Engine Mechanical - 3.9L: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the engine oil fill cap.
2. Remove the oil fill pipe.
3. Pull up on the cover in order to disengage the cover from the studs.

Installation Procedure

1. Align the cover to the studs on the engine, push down on the cover above the studs in order to engage the cover to the studs.
2. Install the oil fill pipe.
3. Install the engine oil fill cap.

1. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
2. Remove the drive belt (1), if equipped with electric power steering.
3. Remove the drive belt (2), if equipped with hydraulic power steering.

1. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
2. Install the drive belt (1), if equipped with electric power steering.
3. Install the drive belt (2), if equipped with hydraulic power steering.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
2. Loosen the required drive belt idler pulley bolt.
3. Remove the drive belt idler pulley.

1. Install the drive belt idler pulley.
2. Tighten the required drive belt idler pulley bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
3. Remove the drive belt tensioner bolt.
4. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Lower the vehicle.
4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
4. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
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) .
7. Remove the engine mount to frame nuts.
8. Place a utility stand and a block of wood under the oil pan in order to raise the engine.
9. Remove the engine mount bracket to oil pan bolts.
10. Remove the engine mount and bracket.
11. Remove the engine mount bracket to engine mount nuts.
12. Remove the engine mount from the bracket.

1. Install the engine mount to the bracket.
2. Install the engine mount bracket to engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the engine mount and bracket to the oil pan.
4. Install the engine mount bracket to oil pan bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
5. Using the utility stand, lower the engine.
6. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
7. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
8. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
9. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
10. Lower the vehicle.
11. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
12. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
4. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
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) .
7. Remove the engine mount to frame nuts.
8. Place a utility stand and a block of wood under the oil pan in order to raise the engine.
9. Remove the engine mount bracket to oil pan bolt.
10. Remove the engine mount bracket to engine block bolt.
11. Remove the engine mount and bracket.
12. Remove the engine mount bracket to engine mount nuts.
13. Remove the engine mount from the bracket.

1. Install the engine mount to the bracket.
2. Install the engine mount bracket to engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the engine mount and bracket.
4. Install the engine mount bracket to the engine block bolt.
5. Install the engine mount bracket to oil pan bolt. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
6. Using the utility stand, lower the engine.
7. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
8. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
9. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
10. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
11. Lower the vehicle.
12. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
13. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
4. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
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) .
7. Remove the engine mount to frame nuts.
8. Place a utility stand and a block of wood under the oil pan in order to raise the engine.
9. Remove the engine mount bracket to oil pan bolts.
10. Remove the engine mount and bracket.
11. Remove the engine mount bracket to engine mount nuts.
12. Remove the engine bracket from the engine mount.

1. Install the engine mount bracket to the engine mount.
2. Install the engine mount bracket to engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the engine mount and bracket to the oil pan.
4. Install the engine mount bracket to oil pan bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
5. Using the utility stand, lower the engine.
6. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
7. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
8. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
9. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
10. Lower the vehicle.
11. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
12. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
4. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
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) .
7. Remove the engine mount to frame nuts.
8. Place a utility stand and a block of wood under the oil pan in order to raise the engine.
9. Remove the engine mount bracket to oil pan bolt.
10. Remove the engine mount bracket to engine block bolt.
11. Remove the engine mount and bracket.
12. Remove the engine mount bracket to engine mount nuts.
13. Remove the engine mount bracket from the engine mount.

1. Install the engine mount bracket to the engine mount.
2. Install the engine mount bracket to engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the engine mount and bracket.
4. Install the engine mount bracket to the engine block bolt.
5. Install the engine mount bracket to oil pan bolt. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
6. Using the utility stand, lower the engine.
7. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
8. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
9. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
10. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
11. Lower the vehicle.
12. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
13. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Loosen the engine mount strut to engine mount strut bracket through bolt (1) and nut (3).
3. Remove the engine mount strut bracket through bolt nut (3).
4. Remove the engine harness clip (2) from the through bolt.
5. Loosen and remove the engine mount strut to engine mount strut bracket through bolt (1) and nut (2).
6. Remove the engine mount strut to engine mount strut bracket through bolt (2).
7. Remove the engine mount strut (1).
8. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut (1).
2. Install the engine mount strut to engine mount strut bracket through bolt (2).
3. Install and tighten the engine mount strut to engine mount strut bracket through bolt (1) and nut (2). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).
4. Install the engine harness clip (2) to the through bolt.
5. Install the engine mount strut bracket through bolt nut (3).
6. Tighten the engine mount strut to engine mount strut bracket through bolt (1) and nut (3). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).
7. Install manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Loosen and remove the engine mount strut to engine mount strut bracket through bolt (3) and nut (4).
3. Loosen and remove the engine mount strut to engine mount strut bracket through bolt (4) and nut (5).
4. Remove the engine mount strut (6).
5. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut (6).
2. Install and tighten the engine mount strut to engine mount strut bracket through bolt (4) and nut (5). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).
3. Install intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
4. Install and tighten the engine mount strut to engine mount strut bracket through bolt (3) and nut (4). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
3. Loosen the engine mount strut to engine mount strut bracket through bolt (1) and nut (3).
4. Remove the engine mount strut bracket through bolt nut (3).
5. Remove the engine harness clip (2) from the through bolt.
6. Remove the engine mount strut to engine mount strut bracket through bolt (2).
7. Rotate the engine mount strut up out of the way.
8. Remove the 2 nuts holding the heater pipes onto the throttle body.
9. Position the heater pipes out of the way.
10. Remove the engine mount strut/engine lift bracket bolts.
11. Remove the engine mount strut/engine lift bracket.

1. Position the engine mount strut/engine lift bracket to the cylinder head.
2. Install the engine mount strut/engine lift bracket bolts Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the nuts holding the heater pipes to the throttle body.
4. Position the back heater pipe to the throttle body.
5. Install the nuts holding the heater pipes to the throttle body.
6. Rotate the engine mount strut into position.
7. Install the engine mount strut to engine mount strut bracket through bolt (2).
8. Install the engine harness clip (2) to the through bolt.
9. Install the engine mount strut bracket through bolt nut (3).
10. Tighten the engine mount strut to engine mount strut bracket through bolt (1) and nut (3). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Loosen and remove the engine mount strut to engine mount strut bracket through bolt (4) and nut (5).
3. Rotate the engine mount strut up out of the way.
4. Remove the engine harness clip (1) from the engine mount strut bracket.
5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
6. Remove the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
7. Remove the right front engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
8. Remove the A/C compressor front bolt and nut.
9. Remove the A/C compressor rear bolt.
10. Reposition the A/C compressor aside.
11. Remove the lower engine mount strut bracket bolts.
12. Lower the vehicle.
13. Remove the engine mount strut bracket bolts.
14. Remove the engine mount strut bracket.

1. Position the engine mount strut bracket to the engine.
2. Install the upper engine mount strut bracket bolt.
3. Raise the vehicle.
4. Install the lower engine mount strut bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Position and install the A/C compressor onto the stud.
6. Install the A/C compressor rear bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
7. Install the A/C compressor front bolt and nut. Tighten: Tighten the bolt/nut to 50 N.m (37 lb ft).
8. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
9. Install right front engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
10. Remove the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
11. Install the engine harness clip (1) to the engine mount strut bracket.
12. Rotate the engine mount strut into position.
13. Install and tighten the engine mount strut to engine mount strut bracket through bolt (4) and nut (5). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).
14. Install intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000)
2. Loosen and remove the engine mount strut to engine mount strut bracket through bolts (1, 3) and nuts (2, 4).
3. Rotate the engine mount struts up out of the way.
4. Remove the engine mount strut bracket bolts (1, 2).
5. Remove the engine mount strut brackets (3, 4).

