Engine Mechanical - 3.5L: Removal & Installation Pontiac G6 I

Removal Procedure

1. Remove the engine oil fill cap.
2. Pull up on the cover in order to disengage the cover from the studs.

Installation Procedure

1. Align the cover to the studs on the engine, push down on the cover above the studs in order to engage the cover to the studs.
2. Install the engine oil fill cap.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls.
2. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243014-S35844413692006082100000) .
3. Rotate the drive belt tensioner counterclockwise to release the spring tension.
4. Remove the drive belt.

1. Rotate the drive belt tensioner counterclockwise to release the spring tension.
2. Install the drive belt.
3. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243014-S35844413692006082100000) .
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Removal»(ref-243014-S41252810882006082100000) .

1. Install the drive belt tensioner. «Drive Belt Tensioner Installation»(ref-243014-S01484865092006082100000) .
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) in Tires and Wheels.
3. Remove the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(ref-243023-S35124382672006082100000) in Engine Cooling.
4. Remove the engine mount to engine mount bracket nuts.
5. Remove the motor mount to frame nuts.
6. Using a suitable jackstand, raise the engine.
7. Remove the motor mount from the vehicle.

1. Position the motor mount on the frame
2. Use the jackstand to lower the engine mount bracket on to the engine mount.
3. Install the engine mount to frame bolts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Install the motor mount to motor mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Install the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(ref-243023-S35124382672006082100000) in Engine Cooling.
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) in Tires and Wheels.
7. Lower the vehicle.

Scheme 60

Scheme 61

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) .
2. Place a block of wood on a adjustable floor jack, and place the jack under the oil pan in order to support the engine.
3. Remove the engine mount to engine mount bracket bolts.
4. Remove the engine mount bolts.
5. Remove the engine mount.

1. Place the engine mount into position on the engine compartment side rail. NOTE: Refer to «Fastener Notice»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the engine mount bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft).
3. Install the engine mount to engine mount bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft).
4. Remove the floor jack and block of wood from under the oil pan.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243014-S39558207372006082100000) .
2. Remove the engine mount bracket bolts from the engine.
3. Remove the engine mount bracket from the vehicle.

1. Position the engine mount bracket to the engine.
2. Install the front mount bracket bolts to the engine. Hand tighten the bolts at this time. Tighten: Tighten the upper engine mount bracket bolts to 90 N.m (66 lb ft). Tighten the lower engine mount bracket bolts to 50 N.m (37 lb ft).
3. Install the engine mount. Refer to «Engine Mount Replacement»(ref-243014-S39558207372006082100000) .

Scheme 62

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-243014-S39558207372006082100000) .
2. Remove the engine mount bracket bolts from the engine.
3. Remove the engine mount bracket.

1. Position the engine mount bracket to the engine front cover.
2. Hold the bracket firmly to the engine front cover and install the engine mount bracket bolts. NOTE: Refer to «Fastener Notice»(ref-246412-S41332073762006122100000) in Cautions and Notices.
3. Tighten the engine mount bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(ref-243014-S30216296742007062000000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls - 3.5L (LX9).
2. Remove the engine mount strut to engine mount bolts.
3. Rotate the engine mount strut to the vertical position.
4. Remove the engine mount strut to body bolts.
5. Remove the engine mount strut from the vehicle.

1. Install the engine mount strut in to the vehicle. Tighten: Tighten the engine mount strut to body bolts to 50 N.m (37 lb ft).
2. Rotate the engine mount strut to the horizontal position.
3. Install the engine mount strut to bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls - 3.5L (LX9).

1. Remove the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(ref-243014-S10756364782006082100000) .
2. Remove the engine mount strut bracket to engine bolts.
3. Remove the engine mount strut bracket from the vehicle.

1. Install the engine mount strut bracket to the engine. Tighten: Tighten the engine mount strut bracket to engine bolts to 25 N.m (18 lb ft).
2. Install the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(ref-243014-S10756364782006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
2. Remove the oil filter. IMPORTANT: If the bypass valve does not need to be replaced, the bolt nearest the air conditioning compressor does not need to be fully removed. The hole in the adapter and the gasket are slotted to allow the bolt to be loosened and the adapter and gasket removed without fully removing the bolt.
3. Remove the oil filter adapter and gasket. IMPORTANT: It is not necessary to evacuate and recharge the air conditioning system, it is only necessary to remove the belt and the compressor fasteners to reposition the compressor.
4. If the bypass valve hole plug or the bypass valve need to be removed, the air conditioning compressor must be removed and repositioned. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) .
5. Remove the oil filter bypass hole plug.
6. Insert a flat bladed tool into the oil filter bypass hole and remove the bypass valve.

1. Install the oil filter bypass valve (1) to the proper depth.
2. Install the oil filter bypass hole plug. Tighten: Tighten the plug to 19 N.m (14 lb ft).
3. If the air conditioning compressor has been removed, reinstall the air conditioning compressor. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) .
4. Install the oil filter and gasket. Tighten: Tighten to 25 N.m (18 lb ft).
5. Install the oil filter.
6. Lower the vehicle.
7. Check and fill the crankcase as necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the oil level indicator.
3. Remove the oil level indicator tube bracket bolt.
4. Remove the oil level indicator tube.

1. Clean the oil level indicator tube.
2. Apply sealant around the oil level indicator tube 12.7 mm (0.50 in) below the bead. Use sealant GM P/N 12346286 (Canadian P/N 10953472) or the equivalent.
3. Install the oil level indicator tube into the engine block.
4. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator.
6. Install the spark plug wire to the number 6 cylinder spark plug.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
3. Remove the vacuum hoses from the following: Evaporative emissions (EVAP) canister purge valve Manifold vacuum source Brake booster Heater and air conditioning (A/C) source
4. Disconnect the electrical connectors from the following: Exhaust gas recirculation (EGR) valve Mass air flow (MAF) sensor Intake air temperature (IAT) sensor Electronic throttle control EVAP canister purge valve
5. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) .
6. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
7. Remove the left side spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) .
8. Remove the following wiring harnesses from the retainers: Camshaft position (CMP) sensor wiring harness Left side spark plug wire harness Engine wiring harness
9. Remove the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(ref-242989-S04608628032006082100000) .
10. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-242989-S09462569612006082100000) .
11. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-242989-S05285947522006082100000) .
12. Remove the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-242989-S19532711262006082100000) .
13. Remove the upper intake manifold bolts and the stud.
14. Remove the upper intake manifold.
15. Remove the upper intake manifold gaskets.
16. If replacing the upper intake manifold, remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-242989-S09786575482006082100000) .
17. Clean the upper intake gasket mating surfaces.

