Engine Mechanical - 3.5L: Other Pontiac G6 I

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

The Vehicle Identification Number - VIN derivative (1) for 3500 LX9 is stamped or laser etched on the left side rear of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

1. The first digit identifies the division.
2. The second digit identifies the model year.
3. The third digit identifies the assembly plant.
4. The fourth through ninth digits are the last six digits of the Vehicle Identification Number - VIN.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

J 35667-A Cylinder Leakdown Tester

With the use of air pressure, a cylinder leakage test will aid in the diagnosis. Use the cylinder leakage test in conjunction with the engine compression test in order to isolate the cause of leaking cylinders.

1. Disconnect the negative battery cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls.
3. Install the J 35667-A .
4. Measure each cylinder on the compression stroke, with both valves closed.
5. Apply air pressure, using the J 35667-A . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system, perform the following procedure: Remove the valve rocker arm cover of the suspect cylinder head. Ensure that both valves are closed. Inspect the cylinder head for a broken valve spring. Remove and inspect the suspect cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) .
9. If air is heard from the crankcase system at the crankcase - oil filler tube, perform the following procedure: Remove the piston from the suspect cylinder. Inspect the piston and connecting rod assembly. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(ref-243014-S07618857722006082100000) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-243014-S13816578612006082100000) .
10. If bubbles are found in the radiator, perform the following procedure: Remove and inspect both cylinder heads. Refer to «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(ref-243014-S13816578612006082100000) .
11. Remove the J 35667-A .
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.

Low or No Oil Pressure

Tools Required J 25087-C Oil Pressure Tester

The following conditions may cause low or no oil pressure

1. Low oil level - Fill to the full mark on the oil level indicator.
2. Incorrect or malfunctioning oil pressure switch - Replace the oil pressure switch.
3. Incorrect or malfunctioning oil pressure gauge - Replace the oil pressure gauge.
4. Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. Install new oil if the oil is diluted.
5. A worn or dirty oil pump - Clean or replace the oil pump.
6. A plugged oil filter - Replace the oil filter.
7. A loose or plugged oil pickup screen - Replace the oil pickup screen.
8. A hole in the oil pickup tube - Replace the oil pickup tube.
9. Excessive rod, main, or cam bearing clearance - Replace the bearings.
10. Cracked, porous, or plugged oil gallery - Repair or replace the engine block.
11. Missing or improperly installed gallery plugs - Install or repair the plugs as needed.
12. A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. Inspect the bore for scoring and burrs.
13. A worn or poorly machined camshaft - Replace the camshaft.
14. Worn valve guides - Repair the valve guides as needed.

J 25087-C Oil Pressure Tester. See Special Tools .

If the vehicle has low oil pressure complete the following steps

1. Inspect the oil level.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
3. Remove the oil filter.
4. Assemble the plunger valve in the large hole of the J 25087-C base. See «Special Tools»(ref-243014-S19831297582006082100000) . Insert the hose in the small hole of the J 25087-C base. See «Special Tools»(ref-243014-S19831297582006082100000) . Connect the gage to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve.
6. Install the J 25087-C on the filter mounting pad. See «Special Tools»(ref-243014-S19831297582006082100000) .
7. Start the engine.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 207-310 kPa (30-45 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump.

J 28428-E High Intensity Black Light Kit

You may repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the leak and the cause of leak.

Locating and Identifying the Leak

Use the visual inspection method in order to determine if the leaking fluid is one of the following items

1. Engine oil
2. Transmission fluid
3. Power steering fluid
4. Brake fluid
5. Some other fluid

Powder Method

1. Completely clean the entire engine and surrounding components.
2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Refer to «Possible Causes for Leaks»(ref-243014-S18247479812006082100000) if necessary.

Black Light and Dye Method

A dye and light kit is available for finding leaks.

1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary Refer to «Possible Causes for Leaks»(ref-243014-S18247479812006082100000) if necessary.

