Engine Mechanical - 5.3L: Removal & Installation GMC Envoy II

Removal Procedure

1. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
2. Install a breaker bar with hex-head socket to the drive belt tensioner bolt.
3. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt.
4. Remove the belt from the generator pulley.
5. Slowly release the tension on the drive belt tensioner.
6. Remove the breaker bar and socket and from the drive belt tensioner bolt.
7. Remove the belt from the remaining pulleys.
8. Clean and inspect the belt surfaces of all the pulleys.

Installation Procedure

1. Route the drive belt around all the pulleys except the generator pulley.
2. Install the breaker bar with hex-head socket to the belt tensioner bolt.
3. Rotate the belt tensioner clockwise in order to relieve the tension on the belt.
4. Install the drive belt on the generator pulley.
5. Slowly release the tension on the belt tensioner.
6. Remove the breaker bar and socket from the belt tensioner bolt.
7. Inspect the drive belt for proper installation and alignment.
8. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Install a ratchet into the square opening of the air conditioning (A/C) belt tensioner.
4. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
5. Remove the A/C belt from the pulleys.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the ratchet from the A/C belt tensioner.
8. Clean and inspect the belt surfaces of all the pulleys.

1. Install the A/C belt around the crankshaft balancer.
2. Install a ratchet into the square opening of the A/C drive belt tensioner.
3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
4. Install the A/C belt over the idler pulley.
5. Install the A/C belt around the A/C compressor pulley.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the ratchet from the A/C belt tensioner.
8. Inspect the A/C belt for proper installation and alignment.
9. Lower the vehicle.
10. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .

1. Remove the accessory drive belt. Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .
2. Remove the drive belt idler pulley and bolt.

1. Install the drive belt idler pulley and bolt to the generator bracket. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. Install the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .
2. Remove the drive belt tensioner bolts.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolts. NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
3. Tighten the drive belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .

1. Remove the air conditioning (A/C) drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-200397-S08784724632005102000000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Remove the A/C belt tensioner bolts.
4. Remove the A/C belt tensioner.

1. Install the A/C belt tensioner.
2. Install the A/C belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Lower the vehicle.
4. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-200397-S08784724632005102000000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
5. Remove the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
6. Remove the front differential carrier. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
9. Remove the 3 retaining bolts to the frame engine mount bracket.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Remove the engine mount frame bracket from the frame.
14. Remove the engine mount with the upper engine mount bracket as an assembly.
15. Separate the engine mount from the upper engine mount bracket.
16. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft).
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft).
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Install the left side engine mount frame bracket.
7. Install the left side engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
8. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
12. Install the front differential carrier. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
13. Install the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
14. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
15. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
16. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
5. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
6. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
7. Remove the 3 frame engine mount bracket retaining bolts.
8. Install a pole jack underneath the oil pan.
9. Insert a block of wood between the oil pan and the pole jack.
10. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
11. Remove the engine mount frame bracket from the frame.
12. Remove the engine mount with the upper engine mount bracket as an assembly.
13. Separate the engine mount from the upper engine mount bracket.
14. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft).
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft).
3. Install the engine mount to the engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the retaining bolts to the engine mount frame bracket.
6. Install the left side engine mount frame bracket.
7. Install the retaining bolts to the left side engine mount frame bracket. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
8. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
12. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
13. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
14. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
5. Remove the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
6. Remove the front differential carrier. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
9. Remove the 3 retaining bolts from the frame engine mount bracket.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Shift the engine towards the left side of the frame.
14. Remove the engine mount frame bracket from the frame.
15. Remove the engine mount with the upper engine mount bracket as an assembly.
16. Separate the engine mount from the upper engine mount bracket.
17. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft).
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft).
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Shift the engine back towards the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the left side engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
9. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
10. Remove the pole jack and block of wood.
11. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
13. Install the front differential carrier. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
14. Install the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000) in Wheel Drive Shafts.
15. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
16. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
17. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
5. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
6. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
7. Remove the 3 bracket retaining bolts from the frame engine mount.
8. Install a pole jack underneath the oil pan.
9. Insert a block of wood between the oil pan and the pole jack.
10. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
11. Shift the engine towards the left side of the frame.
12. Remove the engine mount frame bracket from the frame.
13. Remove the engine mount with the upper engine mount bracket as an assembly.
14. Separate the engine mount from the upper engine mount bracket.
15. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if it has been replaced. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft).
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Shift engine back to the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the retaining bolts to the left side of the engine mount frame bracket. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
9. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
10. Remove the pole jack and the block of wood.
11. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to «Shock Module Replacement»(ref-200421-S14386874552005102000000) in Front Suspension.
13. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-200388-S14237451942005102000000) in Frame and Underbody.
14. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-200391-S25606786272005102000000) in Tires and Wheels.
15. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.

1. Remove the positive crankcase ventilation (PCV) foul air hose from the intake manifold and valve rocker arm cover.
2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
3. Remove the PCV fresh air hose (2) from the valve rocker arm cover (1).

1. Install the PCV fresh air hose (2) to the valve rocker arm cover (1).
2. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
3. Install the PCV foul air hose to the intake manifold and valve rocker arm cover.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000) .
2. Disconnect the electrical connector from the oil pressure sensor.
3. Remove the oil pressure sensor (1) and washer (2).
4. Remove the oil filter (3).
5. Inspect the O-ring (4) for cuts or damage. If the filter is plugged or the O-ring is cut or damaged, replace the filter and O-ring as an assembly.

1. Install a NEW oil filter (3) and O-ring (4) assembly.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the sensor.
3. Install the oil pressure sensor (1) and washer (2). Tighten: Tighten the oil pressure sensor to 20 N.m (15 lb ft).
4. Connect the electrical connector to the oil pressure sensor.
5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-200373-S15552554882005102000000) in Engine Controls - 5.3L.
4. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
5. Remove the harness clip (1) from the cylinder head.
6. Disconnect the electrical connector (1) from the mass air flow (MAF) intake air temperature (IAT) sensor.
7. Remove the harness clips from the fuel rail.
8. Perform the following steps in order to disconnect the fuel injector electrical connectors. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up one click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
9. Disconnect the following electrical connectors: Evaporative emission (EVAP) purge solenoid (3) Throttle body harness (5) Manifold absolute pressure (MAP) sensor (2) Main coil (1) Generator (4)
10. Remove the electrical harness clips from the fuel rail.
11. Remove the positive crankcase ventilation (PCV) hose.
12. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
13. Remove the EVAP purge solenoid vent tubes (1, 2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
14. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200373-S11470256792005102000000) in Engine Controls - 5.3L.
15. Remove the vacuum brake booster hose from the rear of the intake manifold.
16. Remove the upper engine wire harness retainer nut (1).
17. Reposition the upper engine wire harness aside.
18. Remove the intake manifold bolts.
19. Remove the intake manifold.
20. Remove the intake manifold gaskets (1) from the intake manifold.
21. Discard the old intake manifold gaskets.
22. If necessary, clean and inspect the intake manifold. Refer to «Intake Manifold Cleaning and Inspection»(ref-200397-S06922820222005102000000) .

1. Install NEW intake manifold gaskets (1) to the intake manifold.
2. Install the intake manifold.
3. Apply a 5 mm (0.20 in) bead of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts.
4. Install the intake manifold bolts. Tighten: Tighten the bolts a first pass in sequence to 5 N.m (44 lb in). Tighten the bolts a final pass in sequence to 10 N.m (89 lb in).
5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
7. Install the vacuum brake booster hose to the rear of the intake manifold.
8. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200373-S11470256792005102000000) in Engine Controls - 5.3L.
9. Install the EVAP purge solenoid vent tubes (1, 2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-200373-S38404922092005102000000) .
10. Install the heater water shutoff valve actuator inlet hose to the intake manifold.
11. Install the PCV hose.
12. Connect the electrical harness clips to the fuel rail.
13. Connect the following electrical connectors: EVAP purge solenoid (3) Throttle body harness (5) MAP sensor (2) Main coil (1) Generator (4)
14. Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) on the connector in one click. Repeat the steps for each injector electrical connector.
15. Install the electrical harness clips to the fuel rail.
16. Connect the A/C compressor pressure switch electrical connector (2).
17. Install the harness clip (1) to the cylinder head.
18. Connect the MAF/IAT sensor electrical connector (1).
19. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
20. Install the fuel fill cap.
21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
22. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000) .
2. Disconnect the electrical connector from the oil pressure sensor.
3. Remove the valve lifter oil manifold bolts (2).
4. Remove the valve lifter oil manifold (1).
5. Identify the 8 gasket retaining strap locations (1-8).
6. Using a wire-cutter type tool, cut the 8 retaining straps of the outer gasket.
7. Remove the outer gasket (1) from the manifold.

