Engine Mechanical - 3.9L: Removal & Installation Pontiac G6 I

Removal Procedure

1. Remove the engine oil fill cap and tube.
2. Grasp the cover by the sides and pull up, disengaging the cover grommets from the ball studs.

Installation Procedure

1. Place the cover over the ball studs, aligning the cover with the power steering reservoir cap and the oil fill tube opening.
2. Push down on the cover above the studs in order to engage to cover grommets to the studs.
3. Install the engine oil fill cap and tube.

1. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
3. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .
4. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
5. Remove the drive belt (2), if equipped with hydraulic power steering.

1. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
2. Install the drive belt.
3. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
5. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
3. Remove the engine mount bracket bolt.
4. Remove the engine mount bracket spacer (1).
5. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
6. Remove the drive belt.

1. Rotate the drive belt tensioner counterclockwise in order to release the tensioner spring tension.
2. Install the drive belt.
3. Install the engine mount bracket spacer (1).
4. Install the engine mount bracket bolt (2). Tighten: Tighten the bolt to 50 N.m (37 lb ft).
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
2. Loosen the required drive belt idler pulley bolt.
3. Remove the drive belt idler pulley.

1. Install the drive belt idler pulley.
2. Tighten the required drive belt idler pulley bolts. Tighten: Tighten the bolt (1) to 50 N.m (37 lb ft). Tighten the bolt (2) to 30 N.m (22 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
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-243015-S14538549132006082100000) .

Replacement Procedure

1. Raise the hood.
2. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
4. Install the thread support nuts J 28467-33A onto the strut attaching studs.
5. Install the strut tower support assemblies J 28467-5A over the thread support nuts J 28467-33A.
6. Install the T-bolts J 28467-5 with 5/16 inch washers through the strut tower support assemblies J 28467-5A into the thread support nuts J 28467-33A. Hand tighten the bolts.
7. Install the 2 cross bracket assemblies J 28467-1A over the strut tower tube J 28467-3.
8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
9. Install the 1/2 inch x 2.5 inch quick release pin J 28467-10 through the strut tower support assemblies J 28467-5A and the strut tower tube J 28467-3 on one side only.
10. Install the radiator shelf tube J 28467-2A through the driver side cross bracket assembly J 28467-1A on the top of the strut tower tube J 28467-3.
11. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
12. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
13. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
14. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
15. Install the assembled lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
16. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket.
17. Hand tighten the driver side cross bracket assembly J 28467-1A wing nuts.
18. Install the second radiator shelf tube J 28467-2A through the passenger side cross bracket assembly (J 28467-1A) on the top of the strut tower tube J 28467-3.
19. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
20. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
21. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
22. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
23. Install the assemblage lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
24. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the right rear, front of engine, lift hook bracket located next to the generator.
25. Hand tighten the passenger side cross bracket assembly J 28467-1A wing nuts.
26. Hand tighten the lift hook wing nuts J 28467-34 securely in order to remove all slack from the engine support fixture assembly.

1. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
2. Remove the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(ref-243023-S35124382672006082100000) .
3. Remove the engine mount to engine mount bracket nuts.
4. Remove the engine mount to frame nuts.
5. Using an adjustable jack, raise the engine.
6. Remove the engine mount from the frame.

1. Position the engine mount onto the frame
2. Lower the engine using the adjustable jack.
3. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Install the engine mount to engine mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Remove the adjustable jack from under the vehicle.
6. Install the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(ref-243023-S35124382672006082100000) .
7. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
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 nuts.
4. Remove the engine mount bolts.
5. Remove the engine mount.

1. Place the engine mount into position on the engine compartment side rail.
2. Install the engine mount bolts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the engine mount to engine mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Remove the floor jack and block of wood from under the oil pan.
5. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement (Coupe)»(ref-243015-S32973693972006082100000) .
2. Remove the engine mount bracket bolt from the engine.
3. Remove the engine mount bracket bolts from the oil pan.
4. Remove the engine mount bracket from the vehicle.

1. Position the engine mount bracket to the engine.
2. Loose assemble the engine mount bracket to oil pan and engine.
3. Hold the bracket firmly to the front of the engine and snug the engine mount bracket bolts.
4. Tighten the engine mount bracket bolts. Tighten: Tighten the engine mount bracket to engine bolt to 90 N.m (66 lb ft). Tighten the engine mount bracket to oil pan bolts to 50 N.m (37 lb ft).
5. Install the engine mount. Refer to «Engine Mount Replacement (Coupe)»(ref-243015-S32973693972006082100000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement (Convertible»(ref-243015-S36892932492007062000000) .
2. Remove the engine mount bracket bolts (2 and 3) from the engine.
3. Remove the engine mount bracket and spacer (1).

1. Position the engine mount bracket and spacer (1) to the engine front cover.
2. Hold the bracket firmly to the engine front cover and install the engine mount bracket bolts (2 and 3).
3. Tighten the engine mount bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement (Convertible»(ref-243015-S36892932492007062000000) .

1. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
2. Remove the engine mount strut to engine mount strut bracket bolts.
3. Lift the engine mount strut into the vertical position.
4. Remove the engine mount strut to engine compartment side rail bolt.
5. Slide the engine mount strut rearward and remove.

1. Position the engine mount strut tab into the hole and slide the strut forward until the bolt hole aligns.
2. Install and tighten the engine mount strut to engine compartment side rail bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Push the engine mount strut into the horizontal position.
4. Install the engine mount strut to engine mount strut bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .
2. Remove the engine mount strut bracket to engine bolts.
3. Remove the engine mount strut bracket.

