ref-241709-S09370669702006081100000) . Install the third camshaft bearing. Install the second camshaft bearing. Install the outer camshaft bearings.
3. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

Piston Oil Nozzle Installation

1. Position the piston oil nozzle into the engine block.
2. Install the bolt retaining the piston oil nozzle to the engine block. Tighten: Tighten the bolt to 10 N.m (89 lb in).

1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal onto the J 34686 by sliding the crankshaft rear oil seal over the mandrel using a twisting motion until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool. See «Special Tools»(ref-241709-S09370669702006081100000) .
3. Perform the following steps in order to install the crankshaft rear oil seal: Align the dowel pin of the J 34686 with the dowel pin in the crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) . Attach the J 34686 to the crankshaft by hand or tighten attaching screws to 5 N. See «Special Tools»(ref-241709-S09370669702006081100000) .m (45 lb in). Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal into the bore. See «Special Tools»(ref-241709-S09370669702006081100000) . Turn the handle until the collar is tight against the engine block. Ensure that the seal is seated properly. Loosen the T-handle until the T-handle comes to a stop. Remove the attaching screws.

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 8037 onto the piston and compress the piston rings. See «Special Tools»(ref-241709-S09370669702006081100000) .
5. Install the J 41556 into the connecting rod. See «Special Tools»(ref-241709-S09370669702006081100000) .
6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. 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.
8. Using J 41556 , guide the connecting rod end onto the crankshaft journal. See «Special Tools»(ref-241709-S09370669702006081100000) .
9. Install the bearing, bearing cap and bolts. Tighten: Tighten the connecting rod bearing cap bolts a first pass to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts a final pass to 110 degrees using the J 45059 . See «Special Tools»(ref-241709-S09370669702006081100000) .
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 dial indicator. Connecting rod side clearance should be within 0.18-0.44 mm (0.007-0.017 in).

Camshaft Installation

1. Coat the camshaft journals with clean engine oil.
2. Coat the camshaft lobes with prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the camshaft using the following procedure: Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate the camshaft while installing the camshaft into the camshaft bearings.
4. Install the camshaft thrust plate.
5. Install the camshaft thrust plate screws. Tighten: Tighten the camshaft thrust plate screws to 10 N.m (89 lb in).
6. Install the camshaft position sensor.
7. Install the camshaft position sensor bolt. Tighten: Tighten the camshaft position sensor bolt to 10 N.m (89 lb in).

Timing Chain and Sprockets Installation

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain dampener.
4. Install the timing chain dampener bolts. Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
7. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener (3).
8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
9. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
10. Coat the crankshaft and camshaft sprocket with engine oil. Tighten: Tighten the bolt to 140 N.m (103 lb ft).

Engine Front Cover Installation

1. Install the engine front cover gasket.
2. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the lower tabs of the engine front cover gasket. Apply the sealer no less than 5.0 mm (0.20 in) wide.
3. Install the engine front cover.
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolts in the locations pointed out in the graphic.
5. Install the engine front cover bolts (545). Tighten: Tighten the engine front cover bolts to 27 N.m (20 lb ft).
6. Install the engine front cover bolts (540, 541). Tighten: Tighten the engine front cover bolts to 55 N.m (41 lb ft).

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(ref-241709-S09370669702006081100000) .
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(ref-241709-S09370669702006081100000) .

Oil Pump Drive Installation

1. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.
5. Install the oil pump drive gear clamp bolt. Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).

Oil Pump Installation

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pump.
4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).

Oil Pan Installation

1. Apply sealer GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to both sides of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
2. Install the oil pan gasket.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
5. Install the oil pan side bolts. Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
6. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 . See «Special Tools»(ref-241709-S09370669702006081100000) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 . See «Special Tools»(ref-241709-S09370669702006081100000) .

Water Pump Installation

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the threads.
4. Install the valve lifter guides and guide bolts. Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).

Valve Rocker Arm and Push Rod Installation

1. Install the lower intake manifold gaskets.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the push rods in their original location.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 32 N.m (24 lb ft).

Intake Manifold Installation - Lower

1. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of room temperature vulcanizing (RTV) sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to block joints (1).
2. Install the lower intake manifold.
3. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
4. Install the new lower intake manifold bolts if applicable, in sequence. Tighten: Tighten the center lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft). Tighten the visible corner lower intake manifold bolts (5, 8,) to 25 N.m (18 lb ft). Tighten the hidden corner lower intake manifold bolts (6, 7) to 25 N.m (18 lb ft).
5. Inspect the heater inlet pipe and seal for damage and replace if necessary.
6. Install the heater inlet pipe stud, if necessary. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Inspect the fuel rail, fuel injectors and fuel injector O-rings for damage and replace if necessary.
10. Lubricate the fuel injector O-ring using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
11. Install the injector nozzles into the lower intake manifold injector bores.
12. Press on the injector rail using the palms of both hands until the injectors are fully seated.
13. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Intake Manifold Installation - Upper

1. Install the upper intake manifold gaskets and manifold.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the upper intake manifold bolt threads.
3. Install the upper intake manifold bolts and stud. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).
4. Install the exhaust gas recirculation (EGR) gasket and EGR.
5. Install the EGR bolts. Tighten: Tighten the EGR bolts to 30 N.m (22 lb ft).
6. Reconnect the manifold absolute pressure (MAP) sensor.