1. Position the engine mount strut brackets to the radiator support (3, 4).
2. Install the engine mount strut bracket bolts (1, 2). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Rotate the engine mount struts into position.
4. Install and tighten the engine mount strut to engine mount strut bracket through bolts (1, 3) and nuts (2, 4). Tighten: Tighten the bolt/nut to 48 N.m (36 lb ft).
5. Install intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
2. Disconnect the oil pressure sensor electrical connector (2).
3. Remove the nut securing the engine wiring harness clip to the oil filter adapter stud.
4. Reposition the engine wiring harness out of the way.
5. Remove the oil filter adapter bolts and stud.
6. Remove the oil filter adapter and gasket from the engine block.
7. Discard the oil filter gasket.
8. If replacing the oil filter adapter, remove the oil pressure sensor.
9. If replacing the oil filter bypass valve, insert a flat bladed tool into the oil filter bypass hole and remove the valve.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Install the oil filter bypass valve. Seat the valve fully below the bypass valve hole chamfer.
2. If the oil filter adapter was replaced, lubricate the oil pressure sensor seal with clean engine oil.
3. Apply sealant to the threads of the oil pressure sensor. Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) .
4. Install the oil pressure sensor to the oil filter adapter. Tighten: Tighten the bolts and stud to 16 N.m (12 lb ft).
5. Apply sealant to the bolt/stud threads, if required. Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) .
6. Position the NEW oil filter gasket and the oil filter adapter to the engine block.
7. Install the oil filter adapter bolts and stud. Tighten: Tighten the filter to 25 N.m (18 lb ft).
8. Install the engine wiring harness clip to the oil filter adapter stud.
9. Install the engine wiring harness nut. Tighten: Tighten the filter to 12 N.m (106 lb in).
10. Disconnect the oil pressure sensor electrical connector (2). Tighten: Tighten the filter to 30 N.m (22 lb ft).
11. Disconnect the oil pressure sensor electrical connector (2).
12. Install the engine oil cooler. Refer to «Oil Cooler Replacement»(ref-241744-S09264831202006081100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Remove the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
3. Place a suitable drain pan under the oil filter.
4. Remove the oil filter.
5. Reposition the oil cooler outlet hose clamp at the oil cooler.
6. Remove the oil cooler outlet hose from the oil cooler fitting.
7. Reposition the oil cooler inlet hose lamp at the engine.
8. Remove the oil cooler connector.
9. Remove the oil cooler bolts and stud.
10. Remove the oil cooler and gasket from the oil filter adapter.
11. If replacing the oil cooler, reposition the oil cooler inlet hose clamp at the oil cooler.
12. Remove the oil cooler inlet hose from the oil cooler.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Position the oil cooler inlet hose clamp at the oil cooler.
2. Position the oil cooler inlet hose clamp at the oil cooler.
3. Install the NEW oil cooler gasket onto the oil cooler.
4. Install the oil cooler and gasket to the oil filter adapter.
5. Install the oil cooler connector. Tighten: Tighten the to bolts and stud to 25 N.m (18 lb ft).
6. Install the oil cooler inlet hose to the engine fitting.
7. Position the oil cooler inlet hose clamp at the engine.
8. Position the oil cooler outlet hose clamp at the oil cooler fitting.
9. Position the oil cooler outlet hose clamp at the oil cooler.
10. Install the oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft).
11. Remove the drain pan from under the oil filter.
12. Install the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
13. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
14. Check and fill the crankcase, if 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.
5. Inspect the oil level indicator tube O-ring seal, for damage, replace as necessary.

1. Lubricate the oil level indicator tube O-ring seal with clean engine oil.
2. Install the oil level indicator tube into the engine block.
3. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the oil level indicator.
5. 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 intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
3. 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) .
4. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
5. Remove the PCV foul air tube. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
6. Reposition the brake booster vacuum hose clamp at the intake manifold.
7. Remove the vacuum hose from the intake manifold.
8. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
9. Disconnect the engine harness electrical connectors (1, 2) from the following: electrical connector (1). evaporative emission (EVAP) canister purge solenoid electronic throttle control (ETC)
10. Disconnect the engine harness electrical connector (1) from the intake manifold tuning valve.
11. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
12. Disconnect the left side spark plug wires from the spark plugs.
13. Disconnect the left side spark plug wires from the ignition control module.
14. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet pipe.
15. Remove the left side spark plug wires.
16. Remove the heater inlet and outlet pipe nuts (1) from the throttle body studs.
17. Remove the inlet and outlet pipe from the studs.
18. Remove the nut from the generator bracket to the intake manifold.
19. Remove the bolt connecting the generator to the bracket and the generator to the intake manifold.
20. Remove the bracket.
21. Remove the bolt holding the transmission dipstick tube to the upper intake manifold
22. Remove the ignition coils. Refer to «IGNITION COIL REPLACEMENT»(ref-241687-S11115013492007030600000) .
23. Remove the upper intake manifold bolts (1, 2) and stud (3).
24. Separate and remove the upper intake manifold from the lower intake manifold.
25. Remove the upper to lower intake manifold gaskets.
26. Remove the inlet manifold tuning valve bolts and valve.
27. Remove the EVAP canister purge solenoid valve bolt (2) and valve (3).
28. Remove the MAP sensor bracket bolts, bracket and sensor (1).
29. Remove the throttle body bolts/studs and throttle body.
30. Clean the upper intake to lower intake gasket mating surfaces.
31. Inspect the intake manifold tuning valve seal for damage. The tuning valve blade attachment to the motor should be tight, with no looseness or slack present, Replace as necessary.
32. Apply lubricant GM P/N 01050344 (Canadian P/N 993037) or equivalent to the nose of the valve blade (1).

1. Install the inlet manifold tuning valve and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Inspect the EVAP canister purge solenoid valve seal for damage, replace as necessary.
3. Install the EVAP canister purge solenoid valve (3) and bolt (2). Tighten: Tighten the bolts to 16 N.m (12 lb ft).
4. Inspect the MAP sensor seal for damage, replace as necessary.
5. Install the MAP sensor (1), bracket and bolts.
6. Inspect the throttle body seal for damage, replace as necessary.
7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the throttle body bolts/studs threads.
8. Install the throttle body and bolts/studs. Tighten: Tighten the bolts/studs to 10 N.m (89 lb in).
9. Install the NEW upper to lower intake manifold gaskets.
10. Set the upper intake manifold onto the lower intake manifold.
11. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the upper intake manifold bolts/stud threads.
12. Install the upper intake manifold bolts (1, 2) and stud (3). Tighten: Tighten the bolts and stud to 25 N.m (18 lb ft).
13. Install the ignition coil. Refer to «IGNITION COIL REPLACEMENT»(ref-241687-S11115013492007030600000) .
14. Reposition the transmission tube and install the bolt at the intake manifold.
15. Install the bracket from the generator to the intake manifold.
16. Install the bolt connecting the generator, bracket and the intake manifold.
17. Install the nut connecting the generator bracket to the upper intake manifold.
18. Install the inlet and outlet pipe to the studs.
19. Install the heater inlet and outlet pipe nuts (1) to the throttle body studs. Tighten: Tighten the nuts to 10 N.m (89 lb in).
20. Install the left side spark plug wires.
21. Connect the left side spark plug wires to the spark plugs.
22. Connect the left side spark plug wires to the ignition control module.
23. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
24. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
25. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.
26. Connect the engine harness electrical connectors (1, 2) to the following: EVAP canister purge solenoid ETC
27. Connect the MAP sensor electrical connector (1).
28. Install the brake booster vacuum hose to the intake manifold.
29. Position the vacuum hose clamp at the intake manifold.
30. Install the PCV foul air tube. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
31. Install the PCV fresh air tube. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
32. 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) .
33. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
34. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .

1. Remove the coolant crossover pipe. Refer to «COOLANT CROSSOVER PIPE REPLACEMENT - LZ9 (3.9L)»(ref-241700-S28965375232007022300000) .
2. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241744-S03023357302006081100000) .
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241744-S02276881232006081100000) .
4. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-241744-S20680499062006081100000) .
5. Disconnect the engine coolant temperature (ECT) electrical connector.
6. Disconnect the fuel feed line from the fuel rail. Refer to «METAL COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S36532935562007030600000) .
7. Remove the connector position assurance (CPA) retainer (2).
8. Disconnect the engine harness electrical connector (3) from the fuel injector harness electrical connector.
9. Remove the fuel injector harness connector bracket bolt from the intake manifold.
10. Disconnect the camshaft position (CMP) sensor electrical connector.
11. Remove the fuel injector rail bolts.
12. Remove the fuel rail (1).
13. Remove the lower intake manifold bolts.
14. Remove the lower intake manifold.
15. Loosen the valve rocker arm bolts.
16. Remove the valve rocker arms.
17. Remove the push rods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).
18. Remove the lower intake manifold gaskets and seals.
19. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
20. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
21. Remove all the loose room temperature vulcanizing sealer (RTV) (1).

