Engine Mechanical - 5.3l Pontiac Grand Prix VII

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 34

Engine Block - Front/Rear Views

Scheme 35

Engine Block - Left/Right Side Views

Scheme 36

Engine Block - Top/Bottom Views

Scheme 37

Cylinder Head - Top/End Views

Scheme 38

Cylinder Head - Intake/Exhaust Side Views

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

The vehicle identification number (VIN) is located on the left side rear of the engine block (1) and is typically a 9 digit number stamped or laser-etched onto the engine at the vehicle assembly plant.

1. The first digit identifies the division.
2. The second digit identifies the model year.
3. The third digit identifies the assembly plant.
4. The fourth through ninth digits are the last 6 digits of the VIN.

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Lubrication Description (Main Pressure Below 65 psi - DoD Off) or Lubrication Description (Main Pressure Above 65 psi - DoD Off) or Lubrication Description (Main Pressure Below 65 psi - DoD On) or Lubrication Description (Main Pressure Above 65 psi - DoD On) , Displacement on Demand (DoD) System Description and Drive Belt System Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform the «Diagnostic System Check - Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) , «Engine Component Description»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) , «Lubrication Description (Main Pressure Below 65 psi - DoD Off)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) or «Lubrication Description (Main Pressure Above 65 psi - DoD Off)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) or «Lubrication Description (Main Pressure Below 65 psi - DoD On)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) or «Lubrication Description (Main Pressure Above 65 psi - DoD On)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) , «Displacement on Demand (DoD) System Description»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) and «Drive Belt System Description»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__drive-belt-system-description) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Engine. Refer to «Checking Aftermarket Accessories»(/pontiac/grand-prix/vii-2004-2008/remont/body-electrical/#how-to-diagnosis-repair-the-wiring-systems-testing__checking-aftermarket-accessories) in Wiring Systems.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

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

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Base Engine Misfire without Internal Engine Noises»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__base-engine-misfire-without-internal-engine)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__base-engine-misfire-with-excessive-oil)
6. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-noise-on-start-up-but-only)
7. «Upper Engine Noise, Regardless of Engine Speed»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__upper-engine-noise-regardless-of-engine)
8. «Lower Engine Noise, Regardless of Engine Speed»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__lower-engine-noise-regardless-of-engine)
9. «Engine Noise Under Load»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-noise-under-load)
10. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-will-not-crank-crankshaft)
11. «Coolant in Combustion Chamber»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__coolant-in-combustion-chamber)
12. «Coolant in Engine Oil»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__coolant-in-engine-oil)
13. «Displacement on Demand (DoD) System Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-system-diagnosis)
14. «Engine Compression Test»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-compression-test)
15. «Displacement on Demand (DoD) System Compression Test»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-system-compression)
16. «Cylinder Leakage Test»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-leakage-test)
17. «Oil Consumption Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-consumption-diagnosis)
18. «Oil Pressure Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pressure-diagnosis-and-testing)
19. «Displacement on Demand (DoD) Oil Pressure Relief Valve Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-oil-pressure)
20. «Displacement on Demand (DoD) Valve Lifter Oil Manifold Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-valve-lifter)
21. «Oil Leak Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-leak-diagnosis)
22. «Drive Belt Chirping Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
23. «Drive Belt Squeal Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
24. «Drive Belt Whine Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
25. «Drive Belt Rumbling Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
26. «Drive Belt Vibration Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
27. «Drive Belt Falls Off Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
28. «Drive Belt Excessive Wear Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)
29. «Drive Belt Tensioner Diagnosis»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l)

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Upper Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Engine Noise Under Load

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Displacement on Demand (DoD) System Diagnosis

1. Check the engine oil level. Fill, as required.
2. Using the scan tool, check for diagnostic codes within the engine control module (ECM). Refer to «Diagnostic System Check - Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information. Repair, as required.
3. Verify proper engine oil pressure and operation of the displacement on demand (DoD) oil pressure relief valve. Refer to «Oil Pressure Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pressure-diagnosis-and-testing) .
4. Verify proper operation of the DoD system components. Refer to «Displacement on Demand (DoD) System Compression Test»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-system-compression) .
5. Remove the valve lifter oil manifold (VLOM). Refer to «Valve Lifter Oil Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
6. Verify proper operation of the VLOM. Refer to «Displacement on Demand (DoD) Valve Lifter Oil Manifold Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-valve-lifter) .
7. Replace the DoD valve lifters, as required. Both intake and exhaust lifters should be replaced in pairs. Refer to «Valve Lifter Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Engine Compression Test

1. Charge the battery if the battery is not fully charged.
2. Disable the ignition system.
3. Disable the fuel injection system.
4. Remove all spark plugs.
5. Turn the ignition to the ON position.
6. Depress the accelerator pedal to position the throttle plate wide open.
7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs.
8. Check the compression for each cylinder. Record the readings.
9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders.

Displacement on Demand (DoD) System Compression Test

The Displacement on Demand (DoD) System Compression Test is a functional test of the valve lifter oil manifold (VLOM) and valve lifters. Using a compression gage, the technician can monitor the specific cylinders ability to go into and out of DoD as commanded by the scan tool. The actual pressure values on the compression gage are not as critical as is observing the on-off switching action of the solenoid and valve lifters.

1. Measure the engine oil level. Fill, as required.
2. Perform the Diagnostic System Check - Vehicle. Refer to «Diagnostic System Check - Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information.
3. Disable the ignition system for the cylinder to be tested, by disconnecting the electrical wire harness to the ignition coil.
4. Disable the fuel injection system for the cylinder to be tested, by disconnecting the electrical wire harness to the fuel injector.
5. Remove the spark plug and wire for the cylinder to be tested.
6. Install a 0-1378 kPa (0-200 psi) compression gage.
7. Start the engine.
8. Using the scan tool output controls, command the solenoid ON, for the cylinder to be deactivated.
9. Depress the Schrader valve on the compression gage in order to release the pressure and zero the gage. With the engine running and the cylinder in DoD mode, the compression reading should be less than 172 kPa (25 psi).
10. Using the scan tool, de-energize the solenoid while observing the reading on the compression gage. With the engine running and the cylinder NOT in DoD mode, the compression gage reading should increase quickly to greater than 345 kPa (50 psi).
11. Test each of the 4 DoD cylinders, 1 at a time. If the readings are not within specifications, remove and test the VLOM, as required. Refer to «Valve Lifter Oil Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) and «Displacement on Demand (DoD) Valve Lifter Oil Manifold Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-valve-lifter) .
12. If the compression test has been performed and all DoD cylinders are operating within specifications, the DoD system is performing as designed and no repairs are required.
13. Clear the DTCs with a scan tool.

Cylinder Leakage Test

Tools Required

J 35667-A Cylinder Head Leakdown Tester, or equivalent

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) in Engine Controls - 5.3L.
3. Rotate the crankshaft to place the piston in the cylinder being tested at top dead center (TDC) of the compression stroke.
4. Install the J 35667-A , or equivalent.
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage noise at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage noise at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage noise from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Tools Required

1. J 21867 Pressure Gage. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 42907 Oil Pressure Tester. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-3 minutes, and measure the oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following conditions: Oil diluted by water or glycol antifreeze Refer to «Coolant in Engine Oil»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__coolant-in-engine-oil) . Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the J 42907 (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Install J 21867 (2) or equivalent to the J 42907 (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: Oil pump worn or dirty Refer to «Oil Pump Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pump-cleaning-and-inspection) . Oil pump-to-engine block bolts loose Refer to «Oil Pump, Screen and Crankshaft Oil Deflector Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pump-screen-and-crankshaft-oil) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure relief valve Excessive bearing clearance Cracked, porous, or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Plug Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-block-plug-installation) . Improper operation of the Displacement on Demand (DoD) oil pressure relief valve Refer to «Displacement on Demand (DoD) Oil Pressure Relief Valve Diagnosis and Testing»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__displacement-on-demand-dod-oil-pressure) .

Displacement on Demand (DoD) Oil Pressure Relief Valve Diagnosis and Testing

Tools Required

1. J-21867-16 Oil Pressure Adapter. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 21867 Pressure Gage. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 42907 Oil Pressure Testing Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the oil filter and install the J 42907 (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Install J 21867 (2) or equivalent to the J 42907 (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Remove the oil pressure sensor and install the J-21867-16 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Install J 21867 (1) or equivalent to the J-21867-16 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Run the engine and measure the engine oil pressure while observing both gages. Operate the throttle as required to increase and decrease the engine oil pressure. With the engine running and the lower pressure gage (2) measuring below 448 kPa (65 psi), both gages should display the same pressure reading. If the readings are not the same and the lower pressure gage (2) has a higher reading, the oil pressure relief valve is stuck in the open position or the valve lifter oil manifold filter is plugged. With the engine running and the lower pressure gage (2) measuring above 448 kPa (65 psi), the upper gage (1) should display no greater than 448 kPa (65 psi). If the reading on the upper pressure gage (1) is greater than 448 kPa (65 psi), the oil pressure relief valve is stuck in the closed position.
6. Repair as required.

