Engine Mechanical - 4.2L: Removal & Installation GMC Envoy II

Removal Procedure

1. Install 3/8 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drive belt.
2. Remove the drive belt.
3. Release the tension on the tensioner arm.

Installation Procedure

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

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

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).
3. Install the drive belt «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
2. Remove the idler pulley bolt from the idler pulley bracket.
3. Remove idler pulley.

1. Install the idler pulley and secure the pulley with the bolt. Tighten: Tighten the idler pulley bolt to 50 N.m (37 lb ft).
2. Install the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
2. Remove the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
3. Remove the manifold absolute pressure (MAP) sensor electrical connector and the retainer (1).
4. Remove the MAP sensor (2).
5. Remove the left shock module (if frame mount is being removed). Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
6. Remove the right and the left upper engine mount nuts (1).
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody. IMPORTANT: When placing jack onto the oil pan, pay close attention to not damage the oil level sender.
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
11. Raise the engine with the jack just enough to clear the engine mount stud.
12. Remove the left engine mount from the bracket.
13. Remove the left engine mount bracket bolts (1).
14. Remove the left engine mount bracket.
15. Remove the left frame engine mount bracket bolts.
16. Remove the left frame engine mount bracket, if required.

1. Install the left frame engine mount bracket, if removed.
2. Install the left frame engine mount bracket bolts, if removed. Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft).
3. Install the left engine mount bracket and secure the bracket with the bolts (1). Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the left engine mount onto the bracket.
5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts (1). Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the jack from under the vehicle.
8. Install the engine protection shield and secure the shield with the bolts. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
9. Install the right and the left lower engine mount nuts. Tighten: Torque the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the left shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
2. Remove the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
3. Remove the manifold absolute pressure (MAP) sensor electrical connector and retainer (1).
4. Remove the MAP sensor (2).
5. Remove the right shock module, if frame engine mount is being removed. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
6. Remove the right and the left upper engine mount nuts (1).
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
11. Raise the engine with the jack just enough to clear the engine mount studs.
12. Remove the right engine mount from the bracket. Note the location of the heat shield for installation.
13. Graphic shows left, right is similar. Remove the right engine mount bracket bolts.
14. Remove the right engine mount bracket.
15. Graphic shows left, right is similar. Remove the right frame engine mount bracket bolts, if required.
16. Remove the right frame engine mount bracket, if required.

1. Graphic shows left, right is similar. Install the right frame engine mount bracket, if removed.
2. Install the right frame engine mount bracket bolts, if removed. Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft).
3. Graphic shows left, right is similar. Install the right engine mount bracket and secure with the bolts (1). Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the right engine mount.
5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts (1). Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the floor jack from under the vehicle.
8. Install the engine protection shield and secure with the bolts. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
9. Install the right and the left lower engine mount nuts. Tighten: Tighten the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the right shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.

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

1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2).
2. Connect the crankcase clean air hose to the valve cover port.
3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5). Tighten: Tighten the bolts to 6 N.m (53 lb in).
4. Tighten the throttle body clamps (2). Tighten: Tighten the clamps to 4 N.m (35 lb in).
5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator.
6. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent.
7. Connect the crankcase dirty air hose to the intake manifold.
8. Connect the crankcase dirty air hose to the PCV orifice tube.

1. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200372-S19996306352005102000000) .
2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-200372-S22616208372005102000000) in Engine Controls - 4.2L.
3. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
4. Remove the PCM mounting studs (5) and position the PCM out of the way.
5. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
6. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
7. Disconnect the integral clip (3) from the wire harness bracket.
8. Remove the engine wire harness bracket bolt.
9. Position the engine electrical wire harness bracket with wires attached out of the way.
10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
11. Disconnect the crankcase ventilation hose from the intake manifold.
12. Disconnect the vacuum brake booster hose at the intake manifold.
13. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
14. Loosen the intake manifold bolts.
15. Remove the intake manifold.

1. Install a new intake manifold gasket to the intake manifold.
2. Install the intake manifold onto the engine and secure the manifold with the bolts. Tighten: Tighten the intake manifold bolts to 10 N.m (89 lb in).
3. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
4. Install the vacuum brake booster hose to the intake manifold.
5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent.
6. Install the crankcase ventilation hose.
7. Connect the MAP sensor electrical connector.
8. Properly position the engine electrical harness bracket to the intake manifold.
9. Install the engine electrical harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
10. Connect the integral clip (3) to the wire harness bracket.
11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) .
12. Connect the ECT sensor electrical connector (1).
13. Install the PCM mounting studs (5) to the intake manifold. Tighten: Tighten the studs to 6 N.m (53 lb in).
14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
16. Install the PCM retaining nuts (6). Tighten: Tighten the nuts to 8 N.m (71 lb in).
17. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-200372-S22616208372005102000000) in Engine Controls - 4.2L.
18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
19. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-200396-S00607332742005102000000) .
2. Remove the A/C line at the oil level indicator tube bracket nut.
3. Remove the A/C bracket bolt from the engine lift hook.
4. Position the A/C line out of the way.
5. Remove the engine lift bracket.
6. Disconnect the ignition control module electrical connectors.
7. Loosen the ignition control module bolts.
8. Remove the ignition control module.
9. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage the clips that hold the housing in place.
10. Disconnect the fuel injection harness electrical connector.
11. Loosen and remove the camshaft cover bolts.
12. Remove the camshaft cover.
13. Clean and inspect the camshaft cover. Refer to «Camshaft Cover Cleaning and Inspection»(ref-200396-S00650138862005102000000) .