1. Install the service gasket (1) onto the manifold.
2. Install the manifold (2) with gasket.
3. Install the manifold bolts (1). Tighten: Tighten the manifold bolts to 25 N.m (18 lb ft).
4. Connect the electrical connector to the oil pressure sensor.
5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000) .

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

1. Install a NEW rocker cover gasket (1) into the groove of the valve rocker arm cover.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
4. Install the rocker arm cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Install the PCV hose to the rocker arm cover.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
7. If necessary, install the ignition coils and bracket to the rocker arm cover.
8. If necessary, install the ignition coil bracket studs to the rocker arm cover. Tighten: Tighten the studs to 12 N.m (106 lb in).
9. Install the spark plug wires to the ignition coils.
10. Position the engine harness, if necessary.
11. Install the harness clips.
12. Connect the main electrical connector (5) to the ignition coil wire harness.
13. Install the CPA lock.

1. Remove the air conditioning (A/C) compressor hose. Refer to «Compressor Hose Assembly Replacement (LM4)»(ref-200405-S26816323412005102000000) in Heating, Ventilation, and Air Conditioning.
2. Remove the connector position assurance (CPA) lock.
3. Disconnect the main electrical connector (1) to the ignition coil wire harness.
4. Remove the harness clips.
5. Reposition the engine harness, if necessary.
6. Remove the spark plug wires from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
7. If necessary, remove the ignition coil bracket studs from the rocker arm cover.
8. If necessary, remove the ignition coils and bracket from the rocker cover.
9. Remove the vent hose (2) from the valve rocker arm cover (1).
10. Remove the valve rocker arm cover bolts.
11. Remove the valve rocker arm cover.
12. Remove the gasket (1) from the rocker cover.
13. Discard the OLD gasket.
14. Remove the oil fill cap from the oil fill tube.
15. Remove the oil fill tube from the rocker cover, if required.
16. Discard the oil fill tube.

1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position.
4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover.
5. Install the valve rocker arm cover onto the cylinder head.
6. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
7. Install the rocker arm cover bolts and grommets. Tighten: Tighten the bolts to 12 N.m (106 lb in).
8. Install the vent hose (2) to the valve rocker arm cover (1).
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bracket bolts.
10. If necessary, install the ignition coils and bracket to the rocker arm cover.
11. If necessary, install the ignition coil bracket studs to the rocker cover. Tighten: Tighten the studs to 12 N.m (106 lb in).
12. Install the spark plug wires to the ignition coils.
13. Position the engine harness, if necessary.
14. Install the harness clips.
15. Connect the main electrical connector (1) feeding the ignition coils.
16. Install the CPA lock.
17. Install the A/C compressor hose. Refer to «Compressor Hose Assembly Replacement (LM4)»(ref-200405-S26816323412005102000000) in Heating, Ventilation, and Air Conditioning.

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-200397-S29671043092005102000000) or to «Valve Rocker Arm Cover Replacement - Right»(ref-200397-S13761208312005102000000) .
2. Remove the valve rocker arm bolts.
3. Remove the valve rocker arms.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrods.
6. Clean and inspect the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(ref-200397-S16513246462005102000000) .

1. Lubricate the valve rocker arms and pushrods with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.
3. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
4. Install the valve rocker arm pivot support.
5. Install the pushrods.
6. Install the rocker arms and bolts.
7. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank.
8. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
9. Rotate the crankshaft 360 degrees.
10. Tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
11. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-200397-S29671043092005102000000) or to «Valve Rocker Arm Cover Replacement - Right»(ref-200397-S13761208312005102000000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 38606 Valve Spring Compressor. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Remove the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .
2. Disconnect the spark plug wire at the spark plug. Twist each plug wire boot 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
3. Loosen the spark plug 1-2 turns.
4. Brush or air blast away any dirt or debris from around the spark plug.
5. Remove the spark plug.
6. Install J 22794 into the spark plug hole. See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Attach an air hose to J 22794 . See «Special Tools»(ref-200397-S12228589952005102000000) .
8. Apply compressed air to J 22794 in order to hold the valves in place. See «Special Tools»(ref-200397-S12228589952005102000000) .
9. Use J 38606 in order to compress the valve spring. See «Special Tools»(ref-200397-S12228589952005102000000) .
10. Remove the valve stem keys (2).
11. Carefully release the valve spring tension.
12. Remove J 38606 . See «Special Tools»(ref-200397-S12228589952005102000000) .
13. Remove the valve spring cap (3).
14. Remove the valve spring (4).
15. Remove the valve stem oil seal/shim assembly (1, 5).

1. Clean the cylinder head valve spring seat and/or shim area.
2. Lubricate the valve guide and valve stem oil seal with clean engine oil.
3. Install the valve stem oil seal/shim assembly (1, 5).
4. Install the valve spring (4).
5. Install the valve spring cap (3).
6. Compress the valve spring using the J 38606 . See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Install the valve keys. Use grease in order to hold the valve keys in place. Make sure the keys seat properly in the groove of the valve stem. Carefully release the valve spring pressure, making sure the valve keys stay in place. Remove J 38606 . See «Special Tools»(ref-200397-S12228589952005102000000) . Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary).
8. Remove J 22794 from the spark plug port. See «Special Tools»(ref-200397-S12228589952005102000000) .
9. Hand start the spark plug. Tighten: Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the spark plug wires at the ignition coil.
11. Install the spark plug wire to the spark plug.
12. Inspect the wires for proper installation: Push sideways on each boot in order to check for proper installation. Reinstall any loose boot.
13. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .

1. Remove the cylinder number 2 spark plug and wire. Refer to «Spark Plug Replacement»(ref-200373-S34186696572005102000000) in Engine Controls - 5.3L.
2. Remove the oil level indicator from the tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube from the engine block. IMPORTANT: The O-ring seal may be reused if not cut or damaged.
5. Inspect the O-ring seal for cuts or damage.
6. Remove the O-ring seal from the tube, if required.

1. Lubricate the O-ring seal with clean engine oil.
2. Install the O-ring seal onto the oil level indicator tube.
3. Install the oil level indicator tube behind the exhaust manifold.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
5. Install the oil level indicator tube into the block. Install the tube with the collar flush to the block.
6. Lower the vehicle. NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
7. Install the oil level indicator tube bolt Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the oil level indicator to the tube.
9. Install the cylinder number 2 spark plug and wire. Refer to «Spark Plug Replacement»(ref-200373-S34186696572005102000000) in Engine Controls - 5.3L.

1. Remove the generator bracket. Refer to «Generator Bracket Replacement (5.3L Engine)»(ref-200375-S25472433142005102000000) in Engine Electrical.
2. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-200409-S09795657842005102000000) in Engine Cooling.
3. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left»(ref-200436-S31964123882005102000000) in Engine Exhaust.
4. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .
5. If equipped, remove the auxiliary air conditioning (A/C) bracket bolt (5).
6. Remove the cylinder head. Refer to «Cylinder Head Removal - Left»(ref-200397-S41958616672005102000000) .
7. Clean and inspect the cylinder head. Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) «Cylinder Head Cleaning and Inspection»(ref-200397-S15088304552005102000000) .