Displacement on Demand (DoD) Valve Lifter Oil Manifold Diagnosis and Testing

Tools Required

1. EN-46999 Displacement-on-Demand Tester. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. EN-46999-1 Displacement-on-Demand Tester Air Adapter. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. EN-46999-5 Displacement-on-Demand Tester Harness - Small Block V8. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Scheme 47

The manifold bench test provides a maximum 206 kPa (30 psi) of filtered shop air to the manifold and will test each solenoid/valve for the following conditions

1. Proper operation
2. A stuck open condition - constant air flow
3. A stuck closed condition - no air flow
4. A flow restriction within the manifold

1. Individually depress each of the buttons 1-4 on the EN-46999 in order to activate each of the solenoid/valves. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . When activating each solenoid/valve, a loud click should be heard from the solenoid and an increased amount of air will exit the outlet ports. Button 1 will energize the solenoid/valve 1 for engine cylinder number 1. Button 2 will energize the solenoid/valve 2 for engine cylinder number 4. Button 3 will energize the solenoid/valve 3 for engine cylinder number 6. Button 4 will energize the solenoid/valve 4 for engine cylinder number 7.
2. Do not lift the manifold assembly by the electrical lead frame.
3. Install the EN-46999-1 (1) to the manifold. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Install 2 of the manifold bolts (2) to the EN-46999-1 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Connect the air out hose (2) of the EN-46999 (5) to the EN-46999-1 (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Verify the air supply switch (4) is in the off position.
6. Connect the air in hose (6) of the EN-46999 (5) to a shop air source. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Connect the 12 volt power supply connectors (7) of the EN-46999 (5) to a 12 volt power supply. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Verify the Power light (8) on the tool is illuminated. If the light on the tool is not illuminated when connected to a 12 volt power supply, test and/or replace the 3 amp fuse.
8. Connect the EN-46999-5 power cable (3) to the electrical connector of the manifold. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Turn the air supply switch of the EN-46999 to the ON position. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . With the air supply connected to the manifold assembly and the solenoid/valves in the closed position, a limited amount of air will exit each of the bleed holes (3) and outlet ports (1, 2) of the manifold.
10. Position the manifold assembly onto a bench at a 45 degree angle in order to test solenoid/valves 1 and 4.
11. Depress button number 1 on the tool to activate solenoid/valve 1. With button 1 depressed, the solenoid/valve (1) should open, allowing an increased amount of air to exit the outlet ports (2) of the manifold.
12. Depress button number 4 on the tool to activate solenoid/valve 4. With button 4 depressed, the solenoid/valve (4) should open, allowing an increased amount of air to exit the outlet ports (3) of the manifold.
13. Reposition the manifold assembly onto a bench at a 45 degree angle in order to test solenoid/valves 2 and 3.
14. Depress button number 2 on the tool to activate solenoid/valve 2. With button 2 depressed, the solenoid/valve (2) should open, allowing an increased amount of air to exit the outlet ports (4) of the manifold.
15. Depress button number 3 on the tool to activate solenoid/valve 3. With button 3 depressed, the solenoid/valve (3) should open, allowing an increased amount of air to exit the outlet ports (1) of the manifold.
16. When the test is completed, turn the air source switch on the EN-46999 to the off position and disconnect the tool from the 12-volt power supply, shop air source and manifold assembly. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
17. If after testing, it has been determined that 1 or more of the solenoid/valves is not functioning properly, replace the manifold as an assembly.
18. If after testing, it has been determined that the solenoid/valves are functioning properly, replace the valve lifters, as required. Both intake and exhaust lifters should be replaced in pairs.

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

Diagnostic Aids

The chirping noise may be intermittent due to moisture on the drive belts or the accessory drive pulleys. In order to duplicate the customer concern, it may be necessary to spray a small amount of water onto the drive belts. If spraying water onto the drive belts duplicates the symptom, cleaning the accessory drive pulleys may be the most probable solution.

A loose or improper installation of a body or suspension component, or other items on the vehicle may also cause the chirping noise.

Test Description

The numbers below refer to the steps in the diagnostic table.

1. 2: The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table.
2. 3: The noise may be an internal engine noise. Remove the drive belts and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belts or not. With the drive belts removed the water pump will not operate and the engine may overheat. Also DTCs may set when the engine is operated with the drive belts removed.
3. 4: Inspect the drive belts for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust.
4. 6: Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley.
5. 10: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed.
6. 12: Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belts from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley.
7. 14: Replacing the drive belts when it is not damaged or there is not excessive pilling will only be a temporary repair.

Drive Belt Chirping Diagnosis

A loose or improper installation of a body, or suspension component, or other items on the vehicle may cause the squeal noise.

If the squeal is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect.

The numbers below refer to the steps in the diagnostic table.

1. 2: The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table
2. 3: The squeal may be an internal engine noise. Remove the drive belts and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belts or an accessory drive component. With the drive belts removed the water pump will not operate and the engine may overheat. Also, DTCs may set when the engine is operated with the drive belts removed.
3. 4: This test is to verify that an accessory drive components does not have a seized bearing. With the belts removed, test the bearings in the accessory drive components for smooth operation. Also test the accessory drive components with the engine operating by varying the load on the accessory drive components to verify that the components is operating properly.
4. 5: This test is to verify that the drive belts tensioners are not operating properly. If the drive belt tensioners are not operating properly, proper belt tension may not be achieved to keep the drive belts from slipping which could cause a squealing noise.
5. 6: This test is to verify that the drive belts is not too long, which would prevent the drive belt tensioners from operating properly. Also if the incorrect length drive belts was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction.
6. 7: Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley.
7. 8: Inspect the accessory drive pulleys to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys.

Drive Belt Squeal Diagnosis

The drive belts will not cause the whine.

If the whine is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged A/C system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect.

The numbers below refer to the steps in the diagnostic table.

1. 3: This test is to verify that the whine is being caused by the accessory drive components. Remove the drive belts and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belts removed the water pump will not operate and the engine may overheat. Also DTCs may set when the engine is operated with the drive belts removed.
2. 4: This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belts may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure.

Drive Belt Whine Diagnosis

Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise.

The drive belts may have a condition that can not be seen or felt. Sometimes replacing the drive belts may be the only repair for the symptom.

If after replacing the drive belts and completing the diagnostic table, the rumbling is only heard with the drive belts installed, there might be an accessory drive component failure. Varying the load on the accessory drive components may aid in identifying which component is causing the rumbling noise.

The numbers below refer to the steps in the diagnostic table.

1. 2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
2. 3: This test is to verify that the drive belts is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belts or not. With the drive belts removed the water pump will not operate and the engine may overheat. Also DTCs may set when the engine is operated with the drive belts removed.
3. 4: Inspect the drive belts to ensure that the drive belts is not the cause of the noise. Small cracks across the ribs of the drive belts will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt.
4. 5: Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belts does not have a smooth surface for proper operation.

Drive Belt Rumbling Diagnosis

The accessory drive components may have an affect on engine vibration. An overcharged A/C system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The numbers below refer to the step numbers in the diagnostic table.

1. 2: This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain.
2. 3: This test is to verify that the drive belts or accessory drive components may be causing the vibration. Remove the drive belts and operate the engine for a few seconds, this will verify if the vibration is related to the drive belts or not. With the drive belts removed the water pump will not operate and the engine may overheat. Also DTCs may set when the engine is operated with the drive belts removed.
3. 4: The drive belts may cause a vibration. While the drive belts is removed this is the best time to inspect the condition of the drive belts.
4. 6: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed.
5. 8: This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange.
6. 9: Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump.
7. 10: Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate.

Drive Belt Vibration Diagnosis

If the drive belts repeatedly falls off the accessory drive pulleys, this may be caused by a pulley misalignment.

An extra load that is quickly applied or released by an accessory drive component may also cause the drive belts to fall off. Verify that the accessory drive components are operating properly.

If the drive belts is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belts.

The numbers below refer to the steps in the diagnostic table.

1. 2: This inspection is to verify the condition of the drive belts. Damage may have occurred to the drive belts when the drive belts fell off the pulley. Inspect the drive belts for cuts, tears, sections of ribs missing, or damaged belt plys.
2. 4: Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley.
3. 5: Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belts is used to drive the pulley.
4. 6: Accessory drive component brackets that are bent or cracked will also cause the drive belts to fall off.
5. 7: Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive brackets moving under load. Over tightening the fasteners may cause misalignment of the accessory component brackets.

Drive Belt Falls Off Diagnosis

Excessive wear on a drive belts is usually caused by incorrect installation or the incorrect drive belts for the application.

Minor misalignment of the accessory drive pulleys will not cause excessive wear, but will probably cause the drive belts to make a noise or fall off.

Excessive misalignment of the accessory drive pulleys will cause excessive wear and may also make the drive belts fall off.

The numbers below refer to the steps in the diagnostic table.

1. 2: This inspection is to verify that the drive belts is correctly installed on all of the accessory drive pulleys. Wear on the drive belts may be caused by mispositioning the drive belts by one or more grooves on a pulleys.
2. 3: The installation of a drive belts that is too wide or too narrow will cause wear on the drive belts. The drive belts ribs should match all of the grooves on the pulleys.
3. 4: This inspection is to verify that the drive belts is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belts should not come in contact with an engine or a body component when snapping the throttle.

Drive Belt Excessive Wear Diagnosis

Scheme 48

1. Remove the drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Move the drive belt tensioner through its full travel. The movement should feel smooth. There should be no binding. The tensioner should return freely.
3. If any binding is observed, replace the drive belt tensioner. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
4. Install the drive belt. Refer to of «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Tools Required

EN-47988 Serpentine Belt Tension Unloader. See Special Tools .

Removal Procedure

1. Using the EN-47988 , rotate the drive belt tensioner clockwise in order to relieve tension on the drive belt. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Remove the drive belt from the drive belt tensioner and pulleys.
3. Slowly release the tension on the drive belt tensioner.
4. Clean and inspect the belt surfaces of the pulleys.

Installation Procedure

1. Route the drive belt around all the pulleys except the idler pulley.
2. Using the EN-47988 , rotate the drive belt tensioner clockwise in order to relieve the tension on the drive belt tensioner. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Install the drive belt under the idler pulley.
4. Slowly release the tension on the belt tensioner.
5. Inspect the drive belt for proper installation and alignment.

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Loosen the necessary drive belt idler pulley bolt.
3. Remove the necessary drive belt idler pulley.

