Engine Mechanical - 2.4L: Removal & Installation Pontiac G6 I

Removal Procedure

1. Remove the engine oil fill cap.
2. Grasp the intake manifold cover by the lower right corner and pull up to disengage the cover from the air cleaner outlet duct.
3. Grasp the intake manifold cover by the left side and pull up to disengage the cover from the studs.
4. Remove the intake manifold cover.

Installation Procedure

1. Place the intake manifold cover onto the engine over the studs and air cleaner outlet duct.
2. Push down on the intake manifold cover directly over the left side studs in order to engage the cover to the studs.
3. Push down on the intake manifold cover directly over the lower right corner in order to engage the cover to the air cleaner outlet duct.
4. Install the engine oil fill cap.

1. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
2. Install the J 44811 to the drive belt tensioner.
3. Using the J 44811 , rotate the tensioner counterclockwise in order to release the tensioner from the drive belt.
4. Remove the drive belt.
5. Slowly rotate the J 44811 and the tensioner clockwise in order to allow the tensioner to rest.
6. Remove the J 44811 from the drive belt tensioner.

1. Install and position the drive belt around all of the pulleys except for the drive belt tensioner.
2. Install the J 44811 to the drive belt tensioner.
3. Using the J 44811 , rotate the tensioner counterclockwise.
4. Position the drive belt under the tensioner pulley.
5. Using the J 44811 , rotate the tensioner clockwise in order to seat the tensioner pulley onto the drive belt.
6. Install the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Position the drive belt tensioner. Ensure that the tensioner is flush with the front cover.
2. Install the drive belt tensioner bolt. Using the J 45025 tighten the drive belt tensioner bolt. See «Special Tools»(ref-243010-S06683109272006082100000) . Tighten: Tighten the bolt to 45 N.m (33 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
2. Disconnect the engine oil pressure sensor electrical connector (2).
3. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the engine oil pressure sensor electrical connector (2).
3. Lower the vehicle.

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .
2. Remove the engine mount.
3. Remove the engine mount bracket bolts.
4. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .

1. Install until snug the engine mount bracket bolts in the following locations: The long bolts in the forward and front lower holes. The short bolt in the rear upper hole.
2. Tighten the engine mount bracket bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
3. Install the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .
2. Remove the engine mount bracket bolts.
3. Remove the engine mount bracket.

1. Position the engine mount bracket to the engine.
2. Install until snug the engine mount bracket bolts in the following locations: The long bolts in the forward and front lower holes The short bolt in the rear upper hole
3. Tighten the engine mount bracket bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .

1. Use a floor jack and a block of wood to support the powertrain from under the oil pan.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-243018-S16491601992006082100000) .
3. Remove the engine mount bracket nuts.
4. Remove the engine mount bolts.
5. Remove the engine mount.

1. Position the engine mount to the vehicle.
2. Install and finger tighten the engine mount bolts.
3. Install the engine mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft). Tighten the bolts to 50 N.m (37 lb ft).
4. Remove the floor jack and the block of wood from under the oil pan.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-243018-S16491601992006082100000) .

1. Raise the hood.
2. Install the J 28467-33A thread support nuts onto the strut attaching studs.
3. Install the J 28467-5A strut tower support assemblies over the J 28467-33A thread support nuts.
4. Install the J 28467-53 T-bolts with 5/16 inch washers through the J 28467-5A strut tower support assemblies into the J 28467-33A thread support nuts and hand tighten.
5. Install the J 28467-1A 2 cross bracket assemblies over the J 28467-3 strut tower tube.
6. Install the J 28467-3 strut tower tube into the J 28467-5A strut tower support assemblies.
7. Install the J 28467-10 1/2 inch x 2.5 inch quick release pin through the J 28467-5A strut tower support assemblies and the J 28467-3 strut tower tube on one side only.
8. Install the J 28467-2A radiator shelf tube through the J 28467-1A driver side cross bracket assembly on the top of the J 28467-3 strut tower tube.
9. Place the rubber padded foot of the J 28467-4A front support assembly on the vehicle radiator shelf. The foot position used in the J 28467-4A front support assembly depends on the vehicle application.
10. Install the J 28467-9 7/16 inch x 2.0 inch quick release pin through the hole in the J 28467-4A front support assembly in order to level the J 28467-2A radiator shelf tube. The hole used in the J 28467-4A front support assembly depends on the vehicle application.
11. Install the J 28467-7A lift hook through the J 28467-6A lift hook bracket.
12. Install the 1/2 inch lift hook washer and J 28467-34 lift hook wing nut onto the J 28467-7A lift hook.
13. Install the J 28467-6A assembled lift hook bracket over the J 28467-2A radiator shelf tube.
14. Adjust the J 28467-2A radiator shelf tube and the J 28467-6A assemblage lift hook bracket in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket.
15. Hand tighten the J 28467-1A driver side cross bracket assembly wing nuts.
16. Install the J 28467-2A second radiator shelf tube through the J 28467-1A passenger side cross bracket assembly on the top of the J 28467-3 strut tower tube.
17. Place the rubber padded foot of the J 28467-4A front support assembly on the vehicle radiator shelf. The foot position used in the J 28467-4A front support assembly depends on the vehicle application.
18. Install the J 28467-9 7/16 inch x 2.0 inch quick release pin through the hole in the J 28467-4A front support assembly in order to level the J 28467-2A radiator shelf tube. The hole used in the J 28467-4A front support assembly depends on the vehicle application.
19. Install the J 28467-7A lift hook through the J 28467-6A lift hook bracket.
20. Install the 1/2 inch lift hook washer and J 28467-34 lift hook wing nut onto the J 28467-7A lift hook.
21. Install the J 28467-6A assemblage lift hook bracket over the J 28467-2A radiator shelf tube.
22. Adjust the J 28467-2A radiator shelf tube and the J 28467-6A assemblage lift hook bracket in order to align the hook with the right (rear), front of engine, lift hook bracket located next to the generator.
23. Hand tighten the J 28467-1A passenger side cross bracket assembly wing nuts.
24. Hand tighten the J 28467-34 lift hook wing nuts securely to remove all slack from the engine support fixture assembly.