Possible Causes for Leaks

Inspect the vehicle for the following conditions

1. Higher than recommended fluid levels
2. Higher than recommended fluid pressures
3. Plugged or malfunctioning fluid filters or pressure bypass valves
4. Plugged or malfunctioning engine ventilation system
5. Improperly tightened or damaged fasteners
6. Cracked or porous components
7. Improper sealants or gaskets where required
8. Improper sealant or gasket installation
9. Damaged or worn gaskets or seals
10. Damaged or worn sealing surfaces

Engine Support Fixture

Tools Required

1. J 28467-B Engine Support Fixture
2. J 36462 Engine Support Adapter Leg.
3. J 36857 See «Special Tools»(ref-243014-S19831297582006082100000)

Scheme 114

1. Raise the hood.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
3. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
4. Install the thread support nuts J 28467-33A onto the strut attaching studs.
5. Install the strut tower support assemblies J 28467-5A over the thread support nuts J 28467-33A.
6. Install the T-bolts J 28467-5 with 5/16 inch washers through the strut tower support assemblies J 28467-5A into the thread support nuts J 28467-33A. Hand tighten the bolts.
7. Install the 2 cross bracket assemblies J 28467-1A over the strut tower tube J 28467-3.
8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
9. Install the 1/2 inch x 2.5 inch quick release pin J 28467-10 through the strut tower support assemblies J 28467-5A and the strut tower tube J 28467-3 on one side only.
10. Install the radiator shelf tube J 28467-2A through the driver side cross bracket assembly J 28467-1A on the top of the strut tower tube J 28467-3.
11. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
12. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
13. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
14. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
15. Install the assembled lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
16. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket.
17. Hand tighten the driver side cross bracket assembly J 28467-1A wing nuts.
18. Install the second radiator shelf tube J 28467-2A through the passenger side cross bracket assembly (J 28467-1A) on the top of the strut tower tube J 28467-3.
19. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
20. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
21. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
22. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
23. Install the assemblage lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
24. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the right rear, front of engine.
25. Install the J 36857 lift hook bracket (1).
26. Hand tighten the passenger side cross bracket assembly J 28467-1A wing nuts.
27. Hand tighten the lift hook wing nuts J 28467-34 securely in order to remove all slack from the engine support fixture assembly.

J 35468 Cover Aligner and Seal Installer. See Special Tools .

J 45059 Angle Meter

J 45059 Angle Meter

J 37096 Flywheel Holder. See Special Tools .

J 34686 Rear Main Seal Installer. See Special Tools .

J 37088-A Fuel Line Disconnect Tool Set. See Special Tools .

1. Remove the fuel feed pipe bolts.
2. Remove the fuel feed pipe secondary latch.
3. Using J 37088-A remove the fuel feed pipe. See «Special Tools»(ref-243014-S19831297582006082100000) .
4. Remove any remaining spark plug wires from their retainers.
5. Remove the ignition coil assembly bolts and nuts.
6. Remove the ignition coil assembly.
7. Remove the ignition coil assembly studs, if necessary.
8. Remove the positive crankcase ventilation tube from the valve rocker arm cover.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.
11. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
12. Remove the valve rocker arm cover gasket.

J 33049 Camshaft Bearing Service Set. See Special Tools .

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 . See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Drive out the camshaft bearings. Use the J 33049 . See «Special Tools»(ref-243014-S19831297582006082100000) .

Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.

Honing Procedure

1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing the cylinders. Use only clean, sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. When using coarse or medium-grade stones, leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain a fine and uniform surface finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed, and by adding the average of the clearance specification. Measure the block and the piston at normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive material will wear the new rings, the cylinder bores, and the bearings lubricated by the contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.

Bearing Selection

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.

1. Method A yields measurement from which the bearing clearance can be computed.
2. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Method A

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification using J 45059 .
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. 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.
5. Install the bearing cap bolts to specification using J 45059 .
6. 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.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

J 24086-C Piston Pin Remover/Installer Set. See Special Tools .

1. Using piston ring pliers, remove the piston rings from the piston.
2. Install fork insert J 24086-310 into fixture J 24086-10 piston pin remover/installer base, which are part of J 24086-C . See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Install the piston and connecting rod assembly onto J 24086-10.
4. Install the J 24086-107 onto the piston pin and J 24086-88A through the fixture and onto J 24086-107, which are part of J 24086-C . See «Special Tools»(ref-243014-S19831297582006082100000) .
5. Press the piston pin from the piston and connecting rod assembly.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort organize the piston and the matching piston pin.