Valve Rocker Arm Cover Installation - Left

1. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the joint surfaces (1) where the cylinder head and intake manifold meet.
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the positive crankcase ventilation (PCV) tube.
6. Install the PCV clip and tube bolt. Tighten: Tighten the PCV tube bolt to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the joint surfaces (1) where the cylinder head and intake manifold meet.
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the positive crankcase ventilation (PCV) tube into the valve rocker arm cover.
6. Install the ignition coil assembly studs, if necessary. Tighten: Tighten the ignition coil assembly studs to 25 N.m (18 lb ft).
7. Install the ignition coil assembly.
8. Install the ignition coil assembly bolts and nuts. Tighten: Tighten the ignition coil assembly bolts and nuts to 25 N.m (18 lb ft).

Water Outlet and Thermostat Installation

1. Install the thermostat.
2. Install the water outlet.
3. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left

1. Install the exhaust manifold studs. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts working from the center outward to 16 N.m (12 lb ft).
5. Install the left side spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
6. Install the exhaust manifold heat shield.
7. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

Exhaust Manifold Installation - Right

1. Install the exhaust manifold studs. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts working from the center out to 16 N.m (12 lb ft).
5. Install the right side spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
6. Install the spark plug wires onto the spark plugs.
7. Install the lower exhaust manifold heat shield.
8. Install the upper exhaust manifold heat shield.
9. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
10. Coat the threads of the heated oxygen sensor with anti seize compound.
11. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).
12. Install the spark plug wires.

Exhaust Crossover Pipe Installation

1. Install the exhaust crossover pipe studs if necessary (1). Tighten: Tighten the exhaust crossover pipe studs to 25 N.m (18 lb ft).
2. Install the exhaust crossover pipe (3).
3. Install the exhaust crossover pipe nuts (2). Tighten: Tighten the exhaust crossover pipe nuts to 25 N.m (18 lb ft).

Oil Cooler Installation

1. Apply sealer P/N 21485278 to the oil cooler hose fitting threads.
2. Install the oil cooler hose fitting. Tighten: Tighten the oil cooler hose fitting to 19 N.m (14 lb ft).
3. Install the oil cooler inlet hose clamp and the oil cooler inlet hose onto the oil cooler hose fitting.
4. Install the oil cooler inlet hose clamp and oil cooler.
5. Install the oil cooler connector. Tighten: Tighten the oil cooler connector to 50 N.m (37 lb ft).
6. Install the oil cooler outlet hoses and pipe.
7. Connect the lower oil cooler outlet hose to the oil cooler.
8. Connect the upper oil cooler hose to the thermostat bypass pipe.

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter fitting, if necessary. Tighten: Tighten the oil filter fitting to 39 N.m (29 lb ft).
3. Install the oil filter bypass valve plug. Apply sealer GM P/N 12345739 (Canadian P/N 10953541) or the equivalent to the threads. Tighten: Tighten the oil filter bypass valve plug to 19 N.m (14 lb ft).
4. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube and oil level indicator.
2. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
3. Install the thermostat bypass pipe.
4. Install the thermostat bypass pipe to engine front cover bolt. Tighten: Tighten the thermostat bypass pipe to engine front cover bolt to 10 N.m (89 lb in).
5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the throttle body studs.
6. Install the thermostat bypass pipe to throttle body bolt and nuts. Tighten: Tighten the thermostat bypass pipe to throttle body bolt and nuts to 10 N.m (89 lb in).
7. Install the heated oxygen sensor connector to the thermostat bypass pipe.
8. Install the spark plug wire clip to the thermostat bypass pipe.
9. Install the spark plug wires onto the spark plugs.
10. Position the 16 pin connector harness as shown in the graphic and secure the connector in its respective location.
11. Install the thermostat bypass pipe hose to pipe.

Engine Mount Strut and Engine Lift Bracket Installation

1. Install the engine mount strut and lift bracket.
2. Install the engine mount strut and lift bracket bolts. Tighten: Tighten the engine mount strut and lift bracket bolts to 70 N.m (52 lb ft).

Engine Mount Strut and Air Conditioning Compressor Bracket Installation

1. Install the engine mount strut and A/C Compressor bracket.
2. Install the engine mount strut and A/C compressor bracket bolts. Tighten: Tighten the engine mount strut and A/C compressor bracket bolts to 50 N.m (37 lb ft).

Engine Lift Bracket and Generator Bracket Installation

1. Install the front engine lift hook.
2. Install the generator bracket assembly.
3. Install the generator bracket assembly bolts (230, 231, 232). Tighten: Tighten the generator bracket assembly bolts to 50 N.m (37 lb ft).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Engine Flywheel Installation

1. Install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).