1. If removed, install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-242989-S09786575482006082100000) .
2. Install the upper intake manifold gaskets.
3. Install the upper intake manifold.
4. Install the right upper intake manifold bolts and the stud. Tighten: Tighten the bolts and the stud to 25 N.m (18 lb ft).
5. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-242989-S19532711262006082100000) .
6. Install the MAP sensor bracket and the sensor. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-242989-S05285947522006082100000) .
7. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-242989-S09462569612006082100000) .
8. Install the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(ref-242989-S04608628032006082100000) .
9. Install the following wiring harnesses to the retainers: Engine wiring harness Left side spark plug wire harness CMP sensor wiring harness
10. Install the left side spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) .
11. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) .
12. Connect the electrical connectors to the following: EVAP canister purge valve Electronic throttle control IAT sensor MAF sensor EGR valve
13. Install the vacuum hoses to the following: Heater and A/C source Brake booster Manifold vacuum source EVAP canister purge valve
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
15. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
16. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .

1. Disconnect the battery ground negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-243014-S14730261142006082100000) .
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-243014-S41900466802006082100000) .
4. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-243014-S24486937912006082100000) .
5. Disconnect the engine coolant temperature (ECT) wiring harness.
6. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness.
7. Remove the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(ref-242989-S26435212932006082100000) in Engine Controls - 3.5L.
8. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
9. Disconnect the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) or «Radiator Hose Replacement - Inlet (LX9)»(ref-243023-S42214401522006082100000) or «Radiator Hose Replacement - Inlet (LZ9)»(ref-243023-S38695704482006082100000) in Engine Cooling.
10. Remove the water outlet.
11. Remove the thermostat.
12. Remove the lower intake manifold bolts.
13. Remove the lower intake manifold.
14. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
15. Remove the lower intake manifold gaskets and seals.
16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
17. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
18. Remove all the loose room temperature vulcanizing sealer (RTV) (1).

1. Install the lower intake manifold gaskets.
2. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
3. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148), or equivalent, to the 4 corners of the intake manifold to block joints (1).
4. Install the lower intake manifold.
5. Apply sealer GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the lower intake manifold bolt threads.
6. Install the new lower intake manifold bolts, if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Install the thermostat.
10. Install the water outlet bolts. Refer to «Thermostat Replacement (2.4L)»(ref-243023-S15432718372006082100000) or «Thermostat Replacement (3.5L)»(ref-243023-S24517415342006082100000) or «Thermostat Replacement (3.9L)»(ref-243023-S11110837462006082100000) in Engine Cooling.
11. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
12. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
13. Connect the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) or «Radiator Hose Replacement - Inlet (LX9)»(ref-243023-S42214401522006082100000) or «Radiator Hose Replacement - Inlet (LZ9)»(ref-243023-S38695704482006082100000) in Engine Cooling.
14. Connect the heater inlet pipe and heater hose to the lower intake manifold.
15. Install the power steering pump to the front engine cover.
16. Install the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(ref-242989-S26435212932006082100000) in Engine Controls - 3.5L.
17. Connect the fuel feed pipe to the fuel injector rail.
18. Connect the fuel injector and MAP wiring harness.
19. Connect the ECT wiring harness.
20. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-243014-S24486937912006082100000) .
21. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-243014-S41900466802006082100000) .
22. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-243014-S14730261142006082100000) .
23. Connect the battery ground negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
2. Disconnect the vacuum hose from positive crankcase ventilation (PCV) valve.
3. Remove the PCV valve retainer.
4. Remove the PCV valve.

1. Install the PCV valve.
2. Install the PCV valve retainer.
3. Connect the vacuum hose to PCV valve.
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
3. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
4. Remove the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement (3.5L)»(ref-243023-S19701987652006082100000) .
5. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
8. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints (1).
9. Remove the valve cover gasket.
10. Clean the sealing surface on the cylinder head with degreaser.
11. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-243014-S42080861172006082100000) .

1. Apply sealant at the cylinder head to the lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the valve rocker cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the PCV valve vacuum line.
6. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement (3.5L)»(ref-243023-S19701987652006082100000) .
7. Install the front ignition wire harness.
8. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
3. Remove the generator. Refer to «Generator Replacement (2.4L)»(ref-242993-S10209315092006082100000) or «Generator Replacement (3.5L)»(ref-242993-S18150277112006082100000) or «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) in Engine Electrical.
4. Remove the generator bracket. Refer to «Generator Bracket Replacement (3.5L)»(ref-242993-S17416590522006082100000) in Engine Electrical.
5. Remove the right spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
6. Disconnect the vacuum hoses from the evaporative emission (EVAP) purge valve.
7. Remove the EVAP purge valve.
8. Remove the ignition coil bracket with the coils. Refer to «Ignition Coil(s) Replacement»(ref-242989-S15438595322006082100000) in Engine Controls - 3.5L.
9. Remove the ignition coil bracket studs.
10. Remove the vacuum hose from the grommet in the right valve rocker arm cover.
11. Remove the right valve rocker arm cover bolts.
12. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
13. Trim the valve gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
14. Remove the valve cover gasket.
15. Clean the sealing surface on the cylinder head with degreaser.
16. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(ref-243014-S42080861172006082100000) .

1. Apply sealant at the cylinder head to lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the right valve rocker arm cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the vacuum hose to the grommet in the right valve rocker arm cover.
6. Install the ignition coil bracket studs.
7. Install the ignition coil bracket with coils. Refer to «Ignition Coil(s) Replacement»(ref-242989-S15438595322006082100000) in Engine Controls - 3.5L.
8. Install the EVAP purge valve.
9. Connect the vacuum hoses to the EVAP purge valve.
10. Install the right spark plug wires. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
11. Install the generator bracket. Refer to «Generator Bracket Replacement (3.5L)»(ref-242993-S17416590522006082100000) in Engine Electrical.
12. Install the generator. Refer to «Generator Replacement (2.4L)»(ref-242993-S10209315092006082100000) or «Generator Replacement (3.5L)»(ref-242993-S18150277112006082100000) or «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) in Engine Electrical.
13. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-243014-S41900466802006082100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-243014-S24486937912006082100000) .
2. Remove the rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods.

1. Install the pushrods in the original location. Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter.
2. Install the rocker arms.
3. Install the rocker arm bolts. Tighten: Tighten the rocker arm bolts to 32 N.m (24 lb ft).
4. Install the valve rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-243014-S41900466802006082100000) or «Valve Rocker Arm Cover Replacement - Right»(ref-243014-S24486937912006082100000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. EN-47823 Valve Spring Compressor Adapter See «Special Tools»(ref-243014-S19831297582006082100000) .
2. J 22794 Spark Plug Port Adapter. See «Special Tools»(ref-243014-S19831297582006082100000)
3. J 38606 Valve Spring Compressor. See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
3. Install the J 22794 into the spark plug port. See «Special Tools»(ref-243014-S19831297582006082100000) . Apply compressed air in order to hold the valves in place.
4. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the «J 5892-D»(ref-243014-S40595202082006082100000) (1) and the «EN-47823»(ref-243014-S40595202082006082100000) (2).
5. Remove the valve spring cap keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Remove the valve stem oil seal.