1. Position the necessary drive belt idler pulley to the coolant manifold and/or generator bracket.
2. Tighten the necessary drive belt idler pulley bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the power steering gear inlet hose retainer bolt (2).
4. Remove the drive belt tensioner bolts.
5. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the power steering gear inlet hose retainer bolt (2). Tighten: Tighten the bolt to 9 N.m (80 lb in).
4. Lower the vehicle.
5. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Engine Support Fixture

Tools Required

1. J 28467-B Universal Engine Support Fixture
2. J 28467-501 Engine Support Fixture Adapters. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 42451-1 Engine Support Adapter. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the left bank ignition coils. Refer to «Ignition Coil(s) Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
2. Install J 42451-1 bracket onto the left front of engine. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Install the J 28467-501 (1, 7) onto fender rails near the strut towers. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Install the J 28467-3 cross car tube (2) to the J 28467-501 (1, 7). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Install the J 28467-2A radiator shelf tube on top of the J 28467-3 cross car tube (2) over the J 42504 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Install the round tube of the J 28467-4A front support assembly (4) through the large hole in the J 28467-2A radiator shelf tube. The hole used in the J 28467-2A radiator shelf tube (5) depends on the vehicle application.
7. Place the rubber padded foot of the J 28467-4A front support assembly on the upper tie bar.
8. Install the J 28467-9 7/16-inch x 2.0-inch quick release pin through the hole in the J 28467-4A front support assembly in order to level the J 28467-2A radiator shelf tube.
9. Install the J 28467-7A lift hook through the J 28467-6A lift hook bracket (5).
10. Install the J 28467-6A assembled lift hook bracket (6) over the J 28467-3 strut tower tube (2).

Inspection Procedure

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
2. Raise the engine in order to remove the weight from the engine mount and to create slight tension in the rubber.
3. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any of the following conditions: The hard rubber surface is covered with heat check cracks. The rubber is separated from the metal plate of the engine mount. The rubber is split through the center of the engine mount.
4. If there is movement between the metal plate of the engine mount and its attaching points, lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine mount bracket.
5. For information on the transaxle mount, refer to «Transmission Mount Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2__transmission-mount-inspection) in Automatic Transaxle - 4T65-E.

1. Remove the forward engine mount strut bolt (3) and nut (1).
2. Remove the rear engine mount strut bolt (4) and nut (5).
3. Remove the engine mount strut (2).
4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking
5. If necessary, remove the engine mount strut bracket bolts (body side).
6. If necessary, remove the engine mount strut bracket (body side).
7. Remove the heater pipe bracket bolt from the engine mount.
8. If necessary, remove the engine mount strut bracket bolts (engine side).
9. If necessary, remove the engine mount strut bracket (engine side).

1. If necessary, position the engine mount strut bracket (engine side) to the cylinder head.
2. If necessary, install the engine mount strut bracket bolts (engine side). Tighten: Tighten the bolts to 48 N.m (35 lb ft).
3. Install the heater pipe bracket bolt. Tighten: Tighten the bolt to 16 N.m (12 lb ft).
4. If necessary, position the engine mount strut bracket (body side) to the vehicle.
5. If necessary, install the engine mount strut bracket bolts (body side). Tighten: Tighten the bolt to 48 N.m (35 lb ft).
6. Install the engine mount strut (2).
7. Install the rear engine mount strut bolt (4) and nut (5). Tighten: Tighten the bolt/nut to 48 N.m (35 lb ft).
8. Install the forward engine mount strut bolt (3) and nut (1). Tighten: Tighten the bolt/nut to 48 N.m (35 lb ft).

1. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
3. Remove the upper engine mount nuts.
4. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
5. Using the engine support fixture, raise the engine.
6. Remove the engine mount bracket bolts.
7. Remove the engine mount bracket.
8. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the lower engine mount nuts.
10. Remove the engine mount.
11. Remove the engine mount heat shield, if necessary.

1. Install the engine mount heat shield, if necessary.
2. Install the engine mount to the engine.
3. Install the lower engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Lower the vehicle.
5. Install the engine mount bracket.
6. Install the engine mount bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
7. Using the engine support fixture, lower the engine.
8. Remove the engine support fixture.
9. Install the upper engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
10. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
11. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
3. Remove the upper engine mount nuts.
4. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
5. Using the engine support fixture, raise the engine.
6. Remove the engine mount bracket bolts.
7. Remove the engine mount bracket.

1. Install the engine mount bracket.
2. Install the engine mount bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Using the engine support fixture, lower the engine.
4. Remove the engine support fixture.
5. Install the upper engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
6. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
7. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
3. Remove the upper engine mount nuts.
4. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
5. Using the engine support fixture, raise the engine.
6. Remove the engine mount bracket bolts.
7. Remove the engine mount bracket.
8. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the lower engine mount nuts.
10. Remove the engine mount.

1. Install the engine mount.
2. Install the lower engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Lower the vehicle.
4. Install the engine mount bracket.
5. Install the engine mount bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
6. Using the engine support fixture, lower the engine.
7. Remove the engine support fixture.
8. Install the upper engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
9. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
10. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
3. Remove the upper engine mount nuts.
4. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
5. Using the engine support fixture, raise the engine.
6. Remove the engine mount bracket bolts.
7. Remove the engine mount bracket.

1. Install the engine mount.
2. Install the lower engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Using the engine support fixture, lower the engine.
4. Remove the engine support fixture.
5. Install the upper engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
6. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
7. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Pull up on the front and rear of the sight shield in order to disengage sight shield from the studs.
2. Remove the engine sight shield from the vehicle.

1. Align the sight shield to the studs on the intake manifold.
2. Push down in the 3 locations in order to secure the sight shield to the studs.

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. If removing the positive crankcase ventilation (PCV) clean air tube perform the following: Remove the PCV clean air tube from the air intake duct. Remove the PCV clean air tube from the rocker arm cover. Remove the PCV clean air tube.
3. If removing the PCV foul air tube perform the following: Remove the PCV foul air tube from the intake manifold. Remove the PCV foul air tube from the rocker arm cover. Remove the PCV foul air tube.

1. If installing the PCV foul air tube perform the following: Install the PCV foul air tube. Install the PCV foul air tube to the rocker arm cover. Install the PCV foul air tube to the intake manifold.
2. If installing the PCV clean air tube perform the following: Install the PCV clean air tube. Install the PCV clean air tube to the rocker arm cover. Install the PCV clean air tube to the air intake duct.
3. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Remove the oil pressure sensor (706) and washer (707).
4. Remove the oil filter (452) and O-ring seal (454).
5. Inspect the O-ring seal (454) for cuts or damage.
6. If the filter is plugged or the O-ring seal is cut or damaged, replace the filter and O-ring seal as an assembly.

1. Install a NEW oil filter (452) and O-ring seal (454).
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the NEW oil pressure sensor.
3. Install the oil pressure sensor (706) and washer (707). Tighten: Tighten the sensor to 20 N.m (15 lb ft).
4. Connect the oil pressure sensor electrical connector (4).
5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
2. Remove the fuel injectors. Refer to «Fuel Injector Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
3. Remove the brake booster vacuum hose (1) from the intake manifold (2) and the booster check valve (3).
4. Remove the positive crankcase ventilation (PCV) clean air tube from the air intake duct and valve rocker arm cover. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
5. Remove the PCV foul air tube from the intake manifold and valve rocker arm cover. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
6. Remove the evaporative emission (EVAP) purge solenoid tube (2) from the solenoid and reposition. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
7. Disconnect the following electrical connectors: EVAP purge solenoid (1) Manifold absolute pressure (MAP) sensor (2) Oil pressure sensor (4) Valve lifter oil manifold (5)
8. Remove the MAP sensor (714) from the intake manifold.
9. Remove the EVAP purge solenoid valve and bracket.
10. Remove the intake manifold bolts (512).
11. Remove the intake manifold (500).
12. Remove and discard the intake manifold gaskets (514).

1. Install the NEW intake manifold gaskets (514).
2. Install the intake manifold (500).
3. Apply a band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the intake manifold bolts (512).
4. Install the intake manifold bolts. Tighten: Tighten the bolts a first pass in sequence to 5 N.m (44 lb in). Tighten the bolts a first pass in sequence to 10 N.m (89 lb in).
5. Install the EVAP purge solenoid bracket and solenoid.
6. Install the MAP sensor (714) to the intake manifold.
7. Connect the following electrical connectors: EVAP purge solenoid (1) MAP sensor (2) Oil pressure sensor (4) Valve lifter oil manifold (5)
8. Position and install the EVAP purge solenoid tube (2) to the solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
9. Install the PCV foul air tube to the intake manifold and valve rocker arm cover. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
10. Install the PCV clean air tube to the air intake duct and valve rocker arm cover. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
11. Install the brake booster vacuum hose (1) to the intake manifold (2) and the booster check valve (3).
12. Install the fuel injectors. Refer to «Fuel Injector Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
13. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Do not lift the manifold assembly by the electrical lead frame.
3. Remove the valve lifter oil manifold bolts (506).
4. Remove the valve lifter oil manifold (451).
5. Identify the 8 gasket retaining strap locations (1-8).
6. Using a wire-cutter type tool, snip the 8 retaining straps of the outer gasket.
7. Remove the outer gasket (556) from the manifold.

1. Do not lift the manifold assembly by the electrical lead frame.
2. Install the outer gasket (556) onto the manifold.
3. Install the valve lifter oil manifold (451).
4. Install the valve lifter oil manifold bolts (506). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Install the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine sight shield, if required. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the connector position assurance (CPA) retainer (3).
3. Disconnect the ignition coil main electrical connector (4).
4. Reposition the engine harness, as necessary.
5. Remove the spark plug wires (724) from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
6. Remove the ignition coil bracket bolts (720).
7. Remove the ignition coil and bracket assembly (719).
8. Remove the positive crankcase ventilation (PCV) clean air tube from the valve rocker arm cover.
9. Remove the valve rocker arm cover bolts and cover.
10. Remove and discard the old the gasket (504) from the valve rocker arm cover.
11. Remove the valve rocker arm cover bolt grommets, if cut or damaged.
12. Remove the oil fill cap from the oil fill tube, if necessary.
13. Remove the oil fill tube, if necessary.
14. Discard the oil fill tube, if necessary.

