Engine Mechanical - 3.5L: Overhaul Pontiac G6 I

Engine Block Disassemble

1. Remove the camshaft rear bearing hole plug.
2. Remove the rear oil gallery plugs (102, 103).
3. Remove the front oil gallery plugs (107, 110, 137).
4. Remove the engine front cover locating pins (546).
5. Remove the piston oil nozzle bolt (424) and nozzle (423).
6. Remove the engine block plug.
7. Remove the transmission locating pins.
8. Remove the knock sensors.
9. Remove the engine oil pressure indicator switch.

Scheme 80

Remove the engine block heater from engine block.

Engine Block Assemble

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil pressure switch threads.
2. Install the engine oil pressure switch. Tighten: Tighten the engine oil pressure switch to 16 N.m (12 lb ft).
3. Install the knock sensors. Tighten: Tighten the knock sensors to 25 N.m (18 lb ft).
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the engine block plug.
5. Install the engine block plug. Tighten: Tighten the engine block plug to 60 N.m (44 lb ft).
6. Install the transmission locating pins. The installation height should be 8.3-9.3 mm (0.327-0.366 in) (A).
7. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the front oil gallery plug threads (110, 137).
8. Install the front oil gallery plug (110). Tighten: Tighten the front oil gallery plug to 19 N.m (14 lb ft).
9. Install the front oil gallery plug (137). Tighten: Tighten the front oil gallery plug to 33 N.m (24 lb ft).
10. Apply sealer GM P/N 12377901 (Canadian P/N 10953504), or equivalent to the front oil gallery plug (107).
11. Install the front oil gallery plug (107) so that it is 2.3 mm (0.10 in) below flush of the engine block.
12. Install the engine front cover locating pins (546). The installation height should be 5.8-8.2 mm (0.228-0.323 in) (A).
13. Install the piston oil nozzle and bolt. Tighten: Tighten the piston oil nozzle bolt to 10 N.m (89 lb in).
14. Apply Sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the rear oil gallery plugs.
15. Install the rear oil gallery plugs (103). Tighten: Tighten the rear oil gallery plugs to 19 N.m (14 lb ft).
16. Install the rear oil gallery plugs (102). Tighten: Tighten the rear oil gallery plugs to 33 N.m (24 lb ft).
17. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the left and right coolant drain plug threads.
18. Install the left coolant drain plug. Tighten: Tighten the left coolant drain plug to 19 N.m (14 lb ft).
19. Install the right coolant drain plug. Tighten: Tighten the right coolant drain plug to 19 N.m (14 lb ft).

Oil Pump Disassemble

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
2. Remove the oil pump screen, if necessary. The oil pump screen has a press fit into the oil pump cover.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
7. Remove the following items: The oil pump pressure relief valve spring straight pin. The oil pump pressure relief spring. CAUTION: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in cleaning solvent.

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant unless otherwise specified. This will provide initial lubrication when the engine is first started.

Disassembly and Assembly Procedure Revisions

No changes for 2005.