Engine Mechanical - 4.3L: Removal & Installation GMC Savana G2500

Removal Procedure

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls-4.3L.
2. Remove the retaining bolt for the coolant recovery reservoir and set the reservoir aside.
3. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise.
4. Remove the drive belt.
5. Slowly release the tension on the drive belt tensioner arm.

Installation Procedure

1. Route the drive belt over all the pulleys except the drive belt tensioner arm.
2. Observe the drive belt routing for vehicles without air conditioning.
3. Observe the drive belt routing for vehicles with air conditioning.
4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise.
5. Install the drive belt over the drive belt tensioner pulley.
6. Slowly release the tension on the drive belt tensioner arm.
7. Confirm that the belt is properly routed.
8. Inspect for the drive belt being properly installed on the pulleys.
9. Avoid mis-positioning the drive belt by one or more grooves.
10. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed, the fix pointer should align within the indentation on the drive belt tensioner.
11. With a used drive belt installed, the fix pointer should not align past the index mark.
12. Position the coolant recovery reservoir and install the retaining bolt. Tighten: Tighten the coolant recovery reservoir bolt to 11 N.m (97 lb in).
13. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls-4.3L.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
2. Remove the bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner assembly.
2. Install the attaching bolt. Tighten: Tighten the tensioner assembly bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .

1. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) in Engine Cooling.
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
3. Remove the belt idler pulley bolt.
4. Remove the belt idler pulley from the power steering pump mounting bracket.

1. Install the belt idler pulley and bolt to the power steering pump mounting bracket. Tighten: Tighten the idler pulley bolt to 50 N.m (37 lb ft).
2. Install the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
3. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) in Engine Cooling.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Remove the engine mount to frame mounting bolts.
3. Use a jack on the square tab at the rear of the engine block, and raise the engine, left side shown.
4. Remove the engine mount to engine mounting bolts.
5. Remove the engine mount.

1. Install the engine mount to the vehicle.
2. Install the engine mount to engine mounting bolts. Tighten: Tighten the engine mount to engine bolts to 50 N.m (37 lb ft).
3. Lower the engine.
4. Install the engine mount to frame mounting bolts. Tighten: Tighten the engine mount to frame bolts to 60 N.m (44 lb ft).
5. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Remove the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
3. Remove the engine mount to frame mounting bolts.
4. Use a jack on the square tab at the rear of the engine block, and raise the engine, left side shown.
5. Remove the engine mount to engine mounting bolts.
6. Remove the engine mount from the vehicle.

1. Install the engine mount to the vehicle.
2. Install the engine mount to engine mounting bolts. Tighten: Tighten the engine mount to engine mounting bolts to 50 N.m (37 lb ft).
3. Lower the engine.
4. Install the engine mount to the frame mounting bolts. Tighten: Tighten the engine mount to frame mounting bolts to 60 N.m (44 lb ft).
5. Install the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Remove the engine mount. Refer to «Engine Mount Replacement - Left»(ref-186638-S23218287102005083000000) or «Engine Mount Replacement - Right»(ref-186638-S34397472692005083000000) .
3. Remove the engine mount adapter mounting bolts.
4. Remove the engine mount adapter.

1. Install the engine mount adapter.
2. Install the engine mount adapter mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the engine mount. Refer to «Engine Mount Replacement - Left»(ref-186638-S23218287102005083000000) or «Engine Mount Replacement - Right»(ref-186638-S34397472692005083000000) .
4. Lower the vehicle.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.
2. Disconnect the PCV valve hose assembly from the intake manifold.
3. Disconnect the PCV valve hose assembly from the left valve rocker arm cover.
4. Inspect the tube and hose for cuts or cracking.
5. Inspect the grommets in the valve rocker arm covers for cuts or cracking.
6. Replace the PCV hose/tube as required.

1. Connect the PCV valve hose assembly to the intake manifold.
2. Connect the PCV valve hose assembly to the left valve rocker arm cover.
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner duct.
3. Disconnect the PCV tube from the right valve rocker arm cover.
4. Disconnect the PCV valve hose assembly from the intake manifold.
5. Disconnect the PCV valve hose assembly from the left valve rocker arm cover.
6. Inspect the tube and hose for cuts or cracking.
7. Inspect the grommets in the valve rocker arm covers for cuts or cracking.
8. Replace the PCV hose/tube as required.

1. Connect the PCV valve hose assembly to the intake manifold.
2. Connect the PCV valve hose assembly to the left valve rocker arm cover.
3. Connect the positive crankcase PCV tube to the air cleaner duct.
4. Connect the PCV tube to the right valve rocker arm cover.
5. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls-4.3L.
3. Remove the coolant reservoir bolt and set the reservoir aside.
4. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner outlet duct.
5. Remove the retaining nut (1) from the air cleaner outlet.
6. Remove the air cleaner outlet duct (2) from the throttle body assembly.
7. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(ref-186616-S35683245022005083000000) in Engine Controls-4.3L.
8. Disconnect the cruise control cable, if equipped, from the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(ref-186606-S27581933252005083000000) in Cruise Control.
9. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
10. Disconnect the following electrical connectors: The fuel meter body assembly connector (1) The EVAP canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3)
11. Disconnect the following electrical connectors: The throttle position (TP) sensor (1) The idle air control (IAC) motor (2) The engine coolant temperature (ECT) gage sensor (3) The A/C high pressure switch (4), if equipped
12. Remove the engine wiring harness bracket from the intake manifold stud.
13. Move and secure the engine wiring harness out of the way.
14. Disconnect the A/C vacuum hose from the intake manifold.
15. Remove the power brake booster vacuum hose bracket and nut from the intake manifold stud.
16. Disconnect the power brake booster vacuum hose from the intake manifold.
17. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
18. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-186616-S14459726932005083000000) in Engine Controls-4.3L.
19. Remove the fuel lines from the fuel meter body assembly. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(ref-186616-S31652836532005083000000) in Engine Controls-4.3L.
20. Remove the distributor cap. Refer to «Distributor Replacement»(ref-186616-S31785130802005083000000) in Engine Electrical.
21. Remove the ignition control module. Refer to «Ignition Control Module Replacement»(ref-186616-S09016154872005083000000) in Engine Electrical.
22. Remove the studs for the upper intake manifold.
23. Remove the upper intake manifold.
24. Remove the upper intake manifold gasket from the groove.
25. Discard the gasket.
26. Remove the seal from the fuel meter body assembly.
27. Discard the seal.
28. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
29. Inspect the upper intake manifold for the following: Cracks or other damage to the exterior Cracking or damage to the gasket grooves Loose or damaged bolt hole thread inserts
30. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
31. Remove and discard the seal.
32. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
33. Remove and discard the seal.
34. Remove the throttle body if replacing the upper intake manifold. Refer to «Throttle Body Assembly Replacement»(ref-186616-S41462648462005083000000) .
35. Remove the MAP sensor if replacing the upper intake manifold. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-186616-S07996468222005083000000) in Engine Controls-4.3L.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Install the throttle body, if removed. Refer to «Throttle Body Assembly Replacement»(ref-186616-S41462648462005083000000) .
2. Install the MAP sensor, if removed. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-186616-S07996468222005083000000) in Engine Controls-4.3L.
3. Install the PCV valve cover, if removed, using the following procedure: Install a NEW seal (O-ring) on the PCV valve cover. Lubricate the seal with clean engine oil. Install the PCV valve cover in the upper intake manifold. Turn and lock the PCV valve cover in position.
4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure: Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting. Lubricate the seal with clean engine oil. Install the power brake booster vacuum tube fitting in the upper intake manifold. Turn and lock the power brake booster vacuum tube fitting in position.
5. Install a NEW seal on the fuel meter body assembly.
6. Lubricate the seal with clean engine oil.
7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
8. Install the upper intake manifold onto the lower intake manifold.
9. If reusing the fasteners, apply Threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the upper intake manifold attaching bolts.
10. Install the upper intake manifold attaching studs. Tighten: Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in). Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
11. Install the fuel lines to the fuel meter body assembly. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(ref-186616-S31652836532005083000000) in Engine Controls-4.3L.
12. Install the distributor cap. Refer to «Distributor Replacement»(ref-186616-S31785130802005083000000) in Engine Electrical.
13. Install the ignition control module. Refer to «Ignition Control Module Replacement»(ref-186616-S09016154872005083000000) in Engine Electrical.
14. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-186616-S14459726932005083000000) in Engine Controls-4.3L.
15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten: Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).
16. Connect the A/C vacuum hose to the intake manifold.
17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud. Tighten: Tighten the power brake booster vacuum hose bracket nut to 11 N.m (97 lb in).
18. Connect the power brake booster vacuum hose to the intake manifold.
19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
20. Install the engine wiring harness bracket nut. Tighten: Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).
21. Connect the following electrical connectors: The fuel meter body assembly connector (1) The EVAP canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3)
22. Connect the following electrical connectors: The throttle position (TP) sensor (1) The idle air control (IAC) motor (2) The engine coolant temperature (ECT) gage sensor (3) The A/C high pressure switch (4), if equipped
23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
24. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(ref-186606-S27581933252005083000000) in Cruise Control.
25. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(ref-186616-S35683245022005083000000) in Engine Controls-4.3L.
26. Install the air cleaner outlet duct (2) on the throttle body assembly.
27. Tighten the retaining nut (1). Tighten: Tighten the nut to 2 N.m (18 lb in).
28. Connect the PCV tube to the air cleaner outlet duct.
29. Position the coolant reservoir. Install the bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
30. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls-4.3L.
31. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

Scheme 17

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
3. Remove the upper intake. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) .
4. Disconnect the A/C compressor (1) and the exhaust gas recirculation (EGR) connector (2).
5. Remove the ground wire (4) from the stud at the water outlet.
6. Remove the radiator inlet hose at the water outlet. Refer to «Radiator Hose Replacement - Inlet»(ref-186629-S38284589192005083000000) in Engine Cooling.
7. Remove the heater hose from the intake manifold. Refer to «Heater Hose Replacement - Inlet»(ref-186630-S39825653912005083000000) and «Heater Hose Replacement - Outlet»(ref-186630-S29224256932005083000000) in Heating, Ventilation and Air Conditioning.
8. Remove the water pump inlet hose from the intake manifold.
9. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
10. Remove the distributor. Refer to «Distributor Replacement»(ref-186616-S31785130802005083000000) in Engine Controls-4.3L.
11. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
12. In order to remove the front intake manifold bolt, perform the following: Remove the A/C compressor discharge hose from the vehicle. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation, and Air Conditioning. Remove the A/C compressor suction hose from the vehicle. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation, and Air Conditioning. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) . Loosen the nut for the power steering pump rear bracket. Remove the bolts and the nut for the power steering pump mounting bracket. Leave the A/C compressor, if equipped, and the power steering pump on the bracket. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
13. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
14. Remove the lower intake manifold bolts.
15. Remove the intake manifold assembly.
16. Remove and discard the lower intake manifold gaskets.
17. Clean all sealing surfaces and the intake manifold. Refer to «Intake Manifold Cleaning and Inspection»(ref-186638-S38993033102005083000000) .
18. If the intake manifold requires replacement refer to «Intake Manifold Disassemble (LU3)»(ref-186638-S16115955552005083000000) and «Intake Manifold Assemble (LU3)»(ref-186638-S07660550202005083000000) .