1. Install a new camshaft cover seal.
2. Install new rubber ignition control module seals.
3. Install the camshaft cover and secure with the cam cover bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
4. Install the ignition control modules and secure the modules with bolts. Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
5. Connect the ignition control module electrical connectors.
6. Install the fuel injector electrical connectors.
7. Install the engine electrical harness housing (1).
8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. Tighten: Tighten the A/C line bracket nut to 7 N.m (62 lb in).
9. Install the engine lift bracket and secure the lift hook with the bolts. Tighten: Tighten the lift bracket bolts to 50 N.m (37 lb ft).
10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten: Tighten the A/C bracket bolt to 10 N.m (89 lb in).
11. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-200396-S00607332742005102000000) .

Valve Rocker Arm and Valve Lash Adjuster Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44222 Camshaft Sprocket Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Remove the exhaust and the intake sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Carefully move the sprockets with the timing chain off of the camshafts.
5. Remove the camshaft cap bolts.
6. Remove the camshaft caps.
7. Remove the camshafts.
8. Remove the valve rocker arms.
9. Remove the valve lash adjusters.

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm roller.
4. Install the valve rocker arms in their original locations.
5. Coat the camshaft journals with engine oil.
6. Install the camshafts to their original position
7. Install the camshaft caps onto their original journal. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in).
8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 . See «Special Tools»(ref-200396-S26818425802005102000000) .
9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 38820 Valve Stem Seal Remover and Installer. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. J 44222 Camshaft Sprocket Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .
3. J 44228 Valve Spring Compressor. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Remove the cam cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-200372-S40778924732005102000000) in Engine Controls-4.2 L.
3. Remove the exhaust and the intake sprocket bolts.
4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components. See «Special Tools»(ref-200396-S26818425802005102000000) .
5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension.
6. Carefully move the sprockets with the timing chain, off of the camshafts.
7. Remove the camshaft cap bolts.
8. Remove the camshaft caps.
9. Remove the camshafts.
10. Using a suitable adapter, apply air pressure to the cylinder.
11. Install the J 44228 and compress the valve springs. See «Special Tools»(ref-200396-S26818425802005102000000) .
12. Remove the valve keys.
13. Remove the J 44228 . See «Special Tools»(ref-200396-S26818425802005102000000) .
14. Remove the valve spring retainer and the valve spring.
15. Use the J 38820 and remove the seals. See «Special Tools»(ref-200396-S26818425802005102000000) .
16. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-200396-S37667247692005102000000) .

1. Use the J 38820 to install the valve seals. See «Special Tools»(ref-200396-S26818425802005102000000) . There is only one size seal.
2. Install the valve spring and the valve spring retainer.
3. Use the J 44228 and compress the valve springs. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Install the valve keys.
5. Remove the J 44228 . See «Special Tools»(ref-200396-S26818425802005102000000) .
6. Remove the air pressure to the cylinder.
7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil.
8. Install the camshafts to their original position.
9. Install the camshaft caps onto their original journal. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in).
10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 . See «Special Tools»(ref-200396-S26818425802005102000000) .
11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-200372-S40778924732005102000000) in Engine Controls-4.2 L.
13. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .

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

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

Cylinder Head Replacement

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

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (4.2L Engine)»(ref-200436-S04100345482005102000000) .
3. Remove the front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .
4. Remove the cylinder head access hole plugs.
5. Remove the timing chain tensioner shoe bolt.
6. Remove the timing chain tensioner shoe.
7. Remove the timing chain tensioner guide bolts.
8. Remove the timing chain tensioner guide.
9. Remove the timing chain and the sprockets. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-200396-S23581771912005102000000) .
10. Loosen and remove the cylinder head bolts.
11. Remove the cylinder head.
12. Remove the cylinder head gasket.
13. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
14. If replacing cylinder head refer to «Cylinder Head Disassemble»(ref-200396-S38836927362005102000000) .
15. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-200396-S37667247692005102000000) .

1. If installing new cylinder head, refer to «Cylinder Head Assemble»(ref-200396-S28436792262005102000000) .
2. Install the dowel pins, cylinder head locator, if necessary.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
5. Install new cylinder head bolts.
6. Tighten the new cylinder head bolts in the following sequence: Tighten: Tighten the cylinder head bolts (1-14) in sequence to 30 N.m (22 lb ft). Use J 36660-A to tighten the cylinder head bolts in sequence an additional 155 degrees. Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 36660-A to tighten the short cylinder head end bolts an additional 60 degrees. Tighten the (1 Long) end bolt to 7 N.m (62 lb in). Use J 36660-A to tighten the long cylinder head end bolt an additional 120 degrees.
7. Install the cylinder head access hole plugs. Tighten: Tighten the plugs to 5 N.m (44 lb in).
8. Install the timing chain and sprockets. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-200396-S23581771912005102000000) .
9. Install the front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
11. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (4.2L Engine)»(ref-200436-S04100345482005102000000) .

Crankshaft Balancer Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-200396-S26818425802005102000000) .
3. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. J 44226 Crankshaft Balancer Remover/Holder. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
3. Carefully loosen and remove the balancer bolt.
4. Install J 41816-2 into the end of the crankshaft. See «Special Tools»(ref-200396-S26818425802005102000000) .
5. Use a 3 jaw puller to remove the crankshaft balancer.
6. Remove the 3 jaw puller and the J 41816-2 . See «Special Tools»(ref-200396-S26818425802005102000000) .
7. Remove the crankshaft balancer shim from the crankshaft snout.
8. Clean and inspect the crankshaft balancer. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-200396-S01065102742005102000000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the torque converter access plug in the dry part of the oil pan.
3. Use the torque converter holding tool from the J 44226 kit and secure the torque converter while tightening the crankshaft balancer. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Install a new crankshaft balancer shim GM P/N 12573950 over the crankshaft snout, against the crankshaft gear.
5. Using the J 41478 install and seat the crankshaft balancer. See «Special Tools»(ref-200396-S26818425802005102000000) .
6. Remove the J 41478 . See «Special Tools»(ref-200396-S26818425802005102000000) .
7. While still holding the flywheel, install the balancer washer and the bolt. Tighten: Tighten the crankshaft balancer bolt to 150 N.m (110 lb ft). Use the J 36660-A in order to tighten the balancer bolt an additional 180 degrees.
8. Remove the torque converter holding tool.
9. Install the torque converter access plug into the oil pan.
10. Lower the vehicle.
11. Install the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
12. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200396-S11089713542005102000000) .
2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal.