1. Lubricate the valve stem with clean engine oil.
2. Install the valve stem oil seal, ensuring the proper seals (intake - black seal and exhaust - brown seal) are installed.
3. Install the valve spring.
4. Install the valve cap.
5. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the «J 5892-D»(ref-243014-S40595202082006082100000) (1) and the «EN-47823»(ref-243014-S40595202082006082100000) (2).
6. Install the valve locks. If necessary, hold the valve locks in place with grease.
7. Ensure the valve cap keys are seated.
8. Remove the compressed air and remove the «J 22794»(ref-243014-S40595202082006082100000) from the spark plug port.
9. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
3. Remove the intake manifold oil splash shield
4. Remove the lifter guide bolts.
5. Remove the valve lifter guides.
6. Remove the valve lifters.
7. Clean all gasket surfaces with degreaser.
8. Clean the valve train parts.
9. Inspect the valve lifters and the cam lobes for wear. Refer to «Valve Lifters Cleaning and Inspection»(ref-243014-S13142088992006082100000) .

1. Coat the valve lifters with prelube GM P/N 1052367 (Canadian P/N 992869) or equivalent.
2. Install the valve lifters to the same location from which they were removed.
3. Install the valve lifter guides.
4. Install the valve lifter guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the intake manifold oil splash shield
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
7. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .

Crankshaft Balancer Replacement

Tools Required

1. J 29113 Balancer and Crank Sprocket Installer. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. J 37096 Flywheel Holder. See «Special Tools»(ref-243014-S19831297582006082100000) .
3. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
3. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) in Tires and Wheels.
4. Remove the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(ref-243023-S19224180592006082100000) in Engine Cooling.
5. Install the jack stands to the frame.
6. Loosen the left frame bolts and remove the right side frame bolts. Refer to «Frame Replacement (Coupe 2.4L/4T40-E/4T45-E)»(ref-243009-S28939599432006082100000) or «Frame Replacement (Coupe 3.5L/4T40-E/4T45-E)»(ref-243009-S03643259772006082100000) or «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) or «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) or «Frame Replacement (Convertible 3.5L/4T40-E/4T45-E)»(ref-243009-S24938334332006082100000) or «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) in Frame and Underbody.
7. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
8. Remove the torque converter covers.
9. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(ref-243014-S19831297582006082100000) .
10. Remove the crankshaft balancer bolt and the washer.
11. Remove the crankshaft balancer. Use the J 41816 . See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Apply sealant to the keyway of the balancer. Refer to «Sealers, Adhesives, and Lubricants»(ref-243014-S30249129652006082100000) for the correct part number.
2. Install the crankshaft balancer. Use the J 29113 . See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Remove the J 29113 . See «Special Tools»(ref-243014-S19831297582006082100000) .
4. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(ref-243014-S19831297582006082100000) .
5. Install the crankshaft balancer washer and the bolt.
6. Install the used crankshaft balancer bolt. Tighten Tighten the used crankshaft balancer bolt to 125 Nm (92 lb ft).
7. Remove the used crankshaft balancer bolt.
8. Install the NEW crankshaft balancer bolt. Tighten Tighten the crankshaft balancer bolt a first pass to 125 Nm (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059 .
9. Remove the J 37096 from the flywheel.
10. Install the torque converter covers.
11. Raise the frame to the original position.
12. Install and tighten the frame bolts. Refer to «Frame Replacement (Coupe 2.4L/4T40-E/4T45-E)»(ref-243009-S28939599432006082100000) or «Frame Replacement (Coupe 3.5L/4T40-E/4T45-E)»(ref-243009-S03643259772006082100000) or «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) or «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) or «Frame Replacement (Convertible 3.5L/4T40-E/4T45-E)»(ref-243009-S24938334332006082100000) or «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) in Frame and Underbody.
13. Install the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(ref-243023-S19224180592006082100000) in Engine Cooling.
14. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) in Tires and Wheels.
15. Lower the vehicle.
16. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-243014-S15424971832006082100000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
4. Place a suitable drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug and drain the engine oil from the crankcase.
6. Reinstall the oil pan drain plug until snug.
7. Remove the starter. Refer to «Starter Motor Replacement»(ref-242993-S24411766452006082100000) .
8. Remove the oil filter adapter. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(ref-243014-S04225914632006082100000) .
9. Remove the air conditioning (A/C) compressor bolts and position the compressor aside.
10. Remove the engine mount bracket bolts and bracket.
11. Remove the transaxle brace bolts (5 and 6) and remove the brace (7).
12. Remove the transaxle to oil pan brace bolts and brace.
13. Remove the flexplate to torque converter bolts.
14. Lower the vehicle.
15. Remove the engine harness ground nut (2) from the transaxle stud.
16. Remove the engine wiring harness ground (3) and the negative battery cable ground (1) from the transaxle stud.
17. Remove the engine wiring harness clip nut (1) from the transaxle stud.
18. Remove the engine wiring harness clip (2) from the transaxle stud.
19. Remove the engine wiring harness ground nut (2) from the transaxle stud.
20. Remove the engine wiring harness ground (1) from the transaxle stud.
21. Loosen, DO NOT REMOVE the transaxle studs (1) and bolts (2).
22. Using the engine support fixture, raise the engine and transaxle slightly.
23. Raise and support the vehicle.
24. Remove the oil pan bolts (1 and 2).
25. Separate the engine and transaxle approximately 13 mm (1/2 inch).
26. Ensure that when removing the oil pan, the pan clears the boss (1) on the transaxle.
27. Remove the oil pan, if the oil pan cannot be removed, lower the vehicle and perform steps 21 and 23 again until the pan can be removed.
28. Remove and discard the oil pan gasket.
29. Clean the oil pan sealing surfaces.