1. Position the engine mount strut bracket to the engine.
2. Install the engine mount strut bracket to engine bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
2. Remove the oil pressure sensor heat shield bolts and shield.
3. Disconnect the oil pressure sensor electrical connector (1).
4. Remove the oil filter.
5. Remove the oil filter adapter bolts and stud.
6. Remove the oil filter adapter and gasket.
7. Insert a flat bladed tool into the oil filter bypass hole and remove the oil filter bypass valve.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Install the oil filter bypass valve. Seat the valve fully below the bypass valve hole chamfer.
2. Position the oil filter adapter and gasket to the engine.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolt/stud threads, if required.
4. Install the oil filter adapter bolts and stud. Tighten: Tighten the to bolts and stud to 25 N.m (18 lb ft).
5. Install the oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft).
6. Disconnect the oil pressure sensor electrical connector (1).
7. Install the oil pressure sensor heat shield and bolts. Tighten: Tighten the filter to 10 N.m (89 lb in).
8. Lower the vehicle.
9. Check and fill the crankcase, if necessary.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
2. Disconnect the oil pressure sensor electrical connector (1).
3. Remove the oil filter.
4. Reposition the oil cooler outlet hose clamp at the oil cooler.
5. Remove the oil cooler outlet hose from the oil cooler fitting.
6. Reposition the oil cooler inlet hose at the engine.
7. Remove the oil cooler inlet hose from the engine fitting.
8. Remove the oil cooler bolts and stud.
9. Remove the oil cooler and gasket.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolt/stud threads, if required.
2. Position the oil cooler and gasket to the engine.
3. Install the oil cooler bolts and stud. Tighten: Tighten the to bolts and stud to 25 N.m (18 lb ft).
4. Install the oil cooler inlet hose to the engine fitting.
5. Position the oil cooler inlet hose at the engine.
6. Install the oil cooler outlet hose to the oil cooler fitting.
7. Position the oil cooler outlet hose clamp at the oil cooler.
8. Install the oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft).
9. Disconnect the oil pressure sensor electrical connector (1).
10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
11. Check and fill the crankcase, if necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the heated oxygen sensor (HO2S) clip (3) from the fill tube bracket.
3. Remove the oil level indicator.
4. Remove the oil level indicator tube bracket bolt.
5. Remove the oil level indicator tube.
6. Inspect the oil level indicator tube O-ring seal, for damage, replace as necessary.

1. Lubricate the oil level indicator tube O-ring seal with clean engine oil.
2. Install the oil level indicator tube into the engine block.
3. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the oil level indicator.
5. Install the HO2S clip (3) to the fill tube bracket.
6. Install the spark plug wire to the number 6 cylinder spark plug.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF PROCEDURE»(ref-242992-S25705731562006082100000) .
3. Disconnect the fuel feed pipe (3) quick connect fitting from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
4. Disconnect the evaporative (EVAP) emission pipe (1) from the purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
5. Open the retaining clip (2), and remove the fuel and EVAP pipes from the clip.
6. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
7. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
8. Remove the PCV foul air tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
9. Reposition the brake booster vacuum hose clamp at the intake manifold.
10. Remove the vacuum hose (1) from the intake manifold.
11. Reposition the radiator surge tank inlet hose clamp.
12. Remove the radiator surge tank inlet hose from the inlet pipe.
13. Remove the radiator surge tank inlet pipe bolts.
14. Remove the radiator surge tank inlet pipe.
15. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
16. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
17. Disconnect the electronic throttle control (ETC) electrical connector (2).
18. Disconnect the inlet manifold valve electrical connector (1).
19. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
20. Disconnect the left side spark plug wires from the spark plugs.
21. Disconnect the left side spark plug wires from the ignition coil.
22. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet pipe.
23. Remove the left side spark plug wires.
24. Remove the heater inlet and outlet pipe nuts (1) from the throttle body studs.
25. Remove the inlet and outlet pipe (2, 3) from the studs.
26. Remove the 2 ignition coil bolts (1).
27. Remove the generator upper bolt.
28. Remove the generator ball stud.
29. Remove the generator rear brace.
30. Remove the upper intake manifold bolts (1, 2) and stud (3).
31. Separate and remove the upper intake manifold from the lower intake manifold.
32. Remove the upper to lower intake manifold gaskets.
33. Remove the inlet manifold tuning valve bolts and valve.
34. Remove the throttle body bolts/studs and throttle body.
35. Remove the MAP sensor bracket and sensor (1).
36. Remove the EVAP canister purge solenoid valve bolt (2) and valve (3).
37. Clean the upper intake to lower intake gasket mating surfaces.
38. Inspect the intake manifold tuning valve seal for damage. The tuning valve blade attachment to the motor should be tight, with no looseness or slack present, Replace as necessary.
39. Apply lubricant GM P/N 01050344 (Canadian P/N 993037) or equivalent to the nose of the valve blade (1).

1. Inspect the EVAP canister purge solenoid valve seal for damage, replace as necessary.
2. Install the EVAP canister purge solenoid valve (3) and bolt (2). Tighten: Tighten the bolts/studs to 16 N.m (12 lb ft).
3. Inspect the MAP sensor seal for damage, replace as necessary.
4. Install the MAP sensor and bracket
5. Inspect the throttle body seal for damage, replace as necessary.
6. Apply threadlock to the throttle body bolts/studs threads. Refer to «Sealers, Adhesives and Lubricants»(ref-243015-S31611261982006082100000) for the correct part number.
7. Install the throttle body and bolts/studs. Tighten: Tighten the bolts/studs to 16 N.m (12 lb ft).
8. Install the inlet manifold tuning valve, and bolts. Tighten: Tighten the bolts/studs to 10 N.m (89 lb in).
9. Install the NEW upper to lower intake manifold gaskets.
10. Set the upper intake manifold onto the lower intake manifold.
11. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to «Sealers, Adhesives and Lubricants»(ref-243015-S31611261982006082100000) for the correct part number.
12. Install the upper intake manifold bolts (1, 2) and stud (3). Tighten: Tighten the bolts/studs to 25 N.m (18 lb ft).
13. Install the generator rear brace.
14. Install the generator ball stud. Tighten: Tighten the bolts/studs to 20 N.m (15 lb ft).
15. Install the generator upper bolt. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
16. Install the 2 ignition coil bolts (1). Tighten: Tighten the bolts/studs to 25 N.m (18 lb ft).
17. Install the inlet and outlet pipe (2, 3) to the studs.
18. Install the heater inlet and outlet pipe nuts (1) to the throttle body studs. Tighten: Tighten the bolts/studs to 10 N.m (89 lb in).
19. Install the left side spark plug wires.
20. Connect the left side spark plug wires to the spark plugs.
21. Connect the left side spark plug wires to the ignition coil.
22. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
23. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
24. Connect the inlet manifold valve electrical connector (1).
25. Connect the EVAP canister purge solenoid electrical connector (1).
26. Connect the ETC electrical connector (2).
27. Connect the MAP sensor electrical connector (1).
28. Install the radiator surge tank inlet pipe.
29. Install the radiator surge tank inlet pipe bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
30. Install the radiator surge tank inlet hose to the inlet pipe.
31. Position the radiator surge tank inlet hose clamp.
32. Install the brake booster vacuum hose (1) to the intake manifold.
33. Position the vacuum hose clamp at the intake manifold.
34. Install the PCV foul air tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
35. Install the PCV fresh air tube. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
36. Install the fuel and EVAP pipes to the retainer clip (2) and close the clip.
37. Disconnect the fuel feed pipe (3) quick connect fitting from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
38. Connect the evaporative (EVAP) emission pipe (1) from the purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
39. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
40. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
41. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .

1. Remove the coolant crossover pipe. Refer to «Coolant Crossover Pipe Replacement (3.9L)»(ref-243023-S04286874602006082100000) .
2. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(ref-243015-S31466623672006082100000) .
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-243015-S14083211192006082100000) .
4. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right Side»(ref-243015-S03367424982006082100000) .
5. Disconnect the engine coolant temperature (ECT) electrical connector.
6. Disconnect the fuel feed line from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
7. Disconnect the fuel injector inline connector (2).
8. Remove the fuel injector harness connector bracket bolt from the intake manifold.
9. Disconnect the camshaft position (CMP) sensor electrical connector.
10. Remove the fuel injector rail bolts.
11. Remove the fuel rail.
12. Remove the lower intake manifold bolts.
13. Remove the lower intake manifold.
14. Loosen the valve rocker arm bolts.
15. Remove the valve rocker arms.
16. Remove the push rods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).
17. Remove the lower intake manifold gaskets and seals.
18. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
19. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
20. Remove all the loose room temperature vulcanizing sealer (RTV) (1).

1. Install the lower intake manifold gaskets and seals.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or 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 equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (0.031-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to engine block joints (1).
8. Install the lower intake manifold.
9. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
10. Install the lower intake manifold bolts.
11. Tighten the lower intake manifold bolts in the sequence shown. Tighten: Tighten the bolts (1, 2, 3, 4) in sequence to 16 N.m (12 lb ft). Tighten the bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft).
12. Inspect the fuel rail, fuel injectors and fuel injector O-rings for damage and replace as necessary.
13. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182).
14. Install the injector nozzles into the lower intake manifold injector bores.
15. Press on the injector rail using the palms of both hands until the injector are fully seated.
16. Install the fuel injector rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
17. Connect the CMP sensor electrical connector.
18. Position the fuel injector harness connector bracket to the intake manifold.
19. Install the fuel injector harness connector bracket bolt. Tighten: Tighten the bolt to 8 N.m (71 lb in).
20. Connect the fuel injector inline connector (2).
21. Connect the fuel feed line to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
22. Connect the ECT electrical connector.
23. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right Side»(ref-243015-S03367424982006082100000) .
24. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-243015-S14083211192006082100000) .
25. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-243015-S31466623672006082100000) .
26. Install the coolant crossover pipe. Refer to «Coolant Crossover Pipe Replacement (3.9L)»(ref-243023-S04286874602006082100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
2. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
3. Remove the PCV fresh air tube from the rocker arm cover.
4. Remove the PCV fresh air tube from the vehicle.
5. Disconnect the PCV foul air tube from the PCV valve. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
6. Remove the PCV foul air tube from the intake manifold.
7. Remove the PCV foul air tube from the vehicle.

1. Install the PCV foul air tube to the vehicle.
2. Install the PCV foul air tube to the intake manifold.
3. Connect the PCV foul air tube to the PCV valve. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
4. Install the PCV fresh air tube to the vehicle.
5. Install the PCV fresh air tube to the rocker arm cover.
6. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .

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-243015-S06972132842006082100000) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
4. Disconnect the left spark plug wires from the spark plugs.
5. Remove the spark plug wire harness clip from the heater inlet and outlet front pipe bracket.
6. Remove the heater inlet and outer front pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet (LZ9)»(ref-243028-S05328579342006082100000) .
7. Disconnect the positive crankcase ventilation (PCV) foul air tube from the PCV valve. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
8. Remove the valve rocker arm cover bolts.
9. Remove the valve rocker arm cover. If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
10. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
11. Remove the valve cover gasket.
12. Clean the sealing surface on the cylinder head with degreaser.

1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent, at the cylinder head 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. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the PCV foul air tube to the PCV valve. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
6. Install the heater inlet and outer front pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet (LZ9)»(ref-243028-S05328579342006082100000) .
7. Install the spark plug wire harness clip to the heater inlet and outlet front pipe bracket.
8. Connect the left spark plug wires to the spark plugs.
9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
10. Fill the cooling system, as necessary. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .

1. Remove the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .
2. Remove the engine coolant crossover pipe. Refer to «COOLANT CROSSOVER PIPE REPLACEMENT (3.9L)»(ref-243023-S04286874602006082100000) .
3. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
4. Remove the PCV fresh air tube from the right side valve rocker arm cover.
5. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
6. Disconnect the ignition coil electrical connector (2).
7. Remove the heated oxygen sensor (HO2S) electrical connector clip from the ignition coil bracket.
8. Remove the spark plug wires from the ignition coil.
9. Remove the ignition coil bracket bolts (1) and nuts (2).
10. Remove the ignition coil with bracket (3) from the engine.
11. Remove the valve rocker arm cover bolts.
12. Remove the valve rocker arm cover. Bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
13. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
14. Remove the valve cover gasket.
15. Clean the sealing surface on the cylinder head with degreaser.