1. Apply the engine oil to the outside diameter of the crankshaft front oil seal.
2. Use the J 44218 to install the front oil seal. See «Special Tools»(ref-200396-S26818425802005102000000) .
3. Remove the J 44218 . See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Install the crank balancer shaft. Refer to «Crankshaft Balancer Replacement»(ref-200396-S11089713542005102000000) .

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
2. Remove the cooling fan and the shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
4. Remove the water pump. Refer to «Water Pump Replacement (LL8)»(ref-200409-S27792287162005102000000) or «Water Pump Replacement (LM4)»(ref-200409-S42166122922005102000000) in Engine Cooling.
5. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200396-S11089713542005102000000) .
6. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-200416-S40545325892005102000000) or «Power Steering Pump Replacement (5.3L)»(ref-200416-S12863791602005102000000) in Power Steering.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
8. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-200396-S42617181412005102000000) .
9. Lower the vehicle.
10. Remove the 7 mm center bolt (1).
11. Loosen and remove the remaining engine front cover bolts.
12. Place two of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to release the front cover from the engine.
13. Remove the two bolts from the front cover.
14. Remove the oil pump. Refer to «Oil Pump Replacement»(ref-200396-S16042916892005102000000) .
15. Clean and Inspect the front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-200396-S41615177542005102000000) .

1. Install the J 44219 , onto the engine. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 to the trace grooves on back side of the engine front cover (1).
3. Also apply sealant on the inside three bolt hole bosses on the cover.
4. Align the oil pump to the crankshaft sprocket splines.
5. Install the front cover.
6. Install the front cover bolts, tightening the center bolt last (1). Tighten: Tighten the front cover bolts to 10 N.m (89 lb in).
7. Remove the J 44219 . See «Special Tools»(ref-200396-S26818425802005102000000) .
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
9. Install the oil pan. Refer to «Oil Pan Replacement»(ref-200396-S42617181412005102000000) .
10. Lower the vehicle.
11. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-200416-S40545325892005102000000) or «Power Steering Pump Replacement (5.3L)»(ref-200416-S12863791602005102000000) in Power Steering System.
12. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200396-S11089713542005102000000) .
13. Install the water pump. Refer to «Water Pump Replacement (LL8)»(ref-200409-S27792287162005102000000) or «Water Pump Replacement (LM4)»(ref-200409-S42166122922005102000000) in Engine Cooling.
14. Install the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
15. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
16. Fill the engine with coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.

Camshaft Position Actuator Replacement - Exhaust

Tools Required

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

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with the cylinder head to cam cover mating surface.
3. Remove the top chain guide bolts.
4. Remove the top chain guide.
5. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link across from it.
6. Install the J-44217 (1). Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. Tighten the wing nuts. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on the edge of the head.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.

1. Install the exhaust camshaft actuator into the timing chain.
2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator sprocket (1).
3. Install the exhaust camshaft actuator onto the exhaust camshaft.
4. Install the exhaust camshaft actuator bolt. Tighten: Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
5. Remove the J-44217 .
6. Install the top chain guide.
7. Add threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the top chain guide bolt threads.
8. Install the top chain guide bolts. Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .
3. Release the tension on the timing chain by moving the tensioner shoe in.
4. Place the tee into the tensioner to hold the shoe in place.
5. Remove the top chain guide bolts.
6. Remove the top chain guide.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.
9. Remove the intake camshaft sprocket bolt.
10. Remove the intake camshaft sprocket.
11. Remove the timing chain.
12. Remove the crankshaft sprocket.
13. Remove the cylinder head access hole plugs.
14. Remove the timing chain tensioner shoe bolt.
15. Remove the timing chain tensioner shoe.
16. Remove the timing chain tensioner guide bolts.
17. Remove the timing chain tensioner guide.
18. Remove the timing chain tensioner bolts.
19. Remove the timing chain tensioner.

1. Install the timing chain tensioner and secure the tensioner with the bolts. Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
2. Install the timing chain tensioner guide and secure the guide with the bolts. Tighten: Tighten the timing chain tensioner guide to 10 N.m (89 lb in).
3. Install the timing chain tensioner shoe and secure the shoe with the bolt. Tighten: Tighten the timing chain tensioner shoe bolt to 26 N.m (19 lb ft).
4. Install the cylinder head access hole plugs. Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).
5. Install the J 44221 with the camshaft flats up and the number 1 piston at top dead center. See «Special Tools»(ref-200396-S26818425802005102000000) . The crank pin will be at 12 o'clock when the number 1 piston is at top dead center.
6. Install the crankshaft sprocket (1).
7. Install the intake camshaft sprocket into the timing chain.
8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1).
9. Feed the timing chain down through the opening in the head.
10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing mark on to the crankshaft sprocket. IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. See «Special Tools»(ref-200396-S26818425802005102000000) .
11. Install the intake camshaft sprocket onto the intake camshaft.
12. Install the intake camshaft sprocket washer and bolt.
13. Install the exhaust camshaft actuator into the timing chain.
14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1). IMPORTANT: It may be necessary to remove the J 44221 to rotate and hold the camshaft hex to align the pin to the camshaft sprocket. See «Special Tools»(ref-200396-S26818425802005102000000) .
15. Install the exhaust camshaft actuator onto the exhaust camshaft.
16. Install the exhaust camshaft actuator bolt. Tighten: Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
17. Install the intake camshaft sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 ft lb). Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
18. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
19. Remove the J 44221 . See «Special Tools»(ref-200396-S26818425802005102000000) .
20. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown.
21. Install the top chain guide.
22. Add threadlock GM P/N 12345496 on the top chain guide bolt threads.
23. Install the top chain guide bolts. Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
24. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .
25. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .

Camshaft Replacement

Tools Required

1. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. J 44222 Camshaft Sprocket Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .
3. J 36660-A Torque/Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .
2. Remove the intake and the exhaust camshaft sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Carefully move the sprockets with the timing chain, off of the camshafts.
5. Remove the camshaft cap bolts.
6. Remove the camshaft caps and store.
7. Remove the camshafts.

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the intake and exhaust camshafts to their original positions.
3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See «Special Tools»(ref-200396-S26818425802005102000000) .
4. Install the camshaft caps and bolts. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in).
5. Remove the J 44221 . See «Special Tools»(ref-200396-S26818425802005102000000) .
6. Carefully move the sprockets back onto the camshafts and remove the J 44222 . See «Special Tools»(ref-200396-S26818425802005102000000) .
7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
8. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-200396-S39032151612005102000000) .

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-200396-S31000453052005102000000) .
2. Remove the oil filter adapter.
3. Remove the oil filter bypass valve.

1. Install the oil filter bypass valve.
2. Install the oil filter adapter. Tighten: Tighten the oil filter adapter to 30 N.m (22 lb ft).
3. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-200396-S31000453052005102000000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
2. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3).
3. Remove the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-200396-S32918816652005102000000) .
4. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(ref-200421-S28774041082005102000000) in Front Suspension.
5. Remove the front differential and secure to the frame. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-200434-S12077432502005102000000) or «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
6. Remove the front drive axle intermediate shaft bearing assembly. Refer to «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (S4WD)»(ref-200434-S21253512162005102000000) or «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (A4WD)»(ref-200434-S30728033492005102000000) in Front Drive Axle.
7. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-200396-S31000453052005102000000) .
8. Unclip the transmission cooler lines from the engine block.
9. Remove 4 transmission bell housing bolts that are attached to the oil pan.
10. Remove the remaining oil pan bolts.
11. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine (1).
12. Clean and inspect the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-200396-S40129276192005102000000) .

1. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 to the block, rather than the oil pan.
2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly.
3. Install the oil pan bolts.
4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission mounting surface. Tighten: Tighten the oil pan side bolts to 25 N.m (18 lb ft). Tighten the oil pan end bolts to 10 N.m (89 lb in).
5. Install the 4 transmission bell housing bolts that attach to the oil pan. Tighten: Tighten bolts to 47 N.m (35 lb ft).
6. Clip transmission cooler lines to the engine block.
7. Install the front drive axle intermediate shaft bearing assembly. Refer to «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (S4WD)»(ref-200434-S21253512162005102000000) or «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (A4WD)»(ref-200434-S30728033492005102000000) in Front Drive Axle.
8. Install the oil drain plug and filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-200396-S31000453052005102000000) .
9. Install the front differential to the engine. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-200434-S12077432502005102000000) or «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
10. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(ref-200421-S28774041082005102000000) in Front Suspension.
11. Install the A/C compressor 2 bottom bolts (4). Tighten: Tighten all 4 bolts (2, 3, 4) to 50 N.m (37 lb ft).
12. Install the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-200396-S32918816652005102000000) .
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
14. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-200396-S31000453052005102000000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the engine shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
3. Remove the electrical connector from the oil pressure switch.
4. Remove the oil pressure switch.

1. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 20 N.m (15 lb ft).
2. Install the electrical connector to the oil pressure switch.
3. Install the engine shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
4. Lower the vehicle.

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .
2. Remove the oil pump cover bolts.
3. Remove the oil pump cover.
4. Mark the inner and the outer gears in relation to the oil pump housing.
5. Remove the inner and the outer oil pump gears.
6. Remove the oil pump pressure relief valve plug.
7. Remove the oil pump pressure relief valve and the spring.

1. Install the oil pump pressure relief valve and the spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the oil pump pressure relief valve to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
6. Install the front cover. Refer to «Engine Front Cover Replacement»(ref-200396-S26478126712005102000000) .

Crankshaft Rear Oil Seal and Housing Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44219 Cover Alignment Pins. See «Special Tools»(ref-200396-S26818425802005102000000) .
3. J 44227 Rear Seal Installer. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.
2. Remove the flywheel bolts and remove the flywheel.
3. Remove the crankshaft rear oil seal housing bolts.
4. Install 2 bolts into the jackscrew holes (1) to release the cover from the block.
5. Remove the crankshaft and rear oil seal housing.
6. Remove the oil seal from the crankshaft snout.