1. Install the lower intake manifold gaskets and seals.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or 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 equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (0.031-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to engine block joints (1).
8. Install the lower intake manifold.
9. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
10. Install the lower intake manifold bolts.
11. Tighten the lower intake manifold bolts in the sequence shown. Tighten: Tighten the bolts (1, 2, 3, 4) in sequence to 16 N.m (12 lb ft). Tighten the bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft).
12. Inspect the fuel rail (1), fuel injectors and fuel injector O-rings for damage and replace as necessary.
13. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182).
14. Install the injector nozzles into the lower intake manifold injector bores.
15. Press on the injector rail using the palms of both hands until the injector are fully seated.
16. Install the fuel injector rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
17. Connect the CMP sensor electrical connector.
18. Position the fuel injector harness connector bracket to the intake manifold.
19. Install the fuel injector harness connector bracket bolt. Tighten: Tighten the bolt to 8 N.m (71 lb in).
20. Connect the engine harness electrical connector (3) to the fuel injector wiring harness electrical connector.
21. Install the CPA retainer (2).
22. Connect the fuel feed line to the fuel rail. Refer to «METAL COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S36532935562007030600000) .
23. Connect the ECT electrical connector.
24. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-241744-S20680499062006081100000) .
25. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241744-S02276881232006081100000) .
26. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-241744-S03023357302006081100000) .
27. Install the coolant crossover pipe. Refer to «COOLANT CROSSOVER PIPE REPLACEMENT - LZ9 (3.9L)»(ref-241700-S28965375232007022300000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
3. Remove the PCV fresh air tube from the rocker arm cover.
4. Remove the PCV fresh air tube from the vehicle.
5. Disconnect the PCV foul air tube from the PCV valve. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
6. Remove the PCV foul air tube from the intake manifold.
7. Remove the PCV foul air tube from the vehicle.

1. Install the PCV foul air tube to the vehicle.
2. Install the PCV foul air tube to the intake manifold.
3. Connect the PCV foul air tube to the PCV valve. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
4. Install the PCV fresh air tube to the vehicle.
5. Install the PCV fresh air tube to the rocker arm cover.
6. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .

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 intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
3. Disconnect the left spark plug wires from the spark plugs.
4. Remove the spark plug wire harness clip from the heater inlet and outlet front pipe bracket.
5. Remove the heater inlet and outer front pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) .
6. Disconnect the positive crankcase ventilation (PCV) foul air tube from the PCV valve. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
7. Remove the valve rocker arm cover bolts.
8. Remove the valve rocker arm cover. If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
9. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
10. Remove the valve cover gasket.
11. Clean the sealing surface on the cylinder head with degreaser.

1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent, at the cylinder head to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the PCV foul air tube to the PCV valve. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
6. Install the heater inlet and outer front pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet»(ref-241728-S16933141722006081100000) .
7. Install the spark plug wire harness clip to the heater inlet and outlet front pipe bracket.
8. Connect the left spark plug wires to the spark plugs.
9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
10. Fill the cooling system, as necessary. 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. Remove the generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .
2. Drain the cooling system, Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
3. Remove the coolant crossover pipe. Refer to «COOLANT CROSSOVER PIPE REPLACEMENT - LZ9 (3.9L)»(ref-241700-S28965375232007022300000) .
4. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
5. Remove the PCV fresh air tube from the right side valve rocker arm cover. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
6. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
7. Disconnect the engine harness electrical connector (2) from the ignition coil.
8. Remove the heated oxygen sensor (HO2S) electrical connector clip from the ignition coil bracket.
9. Remove the spark plug wires from the ignition coil.
10. Remove the ignition coil bracket bolts (1) and nuts (2).
11. Remove the ignition coil with bracket (3) from the engine.
12. Remove the valve rocker arm cover bolts.
13. Remove the valve rocker arm cover. Bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
14. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
15. Remove the valve cover gasket.
16. Clean the sealing surface on the cylinder head with degreaser.

1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent, at the cylinder head to the surfaces where the cylinder head and intake manifold meet (1).
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 ignition coil with bracket (3) to the engine.
6. Install the ignition coil bracket bolts (1) and nuts (2). Tighten: Tighten the bolts and nuts to 25 N.m (18 lb ft).
7. Install the spark plug wires to the ignition coil.
8. Install the HO2S electrical connector clip to the ignition coil bracket.
9. Connect the engine harness electrical connector (2) to the ignition coil.
10. Connect the engine harness electrical connector (1) to the MAP sensor.
11. Install coolant crossover pipe. Refer to «COOLANT CROSSOVER PIPE REPLACEMENT - LZ9 (3.9L)»(ref-241700-S28965375232007022300000) .
12. Fill cooling system, Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
13. Install the PCV fresh air tube to the right side valve rocker arm cover.
14. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) and «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
15. Install the generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .

1. Remove the valve rocker arm cover(s). Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241744-S02276881232006081100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-241744-S20680499062006081100000) .
2. Loosen the valve rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).

1. Coat the ends of the pushrods using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the pushrods. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with blue stripes.
3. Ensure that the pushrods seat in the lifter bore.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the rocker arms.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
7. Install the valve rocker arm cover(s). Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-241744-S02276881232006081100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-241744-S20680499062006081100000) .

1. Remove the spark plug. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241744-S08624228662006081100000) .
3. Install the J 22794 into the spark plug port. Apply compressed air in order to hold the valves in place.
4. Compress the valve spring using the J 38606 .
5. Remove the Identifying valve spring cap keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Remove the valve stem oil seal.

1. Lubricate the valve stem with clean engine oil.
2. Install the valve stem oil seal.
3. Install the valve spring.
4. Install the valve cap.
5. Compress the valve spring using the J 38606 .
6. Install the valve cap keys. If necessary, use grease in order to hold the valve cap keys in place.
7. Ensure the valve cap keys are seated.
8. Remove the compressed air and remove the J 22794 from the spark plug port.
9. Install the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241744-S08624228662006081100000) .
10. Install the spark plug. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241744-S08624228662006081100000) .
3. Loosen the valve lifter guide bolts.
4. Remove the valve lifter guides.
5. Remove the valve lifters from the valve lifter guides.
6. Clean all gasket surfaces with degreaser.

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the valve lifters to the cylinder bores.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the valve lifter guide bolt threads.
4. Install the valve lifter guides.
5. Tighten the valve lifter guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-241744-S08624228662006081100000) .
7. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .

Note. The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
3. Remove the right engine splash shield.
4. Place adjustable jack stands under the frame
5. Loosen the left side frame bolts (2) and remove the right side frame bolts (1).
6. Using the jack stands, lower the right side of the frame enough to access the crankshaft balancer.
7. Remove the engine to transmission bracket bolts at the rear lower left side of the engine and transaxle assembly.
8. Remove the engine to transmission bracket from the rear lower left side of the engine and transaxle assembly.
9. Remove the torque converter cover.
10. Install the J 37096 to the flywheel in order to prevent flywheel rotation.
11. Remove the crankshaft balancer bolt and the washer.
12. Remove the crankshaft balancer using the J 41816.

1. Apply sealer to the keyway of the crankshaft balancer. Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) for the 3.9L engine.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft.
4. Rotate the hex nut on the J 29113 in order to install the crankshaft balancer onto the crankshaft.
5. Remove the J 29113 from the crankshaft.
6. Install the used crankshaft balancer bolt. Tighten: Tighten the USED crankshaft balancer bolt to 125 Nm (92 lb ft).
7. Remove the used crankshaft balancer bolt.
8. Install the NEW crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 125 Nm (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059.
9. Remove the J 37096 from the flywheel.
10. Install the torque converter cover.
11. Install the engine to transaxle bracket at the rear lower left side of the engine.
12. Install the engine to transaxle bracket bolts at the rear lower left side of the engine.
13. Raise the frame to the original position using the adjustable jacks.
14. Install and tighten the right side frame bolts and tighten the left side frame bolts. Tighten: Tighten the front frame bolts to 130 Nm (96 lb ft). Tighten the rear frame bolts to 240 Nm (177 lb ft).
15. Remove the jackstands supporting the frame.
16. Install the right engine splash shield.
17. Install right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
18. Install drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .

1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) .
2. Remove the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
3. Remove the right front splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
4. Remove the oil pan drain plug.
5. Drain the crankcase.
6. Reinstall the oil pan drain plug until snug.
7. Remove the engine harness clips from the right lower control arm.
8. Remove and discard the lower ball joint castle nut cotter pin (1).
9. Remove the lower ball joint castle nut (1).
10. Install the over J 41820 the ball stud and lower control arm as shown.
11. Rotate the ball stud nut counterclockwise in order to separate the ball stud from the steering knuckle.
12. Remove the air conditioning (A/C) compressor front bolt and nut.
13. Remove the A/C compressor rear bolt and position the compressor aside.
14. Remove the transaxle brace to engine block/oil pan bolts.
15. Remove the transaxle brace to transaxle bolts.
16. Remove the transaxle brace.
17. Remove the transaxle brace to oil pan bolts.
18. Remove the transaxle brace to transaxle bolt.
19. Remove the transaxle brace
20. Remove the starter. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) .
21. Disconnect the engine harness electrical connector from the oil level sensor.
22. Remove the engine harness clip from the oil pan.
23. Remove the engine mount. Refer to «Engine Mount Replacement (FWD)»(ref-241744-S24490016972006081100000) or «Engine Mount Replacement (AWD)»(ref-241744-S19668767692006081100000) .
24. Place adjustable jack stands under the frame.
25. Loosen the left side frame bolts (2) and remove the right side frame bolts (1).
26. Using the jack stands, lower the right side of the frame enough to remove the oil pan.
27. Remove the oil pan side bolts (1). .
28. Remove the oil pan bolts (2).
29. Remove the oil pan.
30. Remove the oil pan gasket
31. Clean the following items: The oil pan flanges The oil pan rail The front cover The threaded holes

1. Apply sealer to both sides of the crankshaft rear main bearing cap (1). Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) . Press sealer into the gaps using a putty knife.
2. Apply sealer to both sides of the front cover/block mating area (1). Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) .
3. Install the oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts (2). Tighten : Tighten the bolts to 25 Nm (18 lb ft).
6. Install the oil pan side bolts (1). Tighten : Tighten the bolts to 25 Nm (18 lb ft).
7. Using the jack stands, raise the right side of the frame.
8. Install and tighten the right side frame bolts (1) and tighten the left side frame bolts (2). Tighten : Tighten the front frame bolts to 130 Nm (96 lb ft). Tighten the rear frame bolts to 240 Nm (177 lb ft).
9. Install the engine mount. Refer to «Engine Mount Replacement (FWD)»(ref-241744-S24490016972006081100000) or «Engine Mount Replacement (AWD)»(ref-241744-S19668767692006081100000) .
10. Install the engine harness clip to the oil pan.
11. Connect the engine harness electrical connector to the oil level sensor.
12. Install the starter. Refer to «STARTER MOTOR REPLACEMENT»(ref-241706-S19408317592007022100000) .
13. Position the transaxle brace to the transaxle and oil pan.
14. Install the transaxle brace to transaxle bolt.
15. Install the transaxle brace to oil pan bolts. Tighten: Tighten the bolt/nut to 43 Nm (32 lb ft).
16. Position the transaxle brace to the transaxle and the engine block/oil pan.
17. Install the transaxle brace to transaxle bolts.
18. Install the transaxle brace to engine block/oil pan bolts. Tighten: Tighten the bolt/nut to 43 Nm (32 lb ft).
19. Position the A/C compressor over the front stud and install the A/C compressor front bolt and nut. Tighten: Tighten the bolt/nut to 50 Nm (37 lb ft).
20. Install the A/C compressor rear bolt. Tighten: Tighten the bolt/nut to 50 Nm (37 lb ft).
21. Install the lower ball joint to the steering knuckle.
22. Install the lower ball joint castle nut (1). Tighten: Tighten the bolt/nut to 50 Nm (37 lb ft).
23. If necessary, tighten the castle nut in order to align one of the slots (1) to the ball joint stud pin hole (2) as shown
24. Install a NEW cotter pin to the castle nut and ball joint stud.
25. Bend the NEW cotter pin ends as shown in either example.
26. Install the engine harness clips to the right lower control arm.
27. Install right front splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
28. Install right front wheel and tire. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
29. Remove engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) .
30. Fill the crankcase with NEW oil.

Scheme 42

1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
3. Remove the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
4. Disconnect the engine harness electrical connector (2) from the engine oil pressure sensor.
5. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 16 Nm (12 lb ft).
2. Connect the engine harness electrical connector (2) to the engine oil pressure sensor.
3. Install the radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
4. Lower the vehicle.
5. Connect the negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
2. Remove the oil pan drain plug
3. Drain the crankcase.
4. Reinstall the oil pan drain plug.
5. Disconnect the engine oil level sensor electrical connector.
6. Remove the engine oil level sensor bolt and sensor

1. Install the engine oil level sensor and bolt. Tighten: Tighten the bolt to 10 Nm (89 lb in).
2. Connect the engine oil level sensor electrical connector.
3. Refill the crankcase with new engine oil.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241744-S22842941392007030800000) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.

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-241744-S22842941392007030800000) .

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
2. Remove the oil pump drive bolt. (cylinder heads shown removed for clarity).

1. Apply prelube to the oil pump drive gear. Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) for the 3.9L engine.
2. Install the oil pump drive.
3. Install the oil pump drive bolt. Tighten: Tighten the bolt to 36 Nm (27 lb ft).
4. Install lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241744-S01514116932007030900000) .
2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

1. Lubricate the NEW oil seal with clean engine oil.
2. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
3. Install the crankshaft front oil seal using J 35468 and a suitable tool.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241744-S01514116932007030900000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .
2. Remove the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-241701-S10261093362006081100000) .
3. Disconnect the engine harness electrical connector from the camshaft position actuator magnet.
4. Remove the camshaft position actuator magnet bolts.
5. Remove the camshaft position actuator magnet and O-ring seal.

1. Install the camshaft position actuator magnet O-ring seal and magnet.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the bolts to 10 Nm (89 lb in).
3. Connect the engine harness electrical connector to the camshaft position actuator magnet.
4. Install the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-241701-S10261093362006081100000) .
5. Install intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) .

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
2. Remove drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-241744-S22013616802006081100000) .
3. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241744-S22842941392007030800000) .
4. Remove crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241744-S01514116932007030900000) .
5. Remove the camshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-241744-S13834082332007030900000) .
6. Remove thermostat housing. Refer to «THERMOSTAT HOUSING REPLACEMENT - LZ9 (3.9L)»(ref-241700-S09275069972007022300000) .
7. Remove the water pump. Refer to «WATER PUMP REPLACEMENT - LZ9 (3.9L)»(ref-241700-S03936485442007022300000) .
8. Remove the engine front cover bolts.
9. Remove the engine front cover.
10. Remove the engine front cover gasket.

1. Position the engine front cover gasket to the engine block.
2. Install the engine front cover.
3. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 Nm (18 lb ft).
4. Install water pump. Refer to «WATER PUMP REPLACEMENT - LZ9 (3.9L)»(ref-241700-S03936485442007022300000) .
5. Install the thermostat housing. Refer to «THERMOSTAT HOUSING REPLACEMENT - LZ9 (3.9L)»(ref-241700-S09275069972007022300000) .
6. Install camshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-241744-S13834082332007030900000) .
7. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-241744-S01514116932007030900000) .
8. Install oil pan. Refer to «Oil Pan Replacement»(ref-241744-S22842941392007030800000) .
9. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-241744-S22013616802006081100000) .
10. Fill cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-241744-S29352392172007030900000) .
2. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
3. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).
4. Remove the camshaft sprocket bolts.
5. Remove the timing chain, camshaft and crankshaft sprockets.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.
8. Remove and discard the camshaft position actuator filter (1) from the end of the camshaft.

1. Install s NEW camshaft position actuator filter (1) to the end of the camshaft.
2. Install the crankshaft sprocket.
3. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent to the crankshaft sprocket thrust surface.
4. Install the timing chain tensioner.
5. Install the timing chain tensioner bolts. Tighten: Tighten the bolts 21 N.m (15 lb ft).
6. Using the EN-47719 , fully collapse the tensioner and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-241744-S39714852612006081100000) .
7. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
8. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
9. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).
10. Align the dowel in the camshaft sprocket with the dowel hole in the camshaft.
11. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts 16 N.m (12 lb ft).
12. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
13. Coat the crankshaft and camshaft sprockets with clean engine oil.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-241744-S29352392172007030900000) .

Note. Head gaskets are specific for right hand and left hand applications and also must be installed with the correct side facing up. Note the markings (1) on the head gaskets for proper installation. Failure to do so may lead to engine damage.