1. Install a NEW gasket (504) into the groove of the valve rocker arm cover.
2. Install a NEW oil fill tube to the valve rocker arm cover, if necessary.
3. Install NEW valve rocker arm cover bolt grommets, if necessary.
4. Install the valve rocker arm cover and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Remove the positive crankcase ventilation (PCV) clean air tube from the valve rocker arm cover.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bracket bolts.
7. Install the ignition coil and bracket assembly.
8. Install the ignition coil bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
9. Install the spark plug wires (724) to the ignition coils.
10. Position the engine harness, as necessary.
11. Connect the ignition coil main electrical connector (4).
12. Install the CPA retainer (3).
13. Install the engine sight shield, if required. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine sight shield, if required. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the connector position assurance (CPA) retainer (3).
3. Disconnect the ignition coil main electrical connector (4).
4. Reposition the engine harness, if necessary.
5. Remove the spark plug wires (724) from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
6. Remove the ignition coil bracket bolts (720).
7. Remove the ignition coil and bracket assembly (719).
8. Remove the positive crankcase ventilation (PCV) foul air hose from the intake manifold and valve rocker arm cover.
9. Remove the valve rocker arm cover bolts and cover.
10. Remove and discard the old the gasket (504) from the valve rocker arm cover.
11. Remove the valve rocker arm cover bolt grommets, if cut or damaged.

1. Install a NEW gasket (504) into the groove of the valve rocker arm cover.
2. Install NEW valve rocker arm cover bolt grommets, if necessary.
3. Install the valve rocker arm cover and bolts.
4. Install the rocker arm cover bolts and grommets. Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Install the PCV foul air hose to the intake manifold and valve rocker arm cover.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bracket bolts.
7. Install the ignition coil and bracket assembly (719).
8. Install the ignition coil bracket bolts (720). Tighten: Tighten the bolts to 12 N.m (106 lb in).
9. Install the spark plug wires (724) from the ignition coils.
10. Position the engine harness, if necessary.
11. Connect the ignition coil main electrical connector (4).
12. Install the CPA retainer (3).
13. Install the engine sight shield, if required. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) and/or «Valve Rocker Arm Cover Replacement - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the valve rocker arm bolt.
3. Remove the valve rocker arm.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrod.
6. Clean and inspect the valve rocker arm and pushrod. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-and-push-rods) .

1. Lubricate the valve rocker arm and pushrod with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolt with clean engine oil.
3. Install the valve rocker arm pivot support.
4. Install the pushrod.
5. Install the rocker arm and bolt.
6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5, and 7 are the left bank. Cylinder 2, 4, 6, and 8 are the right bank.
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 1, 2, 7, and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 1, 3, 4, and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 3, 4, 5, and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 2, 6, 7, and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) and/or «Valve Rocker Arm Cover Replacement - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 38606 Valve Spring Compressor. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Loosen the spark plug 1 or 2 turns.
3. Brush or air blast away any dirt or debris from around the spark plug.
4. Remove the spark plug.
5. Install the J 22794 into the spark plug hole. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Attach an air hose to the J 22794 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Apply compressed air to the J 22794 in order to hold the valves in place. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Using the J 38606 compress the valve spring. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Remove the valve stem keys (225).
10. Using the J 38606 carefully release the valve spring tension. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
11. Remove the J 38606 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
12. Remove the valve spring cap (224).
13. Remove the valve spring (223).
14. Remove the valve stem oil seal (222).

1. Clean the cylinder head valve spring seat and area.
2. Install the valve stem oil seal (222).
3. Install the valve spring (223).
4. Install the valve spring cap (224).
5. Compress the valve spring using the J 38606 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. Make sure the keys seat properly in the groove of the valve stem. Using the J 38606 carefully release the valve spring tension, making sure the valve stem keys stay in place. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Remove the J 38606 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary.
7. Remove the compressed air supply from the J 22794 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Remove the J 22794 from the spark plug port. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Hand start the spark plug. Tighten: Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the oil level indicator (418) from the tube.
2. Remove the oil level indicator tube bolt (419).
3. Remove the oil level indicator tube (420) from the engine block.
4. Remove the O-ring seal from the tube, if necessary.

1. Lubricate the O-ring seal with clean engine oil.
2. Install the O-ring seal onto the oil level indicator tube, if necessary.
3. Install the oil level indicator tube (420) to the engine block. The tube must be installed with the collar flush to the block.
4. Install the oil level indicator tube bolt (419) Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator (418) to the tube.

Cylinder Head Replacement - Left

Tools Required

1. J 42385-100 Head/Main Bolt Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 42385-200 Common Threads Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 45059 Torque Angle Meter

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
4. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
5. Remove the power steering pump pulley. Refer to «Power Steering Pulley Replacement (3.8L V6)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement-38l-v6) or «Power Steering Pulley Replacement (5.3L V8)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement-53l-v8) .
6. Remove the 3 coolant manifold bolts to the cylinder head.
7. Remove the engine mount strut and bracket. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
8. Remove and discard the cylinder head bolts (220, 221).
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket (217).
11. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-cleaning-and-inspection) .

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

1. Clean the cylinder head bolt holes, if required. J 42385-100 can be used to clean the threads of old threadlocking material. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Clean the engine block bolt holes, if required. J 42385-200 can be used to clean the threads of old threadlocking material. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Use spray cleaner GM P/N 12346139 or P/N 12377981, (Canadian P/N 10953463), or equivalent into the hole.
4. Clean the cylinder head bolt holes with compressed air.
5. Check the cylinder head locating pins for proper installation.
6. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head onto the locating pins.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees using J 45059 . Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees using J 45059 . Tighten the M8 bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
11. Install the engine mount strut and bracket. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
12. Install the 3 coolant manifold bolts to the cylinder head. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Install the power steering pump pulley. Refer to «Power Steering Pulley Replacement (3.8L V6)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement-38l-v6) or «Power Steering Pulley Replacement (5.3L V8)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement-53l-v8) .
14. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
15. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
16. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Install the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Cylinder Head Replacement - Right

Tools Required

1. J 42385-100 Head/Main Bolt Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 42385-200 Common Threads Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 45059 Torque Angle Meter

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the generator bracket. Refer to «Generator Bracket Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
5. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
6. Remove and discard the cylinder head bolts (220, 221).
7. Remove the cylinder head (217).
8. Remove and discard the cylinder head gasket (217).
9. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-cleaning-and-inspection) .

Note. Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

1. Clean the cylinder head bolt holes, if required. J 42385-100 can be used to clean the threads of old threadlocking material. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Clean the engine block bolt holes, if required. J 42385-200 can be used to clean the threads of old threadlocking material. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Use spray cleaner GM P/N 12346139 or P/N 12377981, (Canadian P/N 10953463), or equivalent into the hole.
4. Clean the cylinder head bolt holes with compressed air.
5. Check the cylinder head locating pins for proper installation.
6. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (217) onto the locating pins.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees using J 45059 . Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees using J 45059 . Tighten the M8 bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
11. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
12. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
13. Install the generator bracket. Refer to «Generator Bracket Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
14. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
15. Install the intake manifold. Refer to «Intake Manifold Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

J 3049-A Valve Lifter Remover. See Special Tools .

1. Remove the cylinder head. Refer to «Cylinder Head Replacement - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-replacement-left) and/or «Cylinder Head Replacement - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-replacement-right) .
2. Remove the lifter guide bolts (211).
3. Remove the lifter guides (210) with lifters.
4. Use the J 3049-A or equivalent in order to remove the valve lifters, if necessary. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Remove the valve lifters (209, 219) from the guide (210).
6. Organize or mark the components so that they can be installed in the same location from which they were removed. The displacement on demand lifters are installed into the guide by aligning the notched area of the guide (1) with the raised surface on the side of the lifter (2).
7. Clean and inspect the valve lifters. Refer to «Valve Lifters and Guides Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides (210). Align the flat area (3) on the top of the non-displacement on demand lifter with the flat area in the lifter guide bore. The displacement on demand lifters are to be installed into the guide, with the notch in the guide (2) of the lifter.
3. Install the valve lifter guides (210) with lifters to the engine block.
4. Install the valve lifter guide bolts (211). Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Install the cylinder head. Refer to «Cylinder Head Replacement - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-replacement-left) and/or «Cylinder Head Replacement - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-replacement-right) .