1. Use the J 44227 to install the crankshaft rear oil seal. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. Remove the J 44227 . See «Special Tools»(ref-200396-S26818425802005102000000) .
3. Apply a 3 mm (0.12 in) bead of GM P/N 12378521 to the rear oil seal housing (1).
4. Install the J 44219 guide pins (1) into the block. See «Special Tools»(ref-200396-S26818425802005102000000) .
5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft. See «Special Tools»(ref-200396-S26818425802005102000000) .
6. Install the crankshaft rear oil seal housing bolts, except the 2 in place of the guide pins.
7. Remove the J 44219 guide pins. See «Special Tools»(ref-200396-S26818425802005102000000) .
8. Install the remaining 2 crankshaft rear oil seal housing bolts. Tighten: Tighten all the oil seal housing bolts to 10 N.m (89 lb in).
9. Wipe off any excess material from the bottom of the oil pan sealing area (1).
10. Install the flywheel and secure with the bolts. Tighten: Tighten the flywheel bolts in sequence to 25 N.m (18 lb ft).
11. Use the J 36660-A to tighten the bolts an additional 50 degrees.
12. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.

1. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.
2. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-200396-S21287136542005102000000) .
3. Pry the crankshaft rear oil seal out of the rear oil seal housing using a suitable tool.

1. Use J 44227 to install the crankshaft rear oil seal. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. Remove the J 44227 . See «Special Tools»(ref-200396-S26818425802005102000000) .
3. Remove the seal installation sleeve after the seal is installed. Discard the sleeve.
4. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-200396-S21287136542005102000000) .
5. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.

1. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.
2. Remove the flywheel bolts.
3. Remove the flywheel.
4. Clean and Inspect the flywheel. Refer to «Engine Flywheel Cleaning and Inspection»(ref-200396-S42764440622005102000000) .

1. Add threadlock GM P/N 12345493 (Canadian P/N 10953488) to the new flywheel bolts.
2. Install the flywheel and secure the flywheel with the new bolts. Tighten: Tighten the bolts in sequence to 25 N.m (18 lb ft). Use the J 36660-A in order to tighten the bolts an additional 50 degrees.
3. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60-E/4L65-E.

1. Remove the hood. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) in Body Front End.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
3. Drain engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
4. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) in Heating, Ventilation and Air Conditioning.
5. Remove the oil pan drain plug and drain the oil.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
7. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L.
8. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-200372-S22616208372005102000000) in Engine Controls - 4.2L.
9. Remove the manifold absolute pressure (MAP) sensor. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-200372-S27588536682005102000000) in Engine Controls - 4.2L.
10. Remove the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
11. Remove the grill. Refer to «Grille Replacement (Envoy, Envoy XUV)»(ref-200387-S13203650082005102000000) or «Grille Replacement (TrailBlazer)»(ref-200387-S07007051252005102000000) or «Grille Replacement (Rainier)»(ref-200387-S33108349192005102000000) in Exterior Trim.
12. Remove the headlamp housing. Refer to «Headlamp Housing Panel Replacement (TrailBlazer)»(ref-200376-S31921646032005102000000) or «Headlamp Housing Panel Replacement (Envoy, Envoy XUV, Rainier)»(ref-200376-S16663333762005102000000) in Body Front End.
13. Remove the radiator support brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) in Body Front End.
14. Remove the hood latch. Refer to «Hood Latch Support Replacement»(ref-200376-S02255384832005102000000) in Body Front End.
15. Disconnect A/C lines at the condenser.
16. Disconnect the transmission cooler lines at the engine, not the radiator.
17. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
18. Remove the radiator with condenser and transmission cooler lines. Refer to «Radiator Replacement (LL8)»(ref-200409-S04826414272005102000000) or «Radiator Replacement (LM4)»(ref-200409-S24517500112005102000000) in Engine Cooling.
19. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
20. Remove the power steering pump bolts and lay the pump aside.
21. Ensure the heater hoses (1, 2) at the heater core are disconnected.
22. Remove the secondary air injection (AIR) reaction solenoid valve. Refer to «Secondary Air Injection (AIR) Solenoid Valve Replacement»(ref-200372-S21488752182005102000000) in Engine Controls - 4.2L.
23. Install the lift hook J 44220 to the AIR port on the engine head. See «Special Tools»(ref-200396-S26818425802005102000000) .
24. Disconnect the oxygen sensor electrical connector.
25. Disconnect the A/C line at the accumulator.
26. Disconnect the front axle actuator electrical connector.
27. Disconnect the camshaft phaser actuator valve electrical connector.
28. Unclip the transmission cooler lines from right side of the engine block.
29. Disconnect the ignition coil harness connectors.
30. Carefully disconnect harness retainer at clips (1) and remove.
31. Remove power brake hose at booster.
32. Remove the powertrain control module (PCM). Refer to «Powertrain Control Module (PCM) Replacement»(ref-200372-S14326151672005102000000) in Engine Controls - 4.2L.
33. Remove all harnesses from the engine harness bracket.
34. Disconnect the front differential vent hose from the engine harness bracket.
35. Remove the engine harness bracket bolt and remove bracket.
36. Disconnect starter electrical connections (1).
37. Disconnect the A/C pressure sensor and clutch electrical connector.
38. Disconnect generator electrical connector and battery lead (1).
39. Disconnect the knock sensor electrical connector.
40. Disconnect the crankshaft sensor electrical connector.
41. Disconnect the camshaft sensor electrical connector.
42. Remove 4 grounds on the left side of the block (1).
43. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
44. Remove the wheel drive shafts, left and right. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
45. Remove the propeller shaft from the front axle pinion yoke. Refer to «Propeller Shaft Replacement - Front»(ref-200422-S39219319742005102000000) in Propeller Shaft.
46. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Body Front End.
47. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
48. Remove the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
49. Disconnect the AIR pipes from the AIR pump.
50. Remove the torque converter bolt access cover.
51. Remove the torque converter bolts.
52. Place a jack on the transmission oil pan for support.
53. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody.
54. Lower the transmission enough to reach the top bell housing bolts.
55. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
56. Raise the transmission.
57. Reinstall the transmission support using only 2 through bolts.
58. Remove the remaining bell housing bolts, for a total of 11 bolts.
59. Remove the left and right engine lower mount nuts.
60. Disconnect the oil pressure switch electrical connector.
61. Lower the vehicle.
62. Remove the left upper engine mount nut (1).
63. Remove the right upper engine mount nut (1).
64. Install the engine hoist.
65. Raise the engine out of the compartment slowly keeping the transmission supported.
66. Remove both engine mounts for clearance.
67. Remove the fasteners securing the AIR pipes to the back of the engine head.
68. Remove the AIR pipes from the vehicle.
69. Continue raising the engine out of the vehicle.
70. Install the engine to the engine stand.