1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent, at the cylinder head to the surfaces where the cylinder head and intake manifold meet (1).
3. 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.
4. Install the right valve rocker arm cover.
5. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the ignition coil with bracket (3) to the engine.
7. Install the ignition coil bracket bolts (1) and nuts (2). Tighten: Tighten the bolts and nuts to 25 N.m (18 lb ft).
8. Install the spark plug wires to the ignition coil.
9. Install the HO2S electrical connector clip to the ignition coil bracket.
10. Connect the ignition coil electrical connector (2).
11. Connect the MAP sensor electrical connector (1).
12. Install the PCV fresh air tube to the right side valve rocker arm cover.
13. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
14. Install the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .

1. Remove the valve rocker arm cover(s). Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-243015-S14083211192006082100000) or «Valve Rocker Arm Cover Replacement - Right Side»(ref-243015-S03367424982006082100000) .
2. Loosen the valve rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).

1. Coat the ends of the pushrods using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the pushrods. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with blue stripes.
3. Ensure that the pushrods seat in the lifter bore.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the rocker arms.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
7. Install the valve rocker arm cover(s). Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-243015-S14083211192006082100000) or «Valve Rocker Arm Cover Replacement - Right Side»(ref-243015-S03367424982006082100000) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
3. Install the J 22794 into the spark plug port. 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 (1) and the EN-47823 (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.
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 (1) and the EN-47823 (2).
6. Install the valve cap keys. If necessary, use grease in order to hold the valve cap keys in place.
7. Ensure the valve cap keys are seated.
8. Remove the compressed air and remove the J 22794 from the spark plug port.
9. Install the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
3. Loosen the valve lifter guide bolts.
4. Remove the valve lifter guides.
5. Remove the valve lifters from the valve lifter guides.
6. Clean all gasket surfaces with degreaser.

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the valve lifters to the cylinder bores.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the valve lifter guide bolt threads.
4. Install the valve lifter guides.
5. Tighten the valve lifter guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
7. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
3. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
4. Remove the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(ref-243023-S19224180592006082100000) .
5. Install adjustable jack stands under the frame.
6. Loosen the left side frame bolts and remove the right side frame bolts.
7. Using the jack stands, lower the right side of the frame in order to access the crankshaft balancer.
8. Remove the torque converter covers.
9. Install the J 37096 to the flywheel in order to prevent flywheel rotation.
10. Remove the crankshaft balancer bolt and the washer.
11. Remove the crankshaft balancer using the J 41816 and EN 46359 .

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Thread the J 29113 into the crankshaft.
4. Rotate the hex nut on the J 29113 in order to install the crankshaft balancer onto the crankshaft.
5. Remove the J 29113 from the crankshaft.
6. Install the crankshaft balancer washer and the bolt.
7. Tighten the crankshaft balancer bolt. Tighten: Tighten the bolt to 70 N.m (52 lb ft) plus an additional 70 degrees using the J 45059 .
8. Remove the J 45059 from the flywheel.
9. Install the torque converter covers.
10. Raise the frame into the original position.
11. Install and tighten the right and left side frame bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft) plus an additional 90 degrees using the J 45059 .
12. Install the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(ref-243023-S19224180592006082100000) .
13. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
14. Lower the vehicle.
15. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
3. Place a suitable drain pan under the oil pan drain plug.
4. Remove the oil pan drain plug and drain the engine oil from the crankcase.
5. Reinstall the oil pan drain plug until snug.
6. Remove the starter. Refer to «STARTER MOTOR REPLACEMENT (LZ9/3.9L)»(ref-242993-S31692867382006082100000) .
7. Remove the air conditioning (A/C) compressor bolts and position the compressor aside.
8. Remove the frame. Refer to «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) , «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) , «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) .
9. Disconnect the oil level sensor electrical connector.
10. Remove the transaxle brace to oil pan bolts.
11. Remove the transaxle brace to transaxle bolt and remove the brace.
12. Remove the transaxle brace to oil pan bolts, if equipped with regular production option (RPO) MT2.
13. Remove the transaxle brace to transaxle bolt and remove the brace, if equipped with RPO MT2.
14. Remove the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15.
15. Remove the oil pan bolts (1 and 2).
16. Remove the oil pan.
17. Remove and discard the oil pan gasket.
18. Clean the oil pan sealing surfaces.

1. sealer to both sides of the crankshaft rear main bearing cap. Press the sealer into the gap using a putty knife. Refer to «Sealers, Adhesives and Lubricants»(ref-243015-S31611261982006082100000) .
2. Apply sealer to both sides of the front cover/block mating area. Refer to «Sealers, Adhesives and Lubricants»(ref-243015-S31611261982006082100000) .
3. Install a NEW oil pan gasket.
4. Position the oil pan to the engine.
5. install the oil pan bolts (1 and 2). Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolts (2) to 25 N.m (18 lb ft).
6. Install the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
7. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug, if equipped with RPO MT2.
8. Install the transaxle brace to oil pan bolts, if equipped with RPO MT2. Tighten: Tighten the drain plug to 50 N.m (37 lb ft).
9. Install the transaxle brace to oil pan bolts.
10. Install the transaxle brace to oil pan bolts. Tighten: Tighten the drain plug to 50 N.m (37 lb ft).
11. Connect the oil level sensor electrical connector.
12. Install the frame. Refer to «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) , «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) , «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) .
13. Position the A/C compressor and install the bolts. Tighten: Tighten the drain plug to 50 N.m (37 lb ft).
14. Install the starter. Refer to «STARTER MOTOR REPLACEMENT (LZ9/3.9L)»(ref-242993-S31692867382006082100000) .
15. Ensure that the oil pan drain plug is tight. Tighten: Tighten the drain plug to 26 N.m (19 lb ft).
16. Lower the vehicle.
17. Fill the crankcase.
18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .

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

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 16 N.m (12 lb ft).
2. Connect engine oil pressure sensor electrical connector (1).
3. Install the oil pressure heat shield and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
2. Remove the oil pan drain plug.
3. Drain the crankcase.
4. Reinstall the oil pan drain plug.
5. Disconnect the engine oil level sensor electrical connector.
6. Remove the engine oil level sensor bolt and sensor.

1. Install the engine oil level sensor and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
2. Connect the engine oil level sensor electrical connector.
3. Lower the vehicle.
4. Refill the crankcase with new engine oil.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-243015-S25094440112006082100000) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.