Scheme 75

1. Apply sealer to both sides of the front cover/block mating area. «Sealers, Adhesives, and Lubricants»(ref-243014-S30249129652006082100000)
2. Apply sealer to both sides of the crankcase rear main bearing cap. Press the sealer into the gap using a putty knife. Refer to «Sealers, Adhesives, and Lubricants»(ref-243014-S30249129652006082100000) .
3. Install a NEW oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts. Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolts (2) to 25 N.m (18 lb ft).
6. Lower the vehicle. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
7. Using the engine support fixture, lower the engine and transaxle.
8. Tighten the transaxle studs (1) and bolts (2).
9. Install the engine wiring harness ground (1) to the transaxle stud.
10. Install the engine wiring harness ground nut (2) to the transaxle stud. Tighten Tighten the nut to 25 Nm (18 lb ft).
11. Install the engine wiring harness clip (2) to the transaxle stud.
12. Install the engine wiring harness clip nut (1) to the transaxle stud. Tighten Tighten the nut to 25 Nm (18 lb ft).
13. Install the negative battery cable ground (1) and the engine wiring harness ground (3) to the transaxle stud.
14. Install the engine harness ground nut (2) to the transaxle stud. Tighten Tighten the nut to 25 Nm (18 lb ft).
15. Raise and support the vehicle.
16. Install the flexplate to torque converter bolts. Tighten Tighten the bolts to 62 Nm (46 lb ft).
17. Position the transaxle to oil pan brace and install the bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft).
18. Position the transaxle brace (7) to the transaxle and install the bolts (5 and 6) until snug.
19. Install the engine wiring harness clip to the rear of the transaxle brace.
20. Position the engine mount bracket to the engine and install the bolts until snug.
21. Tighten the engine mount bracket bolts and transaxle brace bolts. Tighten Tighten the engine mount bracket upper bolt to 90 Nm (66 lb ft). Tighten the engine mount bracket lower bolts to 50 Nm (37 lb ft). Tighten the transaxle brace bolts to 72 Nm (53 lb ft).
22. Position the A/C compressor and install the bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft).
23. Install the oil filter adapter. «Oil Filter Adapter and Bypass Valve Assembly Replacement»(ref-243014-S04225914632006082100000) .
24. Install the starter. Refer to «Starter Motor Replacement»(ref-242993-S24411766452006082100000) .
25. Ensure that the oil pan drain plug is tighten. Tighten Tighten the drain plug to 26 Nm (19 lb ft).
26. Lower the vehicle.
27. Remove the engine support fixture.
28. Fill the crankcase with oil.
29. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
30. Start the vehicle and inspect for leaks.

1. Disconnect the battery negative cable from the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Remove the electrical connector from the engine oil pressure sensor.
3. Remove the engine oil pressure switch.

1. Install the engine oil pressure switch. Tighten: Tighten the switch to 16 N.m (12 lb ft).
2. Install the electrical connector to the engine oil pressure switch.
3. Connect the battery negative cable to the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-243014-S32527833182006082100000) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.
4. Inspect the oil pump drive shaft and the oil pump. Refer to «Oil Pump Cleaning and Inspection»(ref-243014-S25281707022006082100000) .

1. Install the oil pump drive shaft and the oil pump.
2. Install the oil pump bolt. Tighten: Tighten the bolt to 41 N.m (30 lb ft).
3. Install the oil pan. Refer to «Oil Pan Replacement»(ref-243014-S32527833182006082100000) .

1. Remove the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) in Engine Controls - 3.5L.
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
3. Remove the oil pump drive bolt.
4. Remove the oil pump drive clamp.
5. Remove the oil pump drive.
6. Remove the oil pump drive seal.

1. Install the oil pump drive seal. Coat the seal or bore in the engine block with engine oil.
2. Coat the drive gear on the oil pump drive with prelube GM P/N 1052367 (Canadian P/N 992869) or the equivalent.
3. Install the oil pump drive.
4. Install the oil pump drive clamp.
5. Install the oil pump drive bolt. Tighten: Tighten the bolt to 36 N.m (27 lb ft).
6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
7. Install the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) in Engine Controls - 3.5L.

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243014-S31791935852006082100000) .
2. Pry out the oil seal using a large screwdriver or the equivalent.
3. Inspect the following items for scratches: The front cover The crankshaft

1. Lubricate the oil seal using clean engine oil.
2. Insert the oil seal into the front cover with the lip facing the engine. Use the J 35468 . See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243014-S31791935852006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
3. Remove the engine mount bracket, if equipped with a convertible top. Refer to «Engine Mount Bracket Replacement»(ref-243014-S26339419282007062000000) .
4. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-243014-S37454282042006082100000) .
5. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
6. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-243014-S32527833182006082100000) .
7. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243014-S31791935852006082100000) .
8. Remove the thermostat bypass pipe from the engine front cover. Refer to «Thermostat Bypass Pipes Replacement (3.5L)»(ref-243023-S19701987652006082100000) in Engine Cooling.
9. Remove the radiator outlet hose from the engine front cover. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000) or «Radiator Hose Replacement - Outlet (LX9)»(ref-243023-S38434924012006082100000) or «Radiator Hose Replacement - Outlet (LZ9)»(ref-243023-S37042066022006082100000) in Engine Cooling.
10. Remove the water pump from the engine front cover. Refer to «Water Pump Replacement (2.4L)»(ref-243023-S05460889682006082100000) or «Water Pump Replacement (3.5L)»(ref-243023-S19690908332006082100000) or «Water Pump Replacement (3.9L)»(ref-243023-S08018710632006082100000) in Engine Cooling.
11. Remove the CKP sensor wiring harness bracket.
12. Remove the engine front cover bolts (1, 2, 3).
13. Remove the engine front cover.
14. Remove the engine front cover gasket.
15. Clean and inspect the engine front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-243014-S02491484382006082100000) .
16. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
17. If replacing the engine front cover remove the water pump. Refer to «Water Pump Replacement (2.4L)»(ref-243023-S05460889682006082100000) or «Water Pump Replacement (3.5L)»(ref-243023-S19690908332006082100000) or «Water Pump Replacement (3.9L)»(ref-243023-S08018710632006082100000) in Engine Cooling.

Scheme 76

1. If removed install the water pump. Refer to «Water Pump Replacement (2.4L)»(ref-243023-S05460889682006082100000) or «Water Pump Replacement (3.5L)»(ref-243023-S19690908332006082100000) or «Water Pump Replacement (3.9L)»(ref-243023-S08018710632006082100000) in Engine Cooling.
2. If removed, install the drive belt shield. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Install the drive belt shield bolt.
4. Apply sealant to both sides of the engine front cover gasket with GM P/N 12346004 (Canadian P/N 10953480) or equivalent.
5. Install the engine front cover gasket.
6. Install the engine front cover.
7. Apply sealer to the bolts in the locations pointed out in the graphic. Refer to «Sealers, Adhesives, and Lubricants»(ref-243014-S30249129652006082100000)
8. Install the engine front cover bolts (1, 2, and 3).
9. Install the radiator outlet hose to the engine front cover. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000) or «Radiator Hose Replacement - Outlet (LX9)»(ref-243023-S38434924012006082100000) or «Radiator Hose Replacement - Outlet (LZ9)»(ref-243023-S37042066022006082100000) in Engine Cooling.
10. Install the thermostat bypass pipe to the engine front cover. Refer to «Thermostat Bypass Pipes Replacement (3.5L)»(ref-243023-S19701987652006082100000) in Engine Cooling.
11. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243014-S31791935852006082100000) .
12. Install the oil pan. Refer to «Oil Pan Replacement»(ref-243014-S32527833182006082100000) .
13. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-243014-S37454282042006082100000) .
14. Install the engine mount bracket, if equipped with a convertible top. Refer to «Engine Mount Bracket Replacement»(ref-243014-S26339419282007062000000) .
15. Fill the crankcase with new engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243014-S04923719252006082100000) .
2. Rotate the crankshaft until the timing marks in the following locations are aligned: The camshaft alignment pin (4). The timing chain dampener (1) to the crankshaft sprocket (2).
3. Remove the camshaft sprocket bolt.
4. Remove the camshaft sprocket with the timing chain.
5. Remove the crankshaft sprocket.
6. Remove the timing chain dampener bolts.
7. Remove the timing chain dampener.
8. If necessary, remove the camshaft thrust plate bolts.
9. Remove the camshaft thrust plate.
10. Clean and inspect the timing chain and the gears. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-243014-S35129980092006082100000) .