1. Remove the oil level indicator.
2. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
3. Remove the engine harness clip (1) from the oil level indicator tube.
4. Remove the oil level indicator tube bolt.
5. Remove the oil level indicator tube.

1. Lubricate the oil level indicator tube O-ring seal with lubricant, GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the engine harness clip (1) to the oil level indicator tube.
5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
6. Install the oil level indicator.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
2. Reposition the PCV hose clamp at the camshaft cover.
3. Remove the PCV hose from the camshaft cover.

1. Install the PCV hose to the camshaft cover.
2. Position the PCV hose clamp at the camshaft cover.
3. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .

1. Remove the throttle body. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
2. Remove the fuel rail. Refer to «Throttle Body Assembly Replacement»(ref-243018-S34419967192006082100000) .
3. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-243018-S39336604082006082100000) .
4. Reposition the brake booster vacuum hose clamp at the intake manifold.
5. Remove the brake booster hose from the intake manifold.
6. Remove the oil level indicator tube bolt.
7. Disconnect the engine harness electrical connector (1) from the fuel injector inline electrical connector (2).
8. Remove the fuel injector inline connector clip from the intake manifold.
9. Disconnect the engine harness electrical connector (1) from the knock sensor harness.
10. Remove the knock sensor connector clip from the oil level indicator tube.
11. Remove the intake manifold bolts and nuts.
12. Remove the intake manifold.
13. Remove the intake manifold gasket, if necessary.

1. Install the intake manifold gasket, if necessary.
2. Install the intake manifold. NOTE: Refer to «Fastener Notice»(ref-242977-S25864542072006082100000) .
3. Install the intake manifold bolts and nuts. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
4. Connect the engine harness electrical connector (1) to the knock sensor harness.
5. Install the knock sensor connector clip to the oil level indicator tube.
6. Connect the engine harness electrical connector (1) to the fuel injector inline electrical connector (2).
7. Install the fuel injector inline connector clip to the intake manifold.
8. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Install the brake booster hose to the intake manifold.
10. Position the brake booster vacuum hose clamp at the intake manifold.
11. Install the EVAP canister purge solenoid valve tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-243018-S39336604082006082100000) .
12. Install the fuel rail. Refer to «Throttle Body Assembly Replacement»(ref-243018-S34419967192006082100000) .
13. Install the throttle body. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .

1. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
2. Use the J 38122-A in order to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt.
3. Remove and discard the crankshaft balancer bolt.
4. Remove the crankshaft balancer.

1. Position the crankshaft balancer to the engine.
2. Install a NEW crankshaft balancer bolt.
3. Use the J 38122-A in order to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .
4. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243010-S32641648272006082100000) .
2. Using a flat bladed tool, remove the oil seal from the front cover.

1. Use the J 35268-A in order to install the oil seal to the front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243010-S32641648272006082100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243010-S32641648272006082100000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.
4. Remove the engine front cover to water pump bolt.
5. Remove the remaining engine front cover bolts.
6. Remove the engine front cover.
7. If the engine front cover gasket is damaged perform the following steps
8. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .
9. Remove and discard the engine front gasket.

1. If the engine front cover was damaged perform the following steps, otherwise proceed to step 4 .
2. Position and install a NEW engine front cover gasket to the dowel pins.
3. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement»(ref-243010-S38830058712006082100000) .
4. Position and install the engine front cover.
5. Install the engine front cover to water pump bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the drive belt tensioner.
8. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 45 N.m (33 lb ft).
9. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243010-S32641648272006082100000) .

1. Remove the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-243018-S25070592572006082100000) .
2. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
3. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243010-S03085373392006082100000) .
5. Remove the upper timing chain guide bolts and guide.
6. Remove the timing chain tensioner.
7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
8. Remove and discard the exhaust camshaft actuator bolt (2).
9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
10. Remove the timing chain tensioner guide bolt and guide.
11. Remove the fixed timing chain guide access plug.
12. Remove the fixed timing chain guide bolts and guide.
13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
14. Remove and discard the intake camshaft actuator bolt (2).
15. Remove the intake camshaft actuator (3) and the timing chain through the top of the cylinder head.
16. Remove the timing chain crankshaft sprocket.
17. If replacing the balance shaft timing chain and sprocket, perform the following steps: if not proceed to step 10 in the installation procedure.
18. Remove the balance shaft drive chain tensioner bolts and tensioner.
19. Remove the adjustable balance shaft chain guide bolt and guide.
20. Remove the small balance shaft drive chain guide bolts and guide.
21. Remove the upper balance shaft drive chain guide bolts and guide.
22. Remove the balance shaft drive chain (7).
23. Remove the balance shaft drive sprocket.