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-243015-S25094440112006082100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
3. Remove the oil pump drive bolt.
4. Remove the oil pump drive.

1. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent to the oil pump drive gear.
2. Install the oil pump drive.
3. Install the oil pump drive bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243015-S33793975582006082100000) .
2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

1. Lubricate the NEW oil seal with clean engine oil.
2. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
3. Install the crankshaft front oil seal using J 35468 and a suitable tool.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243015-S33793975582006082100000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
3. Remove the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement (Coupe)»(ref-243015-S37017859012006082100000) .
4. Remove the engine mount bracket, if equipped with a convertible top. Refer to «Engine Mount Bracket Replacement (Convertible)»(ref-243015-S42176258562007062100000) .
5. Disconnect the camshaft position actuator magnet electrical connector.
6. Remove the camshaft position actuator magnet bolts.
7. Remove the camshaft position actuator magnet and O-ring seal.

1. Install the camshaft position actuator magnet O-ring seal and magnet.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Connect the camshaft position actuator magnet electrical connector.
4. Install the engine mount bracket, if equipped with a convertible top. Refer to «Engine Mount Bracket Replacement (Convertible)»(ref-243015-S42176258562007062100000) .
5. Install the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement (Coupe)»(ref-243015-S37017859012006082100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-243015-S08166845642006082100000) .
3. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-243015-S25094440112006082100000) .
4. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243015-S33793975582006082100000) .
5. Remove the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-243015-S31600369992006082100000) .
6. Remove the thermostat housing. Refer to «Thermostat Housing Replacement (3.9L)»(ref-243023-S01737892202006082100000) .
7. Remove the water pump. Refer to «Water Pump Replacement (3.9L)»(ref-243023-S08018710632006082100000) .
8. Remove the engine front cover bolts.
9. Remove the engine front cover.
10. Remove the engine front cover gasket.

1. Install the engine front cover gasket.
2. Install the engine front cover. NOTE: Refer to «Fastener Notice»(ref-242977-S25864542072006082100000) .
3. Install the engine front cover bolts. Tighten: Tighten the bolts to 257 N.m (18 lb ft).
4. Install the water pump. Refer to «Water Pump Replacement (3.9L)»(ref-243023-S08018710632006082100000) .
5. Install the thermostat housing. Refer to «Thermostat Housing Replacement (3.9L)»(ref-243023-S01737892202006082100000) .
6. Install the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-243015-S31600369992006082100000) .
7. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-243015-S33793975582006082100000) .
8. Install the oil pan. Refer to «Oil Pan Replacement»(ref-243015-S25094440112006082100000) .
9. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-243015-S08166845642006082100000) .
10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243015-S33858828982006082100000) .
2. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
3. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).
4. Remove the camshaft sprocket bolts.
5. Remove the timing chain, camshaft and crankshaft sprockets.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.
8. Remove and discard the camshaft position actuator filter (1) from the end of the camshaft.

1. Install s NEW camshaft position actuator filter (1) to the end of the camshaft.
2. Install the crankshaft sprocket.
3. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent to the crankshaft sprocket thrust surface.
4. Install the timing chain tensioner.
5. Install the timing chain tensioner bolts. Tighten: Tighten the bolts 21 N.m (15 lb ft).
6. Using the EN-47719 , fully collapse the tensioner and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-243015-S13943983972006082100000) .
7. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
8. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
9. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).
10. Align the dowel in the camshaft sprocket with the dowel hole in the camshaft.
11. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts 16 N.m (12 lb ft).
12. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
13. Coat the crankshaft and camshaft sprockets with clean engine oil.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-243015-S33858828982006082100000) .

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243015-S08544379702006082100000) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .
4. Remove the valve rocker arms and the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (3.9L)»(ref-243054-S08041764922006082100000) .
6. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-243015-S03252329272006082100000) .
7. Remove the left spark plugs. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder head locator dowel pins, if necessary.
12. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install a NEW cylinder head gasket.
4. Install the cylinder head onto the locator pins and the engine.
5. Install NEW cylinder head bolts finger tight.
6. Tighten the cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft) plus an additional 95 degrees using the J 45059 .
7. Install the left spark plugs. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .
8. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-243015-S03252329272006082100000) .
9. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (3.9L)»(ref-243054-S08041764922006082100000) .
10. Install the valve rocker arms and the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
11. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .
12. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243015-S08544379702006082100000) .
13. Inspect for leaks.

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .
4. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right Side (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) .
6. Remove the right spark plugs. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .
7. Remove the fuel line bracket bolt and stud.
8. Remove the fuel line bracket.
9. Remove the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .
10. Remove and discard the cylinder head bolts.
11. Remove the cylinder head.
12. Remove and discard the cylinder head gasket.
13. Remove the cylinder head locator dowel pins, if necessary.
14. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-243014-S02046394422006082100000) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install a NEW cylinder head gasket.
4. Install the cylinder head onto the locator pins and the engine.
5. Install NEW cylinder head bolts finger tight.
6. Tighten the cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft) plus an additional 95 degrees using the J 45059 .
7. Install the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .
8. Position the fuel line bracket to the cylinder head.
9. Install the fuel line bracket bolt and stud. Tighten: Tighten the bolt and the stud to 50 N.m (37 lb ft).
10. Install the right spark plugs. Refer to «Spark Plug Replacement»(ref-242992-S07064380792006082100000) .
11. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (3.9L w/RPO MT2)»(ref-243054-S22832687812006082100000) or «Exhaust Manifold Replacement - Right Side (3.9L w/PRO M15)»(ref-243054-S04021418152006082100000) .
12. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-243015-S01928371972006082100000) .
13. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-243015-S14088479382006082100000) .
14. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
15. Inspect for leaks.

1. Remove the automatic transaxle, if equipped. Refer to «Transmission Replacement»(ref-243016-S24834387792006082100000) .
2. Remove the clutch, if equipped with a manual transaxle. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-243056-S00062571682006082100000) .
3. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating.
4. Loosen the flywheel bolts.
5. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft.
6. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
7. Remove the engine flywheel.
8. Clean the engine flywheel bolt threads and bolt holes.