1. Install the cylinder head. Refer to «Cylinder Head Installation - Left»(ref-200397-S32361715212005102000000) .
2. If equipped, install the auxiliary A/C bracket bolt (5). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
3. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .
4. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left»(ref-200436-S31964123882005102000000) in Engine Exhaust.
5. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-200409-S09795657842005102000000) in Engine Cooling.
6. Install the generator bracket. Refer to «Generator Bracket Replacement (5.3L Engine)»(ref-200375-S25472433142005102000000) in Engine Electrical.

1. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-200397-S36595344292005102000000) .
2. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-200409-S09795657842005102000000) in Engine Cooling.
3. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right»(ref-200436-S32292269962005102000000) in Engine Exhaust.
4. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .
5. If equipped, remove the auxiliary air conditioning (A/C) bracket nut (2).
6. Remove the cylinder head. Refer to «Cylinder Head Removal - Right»(ref-200397-S37813051442005102000000) .
7. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-200397-S15088304552005102000000) .

1. Install the cylinder head. Refer to «Cylinder Head Installation - Right»(ref-200397-S22014250602005102000000) .
2. If equipped, install the auxiliary air conditioning (A/C) bracket nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft).
3. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-200397-S07025285902005102000000) .
4. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right»(ref-200436-S32292269962005102000000) in Engine Exhaust.
5. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-200409-S09795657842005102000000) in Engine Cooling.
6. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-200397-S36595344292005102000000) .

1. Remove the cylinder head and gasket. Refer to «Cylinder Head Replacement - Left»(ref-200397-S18304611502005102000000) or to «Cylinder Head Replacement - Right»(ref-200397-S01592982322005102000000) .
2. Remove the valve lifter. Refer to «Valve Lifter Removal»(ref-200397-S06031331962005102000000) .
3. Clean and inspect the valve lifters. Refer to «Valve Lifters and Guides Cleaning and Inspection»(ref-200397-S09933636512005102000000) .

1. Install the valve lifter. Refer to «Valve Lifter Installation»(ref-200397-S00222754082005102000000) .
2. Install the cylinder head and gasket. Refer to «Cylinder Head Replacement - Left»(ref-200397-S18304611502005102000000) or to «Cylinder Head Replacement - Right»(ref-200397-S01592982322005102000000) .

Crankshaft Balancer Replacement

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41816-2 Crankshaft End Protector
3. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-200397-S12228589952005102000000) .
4. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-200397-S12228589952005102000000) .
5. J 45059 Angle Meter

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .
2. Remove the air conditioning (A/C) drive belt, if equipped. Refer to «Drive Belt Replacement - Air Conditioning»(ref-200397-S08784724632005102000000) .
3. Remove the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
4. Remove the starter motor. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
5. Install J 42386-A and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) . Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten J 42386-A bolts to 50 N.m (37 lb ft).
6. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
7. Use J 41816 and J 41816-2 in order to remove the crankshaft balancer.
8. Remove J 41816 and. See «Special Tools»(ref-200397-S12228589952005102000000) . J 41816-2 from the crankshaft balancer.
9. Clean and inspect the crankshaft balancer. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-200397-S31245797822005102000000) .

1. Install the crankshaft balancer onto the end of the crankshaft.
2. Use J 41665 in order to install the crankshaft balancer. See «Special Tools»(ref-200397-S12228589952005102000000) . Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tool.
3. Install the used crankshaft balancer bolt. Tighten: Tighten the USED bolt to 330 N.m (240 lb ft).
4. Remove the used crankshaft balancer bolt. IMPORTANT: Recess the nose of the crankshaft 2.4-4.48 mm (0.094-0.176 in) into the balancer bore.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install J 41665 and repeat the installation procedure. See «Special Tools»(ref-200397-S12228589952005102000000) .
6. Install a NEW crankshaft balancer bolt. Tighten: Tighten the bolt a first pass to 50 N.m (37 lb ft). Tighten the bolt a final pass to 140 degrees using J 45059 .
7. Remove J 42386-A and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) .
8. Install the starter motor. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
9. Install the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
10. Install the A/C drive belt, if equipped. Refer to «Drive Belt Replacement - Air Conditioning»(ref-200397-S08784724632005102000000) .
11. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-200397-S04105284972005102000000) .
12. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-200373-S12760983622005102000000) in Engine Controls - 5.3L.

1. Remove the radiator. Refer to «Radiator Replacement (LM4)»(ref-200409-S24517500112005102000000) in Engine Cooling.
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200397-S10242565332005102000000) .
3. Remove the crankshaft oil seal (1) from the front cover.

1. Lubricate the outer edge of the oil seal (1) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal onto the J 41478 guide.
4. Install J 41478 threaded rod with nut, washer, guide, and oil seal into the end of the crankshaft.
5. Use J 41478 in order to install the oil seal into the cover bore. Use a wrench and hold the hex on the installer bolt. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Remove J 41478 . Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.
6. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200397-S10242565332005102000000) .
7. Install the radiator. Refer to «Radiator Replacement (LM4)»(ref-200409-S24517500112005102000000) in Engine Cooling.

1. Remove the air conditioning (A/C) compressor and bracket. Refer to «Compressor Replacement (LM4)»(ref-200405-S36676275322005102000000) in Heating, Ventilation and Air Conditioning.
2. Remove the water pump. Refer to «Water Pump Replacement (LM4)»(ref-200409-S42166122922005102000000) in Engine Cooling.
3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-200397-S10242565332005102000000) .
4. Remove the oil pan-to-front cover bolts.
5. Remove the front cover bolts.
6. Remove the front cover and gasket.
7. Discard the front cover gasket.
8. Clean and inspect the engine front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-200397-S35309170232005102000000) .

1. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) long to the junction of the oil pan and the engine block.
2. Install the front cover gasket and cover.
3. Install the front cover bolts until snug. Do not over tighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.
5. Install J 41476 to the front cover. See «Special Tools»(ref-200397-S12228589952005102000000) .
6. Align the tapered legs of J 41476 with the machined alignment surfaces on the front cover. See «Special Tools»(ref-200397-S12228589952005102000000) . NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices.
7. Install the crankshaft balancer bolt until snug. Do NOT over tighten. Tighten: Tighten the oil pan to front cover bolts to 25 N.m (18 lb ft). Tighten the engine front cover bolts to 25 N.m (18 lb ft).
8. Remove J 41476 . See «Special Tools»(ref-200397-S12228589952005102000000) .
9. Install a NEW crankshaft front oil seal. Refer to «Crankshaft Front Oil Seal Replacement»(ref-200397-S00324955542005102000000) .
10. Install the water pump. Refer to «Water Pump Replacement (LM4)»(ref-200409-S42166122922005102000000) in Engine Cooling.
11. Install the A/C compressor and bracket. Refer to «Compressor Replacement (LM4)»(ref-200405-S36676275322005102000000) in Heating, Ventilation and Air Conditioning.

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-200397-S21935412972005102000000) .
2. Remove the crankshaft rear oil seal (1) from the rear cover.

1. Lubricate the outside diameter of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. See «Special Tools»(ref-200397-S12228589952005102000000) .
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore.
6. Thread J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Align the oil seal into the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore.
9. Remove J 41479 . See «Special Tools»(ref-200397-S12228589952005102000000) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-200397-S21935412972005102000000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-200397-S21935412972005102000000) .
2. Remove the oil pan-to-rear cover bolts (1).
3. Remove the rear cover bolts.
4. Remove the rear cover and gasket.
5. Discard the rear cover gasket.
6. Clean and inspect the rear cover. Refer to «Engine Rear Cover Cleaning and Inspection»(ref-200397-S09935563782005102000000) .

1. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) long to the oil pan to engine block junction.
2. Install the rear cover gasket and cover.
3. Install the rear cover bolts until snug. Do NOT over tighten.
4. Install the oil pan-to-rear cover bolts (1) until snug. Do not over tighten.
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface.
6. Install J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Tighten J 41476 mounting bolts until snug. See «Special Tools»(ref-200397-S12228589952005102000000) . Do not overtighten. Tighten: Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). Tighten the engine rear cover bolts to 25 N.m (18 lb ft).
8. Remove J 41476 . See «Special Tools»(ref-200397-S12228589952005102000000) .
9. Install a NEW crankshaft rear oil seal. Refer to «Crankshaft Rear Oil Seal Replacement»(ref-200397-S21676221582005102000000) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-200397-S21935412972005102000000) .

