Engine Mechanical - 3.9L: Other Pontiac G6 I

Sealers, Adhesives and Lubricants

Sealers, Adhesives and Lubricants

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

The Vehicle Identification Number - VIN derivative (1) for 3900 LZ9 is stamped or laser etched on the front and left side of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

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

Intermittent

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

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

J 35667-A Cylinder Leakdown Tester

Low or No Oil Pressure

The following conditions may cause low or no oil pressure

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

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(ref-243015-S13943983972006082100000) .
2. J 25087-C Oil Pressure Tester

J 28428-E High Intensity Black Light Kit

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

Locating and Identifying the Leak

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

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

Powder Method

1. Completely clean the entire engine and surrounding components.
2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid and the approximate location of the leak, from the discolorations in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Refer to «Possible Causes for Leaks»(ref-243015-S17522524482006082100000) if necessary.

Black Light and Dye Method

A dye and light kit is available for finding leaks.

1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary Refer to «Possible Causes for Leaks»(ref-243015-S17522524482006082100000) if necessary.

Possible Causes for Leaks

Inspect the vehicle for the following conditions

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

1. J 28467-B Engine Support Fixture
2. J 36462 Engine Support Adapter Leg

J 23498 Driveshaft Inclinometer

1. EN-47823 Valve Spring Compressor Adapter
2. J 22794 Spark Plug Port Adapter
3. J 5892-D Valve Spring Compressor

1. EN 46359 Puller End Protector
2. J 29113 Balancer and Crank Sprocket Installer
3. J 37096 Flywheel Holder
4. J 41816 Harmonic Balancer Remover
5. J 45059 Angle Meter

1. J 28467-B Universal Engine Support Fixture
2. J 45059 Angle Meter

J 35468 Cover Aligner and Seal Installer

EN-47719 Tensioner Compressor. See Special Tools .

J 45059 Angle Meter

J 45059 Angle Meter

J 37096 Flywheel Holder

J 34686 Rear Main Seal Installer

1. J 41816 Crankshaft Balancer Remover
2. EN 46359 Puller End Protector

1. J 24270 Cylinder Bore Ridge Reamer
2. J 41556 Connecting Rod Guide

J 33049 Camshaft Bearing Service Set

1. J 8001 Dial Indicator Set
2. J 8087 Cylinder Bore Gage

Procedure

1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Replace the block if it is outside of the specification limit.
10. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file in order to remove any nicks.
11. Inspect the mating surfaces of the transmission case.
12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold the J 8001 gage plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 in). Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is not within the specification, replace the engine block.
13. Inspect the crankshaft main bearing bores. Use the J 8087 in order to measure the bearing bore concentricity and alignment at the following locations: The camshaft The crankshaft
14. Replace the engine block if the bores are out of specification.
15. Use the J 8087 in order to inspect the cylinder bores. Inspect the bores for the following conditions: Wear Taper Runout Ridging
16. Leave sufficient material in order to allow honing when fitting the piston.

Boring Procedure

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

Honing Procedure

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

1. J 8087 Cylinder Bore Gage
2. J 45059 Angle Meter

1. Clean the crankshaft of the following elements: Oil Sludge Carbon
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for the following conditions: A worn crankshaft key (1) A worn crankshaft keyway (2)
4. Inspect the crankshaft threads (3) for damage.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions: Wear without any grooves or scratches (1) Grooves or scoring (2) Scratches or excessive wear (3) Pitting or embedded bearing material (4)-Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of the material. Overheating or discoloration
6. The crankshaft bearings are the precision insert type.
7. Inspect the outer surfaces of the crankshaft bearings for the following conditions: Wear-surface wear indicates either movement of the insert or high spots in the surrounding material - spot wear. Overheating or discoloration Looseness or rotation indicated by flattened tangs and wear grooves
8. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions: Wear Grooving-Grooves are caused by irregularities of the crankshaft thrust surface.
10. Inspect the crankshaft bearings for excessive scoring or discoloration.
11. Inspect the crankshaft main bearings for dirt or imbedded debris.
12. Inspect the crankshaft main bearings for improper seating indicated by bright, polished sections.
13. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
14. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure: Tighten the bearing cap to specification. Use the J 8087 in order to measure the bearing bore for taper and out-of-round. Record the readings for bearing selection. No taper or out-of-round should exist.

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.