1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10 .
2. Install the balance shaft drive sprocket.
3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are three colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
4. Install the upper balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
5. Install the small balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
6. Install the adjustable balance shaft chain guide and bolt. Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
8. Install the balance shaft drive chain tensioner and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.
10. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
11. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
12. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
13. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
14. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
15. Hand tighten the new intake camshaft actuator bolt.
16. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
17. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
18. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the bolts to 10 N.m (89 lb in).
19. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
20. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
21. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
22. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
23. that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
24. Install the fixed timing chain guide and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
25. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
26. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
27. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
28. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
29. Install the timing chain tensioner assembly. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
30. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
31. Using a 23 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolts to 30 N.m (22 lb ft)), plus 100 degrees.
32. Using a 23 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolts to 30 N.m (22 lb ft)), plus 100 degrees.
33. Install the timing chain oiling nozzle. Tighten: Tighten the bolts to 10 N.m (89 lb in)).
34. Apply sealant GM PN 12345382 (Canadian PN 10953489) or equivalent, to the threads and install the timing chain guide bolt access hole plug.
35. Install the timing chain guide bolt access hole plug. Tighten: Tighten the bolts to 90 N.m (66 lb ft)).
36. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243010-S03085373392006082100000) .
37. Install camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
38. Install the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-243018-S25070592572006082100000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp.
3. Remove the PCV hose from the cover.
4. Disconnect the intake (2) and exhaust (1) camshaft position actuator solenoid valve electrical connectors.
5. Remove the fuel feed pipe bracket bolt and bracket.
6. Remove the fuel feed pipe bracket bolt and bracket.
7. Disconnect and remove the ignition coil electrical connector harness clips from the cover.
8. Remove the ignition coils. Refer to «Ignition Coil(s) Replacement»(ref-243018-S35366075842006082100000) .
9. Remove the camshaft cover bolts.
10. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Install the ignition coils. Refer to «Ignition Coil(s) Replacement»(ref-243018-S35366075842006082100000) .
3. Install and connect the ignition coil electrical connector harness clips to the cover.
4. Install the fuel feed pipe bracket and bolt.
5. Install the fuel feed pipe retainer (2) to the fuel pipe bracket.
6. Connect the intake (2) and exhaust (1) camshaft position actuator solenoid valve electrical connectors.
7. Install the PCV hose to the cover.
8. Position the PCV hose clamp.
9. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 into a vise. Install the notch end of the piston assembly into the J 45027-2 . Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
4. the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten: Tighten the plug to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .

1. Remove the intake camshaft position actuator. Refer to «Camshaft Position Actuator Replacement - Intake»(ref-243010-S09152603042006082100000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the intake camshaft (1).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers with GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the intake camshaft (1). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Install intake camshaft position actuator. Refer to «Camshaft Position Actuator Replacement - Intake»(ref-243010-S09152603042006082100000) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Actuator Replacement - Exhaust»(ref-243010-S05842526202006082100000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the exhaust camshaft (3).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element adjusters.

1. Install the hydraulic element adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster, apply lubricate GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the exhaust camshaft (3). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Install exhaust camshaft position actuator. Refer to «Camshaft Position Actuator Replacement - Exhaust»(ref-243010-S05842526202006082100000) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
2. Remove the upper timing chain guide bolts and guide.
3. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
4. Loosen, but DO NOT remove the intake camshaft actuator bolt.
5. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
6. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
7. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
8. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
9. Remove and discard the intake camshaft actuator bolt (2).
10. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW intake camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Install the upper timing chain guide and bolts. Tighten: Tighten the plug to 10 N.m (89 lb in).
8. Install camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .

1. Remove camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .
2. Remove the upper timing chain guide bolts and guide.
3. Remove the timing chain tensioner.
4. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
5. Loosen, but DO NOT remove the exhaust camshaft actuator bolt.
6. one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
7. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
9. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
10. Remove and discard the exhaust camshaft actuator bolt (2).
11. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 .
8. Remove the old oil from the timing chain tensioner.
9. Inspect the timing chain tensioner for scoring or free movement.
10. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
11. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 in) from end to end (a)
12. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 into a vise. Install the notch end of the piston assembly into the J 45027-2 . Using the J 45027-1 , turn the ratchet cylinder into the piston.
13. Inspect the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
14. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
15. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1 through 8.4.
16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.
19. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
20. Install camshaft cover. Refer to «Camshaft Cover Replacement»(ref-243010-S39664017812006082100000) .

1. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-243010-S06174334452006082100000) or «Exhaust Camshaft and Lifter Replacement»(ref-243010-S17351101672006082100000) .
2. Remove the camshaft roller followers.
3. Install the front part of the J 43649 to the cylinder head. See «Special Tools»(ref-243010-S06683109272006082100000) .
4. Install the remaining parts of the J 43649 to the cylinder head.
5. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-243018-S25070592572006082100000) .
6. Install an air hose adapter into the spark plug hole.
7. Attach an air hose to the adapter
8. Using the compressed air, pressurize the cylinder to 690 kPa (100 psi).
9. Compress the valve spring using the J 43649 . See «Special Tools»(ref-243010-S06683109272006082100000) .
10. Remove the valve spring keepers.
11. Remove the valve spring retainer.
12. Remove the valve spring.
13. Using the J 36017 remove the valve seal. See «Special Tools»(ref-243010-S06683109272006082100000) .

1. Using the J 36017 install the NEW valve seal. See «Special Tools»(ref-243010-S06683109272006082100000) . Fully seat the seal onto the valve guide.
2. Install the valve spring.
3. Install the valve spring retainer.
4. Compress the valve spring using the J 43649 . See «Special Tools»(ref-243010-S06683109272006082100000) .
5. Install the valve spring keepers.
6. Disconnect the air hose from the adapter.
7. Remove the air hose adapter from the spark plug hole.
8. Remove the J 43649 from the cylinder head. See «Special Tools»(ref-243010-S06683109272006082100000) .
9. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-243018-S25070592572006082100000) .
10. Install the camshaft roller followers.
11. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-243010-S06174334452006082100000) or «Exhaust Camshaft and Lifter Replacement»(ref-243010-S17351101672006082100000) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-243010-S31905434442006082100000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (2.4L)»(ref-243054-S33916210442006082100000) .
3. Remove the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-243010-S27670320452006082100000) .
4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
5. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
6. Remove the cylinder head.
7. Remove the cylinder head gasket.
8. Clean all of the gasket surfaces.
9. Use the following steps when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface. IMPORTANT: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket. Hold the razor blade as parallel to the gasket surface as possible.
10. Clean the old sealer/lube and any dirt from around the bolt holes.
11. Clean the bolts holes with a nylon bristle brush.
12. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.
5. Install and tighten the cylinder head bolts in the sequence shown. Tighten: Tighten the bolts to 30 N.m (22 lb ft) plus and additional 155 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .
6. Install the NEW front cylinder head bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
7. Install the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-243010-S27670320452006082100000) .
8. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (2.4L)»(ref-243054-S33916210442006082100000) .
9. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-243010-S31905434442006082100000) .
10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243010-S36671984962007060600000) .
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
3. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
4. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
5. Reposition the radiator outlet hose clamp at the oil cooler.
6. Remove the radiator outlet hose from the oil cooler.
7. Remove the oil cooler bolts.
8. Remove the oil cooler.