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-200397-S36892044722005102000000) .
2. Remove the oil filter adapter (1).

1. Install the oil filter adapter (1). Tighten: Tighten the adapter to 55 N.m (40 lb ft).
2. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-200397-S36892044722005102000000) .

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

1. Install the oil filter bypass valve (2).
2. Install the oil filter adapter (1). Tighten: Tighten the adapter to 55 N.m (40 lb ft).
3. Install the oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft).
4. Refill the engine oil. Refer to «Capacities - Approximate Fluid»(ref-200403-S02268484942005102000000) or to «Fluid and Lubricant Recommendations»(ref-200403-S31066184632005102000000) in Maintenance and Lubrication.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-200397-S36595344292005102000000) .
3. Remove the front differential and secure to the frame. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) In Front Drive Axle.
4. If equipped with two wheel drive (2WD), remove the steering gear. See «POWER STEERING GEAR REPLACEMENT»(ref-200416-S18617259072005102000000)
5. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-200397-S36892044722005102000000) .
6. Remove the transmission oil cooler lines (1) from the retainer (2).
7. Remove the transmission oil cooler line retaining bracket bolt and bracket.
8. Remove the starter. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
9. Remove the flywheel inspection cover from the left side of the transmission.
10. Remove the battery cable channel bolt from the front of the oil pan.
11. Remove the battery cable channel from the oil pan.
12. Loosen the 2 upper air conditioning (A/C) compressor bracket bolts (4).
13. Remove the 2 lower A/C compressor bracket bolts (3).
14. Remove the 2 lower bellhousing bolts.
15. Remove the oil pan bolts.
16. Remove the oil pan by tilting the rear of the oil pan down to clear the transmission, pull the oil pan rearward past the front wire harness, then lower the oil pan clear of the vehicle.
17. Drill out the oil pan gasket retaining rivets (2), if required.
18. Remove the gasket (1) from the pan.
19. Discard the gasket and rivets.
20. Clean and inspect the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-200397-S16069670502005102000000) .

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.
2. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.
3. Pre-assemble the oil pan gasket and bolts to the pan. Install the gasket onto the pan. Install the oil pan bolts to the pan and through the gasket.
4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly.
5. Hand thread the oil pan bolts into the engine block until snug. Do not tighten at this time.
6. Install the 2 lower bellhousing bolts. Tighten: Tighten the lower bellhousing bolts to 50 N.m (37 lb ft). Tighten the 2 rear oil pan to rear cover bolts to 12 N.m (106 lb in). Tighten the remaining oil pan bolts to 25 N.m (18 lb ft).
7. Install the 2 lower A/C compressor bracket bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. Tighten the 2 upper A/C compressor bracket bolts (4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Install the battery cable channel to the oil pan.
10. Install the battery cable channel bolt to the oil pan. Tighten: Tighten the bolt to 12 N.m (106 lb in).
11. Install the flywheel inspection cover to the left side of the transmission.
12. Install the starter. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000) in Engine Electrical.
13. Install the inner axle shaft. Refer to «Inner Axle Shaft Replacement - Front Drive Axle»(ref-200434-S36138419872005102000000) in Front Drive Axle.
14. If equipped with two-wheel drive (2WD), install the steering gear. See «POWER STEERING GEAR REPLACEMENT»(ref-200416-S18617259072005102000000) .
15. Install the transmission oil cooler line retaining bracket and bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
16. Install the transmission oil cooler lines (1) to the retainer (2).
17. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-200397-S36595344292005102000000) .
18. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-200397-S36892044722005102000000) .
19. Install the front differential. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000) in Front Drive Axle.
20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000) in Engine Electrical.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-200397-S14373710302005102000000) .
2. Remove the oil transfer tube bolts (435, 446) and gaskets (445, 448).
3. Remove the oil transfer tube (447).
4. Remove the displacement on demand oil pressure regulator valve (1) by pushing downward.

1. Install the displacement on demand oil pressure regulator valve (1) by pushing upward until fully seated.
2. Install the oil transfer tube (447).
3. Install the oil transfer tube bolts (435, 446) and gaskets (445, 448). Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the oil pan. Refer to «Oil Pan Replacement»(ref-200397-S14373710302005102000000) .

1. Disconnect the oil pressure sensor electrical connector (1).
2. Using J 41712 or equivalent, remove the oil pressure sensor. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the oil pressure sensor.
2. Using J 41712 or equivalent, install the oil pressure sensor. See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the oil pressure sensor electrical connector (1).

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-200397-S14373710302005102000000) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-200397-S30876459652005102000000) .
3. Remove the oil pump screen bolt and nuts.
4. Remove the oil pump screen with O-ring seal.
5. Remove the O-ring seal from the pump screen.
6. Discard the O-ring seal.
7. Remove the remaining crankshaft oil deflector nuts.
8. Remove the crankshaft oil deflector.
9. Remove the oil pump bolts.
10. Remove the oil pump.
11. Clean and inspect the oil pump. Refer to «Oil Pump Cleaning and Inspection»(ref-200397-S18552134552005102000000) .

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump.
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector and nuts until snug.
5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen.
7. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs.
8. Install the oil pump screen.
9. Install the oil pump screen bolt and nuts. Tighten: Tighten the bolt to 12 N.m (106 lb in). Tighten the nuts to 25 N.m (18 lb ft).
10. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-200397-S30876459652005102000000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-200397-S14373710302005102000000) .

Timing Chain and Sprockets Replacement

Tools Required

1. J 8433-1 Puller Bar. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(ref-200397-S12228589952005102000000) .
3. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-200397-S12228589952005102000000) .
4. J 41816-2 Crankshaft End Protector

1. Remove the oil pump. Refer to «Oil Pump, Pump Screen and Deflector Replacement»(ref-200397-S09605092232005102000000) .
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned.
3. Remove the camshaft sprocket bolts (1).
4. Remove the camshaft sprocket (2) and timing chain (3).
5. Use J 8433-1 , J 41816-2 and J 41558 in order to remove the crankshaft sprocket. See «Special Tools»(ref-200397-S12228589952005102000000) .
6. Remove the crankshaft sprocket.
7. Remove the crankshaft sprocket key, if required.
8. Clean and inspect the timing chain and sprockets. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-200397-S32880946992005102000000) .

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use J 41665 in order to install the crankshaft sprocket. See «Special Tools»(ref-200397-S12228589952005102000000) . Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Install the camshaft sprocket (2) and timing chain (3).
7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
8. Install the camshaft sprocket bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
9. Install the oil pump. Refer to «Oil Pump, Pump Screen and Deflector Replacement»(ref-200397-S09605092232005102000000) .

1. Remove the condenser. Refer to «Condenser Replacement»(ref-200405-S14605046182005102000000) in Heating, Ventilation and Air Conditioning.
2. Remove the valve lifters from both cylinder heads. Refer to «Valve Lifter Replacement»(ref-200397-S34439083192005102000000) .
3. Remove the camshaft sensor bolt and sensor.
4. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned.
5. Remove the camshaft sprocket bolts.
6. Remove the camshaft sprocket and reposition the timing chain.
7. Remove the camshaft retainer bolts and retainer.
8. Remove the camshaft. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the three bolts from the camshaft.
9. Clean and inspect the camshaft and bearings. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-200397-S42407517542005102000000) .

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the three bolts from the front of the camshaft.
5. Install the camshaft retainer and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
7. Install the camshaft sprocket and the timing chain.
8. Install the camshaft sprocket bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
9. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused.
10. Lubricate the O-ring seal with clean engine oil.
11. Install the camshaft sensor and bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
12. Install the valve lifters. Refer to «Valve Lifter Replacement»(ref-200397-S34439083192005102000000) .
13. Install the condenser. Refer to «Condenser Replacement»(ref-200405-S14605046182005102000000) in Heating, Ventilation and Air Conditioning.

1. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) in Automatic Transmission - 4L60-E.
2. Remove the engine flywheel bolts.
3. Remove the engine flywheel.
4. Clean and inspect the engine flywheel. Refer to «Engine Flywheel Cleaning and Inspection»(ref-200397-S05198279242005102000000) .

1. Install the engine flywheel to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts.
3. Install the engine flywheel bolts. Tighten: Tighten the bolts a first pass in sequence to 20 N.m (15 lb ft). Tighten the bolts a second pass in sequence to 50 N.m (37 lb ft). Tighten the bolts a final pass in sequence to 100 N.m (74 lb ft).
4. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) in Automatic Transmission - 4L60-E.

Engine Replacement

Tools Required

1. J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 21366 . See «Special Tools»(ref-200397-S12228589952005102000000) .
3. J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Remove the hood. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000)
2. Place fender covers over both fenders.
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000)
4. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000)
5. Remove the radiator. Refer to «Radiator Replacement (LM4)»(ref-200409-S24517500112005102000000)
6. Remove the radiator support brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000)
7. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD). Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000)
8. Remove the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000)
9. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000)
10. Disconnect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
11. Remove the air conditioning (A/C) compressor hose. Refer to «Compressor Hose Assembly Replacement (LM4)»(ref-200405-S26816323412005102000000)
12. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
13. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
14. Tie the pipe assembly out of the way.
15. Disconnect the engine coolant temperature (ECT) sensor (1).
16. Remove the ground terminal bolt (2).
17. Remove the retaining clips from the brackets.
18. Disconnect the A/C pressure switch electrical connector (2).
19. Remove the retaining clip (1) from the cylinder head.
20. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000)
21. Remove the ground terminal bolts (2, 4).
22. Remove the starter. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000)
23. Remove the battery cable channel bolt.
24. Remove the battery cable channel from the oil pan.
25. Disconnect the A/C compressor electrical connector.
26. Lower the vehicle.
27. Gather all branches of the engine wiring harness and reposition the harness off to the side.
28. Remove the generator cable from the generator. Perform the following: Slide the boot down revealing the terminal stud. Remove the generator cable nut from the terminal stud. Remove the generator cable.
29. Remove the generator bracket bolts.
30. Position the bracket with generator aside.
31. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
32. Remove the inlet hose from the water outlet.
33. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
34. Remove the outlet hose from the water outlet.
35. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.
36. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
37. Remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.
38. Remove the ignition coils as required for the proper fit of J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) . Refer to «Ignition Coil(s) Replacement»(ref-200373-S14630815782005102000000)
39. Install J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the M8 bolts to 25 N.m (18 lb ft). Tighten the M10 bolts to 50 N.m (37 lb ft).
40. Raise the vehicle.
41. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000)
42. Remove the 3 bracket bolts from both the right and the left sides of the frame engine mount.
43. Remove the torque converter bolts.
44. Remove the transmission oil level indicator tube nut.
45. Remove the transmission oil level indicator tube.
46. Remove the transmission bolt and stud on the right side.
47. Remove the lower transmission bolt/studs.
48. Lower the vehicle.
49. Remove the 3 upper transmission bolts/studs.
50. Install an engine hoist to J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) .
51. Install a floor jack under the transmission for support.
52. Separate the engine from the transmission.
53. Remove the engine.
54. Install the engine to an engine stand.
55. Install J 21366 . See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Remove J 21366 . See «Special Tools»(ref-200397-S12228589952005102000000) .
2. Install an engine hoist to J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) .
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.
7. Install the 3 upper transmission bolts/studs. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
10. Install the transmission bolt and stud on the right side. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
11. Install the transmission oil level indicator tube.
12. Install the transmission oil level indicator tube nut. Tighten: Tighten the nut to 10 N.m (89 lb ft).
13. Install the torque converter bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the 3 bracket bolts to both the right and the left sides of the frame engine mount. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
15. Install the catalytic converter. Refer to «Catalytic Converter Replacement (5.3L Engine)»(ref-200436-S10814057632005102000000)
16. Lower the vehicle.
17. Remove J 41798 . See «Special Tools»(ref-200397-S12228589952005102000000) .
18. Install the ignition coil(s) (as required). Tighten: Tighten the bolts to 8 N.m (71 lb in).
19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump.
20. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
21. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.
22. Install the outlet hose to the water outlet.
23. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
24. Install the inlet hose to the water outlet.
25. Using J 38185 . See «Special Tools»(ref-200397-S12228589952005102000000) .
26. Position the bracket with generator to the engine.
27. Install the generator bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
28. Install the generator cable to the generator, perform the following procedure: Install the generator cable. Install the generator cable nut to the terminal stud. Tighten: Tighten the nut to 9 N.m (80 lb in). Slide the boot down covering the terminal stud.
29. Gather all branches of the engine wiring harness and position the harness over the engine.
30. Raise the vehicle.
31. Connect the A/C compressor electrical connector.
32. Install the battery cable channel to the oil pan.
33. Install the battery cable channel bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
34. Install the starter. Refer to «Starter Motor Replacement (5.3L Engine)»(ref-200375-S38723987142005102000000)
35. Install the ground terminal bolts (2, 4). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
36. Lower the vehicle.
37. Install the retaining clip (1) to the cylinder head.
38. Connect the A/C pressure switch electrical connector (2).
39. Install the retaining clips to the brackets.
40. Install the ground terminal bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
41. Connect the ECT sensor (1).
42. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5). Tighten: Tighten the nut/bolt to 20 N.m (15 lb ft).
43. Connect the rear auxiliary A/C compressor pipe fitting (7). Tighten: Tighten the nut to 16 N.m (12 lb ft).
44. Install the A/C compressor hose. Refer to «Compressor Hose Assembly Replacement (LM4)»(ref-200405-S26816323412005102000000)
45. Connect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
46. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-200397-S07042222722005102000000)
47. Install the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-200418-S34497795532005102000000)
48. Install the front differential drive axle, if equipped with 4WD. Refer to «Differential Carrier Assembly Replacement (V8)»(ref-200434-S01330498392005102000000)
49. Install the radiator support brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000)
50. Install the radiator. Refer to «Radiator Replacement»(ref-200409-S24517500112005102000000)
51. Recharge the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000)
52. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-200375-S07741338702005102000000)
53. Remove the fender covers from both fenders.
54. Prelube the engine. Refer to «Engine Prelubing»(ref-200397-S00670897952005102000000)
55. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-200373-S12760983622005102000000)
56. Install the hood. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
57. Test the vehicle using the following procedure: Disable the ignition system. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. Enable the ignition system. Start the engine and listen for unusual noises. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. Listen for sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Close the hood.

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
4. Place a oil drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug.
6. Drain the engine oil.
7. Remove the oil filter from the oil pan.
8. Inspect the old oil filter to ensure that the filter seal is not left on the oil pan.

1. Wipe the excess oil from the oil filter mounting.
2. Lubricate the oil filter seal with clean engine oil.
3. Install the oil filter to the oil pan. Tighten: Tighten the filter to 30 N.m (22 lb ft).
4. Wipe the excess oil from the drain plug hole.
5. Install the oil drain plug to the oil pan. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
6. Lower the vehicle.
7. Fill the crankcase with the proper quantity and grade of engine oil. Refer to «Capacities - Approximate Fluid»(ref-200403-S02268484942005102000000) and to «Fluid and Lubricant Recommendations»(ref-200403-S31066184632005102000000) in Maintenance and Lubrication.
8. Remove the oil level indicator.
9. Wipe the indicator with a clean cloth.
10. Install the oil level indicator.
11. Remove the oil level indicator in order to check the level.
12. Add oil if necessary.
13. Close the hood.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug (430) and O-ring (429).
2. Remove the engine oil filter (437).
3. Remove the engine block coolant drain hole plug and washer.
4. Remove the engine block coolant heater (114) and washer (115).