Scheme 43

1. Clean the gasket mating surfaces.
2. Install left spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .
3. Install the cylinder head locator dowel pins, if necessary.
4. Inspect the cylinder head locator dowel pins for proper installation.
5. Install a NEW cylinder head gasket.
6. Install the cylinder head onto the locator pins and the engine.
7. Install the NEW cylinder head bolts finger tight.
8. Tighten the cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 Nm (44 lb ft) plus an additional 95 degrees using the J 45059 .
9. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-241744-S26748326442006081100000) .
10. Install the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - LEFT (3.9L)»(ref-241745-S26771118722007030600000) .
11. Install lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
12. Fill engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
13. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
14. Inspect for leaks.

Note. Head gaskets are specific for right hand and left hand applications and also must be installed with the correct side facing up. Note the markings (1) on the head gaskets for proper installation. Failure to do so may lead to engine damage.

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install a NEW cylinder head gasket.
4. Remove the right spark plugs. Refer to «SPARK PLUG REPLACEMENT»(ref-241687-S07054642802007030600000) .
5. Install the cylinder head onto the locator pins and the engine
6. Install the NEW cylinder head bolts finger tight.
7. Tighten the cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 Nm (44 lb ft) plus an additional 95 degrees using the J 45059 .
8. Install the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.9L)»(ref-241745-S04622233512007030600000) .
9. Install lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-241744-S08174346002006081100000) .
10. Fill engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
11. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
12. Inspect for leaks.

1. Remove automatic transaxle. Refer to «TRANSMISSION REPLACEMENT (M15)»(ref-241713-S36188207002006081100000) or «TRANSMISSION REPLACEMENT (M76)»(ref-241713-S39803377572006081100000) .
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating.
3. Loosen the flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Position the flywheel to the crankshaft.
2. Install the flywheel bolts finger tight.
3. Install the flywheel bolts finger tight.
4. Tighten the flywheel bolts. Tighten: Tighten the bolts to 70 Nm (52 lb ft).
5. Install the automatic transaxle. Refer to «TRANSMISSION REPLACEMENT (M15)»(ref-241713-S36188207002006081100000) or «TRANSMISSION REPLACEMENT (M76)»(ref-241713-S39803377572006081100000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-241744-S32122331182007030900000) .
2. Remove the crankshaft rear main oil seal using one of the following techniques
3. If removing the new style seal - seal lip facing outward, insert a flat-bladed or similar tool between the sealing lip and the outer casing of the seal at an angle and gently pry the seal out be moving the tool towards the center of the crankshaft.
4. If removing an old style seal - seal lip faces inward, insert a flat-bladed or similar tool between the outer seal casing and the engine block casting and gently pry the seal out.
5. Repeat the above steps as necessary around the crankshaft rear oil seal, until the seal is removed.

Scheme 44

1. The EN-48108 tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with the installation, review the above illustration to become familiar with the following components: Mandrel (1) Drive Drum (2) Drive Nut (3) Washer (4) Bearing (5)
2. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
3. Using a large flat-bladed screwdriver, tighten the 2 mandrel screws to the crankshaft, ensuring the mandrel is snug to the crankshaft hub.
4. Install the rear main seal (1), with the protective nylon sleeve attached, onto the mandrel
5. Install the outer drive drum onto the mandrel.
6. Install the bearing, washer and the drive nut onto the threaded shaft.
7. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore
8. Turn the wrench until the drive drum is snug and flush against the engine block.
9. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the nylon plastic seal protector.
10. Verify that the seal has seated properly.
11. Use a flat-bladed screwdriver to remove the 2 attachment screws from the mandrel and remove the mandrel from the crankshaft hub.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
2. Position a suitable drain pan under the oil pan drain plug.
3. Remove the oil pan drain plug.
4. Allow the engine oil to drain completely.
5. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary.
6. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
7. Position a suitable drain pan under the oil filter.
8. Remove the oil filter.
9. Ensure that the oil filter gasket is still on the old filter. If not remove the oil filter gasket from the adapter.

1. Apply clean engine oil to the NEW oil filter gasket.
2. Install the NEW oil filter.
3. Tighten the oil pan drain plug. Tighten: Tighten the plug to 26 Nm (19 lb ft).
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant.
7. Start the engine.
8. Inspect the for oil leaks after engine start up.
9. Turn OFF the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil level indicator tube
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level if the engine oil on the oil level indicator.
15. If necessary, adjust the oil level by adding or draining oil.
16. Check for leaks.