Scheme 18

1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end.
2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.
3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
7. Install the lower intake manifold onto the engine block.
8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
10. Tighten the lower intake manifold bolts. Tighten: Tighten the bolts on the first pass in sequence (1-8) to 3 N.m (27 lb in). Tighten the bolts on the second pass in sequence (1-8) to 12 N.m (106 lb in). Tighten the bolts on the final pass in sequence (1-8) to 15 N.m (11 lb ft).
11. Position the power steering pump mounting bracket.
12. Install the power steering pump mounting bracket, 3 bolts and the nut. Tighten: Tighten the power steering pump mounting bracket bolts and the nut to 41 N.m (30 lb ft). Tighten the power steering pump rear bracket nut to 41 N.m (30 lb ft). Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 N.m (30 lb ft).
13. Install the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
14. Install the A/C compressor discharge hose from the vehicle. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation, and Air Conditioning.
15. Install the A/C compressor suction hose from the vehicle. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation, and Air Conditioning.
16. Remove the spark plug for number one cylinder.
17. Rotate the crankshaft until number one cylinder is in the compression stroke.
18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
19. Install the spark plug. Refer to «Spark Plug Replacement»(ref-186616-S29287171892005083000000) in Engine Controls-4.3L.
20. Install the distributor. Refer to «Distributor Replacement»(ref-186616-S31785130802005083000000) in Engine Controls-4.3L.
21. Install the upper intake. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) .
22. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten: Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).
23. Install the water pump inlet hose to the intake manifold.
24. Install the heater hoses. Refer to «Heater Hose Replacement - Inlet»(ref-186630-S39825653912005083000000) and «Heater Hose Replacement - Outlet»(ref-186630-S29224256932005083000000) in Heating, Ventilation and Air Conditioning.
25. Install the radiator inlet hose to the water outlet. Refer to «Radiator Hose Replacement - Inlet»(ref-186629-S38284589192005083000000) in Engine Cooling.
26. Connect the following electrical connectors: The fuel meter body assembly connector (1) The evaporative emission (EVAP) canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3) The A/C high pressure switch (4), if equipped
27. Connect the following electrical connectors: The A/C compressor clutch (1), if equipped The EGR valve (2) The ECT sensor (3)
28. Install the ground wire (4) and the nut to the water outlet stud. Tighten: Tighten the ground wire nut to 10 N.m (88 lb in).
29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(ref-186606-S27581933252005083000000) in Cruise Control.
30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(ref-186616-S35683245022005083000000) in Engine Controls-4.3L.
31. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
32. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls-4.3L.
33. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
34. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.
3. Remove the positive crankcase ventilation hose from the valve rocker arm cover.
4. Disconnect the engine coolant temperature (ECT) gage sensor electrical connector.
5. Remove the ECT gage sensor connector from the bracket.
6. Remove the spark plug wires for the left side of the engine from the distributor cap.
7. Remove the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation and Air Conditioning.
8. Remove the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation and Air Conditioning.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
5. Install the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation and Air Conditioning.
6. Install the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation and Air Conditioning.
7. Connect the spark plug wires to the distributor cap.
8. Install the ECT gage sensor electrical connector to the bracket.
9. Connect the ECT gage sensor electrical connector.
10. Install the PCV hose to the valve rocker arm cover.
11. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.
3. Remove the coolant reservoir bolt and set the reservoir aside.
4. Remove the spark plug wires for the right side of the engine from the distributor cap.
5. Remove the positive crankcase ventilation (PCV) tube from the valve rocker arm cover and the air inlet duct.
6. Move the engine wiring harness aside.
7. Remove the screw holding the oil fill tube to the oil fill tube lower support.
8. Remove the oil fill tube from the right valve rocker arm cover and move aside.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
5. Install the oil fill tube in the right valve rocker arm cover.
6. Install the oil fill tube and bolt to the oil fill tube lower support. Tighten: Tighten the oil fill tube to lower support bolt to 5 N.m (44 lb in).
7. Install the PCV hose in the valve rocker arm cover and to the air inlet duct.
8. Connect the spark plug wires to the distributor cap.
9. Position the engine wiring harness.
10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
11. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-186616-S30400857942005083000000) in Engine Controls - 4.3L.
12. Reposition the coolant reservoir and install the bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-186638-S35570716112005083000000) or «Valve Rocker Arm Cover Replacement - Right»(ref-186638-S13429779272005083000000) .
2. Remove the valve rocker arms.
3. Remove the valve rocker arm supports.
4. Remove the valve pushrods.
5. Clean and inspect the valve rocker arm and the valve pushrod. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(ref-186638-S16281373572005083000000) .

Scheme 19

Scheme 20

1. Install the valve pushrods.
2. Install the valve rocker arm supports.
3. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent to the following valve rocker arm contact surfaces: Valve pushrod socket (1) Roller pivot (2) Valve stem tip (3)
4. Install the valve rocker arm assemblies as follows: Finger start the bolt at location (1) Finger start the bolt at location (2) Finger start the bolt at location (3) Finger start the remaining valve rocker arm bolts
5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2).
6. Tighten the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 30 N.m (22 lb ft).
7. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-186638-S35570716112005083000000) or «Valve Rocker Arm Cover Replacement - Right»(ref-186638-S13429779272005083000000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 38606 Valve Spring Compressor. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. J 5892-D Valve Spring Compressor. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. J 42073 Valve Stem Seal Installer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-186638-S35570716112005083000000) or «Valve Rocker Arm Cover Replacement - Right»(ref-186638-S13429779272005083000000)
2. Remove the required valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
3. Remove the required spark plugs. Refer to «Spark Plug Replacement»(ref-186616-S29287171892005083000000) in Engine Controls - 4.3L.
4. Install the J 22794 into the spark plug hole. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place.
6. Remove a bolt from a valve rocker arm.
7. Install a flat washer on the bolt.
8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal.
9. Use the J 5892-D in order to compress the valve spring. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Apply steady pressure on the valve spring cap until the valve keys are accessible.
10. Use J 38606 when J 5892-D will not fit. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
11. Remove the valve keys (1).
12. Carefully release the valve spring tension.
13. Remove the J 5892-D or J 38606 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
14. Remove the valve spring cap (2) and valve spring (3).
15. Remove the valve stem oil seal (4).

Scheme 21

1. Assemble the valve into the proper valve guide.
2. Select the proper valve stem oil seal for the specific valve guide.
3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil.
4. Assemble the valve stem oil seal onto the valve stem.
5. Using the J 42073 , install the valve stem oil seal onto the valve guide. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the valve stem oil seal and the valve guide.
6. Install the valve spring (3).
7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem.
8. Use the J 5892-D in order to compress the valve spring. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
9. Apply steady pressure on the valve spring cap until the valve keys are accessible.
10. Use the J 38606 if the clearance does not permit use of the J 5892-D . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
11. Install the valve stem O-ring seal.
12. Install the valve stem keys. Use grease in order to hold the valve stem keys in place.
13. Carefully release the valve spring pressure, making sure the valve stem keys stay in place.
14. Remove the J 5892-D or the J 38606 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. Tap the end of the valve stem with a plastic faced hammer in order to seat the valve stem keys, if necessary.
15. Remove the J 22794 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
16. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-186616-S29287171892005083000000) in Engine Controls - 4.3L.
17. Install the valve rocker arms to the cylinder head. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
18. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-186638-S35570716112005083000000) or «Valve Rocker Arm Cover Replacement - Right»(ref-186638-S13429779272005083000000) .

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .
2. Remove the valve rocker arms and the valve pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
3. Remove the bolts and valve lifter pushrod guide.
4. Remove the valve lifters.
5. Use the J 3049-A in order to remove the stuck valve lifters. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
6. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores.
7. Inspect the valve lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring.
8. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-186638-S08701434692005083000000) .
9. Clean and inspect the valve lifters and the valve pushrod guide. Refer to «Valve Lifters and Guides Cleaning and Inspection»(ref-186638-S41565335162005083000000) .

1. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent to the valve lifter rollers.
2. Install the valve lifters.
3. Install the valve lifter pushrod guides. Tighten: Tighten the valve lifter pushrod guide bolts to 16 N.m (12 lb ft).
4. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
5. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
3. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
4. Remove the fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) and to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
6. Remove the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation and Air Conditioning.
7. Remove the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation and Air Conditioning.
8. Remove the mounting bolts (2) for the air conditioning compressor (1), if equipped.
9. Move the compressor aside and support.
10. Remove the drive belt idler pulley if not equipped with A/C. Refer to «Drive Belt Idler Pulley Replacement - without Air Conditioning»(ref-186638-S25319439572005083000000) .
11. Remove the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(ref-186662-S42572585262005083000000) in Power Steering Systems.
12. Remove the 3 bolts holding the power steering pump to the power steering pump mounting bracket. The power steering pump can remain on the engine.
13. Remove the 3 bolts and nut holding the power steering pump mounting bracket to the engine.
14. Slide the power steering pump mounting bracket off the stud and power steering pump.
15. Remove the power steering pump mounting bracket stud from the cylinder head.
16. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .
17. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (4.3L)»(ref-186654-S23478174812005083000000) or «Exhaust Manifold Replacement - Left (4.8L, 5.3L, 6.0L)»(ref-186654-S29209774452005083000000) in Engine Exhaust.
18. Remove the ground wires at the rear of the cylinder head.
19. Remove the transmission control cable bracket.
20. Remove the valve pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
21. Remove the engine coolant temperature sensor if applicable.
22. Remove the engine coolant temperature gage sensor if applicable.
23. Remove the spark plugs.
24. Remove the bolts and the spark plug wire support.
25. Remove the cylinder head bolts.
26. Remove the cylinder head.
27. Remove and discard the cylinder head gasket.
28. Remove the dowel pins cylinder head locator if required.
29. Clean the engine block and the cylinder head sealing surfaces.
30. Clean the cylinder head bolts and the engine block bolt holes.
31. For further service to the cylinder head refer to the following: «Cylinder Head Disassemble»(ref-186638-S22934055792005083000000) , «Cylinder Head Cleaning and Inspection»(ref-186638-S15755033862005083000000) , «Valve Guide Reaming/Valve and Seat Grinding»(ref-186638-S23828916122005083000000) or «Cylinder Head Assemble»(ref-186638-S37331746082005083000000) .