J 8087 Cylinder Bore Gage

1. Clean the piston and connecting rod in solvent.
2. Dry off the piston and connecting rod with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following: Eroded areas (1) on the top of the piston Scuffed or damaged skirt (2) Damage to the pin bore (3) Cracks in the piston ring lands, the piston skirt, or the pin bosses Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage.
7. Measure the piston ring-to-piston ring groove side clearance. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston ring groove. If binding is caused by distorted piston ring groove, replace the piston. If binding is caused by a distorted piston ring, replace the piston ring.
8. Measure the piston ring side clearance with a feeler gage.
9. If the side clearance is too small try another ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. Proper ring-to-piston ring groove clearance for the top ring is 0.03-0.076 mm (0.001-0.003 in). Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.078 mm (0.002-0.003 in).
11. Measure the piston pin diameter using an outside micrometer.
12. Measure the piston pin bore using an inside micrometer.
13. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
14. Piston-to-piston pin bore clearance must measure 0.008-0.016 mm (0.0003-0.0006 in). Replace the piston and the piston pin if the piston and the piston pin are not within specifications.
15. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin removed, and record the measurement. Measure the piston at 43 mm (1.692 in) from dome of piston. Piston diameter must measure no less than 93.960 mm (3.699 in). Replace the piston and the pin as an assembly if the piston is not within specifications.
16. Measure the cylinder bore, using J 8087 .
17. Measure the J 8087 . Record this reading.
18. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore clearance. The cylinder bore clearance must be no more than 0.080 mm (0.003 in).
19. If a used piston is not acceptable, inspect the service piston size and determine if a new piston may be selected. Service pistons are available in standard and 0.5 mm (0.012 in) oversize.
20. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
21. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds 0.005 mm (0.0002 in) the connecting rod must be replaced.
22. Inspect the connecting rod for twisting. Install the connecting rod cap. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting. Do not attempt to straighten the connecting rod. Ensure that the connecting rod meets the following conditions: The connecting rods are not bent more than 0.18 mm (0.007 in). The connecting rods are not twisted more than 0.38 mm (0.0015 in). Replace any bent or twisted connecting rods. Inspect the new connecting rods before using the new rods.
23. Inspect the connecting rod for damage to the bearing cap and bolt threads.
24. Measure the piston compression ring end gap. IMPORTANT: Fit each compression ring to the cylinder in which it will be used. Place the compression ring into the cylinder bore. Push the compression ring into the bottom of the cylinder bore to approximately 6.5 mm (0.25 in) above ring travel. The ring must be square to the cylinder wall. Use a feeler gage in order to measure the end gap. The first compression ring end gap must measure 0.18-0.39 mm (0.007-0.015 in), the second compression ring must measure 0.48-0.74 mm (0.019-0.029 in). Select another size ring set if the end gap exceeds specifications. If ring gap clearance is below specifications, increase the gap by carefully filing off excess material.
25. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatigue.
26. Inspect the connecting rod bearings for excess scoring or discoloration.
27. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
28. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
29. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting rod bearing journal for wear. This indicates high spots.

J 24086-C Piston Pin Remover/Installer Set. See Special Tools .

1. Install fork insert J 24086-310 into fixture J 24086-10, which are part of J 24086-C . See «Special Tools»(ref-243014-S19831297582006082100000) .
2. Lubricate the piston pin with clean engine oil.
3. Assemble the piston, connecting rod and adapter J 24086-6A and install onto fixture J 24086-10, which are part of J 24086-C . See «Special Tools»(ref-243014-S19831297582006082100000) .
4. Adjust installation pin J 24086-9 to G-4.
5. Insert pin J 24086-9 through fixture J 24086-10, which are part of J 24086-C and to the piston pin. See «Special Tools»(ref-243014-S19831297582006082100000) .
6. Press pin J 24086-9 until it bottoms on fixture J 24086-10.
7. Using piston ring pliers, install the piston rings onto the piston. Install the oil control ring spacer into the bottom groove of the piston. Install the lower oil control ring. The oil control rings do not have a dimple or orientation mark and may be installed in either direction. Install the upper oil control ring. Install the middle compression ring with the dot facing up. Install the top compression ring in either direction. The ring has no orientation markings.

J 7872 Magnetic Base Dial Indicator Set

1. Clean the camshaft with cleaning solvent.
2. Inspect the camshaft for the following conditions: Scored camshaft bearing journals (1) Damaged camshaft lobes (2) Damaged camshaft sprocket locator pins (3) Damaged threads (4) Damage to the camshaft reluctor tooth (5)
3. Measure the camshaft journals using a micrometer. If the camshaft journals are not within specifications, replace the camshaft.
4. Measure the camshaft runout using the J 7872 . Mount the camshaft in V-blocks between the centers. Use the J 7872 in order to measure the intermediate camshaft journal.
5. Measure the camshaft lobe lift using the J 7872 . Lubricate the camshaft using GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent. Set the camshaft on V-blocks. Use the J 7872 in order to measure the lobe lift.
6. If the runout or lobe lift is not within specifications, replace the camshaft.

J 38606 Valve Spring Compressor. See Special Tools .