Crankshaft Balancer Replacement

Tools Required

1. EN 47699 Flywheel Holding Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 41816 Crankshaft Balancer Remover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. J 41816-2 Crankshaft End Protector. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. J 42640 Steering Column Anti-Rotation Pin. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. J 45059 Torque Angle Meter

1. Install a J 42640 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Refer to «Steering Column Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/steering-column-switches/#steering-wheel-and-steering-column__steering-column-replacement) .
2. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Remove the air cleaner upper housing. Refer to «Air Cleaner Assembly Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
4. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
5. Remove the starter motor. Refer to «Starter Motor Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
6. Remove the front fender splash shield. Refer to «Splash Shield Replacement - Engine»(/pontiac/grand-prix/vii-2004-2008/remont/exterior-body-panels/#body-front-end) .
7. Remove the transmission bellhousing bolt located at approximately the 10 o'clock position when looking from the rear of the engine.
8. Disconnect the transaxle cooler lines at the transaxle. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) .
9. Remove the stabilizer shaft link lower nuts. Refer to «Stabilizer Shaft Link Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
10. Remove the intermediate steering shaft pinch bolt and separate the shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/steering-column-switches/#steering-wheel-and-steering-column) .
11. Remove the front lower air deflector braces and the deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Remove the radiator to frame braces.
13. Install the engine support fixture. Refer to «Engine Support Fixture»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-support-fixture) .
14. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
15. Remove the frame to body bolts.
16. Install the EN 47699 and bolt to the block and flywheel. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the bolt to 60 N.m (44 lb ft).
17. Remove the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/pontiac/grand-prix/vii-2004-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
18. Lower the engine approximately 100 mm (4 in).
19. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
20. Install the J 41816 (1) and the J 41816-2 (2), to the crankshaft balancer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
21. Remove the crankshaft balancer (138).
22. Remove the J 41816 and the J 41816-2 from the crankshaft balancer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Position the crankshaft balancer (138) onto the end of the crankshaft.
2. Using the J 41665 , install the crankshaft balancer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tool.
3. Install the USED crankshaft balancer bolt (139). Tighten: Tighten the USED bolt to 330 N.m (240 lb ft).
4. Remove the USED crankshaft balancer bolt.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Install a NEW crankshaft balancer bolt (139). Tighten: Tighten the bolt a first pass to 50 N.m (37 lb ft). Tighten the bolt a second pass to 140 degrees using J 45059 .
7. Remove the EN 47699 and bolt from the block and flywheel. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Install the transmission bellhousing bolt located at approximately the 10 o'clock position when looking from the rear of the engine. Tighten: Tighten the bolt to 75 N.m (55 lb ft).
9. Raise and properly position the frame and install the frame to body bolts. Refer to «Frame Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
10. Install the frame to radiator braces.
11. Install the front lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Connect the intermediate steering shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/steering-column-switches/#steering-wheel-and-steering-column) .
13. Install the stabilizer shaft link lower nuts. Refer to «Stabilizer Shaft Link Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
14. Connect the transaxle cooler lines to the transaxle. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) .
15. Remove the engine support fixture.
16. Install the front fender splash shield. Refer to «Splash Shield Replacement - Engine»(/pontiac/grand-prix/vii-2004-2008/remont/exterior-body-panels/#body-front-end) .
17. Install the starter motor. Refer to «Starter Motor Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
18. Install the air cleaner upper housing. Refer to «Air Cleaner Assembly Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
19. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
20. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
21. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/pontiac/grand-prix/vii-2004-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
22. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2__ckp-system-variation-learn-procedure) .

J 41478 Crankshaft Front Oil Seal Installer. See Special Tools .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-balancer-replacement) .
2. Remove and discard the crankshaft oil seal (140).

1. Lubricate the outer edge of the oil seal (140) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal (140) onto the J 41478 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Install the J 41478 threaded rod with nut, washer, guide, and oil seal into the end of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Using the J 41478 , install the oil seal into the cover bore. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Use a wrench and hold the hex on the installer bolt. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Remove the J 41478 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.
6. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-balancer-replacement) .

J 41476 Front and Rear Cover Alignment (at crankshaft seal area). See Special Tools .

1. Remove the generator. Refer to «Generator Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Remove the power steering pump. Refer to «Power Steering Pump Replacement (3.8L V6)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (5.3L V8)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) in Power Steering System.
3. Remove the coolant pump manifold. Refer to «Coolant Pump Manifold Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
4. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-balancer-replacement) .
5. Remove the belt tensioner bolt and reposition the tensioner (which blocks the front cover bolt).
6. Remove the oil pan-to-front cover bolts.
7. Remove the front cover bolts (501).
8. Remove the front cover (502) and gasket (503).
9. Discard the front cover gasket.
10. Remove the oil seal (140), if necessary.
11. Remove the camshaft position (CMP) sensor bolt (705) and sensor (703), if necessary.
12. Remove the O-ring seal (704) from the sensor, if necessary.
13. Clean and inspect the engine front cover. Refer to «Engine Front Cover Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-front-cover-cleaning-and-inspection) .

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378577 or 12346141 (Canadian P/N 89022195) or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction.
2. Install the front cover gasket (503) and cover (502).
3. Install the front cover bolts until snug (502). Do not overtighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.
5. Install the J 41476 to the front cover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Install the crankshaft balancer bolt until snug. Do not overtighten. Tighten: Tighten the oil pan to front cover bolts to 25 N.m (18 lb ft). Tighten the engine front cover bolts to 25 N.m (18 lb ft).
8. Remove the J 41476 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Install a NEW crankshaft front oil seal (140). Refer to «Crankshaft Front Oil Seal Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
10. Install the coolant pump manifold. Refer to «Coolant Pump Manifold Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
11. Inspect the CMP sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused.
12. Lubricate the O-ring seal with clean engine oil.
13. Install the O-ring seal (704) onto the CMP sensor.
14. Install the CMP sensor (703) and bolt (705) from the front cover. Tighten: Tighten the bolt to 12 N.m (106 lb in).
15. Position the belt tensioner and install the bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
16. Install the power steering pump. Refer to «Power Steering Pump Replacement (3.8L V6)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (5.3L V8)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) in Power Steering System.
17. Install the generator. Refer to «Generator Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

J 41479 Crankshaft Rear Oil Seal Installer. See Special Tools .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove and discard the crankshaft rear oil seal (141).

1. Lubricate the outside diameter (OD) of the oil seal (141) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Align the oil seal into the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore.
9. Remove the J 41479 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

J 41476 Front and Rear Cover Alignment (at crankshaft seal area). See Special Tools .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the oil pan-to-rear cover bolts.
3. Remove the rear cover bolts (517).
4. Remove the rear cover (518) and gasket (519). Discard the gasket.
5. Remove and discard the rear oil seal (141).

1. Apply a 5 mm (0.20 in) bead of sealant GM U.S. P/N 12378190, or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction.
2. Install the rear cover gasket (519) and cover (518).
3. Install the rear cover bolts (517) until snug. Do not overtighten.
4. Install the oil pan-to-rear cover bolts until snug. Do not overtighten.
5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface.
6. Install the J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Tighten the J 41476 mounting bolts until snug. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Do not overtighten. Tighten: Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). Tighten the engine rear cover bolts to 25 N.m (18 lb ft).
8. Remove the J 41476 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Install a NEW crankshaft rear oil seal. Refer to «Crankshaft Rear Oil Seal Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the oil pan drain plug (430) and O-ring (429).
5. Allow the oil to drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate container.
7. Remove the oil filter adapter (438).

1. Install a NEW oil filter adapter (438). Tighten: Tighten the adapter to 55 N.m (40 lb ft).
2. Install a NEW engine oil filter (437). Tighten: Tighten the filter to 30 N.m (22 lb ft).
3. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Fill the engine with the appropriate amount and type of NEW engine oil. Refer to «Capacities - Approximate Fluid»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
6. Check the oil level.
7. Install the oil fill cap.
8. Close the hood.
9. Reset the engine oil life monitor, if necessary. Refer to «GM Oil Life System - Resetting»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__gm-oil-life-system-resetting) .

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the oil pan drain plug (430) and O-ring (429).
5. Allow the oil to drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate container.
7. Remove the oil filter adapter (438).
8. Remove the bypass valve (436).

1. Install a NEW bypass valve (436).
2. Install a NEW oil filter adapter (438). Tighten: Tighten the adapter to 55 N.m (40 lb ft).
3. Install a NEW engine oil filter (437). Tighten: Tighten the filter to 30 N.m (22 lb ft).
4. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
5. Lower the vehicle.
6. Fill the engine with the appropriate amount and type of NEW engine oil. Refer to «Capacities - Approximate Fluid»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
7. Check the oil level.
8. Install the oil fill cap.
9. Close the hood.
10. Reset the engine oil life monitor, if necessary. Refer to «GM Oil Life System - Resetting»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__gm-oil-life-system-resetting) .

1. Remove the engine frame. Refer to «Frame Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
2. Drain the engine oil and remove the engine oil filter.
3. Reinstall the drain plug and oil filter until snug.
4. Remove the transaxle converter cover bolt/stud and cover.
5. Disconnect the oil level sensor electrical connector.
6. Remove engine harness retainer from the front of oil pan.
7. Remove the oil pan bolts.
8. Remove the oil pan.
9. Drill (3) out the oil pan gasket retaining rivets (2), if required.
10. Remove the gasket (1) from the pan.
11. Discard the gasket and rivets.
12. Clean and inspect the engine oil pan. Refer to «Oil Pan Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pan-cleaning-and-inspection) .

1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12346141 or 12378577 (Canadian P/N 89022195), or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front/rear cover gasket that protrudes into the oil pan surface.
2. Pre-assemble the oil pan gasket to the pan. Install the gasket onto the pan. Install the oil pan bolts to the pan and through the gasket.
3. Install the oil pan, gasket, and bolts to the engine block. Tighten: Tighten the oil pan and oil pan-to-front cover bolts to 25 N.m (18 lb ft). Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). Tighten the transmission housing, converter cover, and transmission bolts/stud to 50 N.m (37 lb ft).
4. Install engine harness to front of oil pan.
5. Connect the oil level sensor electrical connector.
6. Install the transaxle converter cover and bolt/stud. Tighten: Tighten the bolt/stud to 12 N.m (106 lb in).
7. Install new engine oil and a new oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
8. Install the engine frame. Refer to «Frame Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the oil pan drain plug (430) and O-ring (429).
5. Allow the oil to drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate container.
7. Remove the oil pan cover bolts.
8. Remove the valve lifter oil pressure relief valve (455).

1. Install the valve lifter oil pressure relief valve (455).
2. Inspect the valve lifter oil pressure relief valve for proper operation. Lightly depress the valve (2). The valve spring (1) should seat the valve to the proper closed position.
3. Install the oil pan cover bolts and cover. Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install a NEW engine oil filter (437).
5. Install the oil pan drain plug (430) and O-ring (429).
6. Lower the vehicle.
7. Fill the engine with the appropriate amount and type of NEW engine oil. Refer to «Capacities - Approximate Fluid»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
8. Check the oil level.
9. Install the oil fill cap.
10. Open the hood.
11. Reset the engine oil lift monitor, if necessary. Refer to «GM Oil Life System - Resetting»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__gm-oil-life-system-resetting) .