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

Method A

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

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification using J 45059 .
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

1. J 8087 Cylinder Bore Gage
2. J 43654 Piston Pin Clip Remover and Installer

1. Clean the piston and connecting rod in solvent.
2. Dry off the piston and connecting rod with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following: Eroded areas (1) on the top of the piston Scuffed or damaged skirt (2) Damage to the pin bore (3) Cracks in the piston ring lands, the piston skirt or the pin bosses Piston ring grooves for nicks, burrs or other warpage which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage.
7. Measure the piston ring-to-piston ring groove side clearance. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston ring groove. If binding is caused by distorted piston ring groove, replace the piston. If binding is caused by a distorted piston ring, replace the piston ring.
8. Measure the piston ring side clearance with a feeler gage.
9. If the side clearance is too small try another ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. Proper ring-to-piston ring groove clearance for the top ring is 0.03-0.065 mm (0.001-0.002 in). Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.078 mm (0.002-0.003 in).
11. Using the J 43654 , remove the piston pin retainers (1).
12. Discard the oil piston pin retainers.
13. Slide the piston pin (4) out of the piston (2), disconnecting the piston from the connecting rod (3).
14. Measure the piston pin diameter using and outside micrometer.
15. Measure the piston pin bore using an inside micrometer.
16. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
17. Piston-to-piston pin bore clearance must measure 0.002-0.010 mm (0.00008-0.0004 in). Replace the piston and the piston pin if the piston and the piston pin are not within specifications.
18. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin removed and record the measurement. Measure the piston at 43 mm (1.692 in) from dome of piston. Piston diameter must measure no less than 98.950 mm (3.895 in). Replace the piston and the pin as an assembly if the piston is not within specifications.
19. Measure the cylinder bore, using J 8087 .
20. Measure the J 8087 . Record this reading.
21. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore clearance. The cylinder bore clearance must be no more than 0.080 mm (0.003 in).
22. If a used piston is not acceptable, inspect the service piston size and determine if a new piston may be selected. Service pistons are available in standard and 0.5 mm (0.012 in) oversize.
23. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
24. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds 0.005 mm (0.0002 in) the connecting rod must be replaced.
25. Inspect the connecting rod for twisting. Install the connecting rod cap. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting. Do not attempt to straighten the connecting rod. Ensure that the connecting rod meets the following conditions: The connecting rods are not bent more than 0.18 mm (0.007 in). The connecting rods are not twisted more than 0.38 mm (0.0015 in). Replace any bent or twisted connecting rods. Inspect the new connecting rods before using the new rods.
26. Inspect the connecting rod for damage to the bearing cap and bolt threads.
27. Measure the piston compression ring end gap. IMPORTANT: Fit each compression ring to the cylinder in which it will be used. Place the compression ring into the cylinder bore. Push the compression ring into the bottom of the cylinder bore to approximately 6.5 mm (0.25 in) above ring travel. The ring must be square to the cylinder wall. Use a feeler gage in order to measure the end gap. The first compression ring end gap must measure 0.15-0.30 mm (0.006-0.011 in), the second compression ring must measure 0.25-0.45 mm (0.009-0.017 in). Select another size ring set if the end gap exceeds specifications. If ring gap clearance is below specifications, increase the gap by carefully filing off excess material.
28. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatigue.
29. Inspect the connecting rod bearings for excess scoring or discoloration.
30. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
31. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
32. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting rod bearing journal for wear. This indicates high spots.

J 7872 Magnetic Base Dial Indicator Set

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

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(ref-243015-S13943983972006082100000) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(ref-243015-S13943983972006082100000) .

1. J 8089 Carbon Removing Brush
2. J 9666 Valve Spring Tester

1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure: Improper installation A loose or warped cylinder head Missing, off location or not fully seated dowel pins Low torque on the cylinder head bolts Cylinder head bolts with the incorrect length A warped engine block surface Scratched surfaces Excessive intake manifold torque Cracked engine block threaded holes
3. Use the J 8089 in order to remove the carbon from the combustion chambers.
4. Clean the following components: The gasket surfaces DO NOT use a motorized brush on any gasket sealing surface. Valve stems and heads on a buffing wheel The bolt hole threads Remove all dirt, debris or threadlocking material from the bolt holes.
5. Inspect the cylinder head mating surfaces for flatness. Replace the cylinder head if it is outside of the specification limit.
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If the cylinder head is damaged, replace the cylinder head.
8. Remove the valve spring dampener.
9. Inspect the valve springs for squareness.
10. Use the J 9666 in order to measure the valve spring tension. Replace the spring if the spring tension is not within specification.
11. Install the valve spring dampener.

J 8520 Camshaft Lobe Lift Indicator Set

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

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(ref-243015-S13943983972006082100000) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(ref-243015-S13943983972006082100000) .

J 22144 Oil Suction Pipe Installer

Thread Repair

General purpose thread repair kits are available commercially.

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

J 33049 Camshaft Bearing Service Set

J 45059 Angle Meter

EN-48108 Rear Main Seal Installer

Note. Do not remove protective nylon sleeve prior to installation. The rear main oil seal installation tool is designed to install the rear main seal with the protective sleeve in place. Never apply or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal.

Note. Clean the crankshaft sealing surface with a clean, lint free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage the rear main oil seal. Remove burrs/sharp edges with crocus cloth before proceeding.