1. Remove the heater inlet pipe stud from the right cylinder head, if required.
2. Remove the coolant temperature sensor from the right cylinder head, if required.
3. Remove the cylinder head plug.
4. Compress the valve springs using the J 38606 . See «Special Tools»(ref-243014-S19831297582006082100000) .
5. Remove the valve spring cap keys.
6. Remove the valve spring caps.
7. Remove the valve springs.
8. Remove the valves.
9. Remove the valve stem oil seals and spring seats as an assembly.

J 8520 Camshaft Lobe Lift Indicator Set. See Special Tools .

1. Inspect the valves for the following conditions: Burnt or eroded areas (1) A worn margin (2) A bent stem (3) A worn or scored stem (4) A worn key groove (5) A worn stem tip (6)
2. Inspect the valve face for the following conditions: Worn margin (4) No margin (1) Pitted surfaces (2) Burnt or eroded areas (3)
3. Inspect the valve seats for a loose fit in the cylinder head.
4. Inspect for excessive valve stem (1) to guide (2) clearance.
5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps: Install the valve into the guide. Install the J 8520 onto the cylinder head. See «Special Tools»(ref-243014-S19831297582006082100000) . Locate the dial indicator so that the movement of the valve stem from side to side, crosswise to the cylinder head, will cause a direct movement on the indicator stem. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide. Drop the valve head about 2 mm (1/8 in) off the valve seat. Use light pressure and move the valve stem side to side in order to obtain a clearance reading. If the valve stem to guide clearance is not within specification, replace the valve and/or repair the guide in order to obtain the proper clearances.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
7. Ream the valve guide in order to obtain the proper specification.
8. Inspect the valves for excessive scoring.
9. Inspect the valve face. Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.

J 38606 Valve Spring Compressor. See Special Tools .

1. Lubricate the valve stem with clean engine oil.
2. Install the valves.
3. Lightly tap the new or reconditioned valves into the valve seat.
4. Install the valve stem oil seals.
5. Install the valve springs.
6. Install the valve spring caps.
7. Compress the valve springs using the J 38606 . See «Special Tools»(ref-243014-S19831297582006082100000) .
8. Install the valve spring cap keys. Hold the valves in place with grease, if necessary.
9. Release the valve springs.
10. Ensure that the valve locks are seated.
11. Measure valve spring installed height.
12. If the valve spring installed height is not within specifications install 0.25 mm (0.010 in) rocker arm shims P/N 88894006 as needed. If more than 2 shims are needed replace the cylinder head or valve.
13. Apply sealer P/N 21485278 to the coolant temperature sensor.
14. Install the coolant temperature sensor, if required. Tighten: Tighten the coolant temperature sensor to 23 N.m (17 lb ft).
15. Install the heater inlet pipe stud, if required. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).

J 22144 Oil Suction Pipe Installer. See Special Tools .

1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
3. Install the oil pump cover.
4. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
5. Install the pressure regulator valve.
6. Install the pressure regulator spring.
7. Install the cotter pin.
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using J 22144 and a plastic hammer. See «Special Tools»(ref-243014-S19831297582006082100000) .

J 21882 Oil Suction Pipe Installer. See Special Tools .

1. Remove the intake manifold coolant pipe bolt, if required.
2. Remove the intake manifold coolant pipe, if required.
3. Clean the intake manifold gasket mating surfaces using GM P/N 12346139 (Canadian P/N 10953463) or equivalent.
4. Clean the fuel injector bores.
5. Inspect the intake manifold for damage.
6. Repair or replace the intake manifold as necessary.
7. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the end of the intake manifold coolant pipe, if required.
8. Install the intake manifold coolant pipe using J 21882 . See «Special Tools»(ref-243014-S19831297582006082100000) .
9. Install the intake manifold coolant pipe bolt. Tighten: Tighten the intake manifold coolant pipe bolt to 10 N.m (89 lb in).

Thread Repair

General purpose thread repair kits are available commercially.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

J 33049 Camshaft Bearing Service Set. See Special Tools .

1. Assemble the J 33049 according to the manufacturer's instructions. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. Install the camshaft bearings in the following order: Index the camshaft bearing oil holes with the engine block oil passages. Place the bearing on the J 33049 . See «Special Tools»(ref-243014-S19831297582006082100000) . Install the third camshaft bearing. Install the second camshaft bearing. Install the outer camshaft bearings.
3. Apply sealer GM P/N United States 12377901, GM P/N Canada 10953504 or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

J 45059 Angle Meter

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N.m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-0.21 mm (0.002-0.008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).

J 34686 Rear Main Seal Installer. See Special Tools .