1. Position the oil cooler to the engine block.
2. Install the oil cooler bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install the radiator outlet hose to the oil cooler.
4. Position the radiator outlet hose clamp at the oil cooler.
5. Install the surge tank outlet hose to the thermostat housing and oil cooler.
6. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
2. Place a drain pan under the oil pan drain plug.
3. Remove the oil pan drain plug.
4. Drain the engine oil.
5. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
6. Remove the lower AC compressor bolt.
7. Remove the oil pan bolts.
8. Remove the oil pan
9. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of sealant (1) GM PN 12346286 (Canadian PN 10953472) or equivalent, around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required.
3. Install the oil pan.
4. Install the oil pan bolts.
5. Tighten the oil pan bolts in the sequence shown. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the lower AC compressor bolt.
7. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
8. Lower the vehicle.
9. Fill the engine oil to the proper level.

1. Remove the starter motor. Refer to «STARTER MOTOR REPLACEMENT (2.4L)»(ref-242993-S34214143072006082100000) .
2. Remove the engine-to-transaxle brace.
3. Remove the engine oil pan. Refer to «Oil Pan Replacement»(ref-243010-S06660230472006082100000) .
4. Remove crankcase position sensor. Refer to «CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT»(ref-243018-S32064880002006082100000) .
5. Remove the 3 perimeter bolts.
6. Remove and discard the crankshaft bearing bolts.
7. Using the pry points and an appropriate prying tool, gently separate the upper and lower crankcase.
8. Clean the sealing material from the engine block and lower the crankcase.

1. Apply oil to the crankshaft bearing surfaces.
2. Apply a 2-5 mm (0.08-0.20 in) bead (a) of sealer GM P/N 12378521 (Canadian P/N 88901148) to the surface of the engine block-to-lower crankcase mating surface.
3. Tap gently into place with a suitable tool, if necessary. Ensure it is aligned properly on the dowels.
4. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . Tighten: Tighten the bolts to an additional 70 degrees using the J 45059 .
5. Tighten the lower crankcase perimeter bolts in sequence.
6. Install the crankcase position sensor. Refer to «CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT»(ref-243018-S32064880002006082100000) .
7. Install the engine oil pan. Refer to «Oil Pan Replacement»(ref-243010-S06660230472006082100000) .
8. Install the engine-to-transaxle brace. Tighten: Tighten the bolts to 72 N.m (53 lb ft).
9. Install starter motor. Refer to «STARTER MOTOR REPLACEMENT (2.4L)»(ref-242993-S34214143072006082100000) .
10. Lower the vehicle.
11. Fill with engine oil, start the engine and inspect for leaks.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-243010-S06660230472006082100000) .
2. Remove the cylinder head. Refer to «Cylinder Head Replacement»(ref-243010-S08278692562006082100000) .
3. If a ring ridge is present, remove the ring ridge as follows: Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use a ridge reamer to remove the ring ridge. Turn the crankshaft so the piston is at top of the stroke. Remove the cloth and cutting debris.
4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts.
5. Remove the connecting rod and the piston out of the top of the engine block using the J-43966-1 .
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

1. Coat the following parts with engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the piston into its original bore using the J-43966-1 .
3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the EN-47836 firmly against the engine block until all the piston rings have entered the cylinder bore.
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.
8. Install the new connecting rod bolts and nuts. Tighten the crankshaft bearing bolts in sequence. Tighten: On the first pass, tighten the nuts evenly to 25 N.m (18 lb ft). On the final pass, use the J 45059 in order to tighten the nuts an additional 100 degrees.
9. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-243010-S08278692562006082100000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-243010-S06660230472006082100000) .

Note. DO NOT chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve.

Note. DO NOT damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.

1. Remove the piston and connecting rod. Refer to «Piston, Connecting Rod and Bearing Replacement»(ref-243010-S17238390222007060600000) .
2. Inspect the condition of the piston. Refer to «Piston, Connecting Rod and Bearings Cleaning and Inspection»(ref-243010-S09454494912006082100000) .
3. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
4. Install the EN 45680-852 cylinder bore sleeve puller (1) through the cylinder bore.
5. Align the shoe (1) of the EN 45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2).
6. Hold the threaded shaft of the EN 45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
7. Install the EN 456850-851 fixture (4) onto the threaded shaft of the EN 45680-852 cylinder bore sleeve puller and the engine block.
8. Install the bearing (3) and the nut (1).
9. Tighten the nut (1) to the bearing (3).
10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
11. Rotate the nut clockwise in order to remove the cylinder bore liner.
12. Remove EN 45680-851 fixture, EN 45680-852 cylinder bore sleeve puller and the cylinder bore sleeve from the engine block.
13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.

Note. Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve.

Note. Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve.

1. Place the NEW cylinder bore sleeve onto the cylinder block.
2. Install EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
3. Insert the 4 attachment bolts into the legs of the EN 45680-851 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
6. Align the pusher block (2) of EN 45680-853 cylinder bore sleeve installer into the groove of EN 45680-851 fixture (1).
7. Using a ratchet, rotate the threaded shaft of EN 45680-85 fixture and EN 45680-853 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block.
8. DO NOT completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
9. Using a torque wrench, tighten the threaded shaft of the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface.
10. Remove the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly (1) from the cylinder block (2).