Crankshaft Balancer Removal

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41816-2 Crankshaft End Protector
3. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Install the J 42386-A and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) . Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten the J 42386-A bolts to 50 N.m (37 lb ft).
2. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
3. Use the J 41816 (1) and the J 41816-2 (2) in order to remove the crankshaft balancer.
4. Remove the balancer (138).
5. Remove the J 42386-A and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) .

Engine Flywheel Removal

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

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator (418) from the tube.
2. Remove the oil level indicator tube bolt (419).
3. Remove the oil level indicator tube (420) from the engine block.
4. Remove the O-ring (421) from the tube as required.

Exhaust Manifold Removal - Left

1. Remove the spark plug wires from the spark plugs.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (603) and bolts (604) from the manifold (600) as required.
5. Remove the studs (605) as required.

Exhaust Manifold Removal - Right

1. Remove the spark plug wires from the spark plugs.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (603) and bolts (604) from the manifold (600) as required.
5. Remove the studs (605) as required.

Water Pump Removal

1. Remove the water pump bolts (301).
2. Remove the water pump (300) and gaskets (306).
3. Discard the water pump gaskets.

Throttle Body Removal

1. Remove the electrical wire harness connectors from the throttle body.
2. Remove the throttle body nuts (507) and bolts (538).
3. Remove the throttle body (508).
4. Remove the throttle body gasket (509).
5. Discard the gasket.

Fuel Rail and Injectors Removal

1. Remove the fuel rail stop bracket and bolt as required.
2. Remove the evaporative emission (EVAP) purge valve (730) and tubes (729, 735).
3. Remove the fuel rail bolts (511).
4. Remove the fuel rail (510) with injectors. Lift evenly on both sides of the fuel rail until all the injectors have left their bores.
5. Remove the fuel injector retaining clips (521) and fuel injectors (533) as required.
6. Remove the O-rings (532, 534) from the injectors as required.

Intake Manifold Removal

1. Remove the positive crankcase ventilation (PCV) hose - dirty air (716).
2. Remove the manifold absolute pressure (MAP) sensor (714) and retainer (736) as required.
3. Remove the O-ring (715) from the sensor as required.
4. Remove the intake manifold bolts (512).
5. Remove the intake manifold (500) with gaskets.
6. Remove the intake manifold gaskets (514).
7. Discard the intake manifold gaskets.

Coolant Air Bleed Pipe Removal

1. Remove the engine coolant air bleed pipe bolts (309).
2. Remove the pipe (307) with seals (308).
3. Remove the engine coolant air bleed cover bolts (312).
4. Remove the covers (313) with seals (308).
5. Remove the seals (308) from the pipe and covers.
6. Discard the seals.

Valve Lifter Oil Manifold Removal

1. Do not lift the manifold by the electrical lead frame.
2. Remove the valve lifter oil manifold (VLOM) bolts (506).
3. Remove the VLOM (451).
4. Identify the eight gasket retaining strap locations (1-8).
5. Using a wire-cutter type tool, snip the eight retaining straps.
6. Remove the outer gasket (556) from the manifold.

Valve Lifter Oil Filter Removal

1. Remove the oil pressure sensor (706).
2. Remove the oil filter (452).
3. Inspect the O-ring (454) for cuts or damage. If the filter is plugged or the O-ring is cut or damaged, replace the filter and O-ring as an assembly.

Valve Rocker Arm Cover Removal - Left

1. Remove the spark plug wires (724).
2. Remove the ignition coil bracket bolts (720).
3. Remove the ignition coil and bracket assembly (719).
4. Disconnect the ignition coil electrical connectors.
5. Remove the bolts (723), coils (722), and wire harness (721) from the bracket (719) as required.
6. Remove the valve rocker arm cover bolts and cover.
7. Remove the gasket (504) from the cover.

Valve Rocker Arm Cover Removal - Right

1. Remove the spark plug wires (724).
2. Remove the ignition coil bracket bolts (720).
3. Remove the ignition coil and bracket assembly (719).
4. Disconnect the ignition coil electrical connectors.
5. Remove the bolts (723), coils (722), and wire harness (721) from the bracket (719) as required.
6. Remove the valve rocker arm cover bolts and cover.
7. Remove the gasket (504) from the cover.
8. Remove the oil fill cap (424) from the oil fill tube (423).
9. Remove the oil fill tube as required.
10. Discard the oil fill tube.

Valve Rocker Arm and Push Rod Removal

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

Cylinder Head Removal - Left

1. Remove the cylinder head bolts (220, 221).
2. Remove the cylinder head (218).
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts (220, 221).
2. Remove the cylinder head (218).
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Oil Filter and Adapter Removal

1. Remove the oil filter (437).
2. Remove the oil filter fitting (438) and bypass valve (436) as required.

Oil Pan Removal

1. Remove the left closeout cover and bolt.
2. Remove the right closeout cover and bolt.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Drill (2) out the oil pan gasket retaining rivets (1), if required.
6. Remove the gasket (426) from the pan.
7. Discard the gasket and rivets.
8. Remove the oil filter tube, baffle, and other internal components, as required. Refer to «Oil Pan Cleaning and Inspection»(ref-200397-S16069670502005102000000) .

Engine Front Cover Removal

1. Remove the front cover bolts (501).
2. Remove the front cover (502) and gasket (503).
3. Discard the front cover gasket.
4. Remove the oil seal (140).
5. Remove the bolts (705, 738), camshaft position (CMP) sensor (703), and wire harness (737).
6. Remove the O-ring (704) from the sensor as required.

Engine Rear Cover Removal

1. Remove the rear cover bolts (517).
2. Remove the rear cover (518) and gasket (519).
3. Discard the rear cover gasket.
4. Remove the rear oil seal (141).

Oil Pump, Pump Screen and Deflector Removal

1. Remove the oil pump screen bolt (405) and nut (404).
2. Remove the oil pump screen (407) with O-ring seal.
3. Remove the O-ring seal (406) from the pump screen.
4. Discard the O-ring seal.
5. Remove the crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.
7. Remove the oil pump bolts (411).
8. Remove the oil pump (413).

Timing Chain and Sprockets Removal

Tools Required

1. J 8433-1 Puller Bar. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(ref-200397-S12228589952005102000000) .
3. J 41816-2 Crankshaft End Protector

1. Remove the camshaft sprocket bolts (206).
2. Remove the camshaft sprocket (205) and timing chain (208).
3. Remove the bolts (231) and chain dampener (232).
4. Use the J 41816-2 (1), the J 41558 (2), and the J 8433-1 (3) in order to remove the crankshaft sprocket. See «Special Tools»(ref-200397-S12228589952005102000000) .
5. Remove the crankshaft sprocket.
6. Remove the crankshaft sprocket key as required.

Camshaft Removal

1. Remove the camshaft retainer bolts (204) and retainer (203).
2. Remove the camshaft. Install the 3 M8-1.25 x 100 mm bolts in the camshaft front bolt holes. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the bolts from the front of the camshaft.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41556 Connecting Rod Guide

1. Use the J 24270 in order to remove the cylinder bore ring ridge, if required. See «Special Tools»(ref-200397-S12228589952005102000000) . Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use the J 24270 , or equivalent, in order to remove a cylinder ring ridge. See «Special Tools»(ref-200397-S12228589952005102000000) . Turn the crankshaft so the piston is at the top of the stroke. Remove the cloth. Remove the cutting debris from the cylinder and piston.
2. Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction. A stamping mark on the side of the connecting rod, at the crankshaft journal, may affect component geometry. Mark the top of the piston to the specific cylinder bore.
3. Remove the connecting rod bolt (102), cap (103) and bearing (104).
4. Install the J 41556 to the connecting rod.
5. Using a hammer, tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore.
6. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolt onto the matching connecting rod.