1. If removed, install the camshaft thrust plate.
2. Install the camshaft thrust plate bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the crankshaft sprocket.
4. Apply engine oil supplement to the sprocket thrust surface.
5. Install the timing chain dampener.
6. Install the timing chain dampener bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
7. Install the timing chain onto the camshaft gear.
8. Hold the camshaft sprocket with the chain hanging down, and install the chain to the crankshaft gear.
9. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
10. Align the timing mark on the camshaft gear, center line of the locator hole (4), with the timing mark on the top of the chain dampener (3).
11. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket (1).
12. Install the camshaft sprocket bolt. Tighten: Tighten the bolt to 140 N.m (103 lb ft).
13. Coat the crankshaft and camshaft sprocket with engine oil.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243014-S04923719252006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .
6. Remove the valve rocker arms and the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
7. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.5L)»(ref-243054-S27539983162006082100000) or «Exhaust Manifold Replacement - Left (3.9L)»(ref-243054-S08041764922006082100000) in Engine Exhaust.
8. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-243014-S07334792192006082100000) .
9. Remove the left spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
10. Remove the left spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.
11. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.5L)»(ref-243054-S27539983162006082100000) or «Exhaust Manifold Replacement - Left (3.9L)»(ref-243054-S08041764922006082100000) in Engine Exhaust.
12. Remove the left cylinder head bolts and discard.
13. Remove the left cylinder head.
14. Remove the left cylinder head gasket.
15. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(ref-243014-S13816578612006082100000) and «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) .

1. Install a new left cylinder head gasket.
2. Install the left cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 45059 to rotate the bolts in sequence an additional 95 degrees.
4. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.5L)»(ref-243054-S27539983162006082100000) or «Exhaust Manifold Replacement - Left (3.9L)»(ref-243054-S08041764922006082100000) in Engine Exhaust.
5. Install the left spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.
6. Install the left spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
7. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-243014-S07334792192006082100000) .
8. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.5L)»(ref-243054-S27539983162006082100000) or «Exhaust Manifold Replacement - Left (3.9L)»(ref-243054-S08041764922006082100000) in Engine Exhaust.
9. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
10. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .
11. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
13. Inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .
6. Remove the valve rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
7. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.5L)»(ref-243054-S06025603172006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) in Engine Exhaust.
8. Remove the right spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
9. Remove the right spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.
10. Remove the fuel line bracket bolt and the stud.
11. Remove the fuel line bracket.
12. Remove the generator. Refer to «Generator Replacement (2.4L)»(ref-242993-S10209315092006082100000) or «Generator Replacement (3.5L)»(ref-242993-S18150277112006082100000) or «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) in Engine Electrical.
13. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.5L)»(ref-243054-S06025603172006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) in Engine Exhaust.
14. Remove the right cylinder head bolts and discard.
15. Remove the right cylinder head.
16. Remove the right cylinder head gasket.
17. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(ref-243014-S13816578612006082100000) and «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) .

1. Install a new right cylinder head gasket.
2. Install the right cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 45059 to rotate the bolts in sequence an additional 95 degrees.
4. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.5L)»(ref-243054-S06025603172006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) .
5. Install the generator. Refer to «Generator Replacement (2.4L)»(ref-242993-S10209315092006082100000) or «Generator Replacement (3.5L)»(ref-242993-S18150277112006082100000) or «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) in Engine Electrical.
6. Install the fuel line bracket.
7. Install the fuel line bracket bolt and the stud. Tighten: Tighten the bolt and the stud to 50 N.m (37 lb ft).
8. Install the right spark plugs. Refer to «Spark Plug Replacement»(ref-242989-S20170071502006082100000) in Engine Controls - 3.5L.
9. Install the right spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(ref-242989-S11574435952006082100000) in Engine Controls - 3.5L.
10. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.5L)»(ref-243054-S06025603172006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) in Engine Exhaust.
11. Install the push rods and valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243014-S16955760702006082100000) .
12. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243014-S35292296442006082100000) .
13. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
14. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
15. Inspect for leaks.

1. Remove the automatic transaxle. Refer to «Transmission Replacement»(ref-243013-S10068892782006082100000) in Automatic Transaxle - 4T40-E/4T45-E.
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Loosen the 6 flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft rotation.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel retainer and the flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Install the flywheel and the flywheel retainer.
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-243014-S19831297582006082100000) .
3. Install the engine flywheel bolts. Tighten: Tighten the bolts to 71 N.m (52 lb ft).
4. Measure the flywheel runout: Install a dial indicator on the engine block and inspect the engine flywheel runout at 3 attaching bosses. Refer to «Engine Mechanical Specifications»(ref-243014-S07752457592006082100000) . If the condition cannot be corrected, replace the engine flywheel.
5. Install the automatic transaxle. Refer to «Transmission Replacement»(ref-243013-S10068892782006082100000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .
2. Remove the crankshaft rear oil seal. Refer to «Crankshaft Rear Oil Seal Removal»(ref-243014-S10779365492006082100000) .

1. Install the rear main seal. Refer to «Crankshaft Rear Oil Seal Removal»(ref-243014-S10779365492006082100000) .
2. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer GM P/N 12377901 (Canadian P/N 10953504) or equivalent.
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
4. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
5. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls - 3.5L.
6. Remove the hood. Refer to «Hood Replacement»(ref-243002-S37879464402006082100000) in Body Front End.
7. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243014-S35844413692006082100000) .
8. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
9. Disconnect the following electrical connectors: The knock sensor (KS) The camshaft position (CMP) sensor The crankshaft position (CKP) sensor The heated oxygen sensor (HO2S) The manifold absolute pressure (MAP) sensor The exhaust gas recirculation (EGR) valve The evaporative emission (EVAP) canister purge solenoid The electronic throttle control The ignition coil The body wiring harness-to-engine harness
10. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
11. Remove the catalytic converters. Refer to «Catalytic Converter Replacement - Left (3.5L)»(ref-243054-S22757664402006082100000) and «Catalytic Converter Replacement - Right (3.5L)»(ref-243054-S00702071112006082100000) .
12. Remove the engine wiring harness grounds from the transaxle.
13. Remove the engine mount lower nuts.
14. Remove the torque converter covers.
15. Remove the starter motor. Refer to «Starter Motor Replacement (3.5L)»(ref-242993-S24411766452006082100000)
16. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) .
17. Remove the torque converter bolts. .
18. Remove the engine mount bracket bolts and bracket.
19. Remove the engine wiring harness clip from the rear of the transaxle brace.
20. Remove the transaxle brace bolts (5 and 6) and remove the brace (7).
21. Remove the transaxle to oil pan brace bolts and brace.
22. Remove the lower transaxle-to-engine bolt (6) and the stud (1).
23. Remove the radiator outlet hose from the engine. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000)
24. Lower the vehicle and support the transaxle.
25. Remove the heater outlet and inlet hoses from the engine.
26. Remove the vacuum hoses from the upper intake manifold.
27. Remove the brake booster vacuum hose from the upper intake manifold.
28. Remove the fuel lines from the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-242989-S26435212932006082100000) in Engine Controls - 3.5L.
29. Remove the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000)
30. Install the engine lifting device to the engine.
31. Remove the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).
32. Remove the engine from the vehicle.
33. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .
34. Install the engine to the engine stand.