1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. Install the AIR pipes to the engine.
4. Install the fasteners securing the AIR pipes to the back of the engine head.
5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.
6. Lower the engine onto the mounts and install the upper engine mount nuts (1). Tighten: Tighten the nuts to 70 N.m (51 lb ft).
7. Remove the engine hoist.
8. Lay the radiator into the radiator support, but do not install the radiator completely.
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
10. Install all of the lower bell housing bolts, excluding the top 4.
11. Remove the 2 through bolts securing the transmission support.
12. Lower the transmission.
13. Install the top 4 bell housing bolts. Tighten: Tighten all 11 bell housing bolts to 50 N.m (37 lb ft).
14. Raise the transmission.
15. Install the transmission support. Refer to «Transmission Support Replacement»(ref-200388-S26539159952005102000000) in Frame and Underbody.
16. Install the 3 torque converter bolts. Tighten: Tighten the torque converter bolts to 60 N.m (44 lb ft).
17. Install the torque converter bolt cover.
18. Install the fuel tank shield, if removed. Refer to «Fuel Tank Shield Replacement (TrailBlazer, Envoy)»(ref-200388-S37284800062005102000000) or «Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL)»(ref-200388-S31467977892005102000000) in Frame and Underbody.
19. Connect the AIR pipes to the AIR pump.
20. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) .
21. Install the propeller shaft to the front axle pinion yoke. Refer to «Propeller Shaft Replacement - Front»(ref-200422-S39219319742005102000000) in Propeller Shaft.
22. Connect the exhaust pipe to the manifold and secure the pipe with the bolts. Tighten: Tighten the exhaust pipe bolts to 50 N.m (37 lb ft).
23. Connect the oil pressure sensor electrical connector.
24. Install the oil pan drain plug. Tighten: Tighten the plug to 26 N.m (19 lb ft).
25. Install the lower radiator hose (1).
26. Install the left and right wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
27. Lower the vehicle.
28. Install the 4 grounds on the left side of the block (1).
29. Install the camshaft sensor electrical connectors.
30. Install the crankshaft sensor electrical connector.
31. Install the knock sensor electrical connector.
32. Install the generator electrical connector and battery lead (1). Tighten: Tighten the generator battery lead nut to 9 N.m (80 lb in).
33. Install the A/C pressure sensor and clutch electrical connector.
34. Install starter electrical connectors and battery lead (1). Tighten: Tighten the starter battery lead to 9 N.m (80 lb in).
35. Install the engine harness bracket and bolt. Tighten: Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
36. Install the front differential vent hose, to the engine harness bracket.
37. Install all the harnesses to the engine harness bracket.
38. Install the PCM. Refer to «Powertrain Control Module (PCM) Replacement»(ref-200372-S14326151672005102000000) in Engine Controls - 4.2L.
39. Install the power brake hose at booster
40. Install the harness retainer (1) to the original location.
41. Install the ignition coil harness electrical connectors.
42. Clip the transmission cooler lines to the right side of the engine block.
43. Connect the camshaft phaser actuator valve electrical connector.
44. Connect the front axle actuator electrical connector.
45. Connect the A/C line at the accumulator.
46. Install the oxygen sensor electrical connector.
47. Remove the lift hook J 44220 . See «Special Tools»(ref-200396-S26818425802005102000000) .
48. Install the secondary AIR solenoid valve. Refer to «Secondary Air Injection (AIR) Solenoid Valve Replacement»(ref-200372-S21488752182005102000000) in Engine Controls - 4.2L.
49. Install the heater hoses to the heater core. Refer to «Heater Hose Replacement - Inlet (Front System Only)»(ref-200405-S17795612732005102000000) or «Heater Hose Replacement - Inlet (Auxiliary System)»(ref-200405-S37996325272005102000000) and «Heater Hose Replacement - Outlet (Front Only System)»(ref-200405-S23020269892005102000000) or «Heater Hose Replacement - Outlet (Auxiliary System)»(ref-200405-S13569052292005102000000) in Heating, Ventilation, and Air Conditioning.
50. Install the power steering pump.
51. Install the power steering pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
52. Install the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) .
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator. Refer to «Radiator Replacement (LL8)»(ref-200409-S04826414272005102000000) or «Radiator Replacement (LM4)»(ref-200409-S24517500112005102000000) in Engine Cooling.
55. Install transmission cooler lines together.
56. Install the MAP sensor. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-200372-S27588536682005102000000) in Engine Controls - 4.2L.
57. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-200372-S22616208372005102000000) in Engine Controls - 4.2L.
58. Install the hood latch. Refer to «Hood Latch Support Replacement»(ref-200376-S02255384832005102000000) in Body Front End.
59. Install the head lamp housing. Refer to «Headlamp Housing Panel Replacement (TrailBlazer)»(ref-200376-S31921646032005102000000) or «Headlamp Housing Panel Replacement (Envoy, Envoy XUV, Rainier)»(ref-200376-S16663333762005102000000) in Body Front End.
60. Install the grill. Refer to «Grille Replacement (Envoy, Envoy XUV)»(ref-200387-S13203650082005102000000) or «Grille Replacement (TrailBlazer)»(ref-200387-S07007051252005102000000) or «Grille Replacement (Rainier)»(ref-200387-S33108349192005102000000) in Exterior Trim.
61. Install the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
62. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L.
63. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
64. Install the hood. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) in Body Front End.
65. Service the engine oil.
66. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
67. Recharge the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) in Heating, Ventilation and Air Conditioning.
68. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-200372-S14520124782005102000000) in Engine Controls - 4.2L. IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle. Disable the ignition system. Crank the engine several times. Listen for unusual noises or evidence that parts are binding. Enable the ignition system. Start the engine and listen for unusual noises. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature. Listen for a sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Perform a final inspection for the proper engine oil and coolant levels.
69. Install the hood. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) in Body Front End.