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.
4. Install the NEW cylinder head gasket in position over the dowel pins, cylinder head locator.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten: Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Using the J 45059 tighten the cylinder head bolts in sequence on the final pass. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12, and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten: Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
11. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification: Spark plug gap: 1.52 mm (0.060 in).
12. Install the spark plugs. Tighten: Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
13. If reusing the engine coolant temperature gage sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant temperature gage sensor.
14. Install the engine coolant temperature gage sensor, if applicable. Tighten: Tighten the engine coolant temperature gage sensor to 20 N.m (15 lb ft).
15. If reusing the engine coolant temperature sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant temperature gage sensor.
16. Install the engine coolant temperature sensor, if applicable. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).
17. Install the valve pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
18. Install the ground wires and nut at the rear of the cylinder head. Tighten: Tighten the ground wire nut to 10 N.m (88 lb in).
19. Install the transmission control cable bracket and bolts at the rear of the cylinder head. Tighten: Tighten the transmission control cable bracket bolts to 40 N.m (30 lb ft).
20. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (4.3L)»(ref-186654-S23478174812005083000000) or «Exhaust Manifold Replacement - Left (4.8L, 5.3L, 6.0L)»(ref-186654-S29209774452005083000000) in Engine Exhaust.
21. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .
22. Install the stud for the power steering pump mounting bracket to the cylinder head. Tighten: Tighten the power steering pump mounting bracket stud to 20 N.m (15 lb ft).
23. Slide the power steering pump mounting bracket on the stud and the power steering pump.
24. Install the 3 bolts and the nut. Tighten: Tighten the power steering pump mounting bolts and the nut to 41 N.m (30 lb ft).
25. Install the 3 bolts for the power steering pump. Tighten: Tighten the power steering pump mounting bracket to the power steering pump bolts to 50 N.m (37 lb ft).
26. Install the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(ref-186662-S42572585262005083000000) in Power Steering Systems.
27. Install the air conditioning compressor, if equipped. Refer to «Compressor Replacement (4.3L)»(ref-186630-S07561965512005083000000) or «Compressor Replacement (4.8L, 5.3L, 6.0L)»(ref-186630-S22305729062005083000000) in Heating, Ventilation and Air Conditioning.
28. Install the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation and Air Conditioning.
29. Install the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation and Air Conditioning.
30. Install the drive belt idler pulley if not equipped with A/C. Refer to «Drive Belt Idler Pulley Replacement - without Air Conditioning»(ref-186638-S25319439572005083000000) .
31. Install the fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) and to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
32. Fill the engine coolant system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
33. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
34. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
3. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
4. Remove the fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) and to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
5. Remove the generator mounting bracket. Refer to «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S13145054202005083000000) in Engine Electrical.
6. Remove the generator mounting bracket stud from the cylinder head.
7. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .
8. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (4.3L)»(ref-186654-S12194338692005083000000) or «Exhaust Manifold Replacement - Right (4.8L, 5.3L, 6.0L)»(ref-186654-S11907835852005083000000) in Engine Exhaust.
9. Remove the ground wires at the rear of the cylinder head.
10. Remove the valve pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
11. Remove the spark plugs.
12. Remove the rear bolt and the spark plug wire support.
13. Remove the cylinder head bolts.
14. Remove the cylinder head.
15. Remove and discard the cylinder head gasket.
16. Remove the dowel pins (cylinder head locator), if required.
17. Clean the engine block and the cylinder head sealing surfaces.
18. Clean the cylinder head bolts and the engine block bolt holes.
19. For further service to the cylinder head refer to the following: «Cylinder Head Disassemble»(ref-186638-S22934055792005083000000) , «Cylinder Head Cleaning and Inspection»(ref-186638-S15755033862005083000000) , «Valve Guide Reaming/Valve and Seat Grinding»(ref-186638-S23828916122005083000000) or «Cylinder Head Assemble»(ref-186638-S37331746082005083000000) .

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.
4. Install the NEW cylinder head gasket in position over the dowel pins cylinder head locator.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 12346004) or equivalent to the threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten: Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Using the J 45059 tighten the cylinder head bolts in sequence on the final pass. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten: Tighten only the rear spark plug wire support bolt to 12 N.m (106 lb in).
11. Remove the front spark plug wire support bolt. The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.
12. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification: Spark plug gap to 1.52 mm (0.060 in).
13. Install the spark plugs. Tighten: Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
14. Install the valve pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-186638-S14339114422005083000000) .
15. Install the ground wires and nut at the rear of the cylinder head. Tighten: Tighten the ground wire nut to 10 N.m (88 lb in).
16. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (4.3L)»(ref-186654-S12194338692005083000000) or «Exhaust Manifold Replacement - Right (4.8L, 5.3L, 6.0L)»(ref-186654-S11907835852005083000000) in Engine Exhaust.
17. Install the intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-186638-S08737972032005083000000) .
18. Install the stud for the generator mounting bracket to the cylinder head. Tighten: Tighten the generator mounting bracket stud to 20 N.m (15 lb ft).
19. Install the generator mounting bracket. Refer to «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S13145054202005083000000) in Engine Electrical.
20. Install the fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-186629-S15713606392005083000000) and to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
21. Fill the engine coolant system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
22. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
23. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Remove the fan shroud assembly. Refer to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
4. Remove the crankshaft balancer bolt and washer.
5. Remove the bolts and the crankshaft pulley.
6. Use the J 23523-F in order to remove the crankshaft balancer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 23523-F plate and bolts onto the crankshaft balancer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the bolts to 25 N.m (18 lb ft). Install the J 23523-F forcing screw into the plate. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
7. Remove the J 23523-F from the crankshaft balancer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
8. Note the position and length of any front groove pins (crankshaft balancer), if applicable.
9. Clean and inspect all parts. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-186638-S34992348012005083000000) .

Scheme 22

1. Apply a small amount of grease to the crankshaft front cover oil seal sealing surface.
2. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location if applicable. The length and location of the pins must be the same as the original length and location.
3. Apply a small amount of adhesive GM P/N 12346141 (Canadian P/N 1093433) or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.
4. Align the keyway of the crankshaft balancer with the crankshaft balancer key.
5. Install the crankshaft balancer onto the end of the crankshaft.
6. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . NOTE: Refer to «Fastener Notice»(ref-186604-S39582545662005083000000) in Cautions and Notices. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the plate bolts to 25 N.m (18 lb ft). Install the J 23523-F screw into the end for the crankshaft. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 23523-F bearing, the washer, and the nut onto the screw. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
7. Remove the J 23523-F . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
8. Install the crankshaft pulley and bolts. Tighten: Tighten the crankshaft pulley bolts to 58 N.m (43 lb ft).
9. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
10. Install the crankshaft balancer washer and the bolt. Tighten: Tighten the crankshaft balancer bolt to 95 N.m (70 lb ft).
11. Install the drive belt. Refer to «Drive Belt Replacement»(ref-186638-S26656625452005083000000) .
12. Install the fan shroud assembly. Refer to «Fan Shroud Replacement - Lower»(ref-186629-S37023108352005083000000) in Engine Cooling.
13. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-186638-S17629423312005083000000) .
2. Use a suitable prying tool to remove the crankshaft front oil seal.
3. Inspect the engine front cover seal bore for damage.
4. Inspect the crankshaft balancer seal area. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-186638-S34992348012005083000000) .

1. Lubricate the exterior of the crankshaft front oil seal with clean engine oil.
2. Use the J 35468 with a hammer in order to install the crankshaft front oil seal. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. Inspect to ensure the crankshaft front oil seal is flush and square to the engine front cover.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-186638-S17629423312005083000000) .

1. Remove the engine oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-186638-S17629423312005083000000) .
3. Remove the water pump. Refer to «Water Pump Replacement (4.3L Engine)»(ref-186629-S00897105062005083000000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-186629-S36003682102005083000000) in Engine Cooling.
4. Remove the crankshaft position (CKP) sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(ref-186616-S02905641782005083000000) in Engine Controls.
5. Remove the crankshaft position sensor seal (O-ring).
6. Discard the crankshaft position sensor seal (O-ring).
7. Remove the engine front cover bolts.
8. Remove the engine front cover.
9. Discard the engine front cover.
10. Clean all sealing surfaces.

1. Install the NEW engine front cover.
2. Install the engine front cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Lubricate the NEW crankshaft position sensor seal (O-ring) with clean engine oil.
4. Install the NEW crankshaft position sensor seal (O-ring) onto the crankshaft position sensor.
5. Install the CKP sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(ref-186616-S02905641782005083000000) in Engine Controls.
6. Install the engine oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .
7. Install the water pump. Refer to «Water Pump Replacement (4.3L Engine)»(ref-186629-S00897105062005083000000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-186629-S36003682102005083000000) in Engine Cooling.
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-186638-S17629423312005083000000) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-186638-S23590279692005083000000) .
2. Remove the crankshaft position sensor reluctor ring.

Scheme 23

1. Install the crankshaft position sensor reluctor ring. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-186638-S23590279692005083000000) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 5590 Rear Pinion Bearing Race Installer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 5825-A Crankshaft Gear Remover. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Note. In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt.

Scheme 24

1. Remove the crankshaft position (CKP) sensor reluctor ring. Refer to «Crankshaft Position (CKP) Reluctor Ring Replacement»(ref-186638-S32753925122005083000000) .
2. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft.
3. Rotate the crankshaft until: The timing marks on both sprockets line up. The number 4 cylinder is at top dead center (TDC) of the compression stroke.
4. Unsnap the timing chain tensioner shoe from the pin (1).
5. Remove the camshaft sprocket bolts.
6. Remove the camshaft sprocket and the camshaft timing chain.
7. Using J 5825-A and an open end wrench, remove the crankshaft sprocket. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
8. Remove the crankshaft balancer key.
9. If necessary, remove the timing chain tensioner bracket bolt and bracket.
10. Clean and inspect the timing chain and sprockets, if necessary. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-186638-S37179628412005083000000) .

1. If necessary, install the timing chain tensioner bracket and bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
2. Install the key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
3. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.
4. Using J 5590 , install the crankshaft sprocket. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
5. Install the camshaft sprocket and the camshaft timing chain. Wrap the timing chain around the crankshaft sprocket and position to the driver's side of the engine.
6. Install the timing chain tensioner shoe onto the bracket and position the top of the shoe under the tab at the top of the bracket.
7. Insert the camshaft timing chain sprocket into the timing chain and position so when the camshaft timing chain sprocket is installed on the camshaft, the camshaft timing marks will line up. IMPORTANT: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug.
8. Install the camshaft sprocket bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
9. Ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position.
10. Remove the bolt that was installed in the end of the crankshaft.
11. Install the CKP sensor reluctor ring. Refer to «Crankshaft Position (CKP) Reluctor Ring Replacement»(ref-186638-S32753925122005083000000) .