Crankshaft and Bearings Removal

Tools Required

1. J 6125-1B Slide Hammer with Adapter
2. J 41818 Crankshaft Bearing Cap Remover. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Remove the crankshaft position (CKP) sensor bolt (702).
2. Remove the CKP sensor (701).
3. Remove the O-ring (750) from the sensor as required.
4. Remove the crankshaft bearing cap M8 bolts (127).
5. Remove the crankshaft bearing cap M10 bolts (129) and studs (128).
6. Install the J 41818 . See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the J 41818 bolts to 11 N.m (100 lb in).
7. Install the J 6125-1B to the J 41818 in order to remove the crankshaft bearing caps. See «Special Tools»(ref-200397-S12228589952005102000000) .
8. Remove the bearing caps.
9. Remove the crankshaft.
10. Lay the crankshaft onto wooden V blocks or other protective surface.
11. Remove the crankshaft bearings from the bearing caps and the engine block.
12. Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location. Refer to «Separating Parts»(ref-200397-S15772230512005102000000) .

Engine Block Plug Removal

1. Remove the engine block coolant heater.
2. Remove the engine block coolant drain hole plug.
3. Remove the engine block left front oil gallery plug.
4. Remove the engine block left rear oil gallery plug.
5. Inspect the block plug sealing washers. If the block plug and heater sealing washers are not damaged, they may be used during assembly.
6. Remove the engine block rear oil gallery plug.
7. Inspect the O-ring seal of the rear oil gallery plug. If the O-ring seal is not cut or damaged, the plug and O-ring seal may be used during assembly.
8. Remove the engine block front oil gallery plug.
9. Remove the left side knock sensor (718) and bolt (739).
10. Remove the right side knock sensor (718) and bolt (739).

Engine Block Plug Installation

1. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block coolant heater sealing washer, if applicable. Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
2. Install the engine block coolant heater to the engine block. Tighten: Tighten the block coolant heater to 50 N.m (37 lb ft).
3. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block coolant drain hole plug sealing washer.
4. Install the engine block coolant drain hole plug. Tighten: Tighten the coolant drain hole plug to 60 N.m (44 lb ft).
5. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block left front oil gallery plug sealing washer.
6. Install the engine block left front oil gallery plug. Tighten: Tighten the block left front oil gallery plug to 60 N.m (44 lb ft).
7. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block left rear oil gallery plug sealing washer.
8. Install the engine block left rear oil gallery plug. Tighten: Tighten the block left rear oil gallery plug to 60 N.m (44 lb ft).
9. Inspect the engine block rear oil gallery plug and O-ring seal. If the O-ring seal on the plug is not cut or damaged, the rear oil gallery plug may be used again.
10. Lubricate the O-ring seal with clean engine oil.
11. Install the O-ring seal onto the plug.
12. Install the engine block rear oil gallery plug into the oil gallery bore. A properly installed block plug will protrude 0.8-1.4 mm (0.0315-0.055 in) beyond the rear face of the block.
13. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the sides of the NEW front oil gallery plug.
14. Install a NEW engine block front oil gallery plug. Install the plug into the oil gallery bore 2.2-2.8 mm (0.0086-0.011 in) below flush.
15. Install the left side knock sensor (718) and bolt (739). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
16. Install the right side knock sensor (718) and bolt (739). Tighten: Tighten the bolt to 20 N.m (15 lb ft).

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 8087 Cylinder Bore Gage
3. J 41556 Connecting Rod Guide
4. J 45059 Angle Meter

Piston, Pin, and Connecting Rod Installation

1. Lightly lubricate the following components with clean engine oil: Piston (107) Piston rings Cylinder bore Bearings (104) and bearing surfaces
2. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other.
3. Position the compression ring end gaps 180 degrees opposite each other.
4. Install the J 41556 to the connecting rod.
5. Identify the proper installation direction of the piston and connecting rod assembly. When installing the piston and connecting rod assembly, the mark on the top of the piston (1) and the tab (2) on the side of the connecting rod should face the front of the engine.
6. Install the J 8037 onto the piston and compress the piston rings. See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Install the piston, pin, and connecting rod assembly into the cylinder bore. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all the piston rings have entered the cylinder bore.
8. Use the J 41556 to guide the connecting rod onto the crankshaft journal.
9. Remove the J 41556 from the connecting rod.
10. Install the bearing cap (103), bearing (104), and bolts (102). Tighten: Tighten the bolts a first pass to 20 N.m (15 lb ft). Tighten the bolts a final pass to 75 degrees using the J 45059 .
11. Measure the connecting rods for the proper side clearance. Refer to «Engine Mechanical Specifications»(ref-200397-S27357677232005102000000) .

Camshaft Installation

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install 3 M8 - 1.25 x 100 mm (M8 - 1.25 x 4.0 in) bolts into the camshaft front bolt holes.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the 3 bolts from the front of the camshaft.
5. Install the camshaft retainer (203) and the bolts (204). Tighten: Tighten the camshaft retainer bolts to 25 N.m (18 lb ft).

Oil Pump, Pump Screen and Deflector Installation

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump (413).
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts (411). Tighten: Tighten the oil pump bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector.
5. Lubricate a NEW oil pump screen O-ring seal (406) with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen.
7. Install the oil pump screen (407).
8. Install the oil pump screen bolt (405) and the deflector nut (404). Tighten: Tighten the oil pump screen bolt to 12 N.m (106 lb in). Tighten the crankshaft oil deflector nut to 25 N.m (18 lb ft).

Engine Rear Cover Installation

Tools Required

1. J 41480 Front/Rear Cover Alignment - Oil Pan Surface. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41476 Front/Rear Cover Alignment - Crankshaft Oil Seal Area. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Inspect the rear oil gallery plug for proper installation.
2. Install the rear cover gasket (519), rear cover (518), and bolts (517).
3. Tighten the bolts finger tight. Do not overtighten.
4. Install the J 41480 and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface.
6. Install the J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the tool mounting bolts until snug. Do not overtighten. Tighten the J 41480 tool-to-rear cover bolts evenly to 12 N.m (106 lb in). Tighten the rear cover bolts to 25 N.m (18 lb ft).
7. Remove the tools.
8. Measure the rear cover-to-engine block oil pan surface for flatness. Place a straight edge onto the engine block and rear cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the rear cover and the straight edge. The cover must be flush with the oil pan or no more than 0.5 mm (0.02 in) below flush.
9. If the rear cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
10. If the correct rear cover-to-engine block alignment at the oil pan surface cannot be obtained, replace the rear cover.

Engine Front Cover Installation

Tools Required

1. J 41480 Front/Rear Cover Alignment - Oil Pan Surface. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 41476 Front/Rear Cover Alignment - Crankshaft Oil Seal Area. See «Special Tools»(ref-200397-S12228589952005102000000) .

1. Install the front cover gasket (503), front cover (502), and bolts (501).
2. Tighten the cover bolts finger tight. Do not overtighten.
3. Install the J 41480 . See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
4. Install the J 41476 . See «Special Tools»(ref-200397-S12228589952005102000000) .
5. Install the crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. Tighten the J 41480 . See «Special Tools»(ref-200397-S12228589952005102000000) . Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface, or no greater than 0.5 mm (0.02 in) (a) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
10. Inspect the camshaft position (CMP) sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be used again.
11. Lubricate the O-ring seal with clean engine oil.
12. Install the O-ring seal onto the sensor (703).
13. Install the sensor to the cover.
14. Install the CMP sensor wire harness (737) and bolts (705, 738). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Oil Pan Installation

1. Install the oil filter tube, baffle, and other internal components as required. Refer to «Oil Pan Cleaning and Inspection»(ref-200397-S16069670502005102000000) .
2. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface. Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
3. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface.
4. Pre-assemble the oil pan gasket to the pan. Install the gasket onto the oil pan. Install the oil pan bolts to the pan and through the gasket.
5. Install the oil pan, gasket and bolts to the engine block.
6. Tighten bolts finger tight. Do not overtighten.
7. Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces.
8. Align the oil pan until the rear of engine block and rear of oil pan are flush or even. Tighten: Tighten the oil pan-to-block and oil pan-to-front cover bolts to 25 N.m (18 lb ft). Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in).
9. Measure the oil pan-to-engine block alignment. Place a straight edge across the rear of the engine block and rear of oil pan at the transmission housing mounting surfaces. IMPORTANT: The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing mounting surfaces. Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface, and inspect to ensure there is no more than a 0.25 mm (0.01 in) gap (a) between the pan and straight edge. If the oil pan alignment is not within specifications, remove the oil pan and repeat the above procedure.