Scheme 2

1. EN 45680-865 Debris Collector (3)
2. EN 45680-861 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction and a 450-600 RPM rotational speed in a clockwise direction

Scheme 3

1. Trim Tool Preloader (1)
2. EN 45680-862 Set Gage Ring (2)
3. EN 45680-863 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-864 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the EN 45680-863 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional EN 45680-863 metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the EN 45680-863 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the EN 45680-862 set gage ring (1) should be positioned upward on a flat surface.
6. Carefully position EN 45680-861 trim tool assembly onto the EN 45680-862 set gage ring.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place the EN 45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
11. Install the EN 45680-864 4 bolts into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten the drive adapter EN 45680-866 into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-861 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place the EN 45680-866 drive adapter and the drill assembly vertically onto the EN 45680-861 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove the EN 45680-866 drive adapter (1) and the drill assembly from the EN 45680-861 trim tool assembly.
16. Turn OFF the compressed air valve.
17. Remove the EN 45680-861 trim tool assembly from the engine block.
18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-863 metal shaving catch plug.
19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
20. Using a light, illuminate the backside of the straight edge.
21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary.
24. Install the piston and the connecting rod. Refer to «Piston, Connecting Rod and Bearing Installation»(ref-243010-S06417421792006082100000) .
25. Install the oil pan. Refer to «Oil Pan Replacement»(ref-243010-S06660230472006082100000) .
26. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-243010-S08278692562006082100000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-243010-S08413422342006082100000) .
2. Pry out the crankshaft rear oil seal using a flat-bladed tool.

1. Using the J 42067 , install a NEW crankshaft real oil seal. See «Special Tools»(ref-243010-S06683109272006082100000) .
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-243010-S08413422342006082100000) .

1. Remove the transmission. Refer to «Transmission Replacement»(ref-243013-S10068892782006082100000) .
2. Using the J 38122-A , hold the crankshaft balancer.
3. Remove the flywheel bolts.
4. Remove the flywheel.
5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .
3. Remove the J 38122-A .
4. Install the transmission. Refer to «Transmission Replacement»(ref-243013-S10068892782006082100000) .

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
3. Remove the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-243018-S31153521452006082100000) .
6. Disconnect the fuel line from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-243018-S29713473812006082100000) .
7. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
8. Remove the radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) , «Radiator Hose Replacement - Inlet (LX9)»(ref-243023-S42214401522006082100000) or «Radiator Hose Replacement - Inlet (LZ9)»(ref-243023-S38695704482006082100000) .
9. Remove the surge tank to cylinder head hose. Refer to «Surge Tank Hose/Pipe Replacement - Inlet (LE5)»(ref-243023-S25461980202006082100000) , «Surge Tank Hose/Pipe Replacement - Inlet (LX9)»(ref-243023-S37541611682006082100000) , «Surge Tank Hose/Pipe Replacement - Inlet (LZ9)»(ref-243023-S26422288742006082100000) and «Surge Tank Hose/Pipe Replacement - Outlet»(ref-243023-S20056677872006082100000) .
10. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000) , «Radiator Hose Replacement - Outlet (LX9)»(ref-243023-S38434924012006082100000) or «Radiator Hose Replacement - Outlet (LZ9)»(ref-243023-S37042066022006082100000) .
11. Remove the inlet (1) and outlet (2) heater hoses. Refer to «Heater Hose Replacement - Inlet»(ref-243028-S15245734552006082100000) and to «Heater Hose Replacement - Outlet»(ref-243028-S27210942202006082100000) .
12. Disconnect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coils The HO2 sensor The vehicle speed sensor The engine temperature sensor The back-up lamp switch The camshaft position actuator solenoid control valves
13. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
14. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
15. Remove the AC compressor bolts and set the compressor aside.
16. Remove the starter solenoid battery cable nut (2).
17. Remove the positive battery cable lead (3) from the starter solenoid.
18. Remove the starter solenoid engine harness nut (1).
19. Remove the engine harness lead (2) from the starter solenoid.
20. Disconnect the generator electrical connector (1).
21. Reposition the engine harness rubber boot (3).
22. Remove the generator nut (2).
23. Remove the engine harness lead (4) from the generator.
24. Drain the engine oil.
25. Disconnect the front exhaust pipe from the exhaust manifold. Refer to «Exhaust Manifold Replacement (2.4L)»(ref-243054-S33916210442006082100000) .
26. Disconnect the transmission harness connectors.
27. Disconnect the transmission shift cable from the transmission.
28. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
29. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .
30. Remove the side transmission mount bracket bolts.
31. Raise the vehicle.
32. Disconnect the stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
33. Disconnect the outer tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
34. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-242976-S27310643062006082100000) .
35. Disconnect the lower control arms from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
36. Disconnect the drive axles from the steering knuckle. Refer to «Wheel Drive Shaft Replacement»(ref-243038-S08355384422006082100000) .
37. Use a paint pen or magic marker in order to mark the frame to body position.
38. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
39. Use wood blocks as necessary between the lift table and the frame to support the assembly.
40. Slowly remove the frame bolts using the following sequence: Remove the front frame bolts. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
41. Slowly lower the table to the floor.
42. Attach the engine lift hoist to the engine lift hooks.
43. Remove the starter.
44. Remove the transmission to engine bolts.
45. Separate the engine from the transmission.
46. If applicable, remove the torque converter to flywheel bolts.
47. If applicable, remove the clutch pressure plate and disk.
48. Remove the following components: The exhaust manifold and catalytic converter assembly The exhaust manifold studs The engine mount bracket The engine block heater The thermostat housing and feed pipe The generator
49. Remove the engine from the engine lift.