Balance Shaft Replacement

Tools Required

1. J 8092 Universal Driver Handle. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. J 36996 Balance Shaft Installer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

1. Remove the radiator. Refer to «Radiator Replacement»(ref-186629-S05105224762005083000000) in Engine Cooling.
2. Remove the A/C condenser, if equipped. Refer to «Condenser Replacement»(ref-186630-S13983267842005083000000) in Heating, Ventilation, and Air Conditioning.
3. Remove the valve lifter pushrod guide. Refer to «Valve Lifter Replacement»(ref-186638-S31727023182005083000000) .
4. Remove the camshaft timing chain and sprockets. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-186638-S00302977542005083000000) .
5. Remove the balance shaft drive gear.
6. Remove the balance shaft driven gear bolt from the balance shaft. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. Remove the balance shaft bolt. Remove the wrench from the balance shaft.
7. Remove the balance shaft driven gear from the balance shaft.
8. Remove the bolts and the balance shaft retainer.
9. Use a soft-faced hammer in order to remove the balance shaft from the engine block.
10. Clean and inspect the balance shaft. Refer to «Balance Shaft Cleaning and Inspection»(ref-186638-S11915755412005083000000) .

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent to the balance shaft front bearing.
2. Use the J 36996 and the J 8092 in order to install the balance shaft. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. Install the balance shaft retainer and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the balance shaft driven gear onto the balance shaft.
5. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the balance shaft driven gear bolt.
6. Install the balance shaft driven gear bolt. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. Install the balance shaft driven gear bolt. Tighten: Tighten the balance shaft driven gear bolt on the first pass to 20 N.m (15 lb ft). Tighten the balance shaft driven gear bolt on the final pass using the J 45059 an additional 35 degrees. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case.
9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time.
10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position.
11. Remove the balance shaft drive gear.
12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position.
13. Position the balance shaft drive gear onto the engine camshaft.
14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.
15. Install the camshaft timing chain and the camshaft sprocket. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-186638-S00302977542005083000000) .
16. Install the crankshaft position reluctor ring and the engine front cover. Refer to «Crankshaft Position (CKP) Reluctor Ring Replacement»(ref-186638-S32753925122005083000000) .
17. Install the valve lifter pushrod guide. Refer to «Valve Lifter Replacement»(ref-186638-S31727023182005083000000) .
18. Install the A/C condenser, if equipped. Refer to «Condenser Replacement»(ref-186630-S13983267842005083000000) in Heating, Ventilation, and Air Conditioning.
19. Install the radiator. Refer to «Radiator Replacement»(ref-186629-S05105224762005083000000) in Engine Cooling.

Balance Shaft Bearing and/or Bushing Replacement

Tools Required

1. J 26941 Bushing/Bearing Remover. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 38834 Balance Shaft Service Kit. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

1. Remove the balance shaft. Refer to «Balance Shaft Replacement»(ref-186638-S41150354192005083000000) .
2. Use the J 38834 and the J 26941 in order to remove the balance shaft rear bearing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install J 26941 legs behind the balance shaft rear bearing and secure. Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. Install the J 38834-1 into J 26941 . Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. Install the J 38834 bearing, washer, and nut onto the J 38834-1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Using a wrench secure the J 38834-1 and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the J 26941 from the balance shaft rear bearing.
3. Discard the balance shaft rear bearing.

1. Use the J 38834 in order to install the balance shaft rear bearing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 38834-3 onto the short threaded end of the J 38834-1. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. Install the J 38834-2 on the inside of the balance shaft front bearing bore. Lubricate the NEW balance shaft rear bearing with clean engine oil. Install the balance shaft rear bearing onto the J 38834-2. Align the balance shaft rear bearing for installation. Using a wrench secure the J 38834-1 into place. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Remove the J 38834 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. Install the balance shaft. Refer to «Balance Shaft Replacement»(ref-186638-S41150354192005083000000) .

Scheme 25

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
3. Remove the radiator. Refer to «Radiator Replacement»(ref-186629-S05105224762005083000000) in Engine Cooling.
4. Remove the A/C condenser. Refer to «Condenser Replacement»(ref-186630-S13983267842005083000000) in Heating, Ventilation, and Air Conditioning.
5. Remove the engine cooling fan. Refer to «Fan Clutch Replacement»(ref-186629-S20719799892005083000000) in Engine Cooling.
6. Remove the valve lifters. Refer to «Valve Lifter Replacement»(ref-186638-S31727023182005083000000) .
7. Remove the timing chain and the camshaft sprocket. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-186638-S00302977542005083000000) .
8. Remove the balance shaft drive gear.
9. Remove the camshaft retainer bolts and retainer.
10. Remove the engine camshaft. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. Remove the bolts from the front of the engine camshaft.
11. Clean and inspect the camshaft and the bearings. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-186638-S08701434692005083000000) .

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, or engine oil supplement GM P/N 1052367 (Canadian P/N 992367) or equivalent to the following components: The engine camshaft lobes The camshaft bearing journals The camshaft bearings
2. Install three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes.
3. Use the bolts as a handle in order to install the engine camshaft.
4. Remove the 3 bolts from the front of the engine camshaft.
5. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the camshaft retainer bolts.
6. Install the camshaft retainer and bolts. Tighten: Tighten the camshaft retainer bolts to 12 N.m (106 lb in).
7. Install the balance shaft drive gear. Refer to «Balance Shaft Replacement»(ref-186638-S41150354192005083000000) for alignment of the balance shaft drive gear and the driven gear.
8. Install the timing chain and camshaft sprocket. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-186638-S00302977542005083000000) .
9. Install the valve lifters. Refer to «Valve Lifter Replacement»(ref-186638-S31727023182005083000000) .
10. Install the A/C condenser. Refer to «Condenser Replacement»(ref-186630-S13983267842005083000000) in Heating, Ventilation, and Air Conditioning.
11. Install the engine cooling fan. Refer to «Fan Clutch Replacement»(ref-186629-S20719799892005083000000) in Engine Cooling.
12. Install the radiator. Refer to «Radiator Replacement»(ref-186629-S05105224762005083000000) in Engine Cooling.
13. Fill the engine cooling system. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
14. Recharge the air conditioning system. Refer to «Refrigerant Recovery and Recharging»(ref-186630-S34430157292005083000000) in Heating, Ventilation, and Air Conditioning.
15. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Position a suitable container to catch the engine oil.
3. Remove the oil filter.
4. Disconnect the engine oil cooler pipes from the oil filter adapter. Refer to «Engine Oil Cooler Hose/Pipe Replacement»(ref-186629-S25357365942005083000000) in Engine Cooling.
5. Remove the oil filter adapter bolts.
6. Remove the oil filter adapter and the oil filter adapter gasket.
7. Discard the oil filter adapter gasket.
8. Remove the oil filter adapter seal O-ring.
9. Discard the oil filter adapter seal O-ring.

1. Install the NEW oil filter adapter seal O-ring into the groove in the oil filter adapter.
2. Install the oil filter adapter and NEW oil filter adapter gasket.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 21 N.m (15 lb ft).
4. Install the oil cooler pipes to the oil filter adapter. Refer to «Engine Oil Cooler Hose/Pipe Replacement»(ref-186629-S25357365942005083000000) in Engine Cooling.
5. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-186638-S29459033042005083000000) .
6. Lower the vehicle.
7. Operate the vehicle and check for leaks.
8. Check the oil level and add as required.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Position a suitable container to catch the engine oil.
3. Remove the oil filter.
4. Remove the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-186638-S01262724532005083000000) .
5. Using a suitable prying tool remove the oil filter bypass valve.
6. Clean and inspect valve bore for damage.

Scheme 26

1. Install a NEW oil filter bypass valve using the following procedure: Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart.
2. Install the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-186638-S01262724532005083000000) .
3. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-186638-S29459033042005083000000) .
4. Lower the vehicle.

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
3. Remove the oil pan drain plug and drain the engine oil into a suitable container.
4. Remove the oil filter.
5. Remove the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-186638-S01262724532005083000000) .
6. If equipped with AWD, remove the front differential carrier. Refer to «Differential Carrier Assembly Replacement»(ref-186678-S14124455252005083000000) in Front Drive Axle.
7. Remove the bolt holding the bracket for the starter wire and the transmission cooler pipes.
8. Remove the crankcase position (CKP) sensor wiring harness from the retainer.
9. Remove the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
10. Remove the transmission cover.
11. Remove the access plugs for the oil pan rear nuts.
12. Remove the transmission to oil pan bolts.
13. Remove and discard the engine oil level sensor, if applicable.
14. Remove the oil pan bolts and nuts.
15. Remove the oil pan.
16. Remove the oil pan gasket.
17. Discard the oil pan gasket.
18. Clean all sealing surfaces on the engine and the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-186638-S41010598872005083000000) .

1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces.
2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces.
3. Install the NEW oil pan gasket into the groove in the oil pan.
4. Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing.
5. Slide the oil pan back against a suitable straight edge.
6. Install the oil pan bolts and nuts, but do not tighten.
7. Measure the pan-to-transmission housing clearance using a feeler gage and a straight edge. Use a feeler gage to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 in) at any of the 3 oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block.
8. Tighten the oil pan bolts and nuts in sequence (1-12). Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
9. Measure the clearance between the 3 oil pan-to-transmission housing measurement points in order to ensure proper alignment.
10. Install a NEW oil pan drain plug seal (O-ring) onto the oil pan drain plug.
11. Install the oil pan drain plug into the oil pan. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
12. Install the NEW engine oil level sensor, if applicable. Tighten: Tighten the engine oil level sensor to 13 N.m (115 lb in).
13. Install the transmission to oil pan bolts. Tighten: Tighten the bolts to 47 N.m (35 lb ft).
14. Install the transmission cover. Tighten: Tighten the transmission cover bolts to 12 N.m (106 lb in).
15. Install the access plugs for the oil pan rear nuts.
16. Install the starter motor. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
17. Install the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes. Tighten: Tighten the bracket bolt to 9 N.m (80 lb in).
18. Install the CKP sensor wiring harness in the retainer.
19. Install the oil filter adapter. Refer to «Oil Filter Adapter Replacement»(ref-186638-S01262724532005083000000) .
20. Install the oil filter and the oil pan drain plug. Refer to «Engine Oil and Oil Filter Replacement»(ref-186638-S29459033042005083000000) .
21. If equipped with AWD, install the front differential carrier. Refer to «Differential Carrier Assembly Replacement»(ref-186678-S14124455252005083000000) in Front Drive Axle.
22. Lower the vehicle.
23. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-186638-S29459033042005083000000) .
24. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-186595-S11053284922005083000000) in Engine Electrical.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Disconnect the engine oil pressure gage sensor electrical connector.
3. Hold the engine oil pressure gage sensor fitting with a wrench.
4. Remove the engine oil pressure gage sensor using J 41712 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
5. Remove the engine oil pressure gage sensor fitting, if necessary.