J 41712 Oil Pressure Sensor Socket. See Special Tools .

1. If necessary, remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor.
2. Using J 41712 , install the oil pressure sensor (706) and washer (707). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the oil pressure sensor electrical connector (4).
4. If necessary, install the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Drain the oil from the oil pan.
3. Disconnect the oil level sensor electrical connector.
4. Remove the oil level sensor bolt (751).
5. Remove the oil level sensor (727) and O-ring (728) from the oil pan.

1. Install the oil level sensor (727) and O-ring (728) to the oil pan.
2. Install the oil level sensor bolt (751). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the oil level sensor electrical connector.
4. Lower the vehicle.
5. Refill the engine oil to the proper level.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Remove the oil pump screen bolt and nuts.
4. Remove the oil pump screen with O-ring seal.
5. Remove the O-ring seal from the pump screen.
6. Discard the O-ring seal.
7. Remove the remaining crankshaft oil deflector nuts.
8. Remove the crankshaft oil deflector.
9. Remove the oil pump bolts (411).
10. Remove the oil pump (413).
11. Clean and inspect the oil pump. Refer to «Oil Pump Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pump-cleaning-and-inspection) .

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump (413).
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts (411). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector and nuts until snug.
5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs.
7. Install the oil pump screen.
8. Install the oil pump screen bolt and nuts. Tighten: Tighten the bolt to 12 N.m (106 lb in). Tighten the nuts to 25 N.m (18 lb ft).
9. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
10. Install the oil pan. Refer to «Oil Pan Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

Timing Chain and Sprockets Replacement

Tools Required

1. J 8433 Two Jaw Puller
2. J 41816-2 Crankshaft End Protector. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the oil pump. Refer to «Oil Pump, Screen and Crankshaft Oil Deflector Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
3. Remove the camshaft sprocket bolts (206).
4. Remove the camshaft sprocket (205) and timing chain (208).
5. Remove the timing chain dampener (232) and bolts (231).
6. Using the J 8433 , J 41816-2 and the J 41558 remove the crankshaft sprocket. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Remove the crankshaft sprocket.
8. Remove the crankshaft sprocket key, if required.
9. Clean and inspect the timing chain and sprockets. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__timing-chain-and-sprockets-cleaning-and) .

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Using the J 41665 , install the crankshaft sprocket onto the crankshaft until fully seated against the crankshaft flange. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Install the timing change guide (232) and bolts (231). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. With the chain dampener properly installed, the heads of the bolts (231) should install to flush or below the face of the guide (232).
8. Install the camshaft sprocket (205) and timing chain (208). If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
9. Install the camshaft sprocket bolts (206). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Inspect the camshaft (1) and crankshaft (2) sprockets for proper timing mark alignment.
11. Install the oil pump. Refer to «Oil Pump, Screen and Crankshaft Oil Deflector Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .

1. Remove the engine. Refer to «Engine Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-replacement) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-balancer-removal) .
3. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-level-indicator-and-tube-removal) .
4. Remove the left and right exhaust manifolds. Refer to «Exhaust Manifold Removal - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__exhaust-manifold-removal-left) and «Exhaust Manifold Removal - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__exhaust-manifold-removal-right) .
5. Remove the water pump. Refer to «Water Pump Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__water-pump-removal) .
6. Remove the coolant pump manifold. Refer to «Coolant Pump Manifold Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Remove the intake manifold. Refer to «Intake Manifold Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__intake-manifold-removal) .
8. Remove the valve lifter oil manifold. Refer to «Valve Lifter Oil Manifold Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-lifter-oil-manifold-removal) .
9. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__coolant-air-bleed-pipe-removal) .
10. Remove the left and right valve rocker arm covers. Refer to «Valve Rocker Arm Cover Removal - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-cover-removal) and «Valve Rocker Arm Cover Removal - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-cover-removal) .
11. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-and-push-rod) .
12. Remove the valve lifters. Refer to «Valve Lifter Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-lifter-removal) .
13. Remove the oil pan-to-front cover bolts.
14. Remove the front cover bolts (501).
15. Remove the front cover (502) and gasket (503).
16. Rotate the crankshaft in order to align the timing marks (1, 2).
17. Remove the camshaft sprocket bolts (206).
18. Remove the camshaft sprocket (205) and timing chain (208).
19. Remove the camshaft retainer bolts (204) and retainer (203).
20. Remove the camshaft. Install 3 M8-125 x 100 mm bolts in the camshaft front bolt holes. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the bolts from the camshaft.

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install 3 M8-125 x 100 mm bolts in the NEW camshaft front bolt holes.
3. Using the bolts as a handle, carefully install the NEW camshaft into the engine block.
4. Remove the 3 bolts from the camshaft.
5. Install the camshaft retainer (203) and bolts (204). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the camshaft sprocket (205) and timing chain (208). If necessary, rotate the camshaft or crankshaft sprocket in order to align the timing marks.
7. Install the camshaft sprocket bolts (206). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
8. Inspect the camshaft (1) and crankshaft (2) sprockets for proper timing mark alignment.
9. Install the front cover (502). Refer to «Engine Front Cover Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-front-cover-installation)
10. Install the oil pan-to-front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
11. Install the valve lifters. Refer to «Valve Lifter Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-lifter-installation) .
12. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-and-push-rod) .
13. Install the left and right valve rocker arm covers. Refer to «Valve Rocker Arm Cover Installation - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-cover-installation) and «Valve Rocker Arm Cover Installation - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-rocker-arm-cover-installation) .
14. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__coolant-air-bleed-pipe-installation) .
15. Install the valve lifter oil manifold. Refer to «Valve Lifter Oil Manifold Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__valve-lifter-oil-manifold-installation) .
16. Install the intake manifold. Refer to «Intake Manifold Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__intake-manifold-installation) .
17. Install the coolant pump manifold. Refer to «Coolant Pump Manifold Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
18. Install the water pump. Refer to «Water Pump Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__water-pump-installation) .
19. Install the left and right exhaust manifolds. Refer to «Exhaust Manifold Installation - Left»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__exhaust-manifold-installation-left) and «Exhaust Manifold Installation - Right»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__exhaust-manifold-installation-right) .
20. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-level-indicator-and-tube-installation) .
21. Install the crankshaft balancer. Refer to «Crankshaft Balancer Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-balancer-installation) .
22. Install the engine. Refer to «Engine Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-replacement) .

1. Remove the automatic transmission. Refer to «Transmission Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) in Automatic Transaxle - 4T65-E.
2. Remove the flywheel bolts and flywheel.
3. Clean and inspect the engine flywheel. Refer to «Engine Flywheel Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-flywheel-cleaning-and-inspection) .

1. Install the flywheel to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the flywheel bolts.
3. Install the engine flywheel bolts. Tighten: Tighten the bolts a first pass in sequence to 20 N.m (15 lb ft). Tighten the bolts a second pass in sequence to 50 N.m (37 lb ft). Tighten the bolts a final pass in sequence to 100 N.m (74 lb ft).
4. Install the automatic transmission. Refer to «Transmission Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) in Automatic Transaxle - 4T65-E.