1. Position the flywheel to the crankshaft.
2. Install the flywheel bolts finger tight.
3. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating.
4. Tighten the engine flywheel bolts. Tighten: Tighten the bolts to 70 N.m (52 lb ft).
5. Install the clutch, if equipped with a manual transaxle. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-243056-S00062571682006082100000) .
6. Install the automatic transaxle, if equipped. Refer to «Transmission Replacement»(ref-243016-S24834387792006082100000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-243015-S21204255672006082100000) .
2. Remove the crankshaft rear main oil seal. Refer to «Crankshaft Rear Oil Seal Removal»(ref-243015-S13100860872006082100000) .

Note. Do not apply or use any oil lubrication on the crankshaft rear oil seal or the seal installer. Do not touch the sealing lip of the oil seal once the protective sleeve is removed. Doing so will damage/deform the 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. Install the crankshaft rear main seal. Refer to «Crankshaft Rear Oil Seal Installation»(ref-243015-S00000993572006082100000) Crankshaft Rear Oil Seal Installation
2. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243015-S21204255672006082100000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-243015-S21204255672006082100000) .
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-243015-S21204255672006082100000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
3. Remove the hood. Refer to «Hood Replacement»(ref-243002-S37879464402006082100000) .
4. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
5. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .
6. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
7. Remove the power steering pump and disconnect the power steering lines, if equipped. Refer to «POWER STEERING PUMP REPLACEMENT»(ref-243012-S25166776782006082100000) .
8. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
9. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
10. Remove the oil pressure sensor heat shield nuts and shield.
11. Disconnect the oil pressure sensor (1) electrical connector.
12. Disconnect the knock sensor (2) electrical connector.
13. Disconnect the air conditioning (A/C) compressor electrical connector.
14. Lower the vehicle.
15. Disconnect the evaporative emission (EVAP) canister purge solenoid (1) electrical connector.
16. Disconnect the electronic throttle control (ETC) (2) electrical connector.
17. Remove the connector position assurance (CPA) retainer (5).
18. Disconnect the heated oxygen sensor (HO2S) (3) electrical connector.
19. Disconnect the manifold absolute pressure (MAP) sensor (1) electrical connector.
20. Disconnect the ignition control module (2) electrical connector.
21. Disconnect the inlet manifold valve (1) electrical connector.
22. Disconnect the fuel injector inline (2) electrical connector.
23. Disconnect the camshaft phasor sensor electrical connector.
24. Remove the CPA retainer (5).
25. Disconnect the rear upper HO2S electrical connector (1).
26. Disconnect the knock sensor electrical connector (1).
27. Disconnect the crankshaft position (CKP) sensor electrical connector (2).
28. Disconnect the engine harness connector (1) from the body harness connector (2).
29. Disconnect the body harness electrical connector from the powertrain control module (PCM).
30. Disconnect the engine harness electrical connectors from the PCM.
31. Disconnect the engine harness electrical connector from the transmission control module (TCM).
32. Remove the engine harness clip nut (2).
33. Remove the engine harness clip (1) from the transmission stud.
34. Remove the engine harness ground nut (2).
35. Remove the engine harness ground terminal (1) from the transmission stud.
36. Remove the engine harness rear clip nut (2).
37. Remove the engine harness rear clip (1) from the transmission stud.
38. Remove the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (3.9L)»(ref-243054-S25744595302006082100000) , «Catalytic Converter Replacement - Right Side (3.9L w/RPO MT2)»(ref-243054-S01429538692006082100000) or «Catalytic Converter Replacement - Right Side (3.9L w/RPO M15)»(ref-243054-S41469803862006082100000) .
39. Remove the engine mount lower nuts.
40. Remove the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-243016-S10104965512006082100000) .
41. Remove the starter motor. Refer to «Starter Motor Replacement (3.9L)»(ref-242993-S31692867382006082100000) .
42. Remove the torque converter bolts. Refer to «Flywheel to Torque Converter Bolt Replacement»(ref-243016-S18182649292006082100000) .
43. Unbolt and reposition the A/C compressor of to the side. DO NOT discharge the A/C system.
44. Remove the transaxle brace to oil pan bolts.
45. Remove the transaxle brace to transaxle bolt and remove the brace.
46. Remove the transaxle brace to oil pan bolts, if equipped with regular production option (RPO) MT2.
47. Remove the transaxle brace to transaxle bolt and remove the brace, if equipped with RPO MT2.
48. Remove the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15.
49. Remove the lower transaxle-to-engine bolt and stud.
50. Reposition the radiator outlet hose clamp at the thermostat housing.
51. Remove the radiator outlet hose from the thermostat housing.
52. Lower the vehicle and support the transaxle.
53. Reposition the radiator surge tank hose clamp at the surge tank pipe.
54. Remove the radiator surge tank hose from the surge tank pipe.
55. Reposition the brake booster vacuum hose clamp at the intake manifold.
56. Remove the brake booster vacuum hose from the intake manifold.
57. Reposition the heater inlet and outlet hose clamps at the engine.
58. Remove the heater outlet and inlet hoses from the engine.
59. Disconnect the fuel feed line from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
60. Disconnect the EVAP purge line from the canister purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
61. Reposition the radiator inlet hose clamp at the engine.
62. Remove the radiator inlet hose from the engine.
63. Install a engine lifting device to the engine.
64. Remove the remaining transaxle-to-engine bolts/studs if equipped with a manual transmission.
65. Remove the remaining transaxle-to-engine bolts/studs if equipped with a automatic transmission.
66. Remove the engine from the vehicle.
67. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-243015-S21204255672006082100000) .
68. Install the engine to the engine stand.