Scheme 27

1. Install the engine oil pressure gage sensor fitting, if removed. Tighten: Tighten the engine oil pressure gage sensor fitting to 15 N.m (11 lb ft). IMPORTANT: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. Tighten the sensor fitting until properly align.
2. Install the engine oil pressure gage sensor.
3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Tighten: Using J 41712 tighten the engine oil pressure gage sensor to 30 N. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .m (22 lb ft).
4. Connect the engine oil pressure gage sensor electrical connector.
5. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
2. Remove the bolt holding the coolant recovery reservoir and set the reservoir aside.
3. Remove the oil level indicator.
4. Remove the screw holding the oil level indicator and the transmission fluid fill tube to the oil fill tube lower support.
5. Remove the top half of the oil level indicator tube from the bottom half.
6. Clean the old sealer from the tube.
7. Remove the oil level indicator tube bolt.
8. Remove the oil level indicator tube from the engine using a twisting motion.
9. Clean the old sealer from the oil level indicator tube and the engine block.

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent around the oil level indicator tube 13 mm (0.5 in) below the tube bead.
2. Install the oil level indicator tube into the engine block. Rotate the oil level indicator tube into position.
3. Apply sealer, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, on the upper oil level indicator tube to the area where it fits into the lower half.
4. Install the oil level indicator tube upper half to the lower half.
5. Install the bolt that holds the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support. Tighten: Tighten the oil fill level indicator tube and the transmission fluid fill tube to lower support bolt to 5 N.m (44 lb in).
6. Install the oil level indicator.
7. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.
8. Position the coolant recovery reservoir and install the bolt.

1. Remove the engine oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .
2. Remove the oil pump bolt.
3. Remove the oil pump.
4. Inspect the pins (oil pump locator) for damage, and replace the pins if required.
5. Clean and inspect all parts. Refer to «Oil Pump Cleaning and Inspection»(ref-186638-S14724093102005083000000) .

1. Inspect for properly installed pins (oil pump locator).
2. Install the oil pump.
3. Position the oil pump onto the pins.
4. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 90 N.m (66 lb ft).
5. Install the oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .

1. Remove the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission-4L60-E.
2. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-186638-S36256654292005083000000) .
3. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing.
4. Discard the crankshaft rear oil seal.
5. Clean off any dirt or rust in the area.

1. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing.
2. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange.
3. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin.
4. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface.
5. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Minor imperfections may be removed with a fine grade emery cloth.
6. Remove the sleeve from the crankshaft rear oil seal.
7. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal.
8. Install the crankshaft rear oil seal onto the J 35621-B . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
9. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
10. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. Turn the J 35621-B wing nut counterclockwise to release the. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . J 35621-B from the crankshaft rear oil seal. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the J 35621-B from the crankshaft. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Wipe off any excess engine oil with a clean rag.
11. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-186638-S36256654292005083000000) .
12. Install the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission-4L60-E.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .
2. Remove the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission - 4L60-E.
3. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-186638-S36256654292005083000000) .
4. Remove the bolts and the nut holding the crankshaft rear oil seal housing to the engine.
5. Remove the crankshaft rear oil seal housing.
6. Remove and discard the crankshaft rear oil seal housing gasket.
7. Clean all the sealing surfaces.
8. Inspect the crankshaft rear oil seal housing for warping, cracks, wear, or damage.

1. Install a NEW crankshaft rear oil seal housing gasket.
2. Install the NEW crankshaft rear oil seal housing with the oil seal to the engine block using the following procedure. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a guide to ease the seal lip over the end of the crankshaft. Push the crankshaft rear oil seal housing with the seal, fully onto the crankshaft until the crankshaft rear oil seal housing is against the crankshaft rear oil seal gasket and the engine.
3. Install the three bolts and the one nut to the crankshaft rear oil seal housing. Tighten: Tighten the crankshaft rear oil seal housing bolts and nut to 12 N.m (106 lb in).
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-186638-S36256654292005083000000) .
5. Install the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission - 4L60-E.
6. Install the oil pan. Refer to «Oil Pan Replacement»(ref-186638-S13693159122005083000000) .

1. Remove the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission.
2. Remove the bolts and the engine flywheel.
3. Clean and inspect all parts. Refer to «Engine Flywheel Cleaning and Inspection»(ref-186638-S34704030162005083000000) .

1. Install the engine flywheel to the crankshaft.
2. Align the locator hole to the pin.
3. Install the engine flywheel bolts. Tighten: Tighten the engine flywheel bolts in sequence to 100 N.m (74 lb ft).
4. Install the transmission assembly. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission.

1. Install the engine assembly to the vehicle.
2. Loosely install the 2 upper transmission to engine bolts.
3. Install the engine mounts to the engine mount frame brackets. Refer to the following procedures: «Engine Mount Replacement - Left»(ref-186638-S23218287102005083000000) «Engine Mount Replacement - Right»(ref-186638-S34397472692005083000000)
4. Remove the engine lifting device.
5. Remove the J 41427 from the engine.
6. Apply thread lock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
7. Install the lower intake manifold bolts. Tighten: Tighten the bolts to 3 N.m (27 lb in). Tighten the bolts to 12 N.m (106 lb in). Tighten the bolts to 15 N.m (11 lb ft).
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
9. Install the remaining bolts from the transmission to the engine. Refer to «Transmission Replacement»(ref-186648-S10601512552005083000000) in Automatic Transmission - 4L60-E/4L65-E for location of the proper bolts and tightening specifications.
10. Install the bolt holding the transmission cooler pipes bracket to the oil pan. Tighten: Tighten the bolt to 9 N.m (80 lb in).
11. Install the torque converter bolts to the flywheel. Tighten: Tighten the bolts to 62 N.m (46 lb ft).
12. Install the transmission cover. Tighten: Tighten the transmission cover bolts to 12 N.m (106 lb in).
13. Install the starter motor. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(ref-186595-S21564992502005083000000) or «Starter Motor Replacement (4.3L)»(ref-186595-S07149347622005083000000) in Engine Electrical.
14. Install the engine oil cooler pipes to the engine. Refer to «Engine Oil Cooler Hose/Pipe Replacement»(ref-186629-S25357365942005083000000) in Engine Cooling.
15. Install the exhaust manifolds. Refer to the following procedures: «Exhaust Manifold Replacement - Left (4.3L)»(ref-186654-S23478174812005083000000) or «Exhaust Manifold Replacement - Left (4.8L, 5.3L, 6.0L)»(ref-186654-S29209774452005083000000) in Engine Exhaust «Exhaust Manifold Replacement - Right (4.3L)»(ref-186654-S12194338692005083000000) or «Exhaust Manifold Replacement - Right (4.8L, 5.3L, 6.0L)»(ref-186654-S11907835852005083000000) in Engine Exhaust
16. Lower the vehicle.
17. Install the upper intake manifold to the engine. Refer to «Intake Manifold Replacement - Upper»(ref-186638-S15188406172005083000000) .
18. Install the EGR valve inlet pipe. Refer to «Exhaust Gas Recirculation (EGR) Pipe Replacement»(ref-186616-S10494703872005083000000) in Engine Controls - 4.3L.
19. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
20. Install the transmission control cable bracket to the rear of the left cylinder head. Tighten: Tighten the transmission control cable bracket bolts to 40 N.m (30 lb ft).
21. Install the distributor. Refer to «Distributor Replacement»(ref-186616-S31785130802005083000000) in Engine Controls - 4.3L.
22. Install the power steering pump with the rear bracket to the engine. Refer to «Power Steering Pump Replacement (4.3L)»(ref-186662-S19496337112005083000000) or «Power Steering Pump Replacement (4.8L, 5.3L, and 6.0L)»(ref-186662-S03166105012005083000000) in Power Steering System.
23. Install the power steering pump mounting bracket.
24. Install the A/C compressor Discharge Hose from the vehicle. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(ref-186630-S40373946652005083000000) or «Discharge Hose Replacement (4.3L)»(ref-186630-S22117990622005083000000) in Heating, Ventilation, and Air Conditioning.
25. Install the A/C compressor Suction Hose from the vehicle. Refer to «Suction Hose Replacement»(ref-186630-S28832685872005083000000) in Heating, Ventilation, and Air Conditioning.
26. Install the radiator inlet and outlet hoses to the engine. Refer to the following procedures: «Radiator Hose Replacement - Inlet»(ref-186629-S38284589192005083000000) in Engine Cooling «Radiator Hose Replacement - Outlet»(ref-186629-S14537323352005083000000) in Engine Cooling
27. Install the heater hoses to the engine. Refer to «Heater Hose Replacement - Inlet»(ref-186630-S39825653912005083000000) and «Heater Hose Replacement - Outlet»(ref-186630-S29224256932005083000000) in Heating, Ventilation, and Air Conditioning.
28. Install the generator mounting bracket.
29. Install the stud and bolt holding the ground wires to the rear of both cylinder heads. Tighten: Tighten the bolt and the stud to 10 N.m (88 lb in).
30. Install the nut holding the engine wiring harness at the transmission to engine stud. Tighten: Tighten the nut to 10 N.m (88 lb in).
31. Connect the crankshaft position (CKP) sensor (3).
32. Install the engine wiring harness clip (1) from the stud on the generator mounting bracket.
33. Install the engine wiring harness clip (2) at the front of the engine.
34. Connect the following electrical connectors: The fuel meter body assembly connector (1) The EVAP canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3)
35. Connect the following electrical connectors: The distributor (2) The engine oil pressure sensor (3) The knock (KS) sensor (1)
36. Connect the following electrical connectors: The throttle position (TP) sensor (1) The idle air control (IAC) motor (2) The engine coolant temperature (ECT) gage sensor (3) The A/C high pressure switch (4), if equipped
37. Disconnect the following electrical connectors: The A/C compressor clutch (1), if equipped The EGR valve (2) The engine coolant temperature (ECT) sensor (3)
38. Install the nut holding the ground wire (4) to the water outlet stud. Tighten: Tighten the nut to 10 N.m (88 lb in).
39. Install the bolt holding the battery negative cable and the ground strap to the front of the engine. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
40. Install a NEW accelerator control cable. Refer to «Accelerator Controls Cable Replacement»(ref-186616-S35683245022005083000000) in Engine Controls - 4.3L.
41. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(ref-186606-S27581933252005083000000) in Cruise Control.
42. Install the fan clutch to the water pump. Refer to «Fan Clutch Replacement»(ref-186629-S20719799892005083000000) in Engine Cooling.
43. Install the radiator support. Refer to «Radiator Support Replacement»(ref-186624-S22509713832005083000000) in Body Front End.
44. Install the oil filter and fill the engine with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-186638-S29459033042005083000000) .
45. Fill the cooling system with the proper quantity and type of coolant. Refer to «Draining and Filling Cooling System»(ref-186629-S37766623502005083000000) in Engine Cooling.
46. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-186630-S34430157292005083000000) in Heating, Ventilation, and Air Conditioning.
47. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
48. Start the engine and listen for unusual noises.
49. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. If necessary, install an oil pressure gage and measure the engine oil pressure.
50. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
51. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
52. Inspect for oil and/or coolant leaks while the engine is operating.
53. Verify that the distributor is properly positioned.
54. Perform a final inspection for the proper engine oil and coolant levels.
55. Install the engine cover. Refer to «Engine Cover Replacement»(ref-186605-S04737176332005083000000) in Interior Trim.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-186615-S04059690442005083000000) in General Information.
2. Remove the oil pan drain plug and drain the engine oil in a suitable container.
3. Remove the engine oil filter.
4. Inspect to ensure the engine oil filter gasket is removed.