Oil Filter and Adapter Installation

1. Install a new oil filter bypass valve (436) into the oil pan as required.
2. Install the oil filter fitting (438). Tighten: Tighten the oil filter fitting to 55 N.m (40 lb ft).
3. Lubricate the oil filter seal with clean engine oil.
4. Install the oil filter (437). Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
5. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides. Align the flat area (3) on the top of the non displacement on demand lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. The displacement on demand lifters are to be installed into the guide, with the notch in the guide (1) aligned with the raised area (2) of the lifter.
3. Install the valve lifters and guide assembly (210) to the engine block.
4. Install the valve lifter guide bolts (211). Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).

Cylinder Head Installation - Left

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 45059 Angle Meter

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Cylinder Head Installation - Right

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 45059 Angle Meter

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Valve Rocker Arm and Push Rod Installation

1. Lubricate the valve rocker arms and pushrods with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.
3. Install the valve rocker arm pivot support.
4. Install the pushrods.
5. Install the rocker arms and bolts.
6. Rotate the crankshaft until number one piston is at top dead center of compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The camshaft and crankshaft sprocket alignment marks will be in the 12 o'clock positions. If viewing from the rear of the engine, the additional crankshaft pilot hole, non-threaded, will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank.
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten: Tighten exhaust valve rocker arm bolts 1, 2, 7, and 8 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 1, 3, 4, and 5 to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten: Tighten exhaust valve rocker arm bolts 3, 4, 5, and 6 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 2, 6, 7, and 8 to 30 N.m (22 lb ft).

Valve Rocker Arm Cover Installation - Left

1. Install a NEW gasket (504) into the valve rocker arm cover.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bolts (723).
5. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bracket bolts (723).
7. Install the ignition coil and bracket assembly (719) and bolts (720). Tighten: Tighten the bracket bolts to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install a NEW gasket (504) into the valve rocker arm cover.
2. Install a NEW oil fill tube (423) to the valve rocker arm cover
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bolts (723).
6. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bracket bolts (723).
8. Install the ignition coil and bracket assembly (719) and bolts (720). Tighten: Tighten the bracket bolts to 12 N.m (106 lb in).

Valve Lifter Oil Filter Installation

1. Install a NEW oil filter (452) and O-ring (454) assembly.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the sensor.
3. Install the oil pressure sensor (706) and washer (707). Tighten: Tighten the oil pressure sensor to 20 N.m (15 lb ft).

Valve Lifter Oil Manifold Installation

1. Do not lift the manifold assembly by the electrical lead frame.
2. Install the service gasket (556) onto the manifold.
3. Install the manifold (451) with gasket.
4. Install the manifold bolts (506). Tighten: Tighten the manifold bolts to 25 N.m (18 lb ft).

Coolant Air Bleed Pipe Installation

1. Install the seals (308) onto the engine coolant air bleed pipe and covers.
2. Install the pipe (307) and seals (308).
3. Install the bolts (309). Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the covers (313) and seals (308).
5. Install the bolts (312). Tighten: Tighten the cover bolts to 12 N.m (106 lb in).

Intake Manifold Installation

1. Install NEW intake manifold-to-cylinder head gaskets (514).
2. Install the intake manifold (500).
3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512). Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
4. Install the intake manifold bolts. Tighten: Tighten the intake manifold bolts (1-10) a first pass in sequence to 5 N.m (44 lb in). Tighten the intake manifold bolts (1-10) a final pass in sequence to 10 N.m (89 lb in).
5. Install the fuel rail. Refer to «Fuel Rail and Injectors Installation»(ref-200397-S29503091782005102000000) .
6. Lubricate the manifold absolute pressure (MAP) sensor grommet (715) with clean engine oil.
7. Install the grommet onto the MAP sensor (714).
8. Install the MAP sensor and retainer (736).
9. Install the positive crankcase ventilation (PCV) hose - dirty air (716).

Fuel Rail and Injectors Installation

1. Lubricate the NEW fuel injector O-ring seals (532, 534) with clean engine oil.
2. Install the O-ring seals to the fuel injectors.
3. Install the fuel injectors (533) and retaining clips (521).
4. Install the fuel rail assembly (510) to the manifold. Push firmly on both sides of the rail until all the injectors have entered their bores.
5. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the fuel rail bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
6. Install the fuel rail bolts (511). Tighten: Tighten the fuel rail bolts to 10 N.m (89 lb in).
7. Install the evaporative emission (EVAP) valve (730) and tubes (729, 735).
8. Install the fuel rail stop bracket and bolt. Tighten: Tighten the fuel rail stop bracket bolt to 50 N.m (37 lb ft).

Throttle Body Installation

1. Install the throttle body studs as required. Tighten: Tighten the throttle body studs to 6 N.m (53 lb in).
2. Install the throttle body gasket (509) to the intake manifold. Align the locating tab of the gasket with the notch in the manifold.
3. Install the throttle body (508), bolts (538), and nuts (507). Tighten: Tighten the throttle body nuts and bolts to 10 N.m (89 lb in).

Water Pump Installation

1. Install the water pump (300) and NEW gaskets (306).
2. Install the water pump bolts (301). Tighten: Tighten the water pump bolts a first pass to 15 N.m (11 lb ft). Tighten the water pump bolts a final pass to 30 N.m (22 lb ft).

Exhaust Manifold Installation - Left

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the heat shield bolts to 9 N.m (80 lb in).
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
4. Install the exhaust manifold, NEW gasket, and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Exhaust Manifold Installation - Right

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the heat shield bolts to 9 N.m (80 lb in).
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-200397-S09862744462005102000000) .
4. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Oil Level Indicator and Tube Installation

1. Inspect the O-ring seal (421) for cuts or damage. If the oil level indicator tube O-ring seal is not cut or damaged, it may be used again.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the O-ring seal onto the oil level indicator tube (420).
4. Install the oil level indicator tube into the engine block and rotate into proper position.
5. Install the tube bolt (419). Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
6. Install the oil level indicator (418) into the tube.

Engine Flywheel Installation

1. Install the flywheel to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the flywheel bolts.
3. Install the engine flywheel bolts. Tighten: Tighten the engine flywheel bolts (1-6) a first pass in sequence to 20 N.m (15 lb ft). Tighten the engine flywheel bolts (1-6) a second pass in sequence to 50 N.m (37 lb ft). Tighten the engine flywheel bolts (1-6) a final pass in sequence to 100 N.m (74 lb ft).

Crankshaft Balancer Installation

Tools Required

1. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-200397-S12228589952005102000000) .
2. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-200397-S12228589952005102000000) .
3. J 45059 Angle Meter

1. Install the J 42386-A and bolts. See «Special Tools»(ref-200397-S12228589952005102000000) . Use one M10 - 1.5 x 120 mm and one M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten the J 42386-A bolts to 50 N.m (37 lb ft).
2. Position the balancer (138) onto the end of the crankshaft.
3. Use the J 41665 in order to install the balancer. See «Special Tools»(ref-200397-S12228589952005102000000) . Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tool.
4. Install the used crankshaft balancer bolt (139). Tighten: Tighten the crankshaft balancer bolt to 330 N.m (240 lb ft).
5. Remove the used crankshaft balancer bolt.
6. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. See «Special Tools»(ref-200397-S12228589952005102000000) .
7. Install the NEW crankshaft balancer bolt (139). Tighten: Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). Tighten the crankshaft balancer bolt a second pass to 140 degrees using the J 45059 .
8. Remove the J 42386-A . See «Special Tools»(ref-200397-S12228589952005102000000) .