1. Lock the steering column by installing the J 42640 into the underside of the steering column.
2. Open the hood.
3. Remove the engine oil fill cap.
4. Pull up on the intake manifold cover in order to disengage the cover from the studs.
5. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .
6. Disconnect the positive battery cable.
7. Disconnect the battery current sensor. Refer to «BATTERY CURRENT SENSOR REPLACEMENT»(ref-241706-S05719106822007022100000) .
8. Disconnect the auxiliary ground cable on the inner fender.
9. Disconnect the positive battery feed at the junction box.
10. Remove the lower radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
11. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
12. Lower the vehicle.
13. Reposition the coolant recovery reservoir hose clamp (1) at the coolant crossover.
14. Remove the coolant recovery reservoir hose (2) from the crossover.
15. Remove the coolant reservoir. Refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(ref-241700-S32885562382006081100000) .
16. Remove the left side diagonal brace. Refer to «BRACE REPLACEMENT - SHEET METAL DIAGONAL»(ref-241699-S30005671862006081100000) .
17. Unsnap and remove the junction block cover.
18. Loosen the air cleaner cover bolts. .
19. Remove the air cleaner cover.
20. Remove the engine control module (ECM) from the air cleaner cover.
21. Disconnect the engine harness electrical connector (1) from the transaxle control module (TCM).
22. Disconnect the engine harness electrical connector (3) from the instrument panel (I/P) harness electrical connector (2).
23. Disconnect the engine harness electrical connector (5) from the I/P harness electrical connector (4).
24. Disconnect the engine harness electrical connector (6) from the ABS module.
25. Remove the engine harness clip (1) from the air conditioning (A/C) line.
26. Remove the engine harness clip (1) from the A/C line.
27. Remove the underhood junction. Refer to «UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT»(ref-241671-S41230725642006081100000) .
28. Unsnap and remove the engine harness connector from the junction block retainer.
29. Disconnect the engine harness electrical connector from the mass air flow (MAF)/intake air temperature (IAT) sensor.
30. Disconnect the positive crankcase ventilation (PCV) fresh air tube quick connect fitting from the air cleaner outlet duct.
31. Loosen the air cleaner outlet duct clamps at the throttle body and the MAF/IAT sensor.
32. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor.
33. Gather the outer branches of the engine harness and lay them on top of the engine.
34. Using the J 38185 , release the tension on the radiator inlet hose clamp and reposition the clamp.
35. Remove the radiator inlet hose from the coolant crossover.
36. Using the J 38185 , release the tension on the radiator outlet hose clamp and reposition the clamp.
37. Remove the radiator outlet hose from the thermostat housing.
38. Disconnect the heater inlet (2) and outlet (1) hose quick connect fittings from the inlet and outlet pipes.
39. Remove the brake booster vacuum hose from the upper intake manifold fitting.
40. Disconnect the fuel feed (1) and evaporative emission (EVAP) (2) line quick connect fittings. Refer to «METAL COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S36532935562007030600000) or «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
41. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
42. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
43. Remove the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
44. Remove rear propeller shaft, if equipped with all wheel drive (AWD). Refer to «PROPELLER SHAFT REPLACEMENT»(ref-241711-S04499692822006081100000) .
45. Disconnect the engine harness electrical connectors (1) from the left and right wheel speed sensors. (right side shown, left side similar).
46. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
47. Disconnect the engine harness electrical connectors from the A/C compressor.
48. Remove the A/C compressor front bolt and nut.
49. Remove the A/C compressor rear bolt. Reposition and support the A/C compressor out of the way.
50. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
51. Remove the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
52. Remove the engine harness clips (1, 2) from the catalytic converter heat shield, if equipped with AWD.
53. Disconnect the battery cable retainers at the core support.
54. Remove the engine harness clips (1, 2) from the heat shield, if equipped with front wheel drive (FWD).
55. If equipped with FWD, remove the stabilizer shaft link lower nuts (3). (left side shown, right side similar)
56. Remove the stabilizer shaft links (2) from the stabilizer shaft.
57. Remove the tie rod end nuts (1) at the steering knuckles. (FWD shown, AWD similar).
58. Using the J 24319-B, separate the outer tie rod ends from the steering knuckle.
59. Remove the lower ball joint cotter pins (2) from the ball joints.
60. Loosen the lower ball joint castle nuts (1).
61. Install the J 41820 over the ball joint and lower control arm as shown.
62. Rotate the castle nut counterclockwise in order to separate the ball joint from the steering knuckle.
63. Assemble the J 33008-A, J 29794 and the J 2619-O1 .
64. Using the J 33008-A, J 29794 and the J 2619-O1 , disengage the wheel drive shafts from the transaxle. (left side shown, right side similar).
65. Secure the wheel drive shafts to the steering knuckle/struts.
66. Reposition the intermediate steering shaft seal in order to provide access to the intermediate steering shaft pinch bolt.
67. Remove the intermediate steering shaft pinch bolt.
68. Disconnect the intermediate steering shaft from the power steering gear.
69. Place the J 39580 under the frame.
70. Lower the vehicle until the frame contacts the J 39580 .
71. Remove the front and rear frame bolts (1, 2).
72. Remove the frame rear strap bolts (2, 3).
73. Remove the frame rear straps (1, 4).
74. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
75. If necessary perform the following steps, remove the engine harness ground wire nut (1).
76. Remove the engine harness positive battery cable (2) from the stud.
77. Disconnect the engine harness electrical connector (3) from the starter.
78. Remove the engine harness ground nuts (1, 2) from the transaxle studs.
79. Remove the engine harness grounds from the studs.
80. Remove the negative battery cable from the transaxle stud.
81. Remove the engine to transaxle brace .
82. Remove the starter motor bolts and starter.
83. Remove the torque converter cover bolts (1, 3).
84. Remove the torque converter covers (2, 4).
85. Use the J 37096 in order to hold the flywheel and also rotate the flywheel to access the torque converter bolts.
86. Remove the torque converter bolts.
87. Remove the engine mount to frame nuts.
88. Remove the engine harness clips (1) from the transaxle brace.
89. Remove the engine harness clips (1) from the transaxle brace.
90. Remove the engine harness clips (1) from the transaxle brace.
91. Remove the exhaust crossover pipe shield bolts (1) and shield (2).
92. Remove the exhaust crossover pipe nuts (1) and pipe (2).
93. Disconnect the engine harness electrical connector (1) from the EVAP purge solenoid.
94. Disconnect the engine harness electrical connector (2) from the throttle actuator.
95. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
96. Disconnect the engine harness electrical connector (2) from the ignition coil.
97. Remove the engine harness clip (1) from the ignition coil bracket.
98. Remove the engine harness clip (1) from the ignition coil bracket.
99. Remove the engine harness clip from the engine.
100. Remove the engine harness bolt.
101. Disconnect the engine harness electrical connector from the camshaft actuator magnet.
102. Remove the engine harness bracket nut (1).
103. Remove the engine harness bracket (2) from the stud.
104. Remove the engine harness clip (1) from the bracket.
105. Disconnect the engine harness electrical connector (1) from the intake manifold tuning valve.
106. Remove the connector position assurance (CPA) retainer (2).
107. Disconnect the engine harness electrical connector (3) from the fuel injector harness electrical connector.
108. Remove the generator terminal nut (1).
109. Remove the engine harness lead (2) from the generator.
110. Disconnect the engine harness electrical connector (3) from the generator.
111. Disconnect the engine harness electrical connector (4) from the heated oxygen sensor (HO2S).
112. Remove the engine harness clip (1) from the strut bracket.
113. Disconnect the engine harness electrical connector (1) from the crankshaft position (CKP) sensor.
114. Disconnect the engine harness electrical connector (1) from the knock sensor.
115. Disconnect the engine harness electrical connector (2) from the oil pressure sensor.
116. Disconnect the engine harness electrical connector from the transaxle.
117. Disconnect the engine harness electrical connector from the vehicle speed sensor (VSS).
118. Remove the engine harness clip (1) from the stud on the transaxle.
119. Remove the engine harness clamp bolt from the transaxle.
120. Remove the engine harness clips (1) from the transaxle studs.
121. Disconnect the engine harness electrical connector from the oil level sensor.
122. Remove the engine harness clip from the oil pan.
123. Gather all branches of the engine harness together and remove the engine harness from the engine.
124. Disconnect the power steering line retainer from the generator bracket.
125. Remove the power steering pressure pipe and return line from the power steering pump and position out of the way. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT»(ref-241712-S05110546692006081100000) .
126. Install an engine hoist to the engine.
127. Remove the transaxle bolts and studs.
128. Support the transaxle.
129. Separate and remove the engine from the transaxle and the frame.
130. Use the J 37096 in order to hold the flywheel.
131. Loosen the flywheel bolts.
132. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft.
133. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
134. Remove the engine flywheel.
135. Install the engine to the engine stand.
136. Remove the engine hoist from the engine.