Engine Replacement

Tools Required

1. J 38185 Hose Clamp Pliers. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 39580 Universal Engine Support Table

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Disconnect/Connect Procedure (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Evacuate the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
4. Remove the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/pontiac/grand-prix/vii-2004-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (LS4 Static Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (L26, L32 Static Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716 Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) .
6. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
7. Lower the vehicle.
8. Using the J 38185 reposition the inlet hose clamp at the radiator. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Remove the inlet hose from the radiator.
10. Using the J 38185 reposition the outlet hose clamp at the radiator. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
11. Disengage the outlet hose clips from the fan shroud.
12. Remove the outlet hose from the radiator.
13. Remove the A/C compressor hose nut at the A/C receiver/dehydrator tube.
14. Remove the A/C compressor hose.
15. Remove the A/C compressor hose nut at the A/C condenser.
16. Remove the A/C compressor hose.
17. Remove the brake booster vacuum hose from the brake booster (3).
18. Remove the brake booster vacuum hose (1) from the intake manifold (2).
19. Disconnect the engine harness electrical connectors (1, 2) from the instrument panel (I/P) harness electrical connectors.
20. Disconnect the brake fluid level switch electrical connector (3) from the master cylinder.
21. Remove brake fluid from the master cylinder.
22. Disconnect the from brake pipe fittings (1, 2) from the master cylinder.
23. Disconnect the brake pipe fittings (1, 2) from the antilock brake (ABS) module.
24. Remove the master cylinder nuts.
25. Position the master cylinder to the engine. Hold the master cylinder in place using mechanic's wire.
26. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2__fuel-pressure-relief-procedure) .
27. Disconnect the fuel feed line (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
28. Disconnect the evaporative emission (EVAP) line (2) from the purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
29. Remove the right front fender diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/pontiac/grand-prix/vii-2004-2008/remont/exterior-body-panels/#body-front-end) .
30. Remove the underhood electrical center cover (1).
31. Loosen the 4 integral bolts (2) attaching the fuse block. Reposition the fuse block.
32. Loosen the engine harness connector bolt (1). Remove the engine harness connector from the bracket.
33. Disconnect the camshaft position sensor lead.
34. Disconnect the engine harness electrical connector from the ABS module.
35. Disconnect the engine harness electrical connector from the electronic brake control module (EBCM).
36. Remove the air cleaner assembly. Refer to «Air Cleaner Element Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
37. Disconnect the following electrical connectors: Transmission control module (TCM) (1) Engine control module (ECM) (2) A/C pressure sensor (3)
38. Disconnect the engine harness electrical connector (1) from the crankshaft position (CKP) sensor harness.
39. Disconnect the engine harness electrical connector (2) from the power steering gear harness.
40. Remove the clip attaching the power steering gear harness to the bracket.
41. Remove the shift cable clip.
42. Disconnect the shift cable from the transaxle selector lever stud.
43. Remove the shift cable from the bracket.
44. Remove the vehicle speed sensor (VSS) shield nut (1) and bolt (3). Remove the shield (2).
45. Disconnect the engine harness electrical connector from the VSS.
46. Set all branches of the engine wiring harness on top of the engine.
47. Reposition the intermediate shaft lower boot.
48. Remove the intermediate shaft to steering gear bolt.
49. Separate the intermediate shaft from the steering gear.
50. Disconnect both front wheel speed sensors. Refer to «Wheel Bearing/Hub Replacement - Front»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
51. Unclip the ABS wire harness from the lower control arm.
52. Using the J 38185 reposition the heater inlet and outlet hose clamps. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
53. Remove the heater inlet (2) and outlet (1) hoses from the heater inlet/outlet pipe.
54. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
55. Disconnect the stabilizer links from the stabilizer shaft.
56. Disconnect the ball joints from the steering knuckles. Refer to «Lower Ball Joint Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
57. Disconnect the power steering pressure hose from the steering gear.
58. Disconnect the power steering pressure line clips from the frame.
59. Disconnect the outer tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) .
60. Loosen the power steering hose clamp at the inlet pipe.
61. Remove the power steering hose (2) from the inlet pipe.
62. Remove the left and right wheel drive shafts from the transaxle. Refer to «Wheel Drive Shaft Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/axle-shafts/#wheel-drive-shafts) .
63. Support the wheel drive shafts using mechanic's wire.
64. Remove the transaxle oil cooler line bracket bolt/stud.
65. Disconnect the transaxle oil cooler lines from the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) .
66. Remove the positive battery cable nut (3) from the starter.
67. Remove the cable terminal (2) from the starter.
68. Remove the battery cable ground nut (1).
69. Remove the cable ground terminal (6) from the stud.
70. Remove the battery cable retainers from the engine frame.
71. Disconnect the exhaust system. Refer to «Catalytic Converter Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
72. Disconnect the O2 sensor harness pigtail.
73. Remove the transaxle converter cover bolt/stud.
74. Remove the converter cover.
75. Remove the flywheel bolts.
76. Remove the front air deflectors. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
77. Raise the vehicle enough to place J 39580 under the engine, frame, and front suspension.
78. Support the rear of the vehicle with suitable jackstand.
79. Strap the front of the vehicle to the hoist.
80. Raise the J 39580 , or lower the vehicle to preload the weight of the engine, frame, and front suspension.
81. Remove the radiator to frame brackets.
82. Remove the engine frame front bolts.
83. Remove the engine frame rear bolts.
84. With the aid of an assistant, lower the J 39580 and/or raise the vehicle to remove the engine and the frame from the vehicle.
85. Ensure that all hoses, wires, and pipes clear the vehicle during the removal process.
86. Use a suitable engine lift to support the engine.
87. Remove the front engine mount to frame nuts.
88. Remove the rear engine mount to frame nuts.
89. Remove the transaxle to engine bolts (1) and stud (2).
90. Separate the engine from the transaxle.
91. Using a suitable engine lift, remove the engine from the frame.
92. Install the engine onto a suitable engine stand.

1. Using a suitable engine lift, remove the engine from the engine stand.
2. Position and install the engine to the frame and the transaxle.
3. Install the transaxle to engine bolts (1) and stud (2). Tighten: Tighten the bolts/stud to 75 N.m (55 lb ft).
4. Install the rear engine mount to frame nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Install the front engine mount to frame nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
6. Ensure that all hoses, wires, and pipes clear the vehicle during the installation process.
7. With the aid of an assistant, raise the J 39580 and/or lower the vehicle to install the engine and frame to the vehicle.
8. Install the engine frame rear bolts. Tighten: Tighten the bolts to 160 N.m (118 lb ft).
9. Install the engine frame front bolts. Tighten: Tighten the bolts to 145 N.m (107 lb ft).
10. Install radiator to front frame brackets.
11. Lower the J 39580 , or raise the vehicle to preload the weight of the engine, frame, and front suspension.
12. Remove the support from under the rear of the vehicle.
13. Raise the vehicle enough to remove the J 39580 from under the engine, frame, and front suspension.
14. Connect the exhaust system and connect the O2 sensor harness pigtail. Refer to «Catalytic Converter Replacement (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/exhaust/#engine-exhaust-system) .
15. Install the flywheel bolts. Tighten: Tighten the bolts to 63 N.m (47 lb ft).
16. Install the converter cover.
17. Install the transaxle converter cover bolt/stud. Tighten: Tighten the bolt/stud to 10 N.m (89 lb in).
18. Install the left and right wheel drive shafts into the transaxle. Refer to «Wheel Drive Shaft Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/axle-shafts/#wheel-drive-shafts) .
19. Install the battery cable retainers to the engine frame.
20. Install the front air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
21. Install the cable ground terminal (6) to the stud.
22. Install the battery cable ground nut (1). Tighten: Tighten the nut to 30 N.m (22 lb ft).
23. Install the cable terminal (2) to the starter.
24. Install the positive battery cable nut (3) to the starter. Tighten: Tighten the nut to 10 N.m (89 lb in).
25. Connect the transaxle oil cooler lines to the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-2-of-2) .
26. Install the transaxle oil cooler line bracket bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
27. Install the power steering hose (2) to the inlet pipe.
28. Tighten the power steering hose clamp at the inlet pipe. Tighten: Tighten the clamp to 6 N.m (53 lb in).
29. Connect the power steering pipe to the steering gear. Refer to «Power Steering Pressure Pipe/Hose Replacement (L26 and L32)»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) .
30. Connect the power steering pipe to the frame clips.
31. Lower the vehicle.
32. Position and install the ball joint nuts. Refer to «Lower Ball Joint Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
33. Install the sway links to the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/suspension-front/#front-suspension-system) .
34. Install the tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/manual-power-steering/#power-steering-system) .
35. Connect the wheel speed sensor electrical connectors.
36. Connect the wheel speed sensor wiring harness to the lower control arm.
37. Install the heater inlet (2) and outlet (1) hoses to the heater inlet/outlet pipe.
38. Using the J 38185 position the heater inlet and outlet hose clamps. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
39. Install the intermediate shaft to the steering gear.
40. Install the intermediate shaft to steering gear bolt. Tighten: Tighten the bolt to 48 N.m (35 lb ft).
41. Position the intermediate shaft lower boot.
42. Route all branches of the engine wiring harness to their correct locations.
43. Connect the engine harness electrical connector to the VSS.
44. Install the VSS shield (2). Install the VSS shield nut (1) and bolt (3). Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
45. Install the shift cable to the bracket.
46. Connect the shift cable to the transaxle selector lever stud.
47. Install the shift cable clip.
48. Install the clip attaching the power steering gear harness to the bracket.
49. Connect the engine harness electrical connector (1) to the CKP sensor harness.
50. Connect the engine harness electrical connector (2) to the power steering gear harness.
51. Connect the camshaft position sensor lead to the sensor.
52. Connect the following electrical connectors: TCM (1) ECM (2) A/C pressure sensor (3)
53. Install the air cleaner assembly. Refer to «Air Cleaner Element Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
54. Connect the engine harness electrical connector to the EBCM.
55. Connect the engine harness electrical connector to the ABS module.
56. Install the engine harness connector to the bracket. Tighten the engine harness connector bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
57. Position the fuse block. Tighten the 4 integral bolts (2) attaching the fuse block. Tighten: Tighten the bolts to 10 N.m (89 lb in).
58. Install the electrical center cover (1).
59. Connect the fuel feed line (1) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
60. Connect the EVAP line (2) to the purge solenoid. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(/pontiac/grand-prix/vii-2004-2008/remont/testing-diagnostics/#engine-controls-53l-introduction-2-of-2) .
61. Remove the mechanic's wire holding the master cylinder. Position the master cylinder to the brake booster.
62. Install the master cylinder nuts. Tighten: Tighten the nuts to 33 N.m (24 lb ft).
63. Connect the brake pipe fittings (1, 2) to the ABS module. Tighten: Tighten the fittings to 15 N.m (11 lb ft).
64. Connect the from brake pipe fittings (1, 2) to the master cylinder. Tighten: Tighten the fittings to 30 N.m (22 lb ft).
65. Connect the brake fluid level switch electrical connector (3) to the master cylinder.
66. Connect the engine harness electrical connectors (1, 2) to the I/P harness electrical connectors.
67. Install the brake booster vacuum hose (1) to the intake manifold (2).
68. Install the brake booster vacuum hose to the brake booster (3).
69. Install the A/C compressor hose.
70. Install the A/C compressor hose nut at the A/C condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
71. Install the A/C compressor hose.
72. Install the A/C compressor hose nut at the A/C receiver/dehydrator tube. Tighten: Tighten the nut to 16 N.m (12 lb ft).
73. Install the outlet hose to the radiator.
74. Connect the outlet hose clips to the fan shroud.
75. Using the J 38185 position the outlet hose clamp at the radiator. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
76. Install the inlet hose to the radiator.
77. Using the J 38185 position the inlet hose clamp at the radiator. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
78. Install the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/pontiac/grand-prix/vii-2004-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
79. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (RPOs L26/L32)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Negative Cable Disconnect/Connect Procedure (RPO LS4)»(/pontiac/grand-prix/vii-2004-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
80. Install the right fender diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/pontiac/grand-prix/vii-2004-2008/remont/exterior-body-panels/#body-front-end) .
81. Refill the engine with oil.
82. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
83. Refill the cooling system. Refer to «Draining and Filling Cooling System (LS4 Static Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (L26, L32 Static Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716 Fill)»(/pontiac/grand-prix/vii-2004-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) .
84. Bleed the brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical-hydraulic/#hydraulic-brake-system) .
85. Check the transaxle fluid level, add fluid if necessary. Refer to «Transmission Fluid Checking Procedure»(/pontiac/grand-prix/vii-2004-2008/remont/automatic-trans/#how-to-diagnosis-troubleshooting-the-automatic-transaxle-4t65-e-service__transmission-fluid-checking-procedure) .
86. Install the engine sight shield. Refer to «Engine Sight Shield Replacement»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
87. Run the engine and inspect for leaks.