1. Remove the engine from the engine stand.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-243014-S19557913122006082100000) .
3. Install the engine to the vehicle.
4. Install the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2). Tighten: Tighten the bolts (3, 4, 5) and the stud (2) to 75 N.m (55 lb ft).
5. Remove the engine lifting device.
6. Install the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000)
7. Install the fuel lines to the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-242989-S26435212932006082100000) in Engine Controls - 3.5L.
8. Install the brake booster vacuum hose to the upper intake manifold.
9. Install the vacuum hoses to the upper intake manifold.
10. Install the heater inlet and outlet hoses to the engine.
11. Raise the vehicle and remove the transaxle support.
12. Install the radiator outlet hose to the engine. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000)
13. Install the lower transaxle-to-engine bolt (6) and the stud (1). Tighten: Tighten the bolt (6) and the stud (1) to 75 N.m (55 lb ft).
14. Position the transaxle to oil pan brace and install the bolts. Tighten: Tighten the bolts to 50 Nm (37 lb ft).
15. Position the transaxle brace (7) to the transaxle and install the bolts (5 and 6) until snug.
16. Install the engine wiring harness clip to the rear of the transaxle brace.
17. Position the engine mount bracket to the engine and install the bolts until snug.
18. Tighten the engine mount bracket bolts and transaxle brace bolts. Tighten Tighten the engine mount bracket upper bolt to 90 Nm (66 lb ft). Tighten the engine mount bracket lower bolts to 50 Nm (37 lb ft). Tighten the transaxle brace bolts to 72 Nm (53 lb ft).
19. Install the torque converter bolts.
20. Install the A/C compressor. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000)
21. Install the starter motor. Refer to «Starter Motor Replacement (3.5L)»(ref-242993-S24411766452006082100000)
22. Install the torque converter covers.
23. Install the engine mount lower nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
24. Install the engine wiring harness grounds to the transaxle.
25. Install the engine wiring harness ground nut to the transaxle stud. Tighten: Tighten the nut to 35 N.m (26 lb ft).
26. Install the catalytic converters. Refer to «Catalytic Converter Replacement - Left (3.5L)»(ref-243054-S22757664402006082100000) or and «Catalytic Converter Replacement - Right (3.5L)»(ref-243054-S00702071112006082100000) .
27. Lower the vehicle.
28. Connect the following electrical connectors: The body wiring harness-to-engine harness The ignition coil The electronic throttle control The EVAP canister purge solenoid The EGR valve The MAP sensor The HO2S The CKP sensor The CMP sensor The KS
29. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) .
30. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243014-S35844413692006082100000) .
31. Install the hood. Refer to «Hood Replacement»(ref-243002-S37879464402006082100000) in Body Front End.
32. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242989-S05200829822006082100000) in Engine Controls - 3.5L.
33. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) in Engine Electrical.
34. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
35. Fill cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) in Engine Cooling.
36. Perform a CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-242989-S41004015362006082100000) in Engine Controls - 3.5L.
37. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
38. Inspect for leaks.

Scheme 77

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
2. Position a suitable drain pan under the oil pan drain plug.
3. Remove the oil pan drain plug.
4. Allow the engine oil to drain completely.
5. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary.
6. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
7. Position a suitable drain pan under the oil filter.
8. Remove the oil filter.
9. Install the NEW oil filter.

1. Apply clean engine oil to the NEW oil filter gasket.
2. Install the NEW oil filter. Tighten: Tighten the oil pan drain bolt to 26 N.m (19 lb ft).
3. Tighten the oil pan drain plug. Tighten Tighten the oil pan drain plug to 26 Nm (19 lb ft).
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «Capacities - Approximate Fluid»(ref-243030-S33748577392006082100000) and «Fluid and Lubricant Recommendations»(ref-243030-S04717593722006082100000) .
7. Start the engine.
8. Inspect the for oil leaks after engine start up.
9. Turn OFF the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil level indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level if the engine oil on the oil level indicator.
15. If necessary, adjust the oil level by adding or draining oil.
16. Check for oil leaks.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the coolant drain plug from the left side.
5. Remove the coolant drain plug from the right side.
6. Drain the coolant.

Crankshaft Balancer Removal

Tools Required

1. J 41816-A Crankshaft Balancer Remover. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. EN 46359 Puller End Protector. See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816-A along with EN 46359 or equivalent. See «Special Tools»(ref-243014-S19831297582006082100000) .

Engine Flywheel Removal

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

Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bolt.
2. Remove the drive belt tensioner.

Engine Lift Bracket and Generator Bracket Removal

1. Remove the generator bracket assembly bolts (230, 231, 232).
2. Remove the generator assembly bracket.
3. Remove the front engine lift hook.

Engine Mount Support and Strut Bracket Removal

1. Remove the engine mount support and strut bracket bolts.
2. Remove the engine mount support and strut bracket.

Engine Lift Bracket Removal - Rear

1. Remove the rear engine lift bracket bolts.
2. Remove the rear engine lift bracket.

Oil Level Indicator and Tube Removal

1. Remove the thermostat bypass pipe hose from the thermostat bypass pipe.
2. Remove the 16 pin connector.
3. Remove the spark plug wires from the spark plugs and set aside.
4. Remove the spark plug wire clip from the pipe.
5. Remove the heated oxygen sensor connector from pipe.
6. Remove the thermostat bypass pipe to throttle body nuts.
7. Remove the thermostat bypass pipe to throttle body bolt.
8. Remove the thermostat bypass pipe to engine front cover bolt.
9. Remove the thermostat bypass pipe.
10. Remove the oil level indicator tube bolt.
11. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter adapter bolts.
2. Remove the oil filter adapter and gasket.
3. Remove the oil filter bypass hole plug.
4. Remove the oil filter bypass valve by prying out with a suitable tool.