1. Remove the oil fill cap.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Remove the oil pan drain plug and drain the oil into a suitable container.
4. Remove the oil filter using a suitable wrench.
5. Inspect the old oil filter to ensure the filter seal is not left on the engine block.

1. Wipe the excess oil from the oil filter housing.
2. Lubricate the oil filter seal with clean engine oil.
3. Install the new oil filter. Tighten: Tighten the oil filter to 17 N.m (22 lb ft) plus 150 degrees.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 26 N.m (19 lb ft).
5. Lower the vehicle.
6. Fill the crankcase with the proper quantity of engine oil. Refer to «Capacities - Approximate Fluid»(ref-200403-S02268484942005102000000) and «Fluid and Lubricant Recommendations»(ref-200403-S31066184632005102000000) in Maintenance and Lubrication.
7. Remove the oil level indicator.
8. Wipe the indicator with a clean cloth.
9. Install the oil level indicator.
10. Remove the oil level indicator and check the oil level.
11. Add oil if necessary.
12. Check for any oil leaks.

Engine Flywheel Removal

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

Draining Fluids and Oil Filter Removal

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

Drive Belt Tensioner Removal

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

Power Steering Pump Bracket Removal

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

Drive Belt Idler Pulley Removal

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

Oil Level Indicator and Tube Removal

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

Exhaust Manifold Removal

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

Oil Filter Adapter Removal

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

Scheme 2

Remove the heater inlet hose fitting.

Scheme 3

Remove the heater outlet hose fitting.

Water Outlet Removal

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

Thermostat Housing Removal

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

Intake Manifold Removal

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

Fuel Rail and Injectors Removal

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

Camshaft Position Actuator Valve Removal

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

Camshaft Cover Removal

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

Oil Pan Removal

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

Oil Pump Pipe and Screen Assembly Removal

1. Remove the oil pump pipe bolts.
2. Remove the oil pump pipe.
3. Discard the gasket.

Engine Front Cover Removal

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

Oil Pump Removal

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

Scheme 4

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

Timing Chain and Sprockets Removal

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

Crankshaft Rear Oil Seal and Housing Removal

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

Scheme 5

Remove the crankshaft rear oil seal.

Timing Chain Tensioner Removal

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

Engine Lift Bracket Removal

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

Camshaft Removal

1. Remove the camshaft cap bolts.
2. Remove the camshaft caps.
3. Remove the camshafts.

Valve Rocker Arm and Valve Lash Adjuster Removal

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

Cylinder Head Removal

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

Crankshaft and Bearings Removal

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

Engine Block Plug Removal

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

Engine Block Plug Installation

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

Crankshaft and Bearings Installation

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 45059 Angle Meter. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. J 8037 Piston Ring Compressor
3. J 41556 Connecting Rod Guide. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at Bottom Dead Center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Install J 8037 onto the piston and ring assembly to compress the rings.
6. Install the connecting rod bearings into the connecting rods and caps (1).
7. Lubricate the connecting rod bearing contact surfaces with engine oil (2).
8. Install the J 41556 into the connecting rod. See «Special Tools»(ref-200396-S26818425802005102000000) .
9. Install the connecting rod and piston into the proper cylinder bore.
10. Hold the J 8037 firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
11. Guide the connecting rod end onto the crankshaft journal. Use J 41556 to pull the connecting rod into place. See «Special Tools»(ref-200396-S26818425802005102000000) .
12. Install the connecting rod bearing, cap, and bolts. Tighten: Tighten the connecting rod bearing cap bolts on the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the connecting rod bearing cap bolts on the second pass an additional 110 degrees. See «Special Tools»(ref-200396-S26818425802005102000000) .
13. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankshaft.
14. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be between 0.05-0.35 mm (0.0019-0.0137 in).

Cylinder Head Installation

Valve Rocker Arm and Valve Lash Adjuster Installation

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

Engine Lift Bracket Installation

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

Timing Chain Tensioner Installation

1. Install the timing chain tensioner.
2. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
3. Install the timing chain tensioner guide.
4. Install the timing chain tensioner guide bolts. Tighten: Tighten the timing chain tensioner guide bolts to 12 N.m (107 lb in).
5. Install the timing chain tensioner shoe.
6. Install the timing chain tensioner shoe bolt. Tighten: Tighten the timing chain tension shoe bolt to 25 N.m (18 lb ft).
7. 7. Install the cylinder head access hole plugs. Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).