1. Lubricate the engine oil filter gasket with clean engine oil.
2. Install the engine oil filter.
3. Follow the tightening instructions on the oil filter.
4. Install the oil pan drain plug to the oil pan. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Lower the vehicle.
6. Fill the engine with the proper capacity and quality of engine oil. Refer to «Capacities - Approximate Fluid»(ref-186646-S38685436672005083000000) in Maintenance and Lubrication. Refer to «Explanation of Scheduled Services»(ref-186646-S09297427002005083000000) in Maintenance and Lubrication.
7. Operate the engine, check for leaks and oil pressure.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container.
2. Remove the oil filter.
3. Discard the oil filter.
4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container.

Engine Flywheel Removal

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

Exhaust Manifold Removal - Left

1. Remove the spark plug wires from the spark plugs. Rotate the spark plug wire boot one half turn. Pull outward on the spark plug wire boot to release from the spark plug.
2. Remove the spark plug wires from the spark plug wire retainers.
3. Remove the exhaust manifold bolts and the stud.
4. Remove the spark plug wire shields, if applicable, and the exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.

Exhaust Manifold Removal - Right

1. Remove the spark plug wires from the spark plugs. Rotate the spark plug wire boot one half turn. Pull outward on the spark plug wire boot to release from the spark plug.
2. Remove the spark plug wires from the spark plug wire retainers.
3. Remove the exhaust manifold bolts.
4. Remove the spark plug wire shields and the exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator from the oil level indicator tube, if required.
2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube from the engine block.

Water Pump Removal

Tools Required: J 41240 Fan Clutch Remover and Installer. See Special Tools and Equipment .

1. Remove the bolts and the fan and water pump pulley using the J 41240 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Remove the clamps and the water pump inlet hose.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.

Crankshaft Balancer Removal

Tools Required: J 23523-F Balancer Remover and Installer. See Special Tools and Equipment .

1. Remove the crankshaft balancer bolt and washer.
2. Remove the bolts and the crankshaft pulley.
3. Use the J 23523-F in order to remove the crankshaft balancer. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten: Tighten the bolts to 25 N.m (18 lb ft). Install the J 23523-F forcing screw into the plate. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer.
5. Note the position and length of any crankshaft balancer front groove pins, if applicable.

Valve Rocker Arm Cover Removal - Left

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.
4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Distributor Removal

1. Remove the ignition coil wire harness from the ignition coil and distributor cap.
2. Remove the distributor clamp bolt.
3. Remove the distributor and the distributor clamp.
4. Remove the distributor gasket and discard.

Scheme 28

1. Remove the evaporative emission (EVAP) canister purge solenoid valve harness. Push the quick disconnect clip and hold in place. Pull outward on the harness elbow.
2. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
3. Remove the lower intake manifold bolts.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold gaskets.

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arms.
2. Remove the valve rocker arm supports.
3. Remove the valve pushrods.

Cylinder Head Removal - Left

1. Remove the engine coolant temperature sensor, if applicable.
2. Remove the engine coolant temperature gage sensor, if applicable.
3. Remove the spark plugs.
4. Remove the bolts and the spark plug wire support.
5. Remove the cylinder head bolts and discard.
6. Remove the cylinder head.
7. Remove and discard the cylinder head gasket.
8. Remove the cylinder head locator dowel pins, if required.

Cylinder Head Removal - Right

1. Remove the spark plugs.
2. Remove the rear bolt and the spark plug wire support.
3. Remove the cylinder head bolts and discard.
4. Remove the cylinder head.
5. Remove and discard the cylinder head gasket.
6. Remove the cylinder head locator dowel pins, if required.

Valve Lifter Removal

Tools Required: J 3049-A Valve Lifter Remover. See Special Tools and Equipment .

1. Remove the bolts and valve lifter pushrod guide.
2. Remove the valve lifters.
3. Use the J 3049-A in order to remove the stuck valve lifters. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Oil Filter Adapter Removal

1. Remove the oil filter adapter bolts.
2. Remove the oil filter adapter and the oil filter adapter gasket.
3. Discard the oil filter adapter gasket.
4. Remove the oil filter adapter seal (O-ring).
5. Discard the oil filter adapter seal (O-ring).

Oil Pan Removal

1. Remove the oil pan bolts and nuts.
2. Remove the oil pan.
3. Remove the oil pan gasket.
4. Discard the oil pan gasket.

Oil Pump Removal

1. Remove the oil pump bolt.
2. Remove the oil pump.
3. Inspect the oil pump locator pins for damage, and replace the pins if required.

Engine Front Cover Removal

1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor seal, O-ring.
4. Discard the crankshaft position sensor seal, O-ring.
5. Remove the engine front cover bolts.
6. Remove the engine front cover.
7. Discard the engine front cover.

Timing Chain and Sprockets Removal

Tools Required: J 5825-A Crankshaft Gear Remover. See Special Tools and Equipment .

Scheme 29

1. Remove the crankshaft position sensor reluctor ring.
2. Remove the timing chain tensioner shoe (229) using a downward motion.
3. Remove the timing chain tensioner bracket bolt and bracket (227 and 228).
4. Check the camshaft timing chain free play. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2). Measure the free play on the slack side (3) of the camshaft timing chain. If the camshaft timing chain can be moved side to side in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly.
5. Remove the camshaft sprocket bolts.
6. Remove the camshaft sprocket and the camshaft timing chain.
7. Remove the crankshaft sprocket using the J 5825-A . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
8. Remove the crankshaft balancer key.

Balance Shaft Removal

1. Remove the balance shaft drive gear.
2. Remove the balance shaft driven gear bolt from the balance shaft. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. Remove the balance shaft bolt. Remove the wrench from the balance shaft.
3. Remove the balance shaft driven gear from the balance shaft.
4. Remove the bolts and the balance shaft retainer.
5. Use a soft-faced hammer in order to remove the balance shaft from the engine block.

Camshaft Removal

1. Remove the camshaft retainer bolts and retainer.
2. Remove the engine camshaft. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. Remove the bolts from the front of the engine camshaft.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 5239 Connecting Rod Bolt Guide Set. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Scheme 30

1. Use the J 24270 in order to remove the cylinder ring ridge. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . 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 to remove all of the cylinder ring ridge. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Turn the crankshaft so the piston is at the top of the stroke. Remove the cloth. Remove the cutting debris.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.
4. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
5. Remove the connecting rod bearings. Keep the connecting rod bearings with the original connecting rod and connecting rod cap. Wipe the oil from the connecting rod bearings. Wipe the oil from the crankpins.

Crankshaft Rear Oil Seal and Housing Removal

1. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing.
2. Discard the crankshaft rear oil seal.
3. Remove the crankshaft rear oil seal housing nut and bolts.
4. Remove the crankshaft rear oil seal housing.
5. Remove the crankshaft rear oil seal housing gasket.
6. Discard the crankshaft rear oil seal housing gasket.
7. Remove the crankshaft rear oil seal housing retainer stud from the engine block.

Crankshaft and Bearings Removal

1. Mark or identify the crankshaft bearing cap locations, direction, and positions for assembly.
2. Remove the crankshaft bearing cap bolts and discard.
3. Remove the crankshaft bearing caps.
4. Remove the crankshaft.
5. Remove the crankshaft bearings from the crankshaft bearing caps.
6. Remove the crankshaft bearings from the engine block.

Engine Block Plug Removal

Tools Required: J 41712 Oil Pressure Switch Socket. See Special Tools and Equipment .

Scheme 31

1. Remove the knock sensor retaining bolt (1).
2. Remove the knock sensor (2).
3. Remove the engine oil pressure gage sensor using the J 41712 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. Remove the engine oil pressure sensor fitting.
5. Remove the transmission locator dowel straight pins, if required.
6. Remove the engine block left side oil gallery plug.
7. Remove the engine block left rear oil gallery plug.
8. Remove the engine block right rear oil gallery plug.
9. Remove the expansion cup plug from the camshaft rear bearing hole and discard.
10. Remove the expansion cup plug from the balance shaft rear bearing hole and discard.
11. Remove the crankshaft rear oil seal housing locator spring type S pin, if required.
12. Remove the front oil gallery plugs or balls from the front of the engine block and discard. Insert a 3/8 x 26 inch rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls.
13. Remove the engine block core hole plugs. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket. Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket. Discard the engine block core hole plugs.
14. Remove the oil filter bypass valve and discard.

Camshaft Bearing Removal

Tools Required: J 33049 Camshaft Bearing Service Kit. See Special Tools and Equipment .

Scheme 32

1. Select the cone (1), the handle (10), the expanding driver (4-8), the washer (2 or 3), and the expander assembly (15) from the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Assemble the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. Remove the camshaft inner bearings #2 and #3. Insert the J 33049 through the front of the engine block and into the camshaft inner bearing #2. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft inner bearing #2 from the camshaft inner bearing bore #2. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the camshaft inner bearing #2 from the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Insert the J 33049 expander assembly into the camshaft inner bearing #3. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft inner bearing #3 from the camshaft inner bearing bore #3. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the camshaft inner bearing #3 from the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. Remove the J 33049 from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
5. Remove the camshaft outer bearings #1 and #4. Insert the J 33049 into the camshaft outer bearing #1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the camshaft outer bearing #1 from the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the J 33049 from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Insert the J 33049 into the camshaft outer bearing #4. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft outer bearing #4 from the camshaft outer bearing bore #4. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the camshaft outer bearing #4 from the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
6. Remove the J 33049 from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
7. Discard the camshaft bearings.