Exhaust Manifold Removal - Left

1. Remove the heated oxygen sensor.
2. Remove the spark plugs.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold nuts (1, 2, 3, 4, 5, 6).
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust studs, if required.

Exhaust Manifold Removal - Right

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires.
3. Remove the spark plugs.
4. Remove the exhaust gas recirculation (EGR) pipe bolts from the exhaust manifold.
5. Remove the EGR pipe bolt at the EGR valve.
6. Remove the EGR pipe.
7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shields.
9. Remove the exhaust manifold nuts (1, 2, 3, 4, 5, 6).
10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
12. Remove the exhaust studs, if required.

Water Outlet and Thermostat Removal

1. Remove the water outlet bolts.
2. Remove the water outlet.
3. Remove the thermostat.

Valve Rocker Arm Cover Removal - Left

1. Remove the positive crankcase ventilation (PCV) tube bolt and clip.
2. Remove the PCV tube.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Trim valve cover gasket and sealant away from lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
6. Remove the valve rocker arm cover gasket.

Intake Manifold Removal - Upper

1. Remove the connector from manifold absolute pressure (MAP) sensor.
2. Remove the exhaust gas recirculation (EGR) bolts.
3. Remove the EGR.
4. Remove the upper intake manifold bolts or studs.
5. Remove the upper intake manifold and gaskets.

Intake Manifold Removal - Lower

1. Remove the heater inlet pipe nut.
2. Remove the heater inlet pipe.
3. Remove the heater inlet pipe stud, if necessary.
4. Remove the fuel injector rail bolts.
5. Remove the fuel rail assembly.
6. Remove the lower intake manifold bolts.
7. Remove the lower intake manifold.

Valve Rocker Arm and Push Rod Removal

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 144.18 mm (5.68 in). The exhaust push rods measure 152.51 mm (6.0 in).
4. Remove the intake manifold gaskets.

Valve Lifter Removal

1. Remove the valve lifter guide bolts.
2. Remove the valve lifter guides.
3. Remove the valve lifters.

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gasket.

Cylinder Head Removal - Left

1. Remove the cylinder head bolt and discards.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts and discard.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Oil Pan Removal

1. Remove the oil pan support bracket bolts and brackets as needed
2. Remove the oil pan side bolts.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Remove the oil pan gasket.

Oil Pump Removal

1. Remove the oil pump bolt.
2. Remove the oil pump and oil pump drive shaft.
3. Remove the crankshaft oil deflector nuts.
4. Remove the crankshaft oil deflector.

Oil Pump Drive Removal

1. Remove the oil pump drive clamp bolt.
2. Remove the oil pump drive clamp.
3. Remove the oil pump drive.

Scheme 78

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

Engine Front Cover Removal

1. Remove the engine front cover bolts (540, 541, 545).
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Timing Chain and Sprockets Removal

1. Remove the camshaft sprocket bolt.
2. Remove the camshaft sprocket and timing chain.
3. Remove the crankshaft sprocket.
4. Remove the timing chain dampener bolts.
5. Remove the timing chain dampener.

Camshaft Removal

1. Remove the camshaft position sensor bolt.
2. Remove the camshaft position sensor.
3. Remove the camshaft thrust plate screws.
4. Remove the camshaft thrust plate.
5. Complete the following steps in order to remove the camshaft. Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate and remove the camshaft from the engine block.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See «Special Tools»(ref-243014-S19831297582006082100000) . Complete the following steps: Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Remove the connecting rod bearing half.
7. Install J 41556 into the connecting rod. See «Special Tools»(ref-243014-S19831297582006082100000) .
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

Crankshaft Rear Oil Seal Removal

1. Remove crankshaft rear main oil seal using one of the following techniques: Refer to step #2 for the removal of new style crankshaft rear main oil seal. Refer to step #3 for the removal of old style crankshaft rear main oil seal.
2. If removing a new style seal, seal lip is facing outward, insert a flat-bladed or similar tool between the sealing lip and the outer casing of the seal at an angle, and gently pry seal out by moving tool towards the center of the crankshaft.
3. If removing an old style--seal lip faces inward, insert a flat-bladed or similar tool between the outer seal casing and the engine block casting and gently pry seal out.
4. Repeat above steps as necessary around the crankshaft rear oil seal, until the seal is removed.

Crankshaft and Bearings Removal

1. Remove the crankshaft position sensor heat shield nut and heat shield.
2. Remove the crankshaft position sensor stud.
3. Remove the crankshaft position sensor from the side of the block.
4. Remove the crankshaft main bearing cap bolt and studs.
5. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
6. Remove the crankshaft.
7. Remove the upper crankshaft main bearing halves.

Piston Oil Nozzle Removal

1. Remove the bolt retaining the piston oil nozzle to the engine block.
2. Remove the piston oil nozzle.

Engine Block Heater Installation

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the engine block heater.
2. Install the engine block heater into the engine block. Tighten: Tighten engine block heater to 50 N.m (37 lb ft).

Piston Oil Nozzle Installation

1. Position the piston oil nozzle into the engine block.
2. Install the bolt retaining the piston oil nozzle to the engine block. Tighten: Tighten the bolt to 10 N.m (89 lb in).

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Ring Compressor. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. J 45059 Angle Meter
3. J 41556 Connecting Rod Guide. See «Special Tools»(ref-243014-S19831297582006082100000) .

1. Lightly lubricate the following components with clean engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.
3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
4. Install the J 8037 onto the piston and compress the piston rings. See «Special Tools»(ref-243014-S19831297582006082100000) .
5. Install the J 41556 into the connecting rod. See «Special Tools»(ref-243014-S19831297582006082100000) .
6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
8. Using J 41556 , guide the connecting rod end onto the crankshaft journal. See «Special Tools»(ref-243014-S19831297582006082100000) .
9. Install the bearing, bearing cap and bolts. Tighten: Tighten the connecting rod bearing cap bolts a first pass to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts a final pass to 110 degrees using the J 45059 .
10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting rod side clearance should be within 0.18-0.44 mm (0.007-0.017 in).

Camshaft Installation

1. Coat the camshaft journals with clean engine oil.
2. Coat the camshaft lobes with prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the camshaft using the following procedure: Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate the camshaft while installing the camshaft into the camshaft bearings.
4. Install the camshaft thrust plate.
5. Install the camshaft thrust plate screws. Tighten: Tighten the camshaft thrust plate screws to 10 N.m (89 lb in).
6. Install the camshaft position sensor.
7. Install the camshaft position sensor bolt. Tighten: Tighten the camshaft position sensor bolt to 10 N.m (89 lb in).

Timing Chain and Sprockets Installation

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain dampener.
4. Install the timing chain dampener bolts. Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
7. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener (3).
8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
9. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
10. Coat the crankshaft and camshaft sprocket with engine oil. Tighten: Tighten the bolt to 140 N.m (103 lb ft).