1. Install an engine hoist to the engine.
2. Remove the engine from the engine stand.
3. Position the flywheel to the crankshaft.
4. Install the flywheel bolts finger tight.
5. Use the J 37096 in order to hold the flywheel.
6. Tighten the flywheel bolts. Tighten: Tighten the bolts to 70 Nm (52 lb ft).
7. Install the engine to the transaxle and the frame.
8. Install the transaxle bolts and studs. Tighten: Tighten the bolts to 75 Nm (55 lb ft).
9. Remove the support from the transaxle.
10. Remove the engine hoist from the engine.
11. Install the power steering pressure and return lines to the power steering pump. Refer to «POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT»(ref-241712-S05110546692006081100000) .
12. Connect the power steering line retainer at the generator bracket.
13. Place the engine wiring harness on top of the engine and position the harness branches.
14. Install the engine harness clip to the oil pan.
15. Connect the engine harness electrical connector to the oil level sensor.
16. Install the engine harness clips (1) to the transaxle studs.
17. Install the engine harness clamp bolt to the transaxle. Tighten: Tighten the bolts to 20 Nm (15 lb ft).
18. Install the engine harness clip (1) to the stud on the transaxle.
19. Connect the engine harness electrical connector to the VSS.
20. Connect the engine harness electrical connector to the transaxle.
21. Connect the engine harness electrical connector (1) to the knock sensor.
22. Connect the engine harness electrical connector (2) to the oil pressure sensor.
23. Connect the engine harness electrical connector (1) to the CKP sensor.
24. Install the engine harness clip (1) to the strut bracket.
25. Connect the engine harness electrical connector (4) to the HO2S.
26. Connect the engine harness electrical connector (3) to the generator.
27. Install the engine harness lead (2) to the generator.
28. Install the generator terminal nut (1). Tighten: Tighten the bolts to 30 Nm (22 lb ft).
29. Connect the engine harness electrical connector (3) to the fuel injector harness electrical connector.
30. Install the CPA retainer (2).
31. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.
32. Install the engine harness clip (1) to the bracket.
33. Install the engine harness bracket (2) to the stud.
34. Install the engine harness bracket nut (1).
35. Connect the engine harness electrical connector to the camshaft actuator magnet.
36. Install the engine harness bolt. Tighten: Tighten the bolts to 20 Nm (15 lb ft).
37. Install the engine harness clip to the engine.
38. Install the engine harness clip (1) to the ignition coil bracket.
39. Install the engine harness clip (1) to the ignition coil bracket.
40. Connect the engine harness electrical connector (2) to the ignition coil.
41. Connect the engine harness electrical connector (1) to the MAP sensor.
42. Connect the engine harness electrical connector (2) to the throttle actuator.
43. Connect the engine harness electrical connector (1) to the EVAP purge solenoid.
44. Install the exhaust crossover pipe (2) and nuts (1). Tighten: Tighten the bolts to 25 Nm (18 lb ft).
45. Install the exhaust crossover pipe shield (2) and bolts (1). Tighten: Tighten the bolts to 10 Nm (89 lb in).
46. Install the transaxle brace and bolts. Tighten: Tighten the bolts to 43 Nm (32 lb ft).
47. Install the engine harness clips (1) to the transaxle brace.
48. Install the engine harness clips (1) to the transaxle brace.
49. Install the engine mount to frame nuts. Tighten: Tighten the bolts to 47 Nm (35 lb ft).
50. Install the torque converter bolts.
51. Use the J 37096 in order to hold the flywheel.
52. Tighten the torque converter bolts. Tighten: Tighten the bolts to 63 N.m (`47 lb ft).
53. Install the torque converter covers (2, 4).
54. Install the torque converter cover bolts (1, 3). Tighten: Tighten the bolts to 10 N.m (89 lb in).
55. Install the starter motor and bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
56. Install the transaxle brace and bolts. Tighten: Tighten the bolts to 43 N.m (32 lb ft).
57. Install the negative battery cable to the transaxle stud.
58. Install the engine harness grounds to the studs.
59. Install the engine harness ground nuts (1, 2) to the transaxle studs. Tighten: Tighten the bolts to 25 N.m (`18 lb ft).
60. If necessary perform the following steps, connect the engine harness electrical connector (3) to the starter.
61. Install the engine battery positive wire terminal (2) to the stud.
62. Install the engine battery positive wire nut (1). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
63. Lower the vehicle over the powertrain/frame assembly.
64. Position the frame rear straps (1, 4).
65. Install the frame rear strap bolts (2, 3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
66. Install the front and rear frame bolts (1, 2). Tighten: Tighten the bolts to 240 N.m (177 lb ft).
67. Raise the vehicle off of the J 39580 .
68. Remove the J 39580 from under the frame.
69. Connect the intermediate steering shaft to the power steering gear.
70. Install the intermediate steering shaft pinch bolt. Tighten: Tighten the bolts to 48 N.m (35 lb ft).
71. Position the intermediate steering shaft seal onto the steering gear.
72. Unsecure the wheel drive shafts from the steering knuckle/struts.
73. Install the wheel drive shafts to the transaxle.
74. Verify that the wheel drive shaft is properly engaged to the transaxle by grasping the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The wheel drive shaft will remain firmly in place when properly engaged.
75. Install the ball joints to the knuckles.
76. Install the ball joint castle nuts.
77. If necessary, tighten the castle nut in order to align the nut slot (1) to the cotter pin hole (2) as shown.
78. Tighten the lower ball joint castle nuts (1). Tighten: Tighten the bolts to 55 N.m (40 lb ft).
79. Install NEW lower ball joint cotter pins (2) to the ball joints.
80. Install the tie rod end nuts (1) at the steering knuckles. (FWD shown, AWD similar).
81. Install the outer tie rod (2) to the steering knuckle (1).
82. Install the tie rod end nuts (1) at the steering knuckles. (FWD shown, AWD similar). Tighten: Tighten the nuts to 30 Nm (22 lb ft) plus an additional 120 degrees using the J 45059 .
83. If equipped with FWD, install the stabilizer shaft links (2) to the stabilizer shaft. (left side shown, right side similar).
84. Install the stabilizer shaft link lower nuts (3). Tighten: Tighten the nuts to 23 Nm (17 lb ft).
85. Install the engine harness clips (1, 2) to the heat shield, if equipped with FWD.
86. Connect the battery cable retainers at the core support.
87. Install the engine harness clips (1, 2) to the catalytic converter heat shield, if equipped with AWD.
88. Install the engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
89. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-241745-S34308852242007022700000) .
90. Position and install the A/C compressor onto the stud.
91. Install the A/C compressor front bolt and nut. Tighten: Tighten the nuts to 50 Nm (37 lb ft).
92. Install the A/C compressor rear bolt. Tighten: Tighten the nuts to 50 Nm (37 lb ft).
93. Connect the engine harness electrical connectors to the A/C compressor.
94. Install the drive belt. Refer to «Drive Belt Replacement»(ref-241744-S07589734552006081100000) .
95. Connect the engine harness electrical connectors (1) to the left and right wheel speed sensors. (right side shown, left side similar).
96. Install rear propeller shaft, if equipped with AWD. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-241711-S04499692822006081100000) .
97. Install the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
98. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241744-S13621555592006081100000) and «Engine Mount Strut Replacement - Right»(ref-241744-S28435242272006081100000) .
99. Connect the fuel feed (1) and EVAP (2) line quick connect fittings. Refer to «METAL COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S36532935562007030600000) and «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
100. Install the brake booster vacuum hose to the upper intake manifold fitting.
101. Connect the heater inlet (2) and outlet (1) hose quick connect fittings to the inlet and outlet pipes.
102. Install the radiator outlet hose to the thermostat housing.
103. Using the J 38185 , release the radiator outlet hose clamp.
104. Install the radiator inlet hose to the coolant crossover
105. Using the J 38185 , release the radiator inlet hose clamp.
106. Remove the engine harness wiring branch from on top of the engine.
107. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor.
108. Tighten the air cleaner outlet duct clamps at the throttle body and the MAF/IAT sensor. Tighten: Tighten the nuts to 2 Nm (18 lb in).
109. Connect the PCV fresh air tube quick connect fitting to the air cleaner outlet duct. Refer to «PLASTIC COLLAR QUICK CONNECT FITTING SERVICE»(ref-241687-S19298994912007030600000) .
110. Connect the engine harness electrical connector to the MAF/IAT sensor.
111. Install the engine harness connector to the junction block retainer.
112. Install the underhood junction block. Refer to «UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT»(ref-241671-S41230725642006081100000) .
113. Install the engine harness clip (1) to the A/C line.
114. Install the engine harness clip (1) to the A/C line.
115. Connect the engine harness electrical connector (6) to the ABS module.
116. Connect the engine harness electrical connector (5) to the I/P harness electrical connector (4).
117. Connect the engine harness electrical connector (3) to the I/P harness electrical connector (2).
118. Connect the engine harness electrical connector (1) to the TCM.
119. Install the ECM to the air cleaner cover.
120. Install the air cleaner cover.
121. Tighten the air cleaner cover bolts. Tighten: Tighten the nuts to 4 Nm (35 lb in).
122. Install the junction block cover.
123. Install the left side diagonal brace. Refer to «BRACE REPLACEMENT - SHEET METAL DIAGONAL»(ref-241699-S30005671862006081100000) .
124. Install the coolant reservoir. Refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(ref-241700-S32885562382006081100000) .
125. Install the coolant recovery reservoir hose (2) to the crossover.
126. Position the coolant recovery reservoir hose clamp (1) at the coolant crossover.
127. Remove the J 42640 from the underside of the steering column.
128. Install the lower radiator air baffle. Refer to «RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS»(ref-241700-S36931602902006081100000) .
129. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) .
130. Connect the positive battery cable.
131. Connect the positive battery cable at the junction box.
132. Connect the auxiliary ground cable on the inner fender.
133. Connect the electrical connector to the sensor on the negative battery cable.
134. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) .
135. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-241744-S30059072902006081100000) .
136. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-241687-S36405520112006081100000) .
137. Align the cover to the studs on the engine, push down on the cover above the stud in order to engage the cover to the studs
138. Install the engine oil fill cap.
139. Start the engine listen for unusual noises.
140. Inspect the engine for leaks.

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241744-S32122331182007030900000) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer. Refer to «Sealers, Adhesives and Lubricants»(ref-241744-S02648701942006081100000) .
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install engine flywheel. Refer to «Engine Flywheel Replacement»(ref-241744-S32122331182007030900000) .

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. If equipped with an oil cooler (RPO-KC4), reposition the upper inlet hose clamp (1).
6. Remove the oil cooler inlet hose from the block outlet.
7. If not equipped with an oil cooler (RPO-KC4), remove the coolant drain plug from the right side.
8. Drain the coolant.

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816 along with EN 46359 .

1. If equipped with an automatic transmission, remove the flywheel bolts.
2. Remove the flywheel.

Engine Flywheel Removal (Manual Transmission)

1. Remove the flywheel/pressure plate bolts.
2. Remove the flywheel/pressure plate.
3. Remove the clutch pilot bearing.

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

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

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

1. Remove the idler pulley bolts and pulleys.
2. Loosen thermal bypass hose clamp (3) and remove hose from the coolant crossover pipe.
3. Remove the heater inlet/outlet pipe bolt (1) and remove the heater inlet/outlet pipe.
4. Remove the coolant crossover pipe bolts (2, 3), engine lift bracket (1) and the coolant crossover pipe assembly.

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

1. Remove the oil level indicator tube bolt.
2. Remove the oil level indicator and oil level indicator tube.

1. Remove the oil filter adapter heat shield nuts.
2. Remove the oil filter adapter heat shield (2).
3. Remove the oil filter adapter bolts.
4. Remove the oil filter adapter (1) and gasket.

1. Remove the exhaust crossover heat shield pipe bolts.
2. Remove the exhaust crossover heat shield.
3. Remove the exhaust crossover pipe nuts.
4. Remove the exhaust crossover pipe studs (1) if necessary.
5. Remove the exhaust crossover pipe.