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components: The exhaust manifold - Refer to «Exhaust Manifold Replacement (2.4L)»(ref-243054-S33916210442006082100000) . The engine mount bracket - Refer to «Engine Mount Bracket Replacement»(ref-243010-S38830058712006082100000) . The fuel rail - Refer to «Fuel Rail Assembly Replacement»(ref-243018-S22603131442006082100000) . The engine block heater, if equipped. Refer to «Coolant Heater Replacement (2.4L)»(ref-243023-S09707627772006082100000) or «Coolant Heater Replacement (3.5L and 3.9L)»(ref-243023-S09768372472006082100000) . The drive belt tensioner - Refer to «Drive Belt Tensioner Replacement»(ref-243010-S21249887112006082100000) . The thermostat housing and feed pipe - Refer to «Thermostat Replacement (2.4L)»(ref-243023-S15432718372006082100000) , «Thermostat Replacement (3.5L)»(ref-243023-S24517415342006082100000) or «Thermostat Replacement (3.9L)»(ref-243023-S11110837462006082100000) . The generator - Refer to «Generator Replacement (2.4L)»(ref-242993-S10209315092006082100000) , «Generator Replacement (3.5L)»(ref-242993-S18150277112006082100000) or «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) . The flywheel - Refer to «Engine Flywheel Replacement»(ref-243010-S08413422342006082100000) .
3. Align the engine to the transmission.
4. Install the engine-to-transmission bolts. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
5. Install the torque converter bolts Tighten: Tighten the bolts to 62 N.m (46 lb ft).
6. Position the transaxle brace to the engine and transaxle and install the brace to transaxle bolts.
7. Install the transaxle brace to engine block bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. Install the starter. Refer to «Starter Motor Replacement (2.4L)»(ref-242993-S34214143072006082100000) , «Starter Motor Replacement (3.5L)»(ref-242993-S24411766452006082100000) or «Starter Motor Replacement (3.9L)»(ref-242993-S31692867382006082100000) .
9. Remove the engine lift from the engine.
10. Raise and position the frame and powertrain assembly to the vehicle.
11. Hand start all the frame bolts while aligning the frame to the paint marks.
12. Tighten the frame bolts. Tighten: Tighten the frame bolts to 100 N.m (74 lb ft) plus an additional 180 degrees.
13. Remove the lift table.
14. Connect the drive axles to the steering knuckles. Refer to «Wheel Drive Shaft Replacement»(ref-243038-S08355384422006082100000) .
15. Connect the lower control arm to the steering knuckle. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
16. Connect the intermediate steering shaft to the steering gear. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
17. Connect the outer tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
18. Connect the stabilizer links to the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
19. Install the side transmission mount bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
20. Install the engine mount. Refer to «Engine Mount Replacement»(ref-243010-S40128961992006082100000) .
21. Remove the wood blocks between the powertrain and frame.
22. Connect the transmission shift cable to the transmission.
23. Connect the transmission harness connector.
24. Connect the exhaust takedown pipe to the exhaust manifold. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
25. Lower the vehicle.
26. Install the engine harness lead (4) to the generator.
27. Install the generator nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft).
28. Position the engine harness rubber boot (3).
29. Connect the generator electrical connector (1).
30. Raise the vehicle.
31. Install the engine harness lead (2) to the starter solenoid.
32. Install the starter solenoid engine harness nut (1). Tighten: Tighten the nut to 3 N.m (27 lb in).
33. Install the positive battery cable lead (3) to the starter solenoid.
34. Install the starter solenoid battery cable nut (2). Tighten: Tighten the nut to 17 N.m (13 lb ft).
35. Install the AC compressor to the engine. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) , «Compressor Replacement (LX9)»(ref-243028-S25823289052006082100000) or «Compressor Replacement (LZ9)»(ref-243028-S16491314972006082100000) .
36. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-243010-S31944537162006082100000) .
37. Connect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coils The HO2 sensor The vehicle speed sensor The engine temperature sensor The camshaft position actuator solenoid control valves
38. Install the inlet heater hose (1) and outlet heater hose (2). Refer to «Heater Hose Replacement - Inlet»(ref-243028-S15245734552006082100000) and «Heater Hose Replacement - Outlet»(ref-243028-S27210942202006082100000) .
39. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) , «Radiator Hose Replacement - Inlet (LX9)»(ref-243023-S42214401522006082100000) or «Radiator Hose Replacement - Inlet (LZ9)»(ref-243023-S38695704482006082100000) .
40. Connect the fuel line to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-243018-S29713473812006082100000) .
41. Release the cooling module from the upper body structure.
42. Install the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-243018-S31958997662006082100000) .
43. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
44. Fill the engine with engine oil to the proper level. Refer to «Fluid and Lubricant Recommendations»(ref-243030-S04717593722006082100000) .
45. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
46. Road test the vehicle.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243010-S36671984962007060600000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
3. Place a drain pan under the oil drain plug.
4. Remove the oil pan drain plug.
5. Allow the oil to drain completely.
6. Install the oil pan drain plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Use a 32 mm (1 1/4 in) socket on the hex on top of the oil filter cap or an oil filter wrench on the outside diameter of the oil filter cap.
9. Remove the oil filter cap and filter.
10. Remove the filter from the cap.

1. Install the NEW oil filter to the cap.
2. Install the oil filter cap and filter.
3. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap or an oil filter wrench on the outside diameter of the oil filter cap. Tighten: Tighten the oil filter cap until fully seated, DO NOT exceed 25 N.m (18 lb ft).
4. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(ref-243030-S04717593722006082100000) .
5. Install intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243010-S36671984962007060600000) .

Scheme 4

1. Remove the oil cooler bolt.
2. Remove the oil cooler.

1. Use J 44887 to remove the oil filter cap. See «Special Tools»(ref-243010-S06683109272006082100000) . Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

1. Remove the balancer retaining bolt and washer. Discard the bolt.
2. Remove the balancer using a universal removal tool.

1. Remove the flywheel attaching bolt. Use the J 38122-A to prevent crankshaft rotation.
2. Remove the flywheel retainer.
3. Remove the flywheel.
4. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

1. Remove knock sensor connector from the oil level indicator tube.
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator and the oil level indicator tube from the oil pan.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield.
2. Remove the block heater if equipped.
3. Remove the oxygen sensor.
4. Remove and discard the exhaust manifold to cylinder head retaining nuts.
5. Remove the exhaust manifold.
6. Clean all of the sealing surfaces.
7. If the exhaust manifold is being replaced, transfer the following parts: The exhaust manifold heat shield The oxygen sensor

Intake Manifold Removal

1. Remove the EVAP emission canister valve tube (1).
2. Remove the EVAP emission canister valve (2).
3. Remove the throttle body bolts
4. Remove the throttle body and the accelerator control cable bracket.
5. Remove fuel pipes and clip. Remove the fuel rail assembly.
6. Remove the fuel injector tip insulators and discard.
7. Remove the intake manifold retaining nuts and bolts.
8. Remove the intake manifold.
9. Remove the intake manifold gasket, if necessary. The gasket can be used again if it is not damaged.
10. If the intake manifold needs to be replaced, transfer the throttle body to the new intake manifold.