Camshaft Bearing Installation

Tools Required: J 33049 Camshaft Bearing Service Kit. See Special Tools and Equipment .

Scheme 33

1. Assemble the J 33049 handle (10), the expanding driver (4-8), the washer (2 or 3), and the expander assembly (15). See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Install the NEW camshaft outer bearings #4 and #1. Install the NEW camshaft outer bearing #4 onto the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Align the lubrication hole of the camshaft outer bearing #4 above the 3 o'clock position or the 9 o'clock position of the camshaft outer bearing bore #4 at the rear of the engine block. Drive the camshaft outer bearing #4 into the camshaft outer bearing bore #4 at the rear of the engine block. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the camshaft outer bearing #4 from the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the NEW camshaft outer bearing #1 onto the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Align the lubrication hole of the camshaft outer bearing #1 above the 3 o'clock position or the 9 o'clock position of the camshaft outer bearing bore #1 at the front of the engine block. Drive the camshaft outer bearing #1 into the camshaft outer bearing bore #1 at the front of the engine block. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bores. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. Install the NEW camshaft inner bearings #3 and #2. Install the NEW camshaft inner bearing #3 onto the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Align the lubrication hole of the camshaft inner bearing #3 above the 3 o'clock position or the 9 o'clock position of the camshaft inner bearing bore #3 of the engine block. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft inner bearing #3 into the camshaft inner bearing bore #3. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #2 and the camshaft outer bearing bore #1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the NEW camshaft inner bearing #2 onto the J 33049 expander assembly. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten the J 33049 expander assembly nut until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Align the lubrication hole of the camshaft inner bearing #2 above the 3 o'clock position or the 9 o'clock position of the camshaft inner bearing bore #2 of the engine block. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2. Loosen the J 33049 expander assembly nut. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. Carefully remove the J 33049 from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Balance Shaft Bearing and/or Bushing Removal

Tools Required

1. J 26941 Bushing/Bearing Remover. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 38834 Balance Shaft Service Kit. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

1. Use the J 38834 and the J 26941 in order to remove the balance shaft rear bearing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install J 26941 legs behind the balance shaft rear bearing and secure. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. Install the J 38834-1 into J 26941 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. Install the J 38834 bearing, washer, and nut onto the J 38834-1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Using a wrench secure the J 38834-1 and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Remove the J 26941 from the balance shaft rear bearing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Discard the balance shaft rear bearing.

Scheme 34

Scheme 35

1. Clean the following components in cleaning solvent: The balance shaft (1) The balance shaft retainer (2) The balance shaft rear bearing (3) The balance shaft driven gear (4) The balance shaft drive gear (5)
2. Dry the following components with compressed air: The balance shaft (1) The balance shaft retainer (2) The balance shaft rear bearing The balance shaft driven gear (4) The balance shaft drive gear
3. Inspect the balance shaft bearings for the following: Front ball bearing for damage or wear Front ball bearing for smoothness of operation Rear sleeve bearing for wear, scoring, or other damage
4. Inspect the balance shaft (1) for the following: Wear or scoring on the rear bearing journal Damaged bolt hole threads Damage to the balance shaft driven gear locator pin
5. Inspect the balance shaft retainer (2) for wear or damage.
6. Inspect the balance shaft retainer bolts (3) for damaged threads.
7. Inspect the driven gear (4) for the following: Excessive wear or damage Nicks, burrs, or scoring
8. Inspect the driven gear bolt (5) for damaged threads.
9. Inspect the balance shaft drive gear for the following: Excessive wear or damage Nicks, burrs, or scoring

Balance Shaft Bearing and/or Bushing Installation

Tools Required: J 38834 Balance Shaft Service Kit. See Special Tools and Equipment .

1. Use the J 38834 in order to install the balance shaft rear bearing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 38834-3 onto the short threaded end of the J 38834-1. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. Install the J 38834-2 on the inside of the balance shaft front bearing bore. Lubricate the NEW balance shaft rear bearing with clean engine oil. Install the balance shaft rear bearing onto the J 38834-2. Align the balance shaft rear bearing for installation. Using a wrench secure the J 38834-1 into place. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. Remove the J 38834 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Scheme 36

1. Clean the components with cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the camshaft timing chain for binding or wear.
4. Inspect the camshaft sprocket and the crankshaft sprocket for: Broken teeth (1) Damaged teeth (2) Chipped teeth (3) Worn teeth Uneven wear on the edge of the teeth Worn valleys between the sprocket teeth Crankshaft sprocket keyway for wear
5. Inspect the timing chain tensioner bracket and shoe for cracking and wear.

Scheme 37

1. Mark, sort, and organize the components for assembly.
2. Clean the components with cleaning solvent.
3. Dry the components with compressed air.
4. Inspect the valve rocker arm components for the following: Valve rocker arm valve pushrod socket contact surface (1) The contact surface must be smooth with no scoring or excessive wear. Valve rocker arm roller pivot for binding or damage (2) Valve rocker arm valve stem contact surface (3) The contact surface should be smooth with no scoring or excessive wear. Valve rocker arm bolt threads for damage (4)
5. Inspect the valve pushrods for the following: Restriction of the oil passage (1) Wear or scoring of the end contact surfaces (2) The end contact surfaces must be smooth with no scoring or excessive wear. Shaft for bends (3) Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent.
6. Inspect the valve rocker support for excessive wear or damage.

Scheme 38

1. Mark, sort, and organize the components for assembly.
2. Clean the components in cleaning solvent.
3. Dry the components with compressed air.
4. Inspect the valve lifter pushrod guides for excessive wear.
5. Inspect the valve lifter pushrod guides for cracks or damage.
6. Inspect the valve lifter for the following: Broken or damaged clip (1) Worn pushrod socket (2) Scuffed or worn lifter body (3) If the valve lifter shows scuffing or wear, inspect the engine block valve lifter bores for wear. Worn roller (4) Loose or damaged pin (5) Plugged oil hole (6)

Engine Block Plug Installation

Tools Required: J 41712 Oil Pressure Switch Socket. See Special Tools and Equipment .

1. Install a NEW oil filter bypass valve. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW front engine oil gallery plugs.
3. Install the NEW front engine block oil gallery plugs. A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block.
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the outside diameter of the NEW engine block core hole plugs.
5. Install the NEW engine block core hole plugs. A properly installed engine block core hole plug must be installed flush or below the bottom of the chamfer (1) of the engine block core hole.
6. Install the crankshaft rear oil seal housing locator spring type S pin, if required.
7. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW expansion cup plug.
8. Install the NEW expansion cup plug into the balance shaft rear bearing hole.
9. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the outside diameter of the NEW expansion cup plug.
10. Install the NEW expansion cup plug into the camshaft rear bearing hole.
11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug.
12. Install the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug. Tighten: Tighten the engine block left side oil gallery plug and the engine block right rear oil gallery plug to 20 N.m (15 lb ft). Tighten the engine block left rear oil gallery plug to 30 N.m (22 lb ft).
13. Install the transmission locator dowel straight pins, if required.
14. Install the left side cylinder head locator dowel pins, if required. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
15. Install the right side cylinder head locator dowel pins, if required. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
16. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine block coolant drain hole plugs.
17. Install the engine block coolant drain hole plugs. Tighten: Tighten the engine block coolant hole plugs to 20 N.m (15 lb ft).
18. If reusing the engine oil pressure sensor fitting, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine oil pressure sensor fitting.
19. Install the engine oil pressure sensor fitting. Tighten: Tighten the engine oil pressure sensor fitting to 15 N.m (11 lb ft).
20. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1), 50 degrees from the centerline (2).
21. If reusing the engine oil pressure gage sensor, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine oil pressure gage sensor.
22. Install the engine oil pressure gage sensor using the J 41712 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the engine oil pressure gage sensor to 30 N.m (22 lb ft).
23. Install the knock sensor (2).
24. Install the knock sensor retaining bolt (1). Tighten: Tighten the knock sensor to 25 N.m (18 lb ft).

Crankshaft and Bearings Installation

Tools Required: J 45059 Angle Meter. See Special Tools and Equipment .

1. Install the crankshaft bearings into the engine block.
2. Apply clean engine oil to the crankshaft bearings.
3. Apply clean engine oil to the crankshaft bearing journals.
4. Install the crankshaft.
5. Install the crankshaft bearings into the crankshaft bearing caps.
6. Apply clean engine oil to the crankshaft bearings.
7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
8. Install the NEW crankshaft bearing cap bolts until snug.
9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps.
10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings.
11. Tighten the crankshaft bearing cap bolts. Tighten: Tighten the crankshaft bearing cap bolts on the first pass to 20 N.m (15 lb ft). Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 45059 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
12. Measure the crankshaft end play. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces. With the crankshaft pushed forward, insert a feeler gage between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance. Specification: Crankshaft end play 0.05-0.20 mm (0.002-0.008 in)
13. Rotate the crankshaft in order to check for binding. A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding.
14. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding. A lack of proper crankshaft bearing clearance may be caused by the following: Burrs on the crankshaft bearing cap Foreign material between the crankshaft bearing and the engine block Foreign material between the crankshaft bearing and the crankshaft bearing cap Damaged crankshaft bearing Improper size crankshaft bearing

Crankshaft Rear Oil Seal and Housing Installation

Tools Required: J 35621-B Rear Main Seal Installer. See Special Tools and Equipment .

1. Install the crankshaft rear oil seal housing retainer stud. Tighten: Tighten the crankshaft rear oil seal housing retainer stud to 6 N.m (53 lb in).
2. Install the NEW crankshaft rear oil seal housing gasket.
3. Install the crankshaft rear oil housing onto the crankshaft rear oil seal housing retainer stud.
4. Install the crankshaft rear oil seal housing nut and bolts. Tighten: Tighten the crankshaft rear oil seal housing nut and bolts to 12 N.m (106 lb in).
5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing.
6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange.
7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin.
8. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft seal surface.
9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Minor imperfections may be removed with a fine grade emery cloth.
10. Remove the sleeve from the crankshaft rear oil seal.
11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the J 35621-B . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. Turn the J 35621-B wing nut counterclockwise to release the. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . J 35621-B from the crankshaft rear oil seal. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
15. Remove the J 35621-B from the crankshaft. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
16. Wipe off any excess engine oil with a clean rag.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 5239 Connecting Rod Bolt Guide Set. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 8037 Ring Compressor. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. J 8087 Cylinder Bore Gage. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Camshaft Installation

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, or engine oil supplement GM P/N 1052367 (Canadian P/N 992367) or equivalent, to the following components: The engine camshaft lobes The camshaft bearing journals The camshaft bearings The distributor drive gear
2. Install three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes.
3. Use the bolts as a handle in order to install the engine camshaft.
4. Remove the 3 bolts from the front of the engine camshaft.
5. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the camshaft retainer bolts.
6. Install the camshaft retainer and bolts. Tighten: Tighten the camshaft retainer bolts to 12 N.m (106 lb in).