Engine Front Cover Installation

1. Install the engine front cover gasket.
2. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the lower tabs of the engine front cover gasket. Apply the sealer no less than 5.0 mm (0.20 in) wide.
3. Install the engine front cover.
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolts in the locations pointed out in the graphic.
5. Install the engine front cover bolts (545). Tighten: Tighten the engine front cover bolts to 27 N.m (20 lb ft).
6. Install the engine front cover bolts (540, 541). Tighten: Tighten the engine front cover bolts to 55 N.m (41 lb ft).

Oil Pump Drive Installation

1. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.
5. Install the oil pump drive gear clamp bolt. Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).

Oil Pump Installation

1. Install the oil pump.
2. Position the oil pump onto the pins.
3. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 41 Nm (30 lb ft).
4. Install the crankshaft oil deflector.
5. Install the crankshaft oil deflector nuts. Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).

Scheme 79

1. Apply sealer GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to both sides of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to both sides of the front cover/block mating area (1).
3. Install the oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
6. Install the oil pan side bolts. Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
7. Install the oil pan drain plug. Tighten: Tighten the oil pan drain to 25 N.m (18 lb ft).

Water Pump Installation

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the threads.
4. Install the valve lifter guides and guide bolts. Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).

Valve Rocker Arm and Push Rod Installation

1. Install the lower intake manifold gaskets.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the push rods in their original location.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 32 N.m (24 lb ft).

Intake Manifold Installation - Lower

1. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to block joints (1).
2. Install the lower intake manifold.
3. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
4. Install the lower intake manifold bolts. Tighten: Tighten the center lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft). Tighten the visible corner lower intake manifold bolts (5, 8,) to 25 N.m (18 lb ft). Tighten the hidden corner lower intake manifold bolts (6, 7) to 25 N.m (18 lb ft).
5. Inspect the heater inlet pipe and seal for damage and replace if necessary.
6. Install the heater inlet pipe stud, if necessary. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Inspect the fuel rail, fuel injectors, and fuel injector O-rings for damage and replace if necessary.
10. Lubricate the fuel injector O-ring using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
11. Install the injector nozzles into the lower intake manifold injector bores.
12. Press on the injector rail using the palms of both hands until the injectors are fully seated.
13. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Intake Manifold Installation - Upper

1. Install the upper intake manifold gaskets and manifold.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the upper intake manifold bolt threads.
3. Install the upper intake manifold bolts and stud. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).
4. Install the exhaust gas recirculation (EGR) gasket and EGR.
5. Install the EGR bolts. Tighten: Tighten the EGR bolts to 30 N.m (22 lb ft).
6. Reconnect the manifold absolute pressure (MAP) sensor.

Valve Rocker Arm Cover Installation - Left

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the positive crankcase ventilation (PCV) tube.
6. Install the PCV clip and tube bolt. Tighten: Tighten the PCV tube bolt to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the positive crankcase ventilation (PCV) tube into the valve rocker arm cover.
6. Install the ignition coil assembly studs, if necessary. Tighten: Tighten the ignition coil assembly studs to 25 N.m (18 lb ft).
7. Install the ignition coil assembly.
8. Install the ignition coil assembly bolts and nuts. Tighten: Tighten the ignition coil assembly bolts and nuts to 25 N.m (18 lb ft).
9. Install the fuel feed pipe.
10. Install the fuel feed pipe secondary latch.
11. Install the fuel feed pipe bolts. Tighten: Tighten the fuel feed pipe bolts to 10 N.m (89 lb in).

Water Outlet and Thermostat Installation

1. Install the thermostat.
2. Install the water outlet.
3. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left

1. Install the exhaust manifold studs, if required. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new cylinder head. Tighten the spark plugs to 15 N.m (13 lb ft) when installing spark plugs after initial installation.
8. Install the spark plug wires.
9. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Exhaust Manifold Installation - Right

1. Install the exhaust manifold studs, if required. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
7. Install the Exhaust Gas Recirculation (EGR) pipe.
8. Install the EGR pipe bolt to the EGR Valve. Tighten: Tighten the EGR pipe bolt to 25 N.m (18 lb ft).
9. Install the EGR pipe bolts to the exhaust manifold. Tighten: Tighten the EGR pipe bolts to 30 N.m (22 lb ft).
10. Install the spark plugs. Tighten: Tighten the spark plugs to 15 Nm (11 lb ft).
11. Install the spark plug wires.
12. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter bypass hold plug. Tighten: Tighten the oil filter bypass hole plug to 19 N.m (14 lb ft).
3. Install the oil filter adapter.
4. Apply threadlocker P/N 21485277 to the bolt threads if required.
5. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N.m (18 lb ft).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube and oil level indicator.
2. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
3. Install the thermostat bypass pipe.
4. Install the thermostat bypass pipe to engine front cover bolt. Tighten: Tighten the thermostat bypass pipe to engine front cover bolt to 10 N.m (89 lb in).
5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the throttle body studs.
6. Install the thermostat bypass pipe to throttle body bolt and nuts. Tighten: Tighten the thermostat bypass pipe to throttle body bolt and nuts to 10 N.m (89 lb in).
7. Install the heated oxygen sensor connector to the thermostat bypass pipe.
8. Install the spark plug wire clip to the thermostat bypass pipe.
9. Install the spark plug wires onto the spark plugs.
10. Position the 16 pin connector harness as shown in the graphic and secure the connector in its respective location.
11. Install the thermostat bypass pipe hose to pipe.

Engine Lift Bracket Installation - Rear

1. Install the rear engine lift bracket.
2. Install the rear engine lift bracket bolts. Tighten: Tighten the rear engine lift bracket bolts to 50 N.m (37 lb ft).

Engine Mount Support and Strut Bracket Installation

1. Install the engine mount support and strut bracket.
2. Install the engine mount support and strut bracket bolts. Tighten: Tighten the engine mount support and strut bracket bolts to 25 N.m (18 lb ft).

Engine Lift Bracket and Generator Bracket Installation

1. Install the front engine lift hook.
2. Install the generator bracket assembly.
3. Install the generator bracket assembly bolts (230, 231, 232). Tighten: Tighten the generator bracket assembly bolts to 50 N.m (37 lb ft).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Engine Flywheel Installation

1. Install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).

Crankshaft Balancer Installation

Tools Required

1. J 29113 Balancer and Crank Sprocket Puller. See «Special Tools»(ref-243014-S19831297582006082100000) .
2. J 45059 Angle Meter

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft. See «Special Tools»(ref-243014-S19831297582006082100000) .
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft. See «Special Tools»(ref-243014-S19831297582006082100000) .
5. Remove the J 29113 from the crankshaft. See «Special Tools»(ref-243014-S19831297582006082100000) .
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the used crankshaft balancer bolt to 125 Nm (92 lb ft).
7. Remove the used crankshaft balancer bolt.
8. Install the NEW crankshaft balancer bolt. Tighten Tighten the crankshaft balancer bolt a first pass to 125 Nm (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059 .