Camshaft Cover Removal

1. Remove the bolt and coil.
2. Remove the camshaft position actuator solenoid valve bolts.
3. Remove the camshaft position actuator solenoid valves.
4. Remove the camshaft cover assembly.

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner bolt.
2. Remove the accessory drive belt tensioner.
3. Remove the engine front cover bolts.
4. Remove the long water pump bolt.
5. Remove the engine front cover and gaskets.
6. Remove the crankshaft front cover oil seal with an appropriate tool.

Timing Chain and Tensioner Removal

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide.
3. Remove the timing chain tensioner plunger.
4. Locate hex on the exhaust camshaft and hold with a wrench.
5. Remove the exhaust cam bolt and the exhaust cam actuator. Discard the bolt.
6. Remove the adjustable timing chain guide bolt.
7. Remove the adjustable timing chain guide.
8. Remove the plug to gain access to the fixed timing chain guide bolt.
9. Remove the fixed timing chain guide bolts.
10. Remove the fixed timing chain guide.
11. Locate hex on the intake camshaft and hold with a wrench.
12. Remove the intake cam sprocket bolt, the intake cam sprocket and the timing chain through the top of the cylinder head. Discard the bolt.
13. Remove the crankshaft sprocket.
14. Remove the timing chain oil nozzle bolt.
15. Remove the timing chain oil nozzle.

Intake Camshaft, Bearing Cap and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the intake camshaft cap bolts.
3. Remove the camshaft caps.
4. Remove the intake camshaft.
5. Remove the intake camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Exhaust Camshaft, Bearing Cap and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the exhaust camshaft cap bolts.
3. Remove the camshaft caps ensuring they are marked and refitted in same position on assembly.
4. Remove the exhaust camshaft.
5. Remove the exhaust camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Water Pump and Balance Shaft Chain and Tensioner Removal

1. Remove the balance shaft drive chain tensioner bolts.
2. Remove the balance shaft drive chain tensioner.
3. Remove the adjustable balance shaft chain guide bolt.
4. Remove the adjustable balance shaft chain guide.
5. Remove the small balance shaft drive chain guide bolts.
6. Remove the small balance shaft drive chain guide.
7. Remove the upper balance shaft drive chain guide bolts.
8. Remove the upper balance shaft drive chain guide.
9. Remove the balance shaft drive chain.
10. Remove the balance shaft drive sprocket.

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools»(ref-243010-S06683109272006082100000) . Insert the tool with the foot parallel to the shaft.
4. When the J 43650 is inserted in the block turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(ref-243010-S06683109272006082100000) .
5. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(ref-243010-S06683109272006082100000) .
6. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(ref-243010-S06683109272006082100000) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4. See «Special Tools»(ref-243010-S06683109272006082100000) .6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4. See «Special Tools»(ref-243010-S06683109272006082100000) .5 in) (a), recheck the tool alignment.
7. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(ref-243010-S06683109272006082100000) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(ref-243010-S06683109272006082100000) .

Water Pump Removal

1. Remove the engine coolant temperature sensor.
2. Remove the thermostat and water feed pipe retaining bolts.
3. Remove the thermostat housing and water feed pipe from the water pump cover.
4. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
5. Remove the water pump assembly.

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Clean all of the gasket surfaces.
5. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. IMPORTANT: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
6. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the bolt holes with a nylon bristle brush.
8. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools»(ref-243010-S06683109272006082100000) .

Oil Pan Removal

1. Remove the oil pan bolts.
2. Remove the oil pan at pry points.

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install J-43966-1 on the connecting rod bolts before removing the piston and connecting rod assembly. See «Special Tools»(ref-243010-S06683109272006082100000) .
7. Remove the piston and connecting rod assembly.

Lower Crankcase Removal

1. Remove the crankshaft position sensor. Inspect the position sensor for damage. Replace if necessary.
2. Remove the bedplate perimeter bolts.
3. Remove and discard the crankshaft bearing bolts.
4. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase.

Crankshaft and Bearings Removal

1. Remove the crankshaft from the block.
2. Remove the crankshaft rear oil seal from the block.
3. Remove the bearing inserts from the block.
4. Remove the bearing inserts from the bed plate.
5. Clean the oil, sludge and carbon.
6. Inspect the oil passages for obstructions.
7. Inspect the threads.
8. Inspect the bearing journals and the thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating (discoloration)
9. Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists find the cause and repair it.
10. Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selection of bearing inserts. If not within limits the crankshaft must be replaced. Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-880, through the cylinder bore.
3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN 456850-401 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402 and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings and connecting rod for damage. Refer to «Piston, Connecting Rod and Bearings Cleaning and Inspection»(ref-243010-S09454494912006082100000) .

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. Insert the 4 attachment bolts into the legs of the fixture (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) into the groove of fixture (1).
8. Using a ratchet, rotate the threaded shaft of fixture (1) in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
10. Using a torque wrench, torque the threaded shaft to 102 N.m (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the fixture (1) from the cylinder block (100).

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred. Method A yields measurement from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
2. To measure bearing clearance using Method A, use the following procedure: Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements. Measure the crankshaft bearing journal taper and runout. Install the lower crankcase and tighten the bearing cap bolts to specification. Measure bearing I.D. in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing I.D. measurement to determine clearance. Determine whether clearance is within specification. If out of spec, choose different inserts. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer.
3. To measure bearing clearance using Method B, use the following procedure: Clean the used bearing inserts. Install the used bearing inserts. Place a piece of gaging plastic across the entire bearing width. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Install the bearing cap bolts to specification. IMPORTANT: Do not rotate the crankshaft. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package. Remove the gaging plastic.