1. Install an engine lifting device to the engine.
2. Remove the engine from the engine stand.
3. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-243015-S21204255672006082100000) .
4. Install the engine to the vehicle. NOTE: Refer to «Fastener Notice»(ref-242977-S25864542072006082100000) .
5. Install the transaxle-to-engine bolts/studs if equipped with a automatic transmission. Tighten: Tighten the bolts/studs to 75 N.m (55 lb ft).
6. Install the transaxle-to-engine bolts/studs if equipped with a manual transmission. Tighten: Tighten the bolts/studs to 75 N.m (55 lb ft).
7. Remove the engine lifting device from the engine.
8. Install the radiator inlet hose to the engine.
9. Position the radiator inlet hose clamp at the engine.
10. Connect the EVAP purge line to the canister purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-242992-S27673644472006082100000) .
11. Connect the fuel feed line to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-242992-S42649905742006082100000) .
12. Install the heater outlet and inlet hoses to the engine.
13. Position the heater inlet and outlet hose clamps at the engine.
14. Install the brake booster vacuum hose to the intake manifold.
15. Position the brake booster vacuum hose clamp at the intake manifold.
16. Install the radiator surge tank hose to the surge tank pipe.
17. Position the radiator surge tank hose clamp at the surge tank pipe.
18. Raise and support the vehicle.
19. Install the radiator outlet hose to the thermostat housing.
20. Position the radiator outlet hose clamp at the thermostat housing.
21. Install the lower transaxle-to-engine bolt and stud. Tighten: Tighten the bolts and studs to 75 N.m (55 lb ft).
22. Install the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15 Tighten: Tighten the bolts to 50 N.m (37 lb ft).
23. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug, if equipped with RPO MT2. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
24. Install the transaxle brace to oil pan bolts, if equipped with RPO MT2. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
25. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug.
26. Install the transaxle brace to oil pan bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
27. Position and bolt up the A/C compressor. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
28. Install the torque converter bolts. Refer to «Flywheel to Torque Converter Bolt Replacement»(ref-243016-S18182649292006082100000) .
29. Install the starter motor. Refer to «Starter Motor Replacement (3.9L)»(ref-242993-S31692867382006082100000) .
30. Install the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-243016-S10104965512006082100000) .
31. Install the engine mount lower nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
32. Install the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (3.9L)»(ref-243054-S25744595302006082100000) , «Catalytic Converter Replacement - Right Side (3.9L w/RPO MT2)»(ref-243054-S01429538692006082100000) or «Catalytic Converter Replacement - Right Side (3.9L w/RPO M15)»(ref-243054-S41469803862006082100000) .
33. Install the engine harness rear clip (1) to the transmission stud.
34. Install the engine harness rear clip nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
35. Install the engine harness ground terminal (1) to the transmission stud.
36. Install the engine harness ground nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
37. Install the engine harness clip (1) to the transmission stud.
38. Install the engine harness clip nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
39. Connect the engine harness electrical connector to the TCM.
40. Connect the engine harness electrical connectors to the PCM.
41. Connect the body harness electrical connector to the PCM.
42. Connect the engine harness connector (1) to the body harness connector (2).
43. Connect the CKP sensor electrical connector (2).
44. Connect the knock sensor electrical connector (1).
45. Connect the rear upper HO2S electrical connector (1).
46. Install the CPA retainer (5).
47. Connect the camshaft phasor sensor electrical connector.
48. Connect the fuel injector inline (2) electrical connector.
49. Connect the inlet manifold valve (1) electrical connector.
50. Connect the ignition control module (2) electrical connector.
51. Connect the MAP sensor (1) electrical connector.
52. Connect the HO2S (3) electrical connector.
53. Install the CPA retainer (5).
54. Connect the ETC (2) electrical connector.
55. Connect the EVAP canister purge solenoid (1) electrical connector.
56. Raise and support the vehicle.
57. Connect the A/C compressor electrical connector.
58. Connect the knock sensor (2) electrical connector.
59. Connect the oil pressure sensor (1) electrical connector.
60. Install the oil pressure sensor heat shield and nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
61. Lower the vehicle.
62. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
63. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-243015-S04043729702006082100000) .
64. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
65. Install the hood. Refer to «Hood Replacement»(ref-243002-S37879464402006082100000) .
66. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-242992-S16903688752006082100000) .
67. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-243014-S26290488962006082100000) .
68. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
69. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-242993-S28274277282006082100000) .
70. Inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
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. Ensure that the oil filter gasket is still on the old filter. If not remove the oil filter gasket from the adapter.

1. Lower the vehicle.
2. Install the NEW oil filter. Tighten: Tighten the plug to 26 N.m (19 lb ft).
3. Tighten the oil pan drain plug. Tighten: Tighten the new filter to 3/4 to 1 full turn, after the oil filter gasket contacts the adapter.
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «APPROXIMATE FLUID CAPACITIES»(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. If equipped with an oil cooler (RPO-KC4), reposition the upper inlet hose clamp (1).
6. Remove the oil cooler inlet hose from the block outlet.
7. If not equipped with an oil cooler (RPO-KC4), remove the coolant drain plug from the right side.
8. Drain the coolant.

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816 along with EN 46359 .

Engine Flywheel Removal (Automatic Transmission)

1. If equipped with an automatic transmission, remove the flywheel bolts.
2. Remove the flywheel.

Engine Flywheel Removal (Manual Transmission)

1. Remove the flywheel/pressure plate bolts.
2. Remove the flywheel/pressure plate.
3. Remove the clutch pilot bearing.

Drive Belt Tensioner Removal

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

Coolant Crossover Pipe Removal

1. Loosen thermal bypass hose clamp (3) and remove hose from the coolant crossover pipe.
2. Remove the heater inlet/outlet pipe bolt (1) and remove the heater inlet/outlet pipe.
3. Remove the coolant vent pipe bolt (2) and the coolant vent pipe.
4. Remove the idler pulley bolts and pulleys.
5. Remove the coolant crossover pipe bolts (2, 3), engine lift bracket (1) and the coolant crossover pipe assembly.

Engine Lift Rear Bracket Removal

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

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator tube bolt.
2. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter adapter heat shield nuts.
2. Remove the oil filter adapter heat shield (2).
3. Remove the oil filter adapter bolts.
4. Remove the oil filter adapter (1) and gasket.

Exhaust Manifold Removal - Left Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires from the spark plugs and set aside.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

Exhaust Manifold Removal - Right Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shields.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

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 Side

1. Remove the PCV tube.
2. Remove and discard both PCV tube O-rings.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
6. Remove the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right Side

1. Remove any remaining spark plug wires from their retainers.
2. Remove the ignition coil assembly bolts and nuts.
3. Remove the ignition coil assembly.
4. Remove the ignition coil assembly studs, if necessary.
5. Remove the fresh air tube from the valve rocker arm cover.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover.
8. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
9. Remove the valve rocker arm cover gasket.