Timing Chain and Sprockets Installation

Tools Required

1. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See «Special Tools»(ref-200396-S26818425802005102000000) . The crankshaft pin should be at 12 o'clock when the number 1 piston is at top dead center.
2. Compress the tensioner and lock in place.
3. Install the crankshaft sprocket.
4. Install the intake camshaft sprocket into the timing chain.
5. Align the (dark) link of the timing chain with the timing mark on the intake camshaft sprocket (1).
6. Feed the timing chain down through the opening in the head.
7. Install the timing chain onto the crankshaft sprocket. Align the (dark) link of the timing chain with the timing mark on the crankshaft sprocket (2).
8. Install the intake camshaft sprocket onto the intake camshaft.
9. Install the intake camshaft sprocket washer and new bolt. Tighten: Tighten the new intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use J 45059 to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees. See «Special Tools»(ref-200396-S26818425802005102000000) .
10. Install the exhaust camshaft actuator into the timing chain.
11. Align the (dark) link of the timing chain with the timing mark on the exhaust camshaft actuator (1).
12. Install the exhaust camshaft actuator onto the exhaust camshaft.
13. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the new exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. See «Special Tools»(ref-200396-S26818425802005102000000) .
14. Unlock the tensioner.
15. Remove J 44221 . See «Special Tools»(ref-200396-S26818425802005102000000) .
16. Rotate the camshaft actuator clockwise (as seen from the front of the vehicle).
17. The dark links (1) on the chain should be aligned with marks on sprockets as shown.
18. Install the top chain guide.
19. Add threadlock GM P/N United States 12345498, GM P/N Canada 10953488 to the top chain guide bolt threads.
20. Install the top chain guide bolts. Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).

Camshaft Cover Installation

1. Install a new camshaft cover seal.
2. Install the camshaft cover and bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install new ignition control module seals.
4. Install the ignition control modules and bolts. Tighten: Tighten the ignition control module bolts to 10 N.m (89 lb in).

Camshaft Position Actuator Valve Installation

1. Apply clean engine oil to the camshaft position actuator valve hole.
2. Install the camshaft position actuator valve.
3. Add sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the camshaft position actuator valve bolt threads.
4. Install the camshaft position actuator valve bolt. Tighten: Tighten the camshaft position actuator valve bolt to 10 N.m (89 lb in).

Oil Pump Installation

1. Install the oil pump pressure relief valve and spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the oil pump pressure relief valve plug to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).

Oil Pump Pipe and Screen Assembly Installation

1. Install a new oil pump pipe gasket.
2. Install the oil pump pipe and screen assembly.
3. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil pump pipe bolt threads.
4. Install the oil pump pipe and screen assembly bolts. Tighten: Tighten the oil pump pipe and screen assembly bolts to 10 N.m (89 lb in).

Oil Pan Installation

1. Apply a 3 mm (0.12 in) bead of sealer GM P/N United States 12378521, GM P/N Canada 88901148 to the block.
2. Install the oil pan.
3. Install the oil pan bolts.
4. Check the oil pan alignment. Use a straight edge on the back of the block and oil pan (transmission mounting surface).
5. Tighten the oil pan bolts. Tighten: Tighten the (side) oil pan bolts to 25 N.m (1 lb ft). Tighten the (end) oil pan bolts to 10 N.m (89 lb in).
6. Install the oil level sensor.
7. Install the oil level sensor bolt. Tighten: Tighten the oil level sensor bolt to 10 N.m (89 lb in).

Crankshaft Balancer Installation

Tools Required

1. J 45059 Angle Meter. See «Special Tools»(ref-200396-S26818425802005102000000) .
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-200396-S26818425802005102000000) .

1. Install the crankshaft balancer using J 41478 . See «Special Tools»(ref-200396-S26818425802005102000000) .
2. Remove J 41478 . See «Special Tools»(ref-200396-S26818425802005102000000) .
3. Hold the flywheel or back of the crankshaft. The crankshaft balancer does not have a keyway so the crankshaft could turn when tightening, causing an improper torque.
4. Install the crankshaft balancer washer and new bolt. Tighten: Tighten the new crankshaft balancer bolt while holding the back to 150 N.m (110 lb ft). Use J 45059 to tighten the crankshaft balancer bolt an additional 180 degrees. See «Special Tools»(ref-200396-S26818425802005102000000) .

Fuel Rail and Injectors Installation

1. Lubricate the lower injector O-rings with mineral oil GM P/N 9981704.
2. Install the fuel injector rail.
3. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Intake Manifold Installation

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

Thermostat Housing Installation

1. Install the thermostat housing.
2. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).

Heater Inlet Hose Fitting Installation

1. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the heater inlet hose fitting threads.
2. Install the heater inlet hose fitting. Tighten: Tighten the heater inlet hose fitting to 45 N.m (33 lb ft).

Heater Outlet Hose Fitting Installation

1. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the heater outlet hose fitting threads.
2. Install the heater outlet hose fitting. Tighten: Tighten the heater outlet hose fitting to 45 N.m (33 lb ft).

Water Outlet Installation

1. Install the water outlet.
2. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 10 N.m (89 lb in).

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter adapter. Tighten: Tighten the oil filter adapter to 50 N.m (37 lb ft).

Exhaust Manifold Installation

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

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.
2. Add sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the oil level indicator tube stud threads.
3. Install the oil level indicator tube stud. Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in).
4. Install the oil level indicator.

Power Steering Pump Bracket Installation

1. Install the power steering pump bracket.
2. Install the power steering pump bracket bolts. Tighten: Tighten the power steering pump bracket bolts to 50 N.m (37 lb ft).

Drive Belt Tensioner Installation

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

Drive Belt Idler Pulley Installation

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolts. Tighten: Tighten the drive belt idler pulley bolts to 50 N.m (37 lb ft).