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools»(ref-243010-S06683109272006082100000) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools»(ref-243010-S06683109272006082100000) .

1. Install the connecting rod bearings. Use NEW bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. See «Special Tools»(ref-243010-S06683109272006082100000) . This protects the crankshaft journal during piston and connecting rod installation.
3. Install EN-47836 , piston and the connecting rod to the correct bore. See «Special Tools»(ref-243010-S06683109272006082100000) . Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-47836 against the engine block until all the rings have entered the cylinder bore. See «Special Tools»(ref-243010-S06683109272006082100000) . Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use new bolts. Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence. Use the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).

Intake Camshaft, Bearing Cap and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM P/N 1234550 (Canadian P/N 992704) or equivalent.
3. Lubricate the valve tips.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Set the intake camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
6. Install the camshaft caps and hand start the camshaft cap bolts.
7. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

Exhaust Camshaft, Bearing Cap and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Lubricate the valve tips with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Position the roller followers on the tip of the valve stem and on the lash adjuster, apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
4. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the camshaft caps and hand start the camshaft cap bolts.
6. Tighten the camshaft cap bolts in increments of 3 turns until they are seated, lubricate. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(ref-243010-S06683109272006082100000) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools»(ref-243010-S06683109272006082100000) .
3. When the J 43650 is fully seated in the engine block remove it with a wrench. See «Special Tools»(ref-243010-S06683109272006082100000) .
4. Place the number one piston at TDC.
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts into their bores.
7. Install the balance shaft retaining bolts. Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).

Water Pump Installation

Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1. Install the water pump assembly.
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
5. Install the water pump drain plug, if necessary. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
6. Install the water feed tube.
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing to block bolts and stud. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the engine coolant temperature sensor by hand.
11. Tighten the engine coolant temperature sensor. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
3. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
4. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
5. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
6. Hand tighten the new intake camshaft actuator bolt.
7. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
8. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
9. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
11. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
12. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
13. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
14. that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
15. Install the fixed timing chain guide and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
16. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
17. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
18. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
19. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
20. Install the timing chain tensioner assembly. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
21. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
22. Using a 23 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolts to 30 N.m (22 lb ft)), plus 100 degrees.
23. Using a 23 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolts to 30 N.m (22 lb ft)), plus 100 degrees.
24. Install the timing chain oiling nozzle. Tighten: Tighten the bolts to 10 N.m (89 lb in)).
25. Apply sealant GM PN 12345382 (Canadian PN 10953489) or equivalent, to the threads and install the timing chain guide bolt access hole plug.
26. Install the timing chain guide bolt access hole plug. Tighten: Tighten the bolts to 90 N.m (66 lb ft)).

1. Install the seal into the front cover by driving it in from the timing chain side using J 35268-A . See «Special Tools»(ref-243010-S06683109272006082100000) .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

1. Install the engine front cover with a new gasket.
2. Install the long water pump bolt. Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).
3. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
4. Install the accessory drive belt tensioner.
5. Install the accessory drive belt tensioner bolt. Tighten: Tighten the bolt to 45 N.m (33 lb ft).

Camshaft Cover Installation

1. Assemble the camshaft cover and gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
2. Install the cover on the cylinder head and hand start the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install the front lift bracket.
4. Install the front lift bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the rear lift bracket.
6. Install the rear lift bracket bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
8. Install the ignition coil. Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
9. Install the camshaft position actuator solenoid valves.
10. Install the camshaft position actuator solenoid valve bolts.

Oil Pan Installation

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of GM P/N 12378521 (Canadian P/N 88901148) or equivalent around the perimeter of the oil pan and the oil suction port opening.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

1. Install the damper onto the crankshaft indexing keyway. Use care to properly align the keyway and flats on the damper with the oil pump drive.
2. Install the J 38122-A .
3. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar in order to prevent the crankshaft from rotating when tightening the bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .

1. Install a new oil filter on the oil filter cap.
2. Lubricate the O-ring on the oil filter cap with 5 W 30 engine oil.
3. Use J 44887 to install the oil filter adapter. See «Special Tools»(ref-243010-S06683109272006082100000) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 5 N.m (44 lb in).
2. Install a new intake manifold gasket on the intake manifold.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate the fuel injector tip insulators with engine oil.
6. Install new fuel injector tip insulators.
7. Lubricate the fuel injector oil rings with engine oil.
8. Install the fuel rail assembly.
9. Install the fuel rail stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
10. Install a new throttle body gasket.
11. Install the throttle body and the accelerator control cable bracket. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
12. Install the EVAP emission canister valve (2). Tighten: Tighten the EVAP canister valve to 22 N.m (16 lb ft).
13. Install the EVAP emission canister valve tube (1).

Exhaust Manifold Installation

1. Install new exhaust manifold studs. Tighten: Tighten the studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten: Tighten the nuts to 14 N.m (124 lb in).
6. Coat the threads of the oxygen sensor with antiseize P/N 12397953 or equivalent.
7. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 42 N.m (31 lb ft).
8. Install the exhaust manifold heat shield.
9. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).

Engine Oil Cooler Installation

1. Install the oil cooler.
2. Install the oil cooler bolt and studs. Tighten: Tighten the bolts and studs to 22 N.m (16 lb ft).

Oil Level Indicator and Tube Installation

1. Lubricate the oil level indicator tube O-ring with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the oil level indicator and the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the intake manifold bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the electrical wiring harness to the oil level indicator tube.
5. Install the knock sensor wiring clip into the oil level indicator tube.

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft balancer with the 38122A, tighten the bolts evenly. Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 . See «Special Tools»(ref-243010-S06683109272006082100000) .