Upper Intake Manifold Removal

1. Remove the foul air PCV tube.
2. Remove the upper intake manifold bolts, stud and manifold absolute pressure (MAP) sensor bracket.
3. Remove the upper intake manifold and gaskets.

Lower Intake Manifold Removal

1. Disconnect the coolant temperature sensor (1).
2. Disconnect the camshaft position (CMP) sensor (2).
3. Remove the fuel injector rail bolts.
4. Remove the fuel rail assembly.
5. Remove the lower intake manifold bolts and discard.
6. 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 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 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 Side

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 Side

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.

Camshaft Position Actuator Magnet Removal

1. Remove the camshaft position actuator magnet bolts.
2. Remove the camshaft position actuator magnet and O-ring seal.

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 125

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.
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Timing Chain and Sprockets Removal

1. Install the camshaft position actuator fastener (1).
2. Remove the camshaft sprocket bolts.
3. Remove the timing chain and sprockets.
4. Remove the timing chain tensioner bolts.
5. Remove the timing chain tensioner.

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.

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. 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.
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 bolts retaining the piston oil nozzles to the engine block.
2. Remove the piston oil nozzles.

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 .
3. Drive out the camshaft bearings. Use the J 33049 .

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

Piston Oil Nozzle Installation

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

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

Engine Block Heater Installation

1. Apply sealer GM P/N 12346004 (Canadian P/N 1095380) 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).

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

1. Lightly lubricate the following components with clean engine oil: The piston The piston pin The piston rings The cylinder bore The bearing surfaces
2. There are two styles of pistons in use in the LZ engine, and each piston must use the appropriate matching piston ring set. To identify which make you have, look on the bottom of the piston, in between the piston pin bores (1). If there is an "FM" marking, it is a Federal Mogul piston and must use the Federal Mogul piston rings. If there is no marking, it is a Mahle piston and must use Mahle piston rings. Failure to do so may result in engine damage.
3. Stagger the oil control ring end gaps a minimum of 90 degrees.
4. Stagger the compression ring end gaps a minimum of 25 mm (1 in).
5. Install the J 8037 onto the piston and compress the piston rings.
6. Align the piston pin bore with the connecting rod pin bore.
7. Slide the piston pin (4) into the piston and the connecting rod (3).
8. Install NEW piston pin retainers (1) using the J 43654 .
9. Ensure that the piston pin retainers are fully seated in their grooves.
10. Repeat these procedures for the remaining pistons.
11. Install the J 41556 into the connecting rod.
12. Install the piston and connecting rod assembly into the proper cylinder bore.
13. 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.
14. Using J 41556 s, guide the connecting rod end onto the crankshaft journal.
15. 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 .
16. 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.
17. 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).

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 tensioner.
4. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
5. Using the EN-47719 , fully collapse the tensioner and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-243015-S13943983972006082100000) .
6. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
7. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
8. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain tensioner (3).
9. Align the dowel in the camshaft sprocket with the dowel hole in the camshaft.
10. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
11. Coat the crankshaft and camshaft sprocket with engine oil.
12. Remove the tensioner retaining pin.

Engine Front Cover Installation

1. Install the front cover and the front cover gasket.
2. Install the front cover bolts. Tighten: Tighten the front cover bolts to 25 N.m (18 lb ft).

Oil Pump Drive Installation

1. Apply prelube GM P/N 12345501 (Canadian P/N 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).

Camshaft Position Actuator Magnet Installation

1. Install the camshaft position actuator magnet and O-ring seal into the front cover.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the camshaft position actuator magnet bolts to 10 N.m (89 lb in).

Oil Pump Installation

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pump.
4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).

Oil Pan Installation

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 34 N.m (25 lb ft).

Lower Intake Manifold Installation

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 new lower intake manifold bolts if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in) 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.
5. Inspect the fuel rail and fuel injectors for damage and replace if necessary.
6. Install NEW lower fuel injector O-rings.
7. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
8. Install the injector nozzles into the lower intake manifold injector bores.
9. Press on the injector rail using the palms of both hands until the injectors are fully seated.
10. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
11. Connect the coolant temperature sensor (1).
12. Connect the camshaft position (CMP) sensor (2).

Upper Intake Manifold Installation

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, stud and MAP sensor bracket. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).
4. Install the foul air PCV tube.

Valve Rocker Arm Cover Installation - Left Side

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 two NEW positive crankcase ventilation (PCV) tube O-rings.
6. Install the fresh air tube.

Valve Rocker Arm Cover Installation - Right Side

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 fresh air 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).

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 Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. 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.
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Exhaust Manifold Installation - Right Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. 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.
7. Install the spark plug wires.
8. 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 adapter (1) and gasket.
2. Apply threadlocker P/N 21485277 to the bolt threads if required.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N.m (18 lb ft).
4. Install the oil filter adapter heat shield (2).
5. Install the oil filter adapter heat shield nuts. Tighten: Tighten the oil filter adapter heat shield nuts 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).

Engine Lift Rear Bracket Installation

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).

Coolant Crossover Pipe Installation

1. Install the coolant crossover pipe assembly onto the engine.
2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the side coolant crossover pipe bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the idler pulleys and bolts. Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolt (2) to 30 N.m (22 lb ft).
5. Install the coolant vent pipe and bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the heater inlet/outlet pipe and bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Install the thermal bypass hose and securely fasten the clamp (3).

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 (Automatic Transmission)

1. If equipped with an automatic transmission, install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).

1. Install the clutch pilot bearing.
2. Install the flywheel/pressure plate.
3. Install the flywheel/pressure plate bolts. Tighten: Tighten the flywheel/pressure plate bolts to 50 N.m (37 lb ft) plus an additional 70 degrees using the J 45059 .

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.
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft.
5. Remove the J 29113 from the crankshaft.
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 70 N.m (52 lb ft). Tighten the crankshaft balancer bolt a final pass to 70 degrees using the J 45059 .