Balance Shaft Installation

Tools Required

1. J 8092 Universal Driver Handle. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
2. J 36996 Balance Shaft Installer. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
3. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, to the balance shaft front bearing.
2. Use the J 36996 and the J 8092 in order to install the balance shaft.
3. Install the balance shaft retainer and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the balance shaft driven gear onto the balance shaft.
5. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the balance shaft driven gear bolt.
6. Install the balance shaft driven gear bolt. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. Install the balance shaft driven gear bolt. Tighten: Tighten the balance shaft driven gear bolt on the first pass to 20 N.m (15 lb ft). Tighten the balance shaft driven gear bolt on the final pass using the J 45059 an additional 35 degrees. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
7. Remove the wrench from the balance shaft.
8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case.
9. Install the balance shaft drive gear.
10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position.
11. Remove the balance shaft drive gear.
12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position.
13. Position the balance shaft drive gear onto the engine camshaft.
14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.

Timing Chain and Sprockets Installation

Tools Required: J 5590 Pinion Bearing Race Installer - Rear. See Special Tools and Equipment .

1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.
3. Use the J 5590 in order to install the crankshaft sprocket. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .
4. Rotate the crankshaft until the crankshaft sprocket alignment mark is at the 12 o'clock position.
5. Install the camshaft sprocket and the camshaft timing chain.
6. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position.
7. Install camshaft sprocket bolts. Tighten: Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).
8. Install the timing chain tensioner bracket and bolt (227 and 228). Tighten: Tighten the timing chain tensioner bracket bolt to 12 N.m (106 lb in).
9. Install the timing chain tensioner shoe (229) using an upwards motion.
10. Install the crankshaft position sensor reluctor ring. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) .

Engine Front Cover Installation

1. Install the NEW engine front cover.
2. Install the engine front cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Lubricate the NEW crankshaft position sensor seal, O-ring, with clean engine oil.
4. Install the NEW crankshaft position sensor seal, O-ring, onto the crankshaft position sensor.
5. Install crankshaft position sensor until fully seated into the engine front cover.
6. Install crankshaft position sensor bolt. Tighten: Tighten the crankshaft position sensor bolt to 8 N.m (71 lb in).

Oil Pump Installation

1. Inspect for properly installed oil pump locator pins.
2. Install the oil pump.
3. Position the oil pump onto the pins.
4. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 90 N.m (66 lb ft).

Oil Pan Installation

1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces.
2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the entire crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces.
3. Install the NEW oil pan gasket into the groove in the oil pan.
4. Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing.
5. Slide the oil pan back against a suitable straight edge.
6. Install the oil pan bolts and nuts, but do not tighten.
7. Measure the pan-to-transmission housing clearance using a feeler gage and a straight edge. Use a feeler gage to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 in) at any of the 3 oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block.
8. Tighten the oil pan bolts and nuts in sequence (1-12). Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
9. Measure the clearance between the 3 oil pan-to-transmission housing measurement points in order to ensure proper alignment.
10. Install a NEW oil pan drain plug seal, O-ring, onto the oil pan drain plug.
11. Install the oil pan drain plug into the oil pan. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

Oil Filter Adapter Installation

1. Install the NEW oil filter adapter seal, O-ring, into the groove in the oil filter adapter.
2. Install the oil filter adapter and NEW oil filter adapter gasket.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 21 N.m (15 lb ft).

Crankshaft Balancer Installation

Tools Required: J 23523-F Balancer Remover and Installer. See Special Tools and Equipment .

1. Look to ensure that the crankshaft balancer front groove pin is installed in the proper location, if applicable. The length and location of the pins must be the same as the original length and location.
2. Apply a small amount of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with the crankshaft balancer key.
4. Install the crankshaft balancer onto the end of the crankshaft.
5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten: Tighten the J 23523-F plate bolts to 25 N.m (18 lb ft). Install the J 23523-F screw into the end for the crankshaft. Install the J 23523-F bearing, the washer, and the nut onto the J 23523-F screw. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring.
6. Remove the J 23523-F.
7. Install the crankshaft pulley and bolts. Finger tighten all bolts until snug. Tighten: Tighten the crankshaft pulley bolts to 58 N.m (43 lb ft).
8. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
9. Install the crankshaft balancer washer and the bolt. Tighten: Tighten the crankshaft balancer bolt to 95 N.m (70 lb ft).

Valve Lifter Installation

1. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent, to the valve lifter rollers.
2. Install the valve lifters.
3. Install the valve lifter pushrod guides. Tighten: Tighten the valve lifter pushrod guide bolts to 16 N.m (12 lb ft).

Cylinder Head Installation - Left

Tools Required: J 45059 Angle Meter. See Special Tools and Equipment .

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the cylinder head locator dowel pins for proper installation. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
3. Clean the cylinder head gasket surfaces on the cylinder head.
4. Install the NEW cylinder head gasket in position over the cylinder head locator dowel pins.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the NEW cylinder head bolts.
7. Install the NEW cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten: Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 45059 in order to tighten the cylinder head bolts in sequence on the final pass. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten: Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
11. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification: Spark plug gap to 1.52 mm (0.060 in).
12. Install the spark plugs. Tighten: Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
13. If reusing the engine coolant temperature gage sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine coolant temperature gage sensor.
14. Install the engine coolant temperature gage sensor, if applicable. Tighten: Tighten the engine coolant temperature gage sensor to 20 N.m (15 lb ft).
15. If reusing the engine coolant temperature sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the engine coolant temperature gage sensor.
16. Install the engine coolant temperature sensor, if applicable. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

Cylinder Head Installation - Right

Tools Required: J 45059 Angle Meter. See Special Tools and Equipment .

1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the cylinder head locator dowel pins for proper installation. The installation height should be 6.3-6.5 mm (0.248-0.256 in) (a).
3. Clean the cylinder head gasket surfaces on the cylinder head.
4. Install the NEW cylinder head gasket in position over the cylinder head locator dowel pins.
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the NEW cylinder head bolts.
7. Install the NEW cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass. Tighten: Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 45059 in order to tighten the cylinder head bolts in sequence on the final pass. See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees. Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts. Tighten: Tighten only the rear spark plug wire support bolt to 12 N.m (106 lb in).
11. Remove the front spark plug wire support bolt. The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.
12. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification: Spark plug gap to 1.52 mm (0.060 in).
13. Install the spark plugs. Tighten: Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft). Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).

Valve Rocker Arm and Push Rod Installation

1. Install the valve pushrods.
2. Install the valve rocker arm supports.
3. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent, to the following valve rocker arm contact surfaces: Valve pushrod socket (1) Roller pivot (2) Valve stem tip (3)
4. Install the valve rocker arm assemblies as follows: Finger start the bolt at location (1) Finger start the bolt at location (2) Finger start the bolt at location (3) Finger start the remaining valve rocker arm bolts
5. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover, 1 with 2 and 3 with 4. At that point the number 1 piston should be at TDC of the compression stroke.
6. Tighten the valve rocker arm bolts. Tighten: Tighten valve rocker arm bolts to 30 N.m (22 lb ft).

Intake Manifold Installation

1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the cylinder head side of the lower intake manifold gasket at each end.
2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.
3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent, to the rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
7. Install the lower intake manifold onto the engine block.
8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
10. Tighten the lower intake manifold bolts. Tighten: Tighten the bolts on the first pass in sequence (1-8) to 3 N.m (27 lb in). Tighten the bolts on the second pass in sequence (1-8) to 12 N.m (106 lb in). Tighten the bolts on the final pass in sequence (1-8) to 15 N.m (11 lb ft).
11. Connect the evaporative emission (EVAP) canister solenoid valve harness. Push the elbow inward until the quick connect snaps into place. Pull the elbow outward in order to ensure proper connection.

Distributor Installation

1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke.
2. Remove the distributor cap bolts and discard.
3. Remove the distributor cap.
4. Install a NEW distributor gasket onto the distributor.
5. Align the indent hole on the driven gear with the paint mark on the distributor housing.
6. Ensure that the distributor rotor segment points to the cap hold area.
7. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary.
8. Align the flat (1) in the distributor housing toward the front of the engine.
9. Install the distributor and distributor clamp. The flat in the distributor housing must point toward the front of the engine.
10. Once the distributor is fully seated, align the distributor rotor segment with the number 6 pointer (1) that is cast into the distributor base. If the distributor rotor segment does not come within a few degrees of the number 6 pointer (1), the gear mesh between the distributor and camshaft may be off a tooth or more. Repeat the procedure again in order to achieve proper alignment.
11. Install the distributor clamp bolt. Tighten: Tighten the distributor clamp bolt to 25 N.m (18 lb ft).
12. Install the distributor cap and NEW distributor cap bolts. Tighten: Tighten the distributor cap bolts to 2.4 N.m (21 lb in).
13. Install the ignition coil wire harness.

Valve Rocker Arm Cover Installation - Left

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).

Oil Level Indicator and Tube Installation

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, around the oil level indicator tube 13 mm (0.5 in) below the tube bead.
2. Install the oil level indicator tube into the engine block. Rotate the oil level indicator tube into position.
3. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 12 N.m (106 lb in).
4. Install the oil level indicator into the oil level indicator tube, if required.

Water Pump Installation

Tools Required: J 41240 Fan Clutch Remover and Installer. See Special Tools and Equipment .

1. If reusing the fasteners, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the water pump bolts.
2. Install the water pump and the NEW water pump gaskets.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 45 N.m (33 lb ft).
4. Install the water pump inlet hose and the water pump inlet hose clamps.
5. Install the fan and water pump pulley and bolts using the J 41240 . See «Special Tools and Equipment»(ref-186638-S18531248622005083000000) . Tighten: Tighten the fan and water pump pulley bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left

1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
4. If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the exhaust manifold bolts and stud.
5. Install the exhaust manifold bolts and stud. Tighten: Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts and stud on the final pass to 30 N.m (22 lb ft).
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.

Exhaust Manifold Installation - Right

1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
4. If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the exhaust manifold bolts.
5. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts on the first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts on the final pass to 30 N.m (22 lb ft).
6. Install the spark plug wires to the spark plug wire retainers.
7. Install the spark plug wires onto the spark plugs.

Engine Flywheel Installation

1. Install the engine flywheel to the crankshaft.
2. Align the locator hole to the pin.
3. Install the engine flywheel bolts. Tighten: Tighten the engine flywheel bolts in sequence to 100 N.m (74 lb ft).