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. The EN-48108 tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with installation, review the above illustration to become familiar with the following components: Mandrel (1) Drive Drum (2) Drive Nut (3) Washer (4) Bearing (5)
2. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
3. Using a large flat blade screwdriver, tighten the two mandrel screws to the crankshaft, ensuring the mandrel is snug to the crankshaft hub. IMPORTANT: The seal will only fit one way onto the mandrel, and if properly installed, will center on a step that protrudes from the center of the mandrel.
4. Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel.
5. Install the outer drive drum onto the mandrel.
6. Install the bearing, washer, and the drive nut onto the threaded shaft.
7. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore.
8. Turn the wrench until the drive drum is snug and flush against the engine block.
9. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the nylon plastic seal protector.
10. Verify that the seal has seated properly.
11. Use a flat blade screwdriver to remove the two attachment screws from the mandrel and remove the mandrel from the crankshaft hub.

J 35468 Cover Aligner and Seal Installer. See Special Tools .

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(ref-243014-S19831297582006082100000) .

J 45059 Angle Meter

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 .

J 45059 Angle Meter

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 .

J 45299 Engine Preluber

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Locate the engine oil pressure indicator switch on the left side of the engine and remove.
3. Install the 1/4 inch adapter P/N 509373.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine oil pressure indictor switch. Tighten: Tighten the engine oil pressure indictor switch to 16 N.m (12 lb ft).
8. Top off the engine oil to the proper level.

Scheme 120

A crankcase ventilation system is used to consume crankcase vapors (1) in the combustion process instead of venting them to atmosphere. Fresh air from the throttle body is supplied to the crankcase, mixed with blow by gases, and then passed through a positive crankcase ventilation (PCV) valve (3) into the intake manifold.

Scheme 121

The primary control is through the positive crankcase ventilation (PCV) valve which meters the flow at a rate depending on inlet vacuum. To maintain idle quality, the PCV valve restricts the flow when inlet vacuum is high. If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent into the throttle body to be consumed by normal combustion.

New Product Information

The purpose of New Product Information is to highlight or indicate important product changes from the previous model year.

Changes may include one or more of the following items

1. A component comparison from the previous year
2. Fastener changes
3. Torque values and/or fastener tightening strategies
4. Changed engine specifications
5. New sealants and/or adhesives
6. Disassembly and assembly procedure revisions
7. Engine mechanical diagnostic procedure revisions
8. New special tools required

Component Comparison

No component changes for 2005.

Fastener Changes

No fastener changes for 2005.

New Sealants and/or Adhesives

No new sealants and or adhesives for 2005.

Cleanliness and Care

An automobile engine is a combination of many of the following surfaces

1. Machined
2. Honed
3. Polished
4. Lapped

The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice proper cleaning and protection procedures to the machined surfaces and to the friction areas.

Note. Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.

Whenever you remove the valve train components, keep the components in order. Follow this procedure in order to install the components in the same locations and with the same mating surfaces as when removed.

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to ENGINE ELECTRICAL

Separating Parts

In addition to the room temperature vulcanizing (RTV) sealant's sealing capabilities, the RTV sealants may form an adhesive bond between the components. This may make the components difficult to remove or to separate. If possible, bump the components sideways rather than using prying tools in order to remove the components. This technique prevents damage when the bonding strength of the RTV sealant is stronger than the component itself. Perform bumping at the bends or at the reinforced areas in order to prevent part distortion.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the components. Perform the bumping at the bends or at the reinforced areas in order to prevent the distortion of components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

1. The RTV sealer
2. The anaerobic gasket eliminator sealer

Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks. Do not interchange the 2 types of sealers. Use the sealer recommended in the service procedure.

Applying RTV Sealer

1. Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include the following locations: The exhaust manifold The head gasket The other surfaces where gasket eliminator is specified
2. Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part sideways in order to shear the RTV sealer. Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The RTV sealant is weaker in shear (lateral) strength than in tensile (vertical) strength.
3. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand Paper Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container. IMPORTANT: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
2. Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to the inside of any bolt holes.
3. Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV sealant to skin over.
4. Tighten the bolts to specifications.

Applying Anaerobic Sealer

The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.

Do not use the following items in order to clean the gasket surfaces

1. Abrasive pads
2. Sand paper
3. Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container.
2. Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will reseal.
3. Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
4. Spread the sealer evenly in order to get a uniform coating on the sealing surface.
5. Tighten the bolts to the specifications.
6. Remove the excess sealer from the outside of the joint.

Tools and Equipment

Work in a clean and well-lit area. Have the following components available before you begin to work

1. A suitable parts cleaning tank
2. A compressed air supply
3. Trays, in order to keep the parts and the fasteners organized
4. An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly of various parts.