1. Remove the spark plug wires and the spark plugs and set aside.
2. Remove the exhaust manifold heat shield bolts.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold bolts.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires and spark plugs.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shields.
5. Remove the exhaust manifold bolts.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.

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

1. Remove the positive crankcase ventilation (PCV) tube.
2. Remove and discard both PCV tube O-rings
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
6. Remove the valve rocker arm cover gasket.

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 fresh air tube from the valve rocker arm cover.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover.
8. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
9. Remove the valve rocker arm cover gasket.

1. Remove the foul air PCV tube.
2. Remove the upper intake manifold bolts, stud and manifold absolute pressure (MAP) sensor bracket.
3. Remove the upper intake manifold and gaskets.

1. Disconnect the coolant temperature sensor (1).
2. Disconnect the camshaft position (CMP) sensor (2).
3. Remove the fuel injector rail bolts.
4. Remove the fuel rail assembly.
5. Remove the lower intake manifold bolts and discard.
6. Remove the lower intake manifold.

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).
4. Remove the intake manifold gaskets.

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

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.

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.

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.

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.

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.

1. Remove the camshaft position actuator magnet bolts.
2. Remove the camshaft position actuator magnet and O-ring seal.

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

Scheme 45

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

1. Remove the engine front cover bolts.
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Note. Use only a Torx Plus® Bit when removing or installing the camshaft position actuator fasteners (1). The Torx Plus® design differs from typical Torx® fastener. Use of a standard Torx® bit on Torx Plus® fasteners may result in a rounded out fastener head or incorrect faster torque.

Scheme 46

1. Remove the camshaft sprocket bolts.
2. Remove the timing chain and sprockets.
3. Remove the timing chain tensioner bolts.
4. Remove the timing chain tensioner.

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 a 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. 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.
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-241744-S32122331182007030900000) .
2. Remove the crankshaft rear main oil seal using one of the following techniques
3. If removing the new style seal - seal lip facing outward, insert a flat-bladed or similar tool between the sealing lip and the outer casing of the seal at an angle and gently pry the seal out be moving the tool towards the center of the crankshaft.
4. If removing an old style seal - seal lip faces inward, insert a flat-bladed or similar tool between the outer seal casing and the engine block casting and gently pry the seal out.
5. Repeat the above steps as necessary around the crankshaft rear oil seal, until the seal is removed.

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.

1. Remove the bolts retaining the piston oil nozzles to the engine block
2. Remove the piston oil nozzles.

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 .
3. Drive out the camshaft bearings. Use the J 33049 .

Engine Block Heater Installation

Remove the engine block heater from engine block.

1. Assemble the J 33049 according to the manufacturer's instructions.
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 . 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.

1. Position the piston oil nozzles in the engine block.
2. Install the bolts retaining the piston oil nozzles to the engine block. Tighten: Tighten bolt to 10 Nm (89 lb in).

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N.m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-0.21 mm (0.002-0.008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).

1. The EN-48108 tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with the installation, review the above illustration to become familiar with the following components: Mandrel (1) Drive Drum (2) Drive Nut (3) Washer (4) Bearing (5)
2. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
3. Using a large flat-bladed screwdriver, tighten the 2 mandrel screws to the crankshaft, ensuring the mandrel is snug to the crankshaft hub.
4. Install the rear main seal (1), with the protective nylon sleeve attached, onto the mandrel
5. Install the outer drive drum onto the mandrel.
6. Install the bearing, washer and the drive nut onto the threaded shaft.
7. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore
8. Turn the wrench until the drive drum is snug and flush against the engine block.
9. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the nylon plastic seal protector.
10. Verify that the seal has seated properly.
11. Use a flat-bladed screwdriver to remove the 2 attachment screws from the mandrel and remove the mandrel from the crankshaft hub.

1. Lightly lubricate the following components with clean engine oil: The piston The piston pin 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 in).
4. Install the J 8037 onto the piston and compress the piston rings.
5. Align the piston pin bore with the connecting rod pin bore.
6. Align the piston pin bore with the connecting rod pin bore.
7. Slide the piston pin (4) into the piston and the connecting rod (3).
8. Install NEW piston pin retainers (1) using the J 43654.
9. Ensure that the piston pin retainers are fully seated in their grooves.
10. Repeat these procedures for the remaining pistons.
11. Install the J 41556 into the connecting rod.
12. Install the piston and connecting rod assembly into the proper cylinder bore.
13. 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.
14. Using J 41556 , guide the connecting rod end onto the crankshaft journal
15. 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 .
16. 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.
17. 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).

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 a 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).

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain tensioner.
4. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 21 N.m (15 lb ft).
5. Using the EN-47719 , fully collapse the tensioner and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-241744-S39714852612006081100000) .
6. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
7. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
8. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain tensioner (3).
9. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
10. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
11. Remove the tensioner retaining pin.
12. Coat the crankshaft and camshaft sprocket with engine oil.

1. Install the front cover and the front cover gasket.
2. Install the front cover bolts. Tighten: Tighten the front cover bolts to 25 N.m (18 lb ft).

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.

Oil Pump Drive Installation

1. Apply prelube GM P/N 12345501 (Canadian P/N 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).

1. Install the camshaft position actuator magnet and O-ring seal into the front cover.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the camshaft position actuator magnet bolts to 10 N.m (89 lb in).

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 oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
6. Install the oil pan side bolts. Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
7. 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 .

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 .

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 34 N.m (25 lb ft).

1. 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).
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 lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in) 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.
5. Inspect the fuel rail and fuel injectors for damage and replace if necessary.
6. Install NEW lower fuel injector O-rings.
7. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
8. Install the injector nozzles into the lower intake manifold injector bores.
9. Press on the injector rail using the palms of both hands until the injectors are fully seated.
10. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
11. Connect the coolant temperature sensor (1).
12. Connect the camshaft position (CMP) sensor (2).

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, stud and MAP sensor bracket. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).
4. Install the foul air PCV tube.

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
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 two NEW positive crankcase ventilation (PCV) tube O-rings.
6. Install the fresh air tube.

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
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 fresh air 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).

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).

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

1. Install the exhaust crossover pipe studs (1) if necessary Tighten: Tighten the exhaust crossover pipe studs to 25 Nm (18 lb ft).
2. Install the exhaust crossover pipe.
3. Install the exhaust crossover pipe nuts. Tighten: Tighten the exhaust crossover pipe studs to 25 Nm (18 lb ft).
4. Install the exhaust crossover heat shield.
5. Install the exhaust crossover heat shield bolts. Tighten: Tighten the exhaust crossover pipe studs to 25 Nm (18 lb ft).

1. Install the oil filter adapter (1) and gasket.
2. Apply threadlocker P/N 21485277 to the bolt threads if required.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N.m (18 lb ft).
4. Install the oil filter adapter heat shield (2).
5. Install the oil filter adapter heat shield nuts. Tighten: Tighten the oil filter adapter heat shield nuts to 25 N.m (18 lb ft).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

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).

1. Install the coolant crossover pipe gaskets and the coolant crossover pipe assembly onto the engine.
2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (4). Tighten: Tighten the bolts to 50 Nm (37 lb ft).
3. Install the side coolant crossover pipe bolt (2). Tighten: Tighten the bolts to 10 Nm (89 lb in).
4. Install the thermal bypass hose (3) and securely fasten the hose clamp.
5. Install the idler pulleys and bolts. Tighten: Tighten the bolts (1) to 50 Nm (37 lb ft). Tighten the bolt (2) to 30 Nm (22 lb ft).

Coolant Crossover Pipe Installation

1. Install the coolant crossover pipe assembly onto the engine.
2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the side coolant crossover pipe bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the idler pulleys and bolts. Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolt (2) to 30 N.m (22 lb ft).
5. Install the coolant vent pipe and bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the heater inlet/outlet pipe and bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Install the thermal bypass hose and securely fasten the clamp (3).

1. Install the engine mount support and strut bracket and bracket bolts.
2. Tighten the bolts. Tighten: Tighten the bolts to 50 Nm (37 lb ft).

1. Install the rear engine lift bracket.
2. Install the rear engine lift bracket bolts. Tighten: Tighten the rear engine lift bracket bolts to 50 N.m (37 lb ft).

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).

1. If equipped with an automatic transmission, install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft.
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft.
5. Remove the J 29113 from the crankshaft.
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 70 N.m (52 lb ft). Tighten the crankshaft balancer bolt a final pass to 70 degrees using the J 45059 .