1. J 6125-1B Slide Hammer with Adapter. See «Special Tools»(ref-243015-S13943983972006082100000) .
2. J 8037 Ring Compressor
3. J 41348 Bearing Cap Puller. See «Special Tools»(ref-243015-S13943983972006082100000) .
4. J 41556 Connecting Rod Guide
5. J 43654 Piston Pin Clip Remover and Installer
6. J 43690 Rod Bearing Clearance Checking Tool. See «Special Tools»(ref-243015-S13943983972006082100000) .
7. J 43690-100 Rod Bearing Clearance Checking Tool-Adapter Kit. See «Special Tools»(ref-243015-S13943983972006082100000) .
8. J 45059 Angle Meter

Measuring Connecting Rod Bearing Clearance Using J 43690 and J 43690-100

J 43690 and J 43690-100 have been developed as a more accurate method to measure connecting rod bearing clearances. See Special Tools . The instructions below provide an overview of tool set and usage. For more detailed information, refer to the tool instruction sheets as supplied by the tool manufacturer.

1. J 43690 Rod Bearing Checking Tool includes: See «Special Tools»(ref-243015-S13943983972006082100000) . J 43690-20 Swivel Base (1) J 43690-19 Dial Indicator (2) J 43690-2 Base (3) J 43690-5,-6 Handle (4) J 43690-10,-11 Foot (5) 280307 Screw (6) J 43690-1 Pivot Arm Assembly (7) J 43690-3,-7,-8 Screws (8) 280319 Screw (9) 280311 Screw (10) J 43690-17,-18 Adapter (11) 280310 Pin (12)
2. J 43690-100 Rod Bearing Checking Tool - Adapter Kit includes: See «Special Tools»(ref-243015-S13943983972006082100000) . J 43690-104 Spacer (1) J 43690-105 Retainer Plate (2) 505478 Bolt (3) 511341 Bolt (4) J 43690-106 Retainer Plate (5) J 43690-107 Cap (6) J 43690-102 Foot (7) J 43690-101 Pivot Arm Assembly (8) J 43690-103 Adapter (9) 505439 Adapter (10)

1. Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position.
2. Remove the crankshaft main bearing side bolts if applicable.
3. Remove the crankshaft main bearing cap bolts.
4. Install J 41348 into the crankshaft main bearing cap bolt holes. See «Special Tools»(ref-243015-S13943983972006082100000) . Tighten: Tighten the bolts on J 41348 to 12 N.m (100 lb in).
5. Install J 6125-1B to J 41348 . See «Special Tools»(ref-243015-S13943983972006082100000) .
6. Use J 6125-1B to remove the crankshaft main lower bearing cap. See «Special Tools»(ref-243015-S13943983972006082100000) .
7. Insert a piece of paper stock onto the crankshaft journal.
8. Install the crankshaft main bearing cap and bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the bottom of the channel. Tighten: Tighten the crankshaft main bearing cap bolts in equal increments. Do not completely tighten one bolt at a time to prevent the cap from being cocked. Tighten the bolts to 70 N.m (52 lb ft) to fully seat the crankshaft main bearing caps. Loosen the bolts 360 degrees counterclockwise. Tighten the bolts to 20 N.m (15 lb ft), then 40 N.m (30 lb ft). Use J 45059 to tighten the bolts in steps: 35 degrees + 35 degrees + 40 degrees for a total of 110 degrees.
9. Install the side main bolts. Apply GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the side main bolts. Tighten: Tighten the side crankshaft main bearing cap bolts to 15 N.m (11 lb ft). Use J 45059 to tighten the bolts an additional 45 degrees.
10. Install the following: J 43690-101 (8) J 43690-5 (4) J 43690-2 (3) J 43690-7 (8) 280310 (12) J 43690-17 (11)
11. Install the swivel base (1) and dial indicator (2).
12. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. The connecting rod bearing clearance should be between 0.0127-0.0660 mm (0.0005-0.0026 in).

EN-47719 Tensioner Compressor. See Special Tools .

J 35468 Cover Aligner and Seal Installer

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.

J 45059 Angle Meter

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

J 45059 Angle Meter

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

J 45059 Angle Meter

1. J 29113 Balancer and Crank Sprocket Puller
2. J 45059 Angle Meter

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(ref-243015-S13943983972006082100000) .
2. J 45299 Engine Preluber

Prelubing Procedure

1. Remove the engine oil filter, fill with clean engine oil and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Locate the engine oil pressure indicator switch on the left side of the engine and remove.
3. Install the 1/4 inch adapter P/N 509373 and the J-21867-6 . See «Special Tools»(ref-243015-S13943983972006082100000) .
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine oil pressure indictor switch. Tighten: Tighten the engine oil pressure indictor switch to 16 N.m (12 lb ft).
8. Top off the engine oil to the proper level.

Cleanliness and Care

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

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

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

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

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

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

Separating Parts

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

Replacing Engine Gaskets

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

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

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

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

Applying RTV Sealer

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

These methods of cleaning may damage the part.

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

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

Applying Anaerobic Sealer

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

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

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

These methods of cleaning may damage the part.

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

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

Tools and Equipment

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

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

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