Removal (syclone & Typhoon) GMC Jimmy Typhoon

1. Loosen wing bolt at air cleaner and move air cleaner and duct aside. Drain charge air cooler radiator and engine radiator into suitable container.
2. Disconnect negative battery cable.
3. Loosen charge air cooler clamps. Disconnect charge air cooler ducts and hoses.
4. Remove charge air cooler from supports.
5. Remove charge air cooler lateral (center) support.
6. Label electrical connectors and hoses for reassembly reference. Disconnect electrical connectors and hoses as necessary.
7. Remove multi-use bracket from lower intake manifold.
8. Remove throttle body bolts and throttle body. Remove throttle body gasket and discard. Remove throttle cable bracket from upper intake manifold.
9. Remove upper intake manifold bolts and upper intake manifold. Remove upper intake manifold gasket and discard.
10. Disconnect heater hose at lower intake manifold. Disconnect charge air cooler coolant inlet pipe at radiator.
11. Label fuel injector electrical connectors for reassembly reference. Disconnect fuel injector electrical connectors.
12. Disconnect fuel feed and return pipes at fuel rail.
13. Remove fuel rail retaining bolts. Carefully remove fuel rail with injectors attached.
14. Remove rear brace from A/C compressor.
15. Remove turbocharger coolant return line.
16. Disconnect upper radiator hose from lower intake manifold.
17. Disconnect ground strap from lower intake manifold.
18. Disconnect coolant temperature sensor connector.
19. Label spark plug wires at distributor cap for reassembly reference. Disconnect spark plug wires at distributor cap.
20. Remove distributor cap.
21. Mark distributor rotor in relation to distributor housing. Mark base of distributor housing in relation to intake manifold. Remove distributor.
22. Remove lower intake manifold bolts/studs.
23. Remove lower intake manifold. Remove lower intake manifold gaskets and discard.

Installation

1. Install gaskets on cylinder heads with port blocking plates facing the rear. Apply a 3/16" (5 mm) bead of RTV silicone sealant to front and rear intake manifold-to-cylinder block mounting surfaces. see scheme 5 Extend bead 1/2" (13 mm) beyond cylinder block-to-cylinder head junction.
2. Install lower intake manifold and bolts. Tighten lower intake manifold bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49853-S42132455842001011600000). To complete installation, reverse removal procedure. Tighten upper intake manifold bolts to specification starting with the two middle bolts on each side, then working outward. Fill charge air cooler and charge air cooler radiator. Fill engine radiator.

Remove heat stove tube. Remove all attached brackets and heat shields. If necessary, remove dip stick tube. Disconnect oxygen sensor electrical connector. Disconnect exhaust pipe from manifold. Remove exhaust manifold bolts and exhaust manifold.

Install manifold. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bend lock tabs (if equipped). To complete installation, reverse removal procedure.

1. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(ref-49853-S20719084082001011600000) . Remove intake manifold. Refer to «INTAKE MANIFOLD»(ref-49853-S25875227312001011600000) .
2. Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-49853-S16616769712001011600000) under REMOVAL & INSTALLATION. Remove valve covers. Loosen rocker arm nuts. Rotate rocker arms aside. Remove push rods and mark for reassembly to original locations. Remove cylinder head bolts. Remove cylinder head.

1. Clean gasket surfaces, bolt threads and bolt holes. If using steel head gasket, thinly coat both sides of gasket with sealant. DO NOT apply sealant to composition (steel/asbestos) head gaskets. Position head gasket on cylinder block. Ensure all holes align. Coat head bolt threads with GM(R) Sealant (1052080).
2. Install cylinder head with bolts finger-tight. Tighten head bolts in sequence to specification. see scheme 10 See «TORQUE SPECIFICATIONS»(ref-49853-S42132455842001011600000). Lubricate valve tip, rocker arm pivot and push rod socket with Molykote.
3. To complete installation, reverse removal procedure. Adjust valves. See «VALVE CLEARANCE ADJUSTMENT»(ref-49853-S06911742092001011600000) under ADJUSTMENTS.

Remove accessory drive belt(s) and pulley. Remove crankshaft damper bolt. Using Damper Puller/Installer (J-23523-E), remove crankshaft damper. Carefully pry seal from cover with screwdriver. DO NOT distort front cover.

1. Coat seal lip with engine oil. Using Seal Installer J-35468) on all others, install new seal in front cover with seal lip facing engine. Apply RTV sealant to Woodruff keyway in crankshaft damper.
2. Install crankshaft damper. Install crankshaft damper bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49853-S42132455842001011600000) . To install remaining components, reverse removal procedure.

1. Disconnect battery. Drain cooling system. If necessary, remove radiator shroud. Remove accessory drive belts, fan and pulley. Remove crankshaft damper bolt. Using Damper Puller/Installer (J-23523-E), remove crankshaft damper.
2. Remove all mounting brackets and coolant hoses attached to water pump. Remove water pump. Remove oil pan. See «OIL PAN»(ref-49853-S36605046042001011600000) under REMOVAL & INSTALLATION. Remove front cover and gasket.
3. Rotate crankshaft until timing marks on camshaft and crankshaft sprockets are aligned. (Scheme 8) Remove camshaft sprocket and timing chain. To remove crankshaft sprocket, use Sprocket Puller (J-5825-A).

1. Install Woodruff key in crankshaft (if removed). Using Crankshaft Sprocket Installer (J-5590), install crankshaft sprocket. Install camshaft sprocket and timing chain, ensuring timing marks on sprockets are aligned. (Scheme 8)
2. Install and tighten camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49853-S42132455842001011600000). Install gasket to front cover with gasket sealant. Install front cover and gasket.
3. Apply RTV sealant to Woodruff keyway in crankshaft damper. Install crankshaft damper. Install crankshaft damper bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49853-S42132455842001011600000). To install remaining components, reverse removal procedure.

Scheme 8