1. Open the hood.
2. Remove the oil fill cap.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/grand-prix/vii-2004-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the oil pan drain plug (430) and O-ring (429).
5. Allow the oil to drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate container.

1. Install a NEW engine oil filter (437). Tighten: Tighten the filter to 30 N.m (22 lb ft).
2. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
3. Lower the vehicle.
4. Fill the engine with the appropriate amount and type of NEW engine oil. Refer to «Capacities - Approximate Fluid»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
5. Check the oil level.
6. Install the oil fill cap.
7. Close the hood.
8. Reset the engine oil life monitor, if necessary. Refer to «GM Oil Life System - Resetting»(/pontiac/grand-prix/vii-2004-2008/remont/lubrication-system/#maintenance-and-lubrication__gm-oil-life-system-resetting) .

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug (430) and O-ring (429).
2. Remove the engine oil filter (437).
3. Remove the right side rear engine block coolant drain hole plug and washer.
4. Remove the engine block coolant heater (114) and washer (115).

Crankshaft Balancer Removal

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41816-2 Crankshaft End Protector. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. EN 47699 Flywheel Holding Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Install the EN 47699 (2), spacer (1), and bolt (3) to the block and flywheel. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Tighten the EN 47699 bolt (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the bolt to 60 N.m (44 lb ft).
3. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
4. Use the J 41816 (1) and the J 41816-2 (2) in order to remove the crankshaft balancer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Remove the crankshaft balancer (138).
6. Remove the EN 47699 , bolt, and spacer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Engine Flywheel Removal

1. Remove the engine flex plate bolts.
2. Remove the flex plate.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator (418) from the tube.
2. Remove the oil level indicator tube bolt (419).
3. Remove the oil level indicator tube (420).
4. Remove the O-ring (421) from the tube, as required.

Exhaust Manifold Removal - Left

1. Remove the spark plug wires from the spark plugs.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (603) and bolts (604) from the manifold (600), as required.
5. Remove the studs (605), as required.

Exhaust Manifold Removal - Right

1. Remove the spark plug wires from the spark plugs.
2. Remove the exhaust manifold, bolts, and gasket.
3. Discard the gasket.
4. Remove the heat shield (603) and bolts (604) from the manifold (600), as required.
5. Remove the studs (605), as required.

Water Pump Removal

1. Disconnect the engine coolant air bleed hose and clamp (1).
2. Remove the water pump (300), bolts (318), and gasket (314).
3. Remove the water manifold (315), bolts (301), and gaskets (306).
4. Remove the water inlet housing (303), bolts (302), thermostat (305), and O-ring (304), as required.
5. Discard the gaskets.

Throttle Body Removal

1. Remove the electrical wire harness connectors from the throttle body.
2. Remove the throttle body bolts (538).
3. Remove the throttle body (508).
4. Remove the throttle body gasket (509).
5. Discard the gasket.

Fuel Rail and Injectors Removal

1. Remove the positive crankcase ventilation (PCV) dirty air hose (716).
2. Remove the evaporative emission (EVAP) canister purge solenoid valve (730), bracket (741), and tube (729).
3. Note the location of the fuel rail ground strap (557).
4. Remove the fuel rail bolts (511), ground strap (557), and manifold bolt (512).
5. Remove the fuel rail (510) with injectors. Lift evenly on both sides of the fuel rail until all injectors have left their bores.
6. Remove the fuel injector retainers (521) and fuel injectors (533), as required.
7. Remove the O-rings (532, 534) from the injectors, as required.

Intake Manifold Removal

1. Remove the manifold absolute pressure (MAP) sensor (714), as required.
2. Remove the grommet (715) from the sensor, as required.
3. Remove the intake manifold bolts (512).
4. Remove the intake manifold (500).
5. Remove the intake manifold gaskets (514).
6. Discard the intake manifold gaskets.

Coolant Air Bleed Pipe Removal

1. Remove the engine coolant air bleed pipe bolts (309).
2. Remove the pipe (307) with hose and seals (308).
3. Remove the hose (311) and clamps (322) from the pipe (307), as required.
4. Remove the engine coolant air bleed cover bolts (312).
5. Remove the covers (313) with seals (308).
6. Remove the seals (308) from the pipe and covers.
7. Discard the seals.

Valve Lifter Oil Manifold Removal

1. Do not lift the manifold assembly by the electrical lead frame.
2. Remove the valve lifter oil manifold bolts (506).
3. Remove the valve lifter oil manifold (451).
4. Identify the 8 gasket retaining strap locations.
5. Using a wire-cutter type tool, snip the 8 retaining straps of the outer gasket.
6. Remove the outer gasket (556) from the manifold.

Valve Lifter Oil Filter Removal

1. Remove the oil pressure sensor (706).
2. Remove the oil filter (452).
3. Inspect the O-ring (454) for cuts or damage. If the filter is plugged or the O-ring is cut or damaged, replace the filter and O-ring as an assembly.

Valve Rocker Arm Cover Removal - Left

1. Remove the spark plug wires (724).
2. Remove the ignition coil bracket studs (720).
3. Remove the ignition coil and bracket assembly (719).
4. Disconnect the ignition coil electrical connectors.
5. Remove the bolts (723), coils (722), and wire harness (721) from the bracket, as required.
6. Remove the valve rocker arm cover bolts and cover.
7. Remove the gasket (504) from the cover.
8. Remove the oil fill cap (424) from the oil fill tube, as required.
9. Remove the oil fill tube (423), as required.
10. Discard the oil fill tube.

Valve Rocker Arm Cover Removal - Right

1. Remove the spark plug wires (724).
2. Remove the ignition coil bracket studs (720).
3. Remove the ignition coil and bracket assembly (719).
4. Disconnect the ignition coil electrical connectors.
5. Remove the bolts (723), coils (722), and wire harness (721) from the bracket, as required.
6. Remove the valve rocker arm cover bolts and cover.
7. Remove the gasket (504) from the cover.

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the valve rocker arm pivot support.
4. Remove the pushrods.

Cylinder Head Removal - Left

1. Remove the cylinder head bolts (220, 221).
2. Remove the cylinder head (218).
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts (220, 221).
2. Remove the cylinder head (218).
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Valve Lifter Removal

Tools Required

J 3049-A Valve Lifter Remover. See Special Tools .

1. Remove the bolts (211).
2. Remove the guides (210) with lifters. Note the installed position of the guides. The notched area of the guide is to align with the locating tab of the block.
3. Remove the valve lifters (209, 219) from the guide (210).
4. Organize or mark the components so they can be installed in the same location from which they were removed. The displacement on demand lifters (4) are installed into the guide by aligning the notched area of the guide (1) with the raised surface on the side of the lifter (2). Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .

Oil Filter and Adapter Removal

1. Remove the oil filter (437).
2. Remove the oil filter fitting (438) and bypass valve (436), as required.

Oil Pan Removal

1. Remove the left closeout cover and bolt.
2. Remove the right closeout cover and bolt.
3. Remove the oil pan bolts (439, 453).
4. Remove the oil pan (400).
5. Drill (2) out the oil pan gasket retaining rivets (1), if required.
6. Remove the gasket (426) from the pan.
7. Discard the gasket and rivets.
8. Remove the baffle and other components, as required. Refer to «Oil Pan Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pan-cleaning-and-inspection) .

Engine Front Cover Removal

1. Remove the front cover bolts (501).
2. Remove the front cover (502) and gasket (503).
3. Discard the front cover gasket.
4. Remove the oil seal (140).
5. Remove the bolt (705) and camshaft position (CMP) sensor (703).
6. Remove the O-ring (704) from the sensor, as required.

Crankshaft Rear Oil Seal Housing Removal

1. Remove the rear oil seal housing bolts (517).
2. Remove the housing (518) and gasket (519).
3. Remove the rear oil seal (141).

Oil Pump, Screen and Crankshaft Oil Deflector Removal

1. Remove the oil pump screen bolt and nuts.
2. Remove the oil pump screen with O-ring seal.
3. Remove the O-ring seal from the pump screen.
4. Discard the O-ring seal.
5. Remove the crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.
7. Remove the oil pump bolts (411).
8. Remove the oil pump (413).

Timing Chain and Sprockets Removal

Tools Required

1. J 8433 Two Jaw Puller. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 41816-2 Crankshaft End Protector. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the camshaft sprocket bolts (206).
2. Remove the camshaft sprocket (205) and timing chain (208).
3. Remove the bolts (231) and chain dampener (232).
4. Use the J 41816-2 (1), the J 41558 (2), and the J 8433 (3) in order to remove the crankshaft sprocket. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Remove the crankshaft sprocket.
6. Remove the crankshaft sprocket key, as required.

Camshaft Removal

1. Remove the camshaft retainer bolts (204) and retainer (203).
2. Remove the camshaft. Install the 3 M8-1.25 x 100 mm bolts into the camshaft front bolt holes. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the bolts from the front of the camshaft.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer
2. J 41556 Connecting Rod Guide. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Use the J 24270 in order to remove the cylinder bore ring ridge, if required. Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use the J 24270 , or equivalent, in order to remove a cylinder ring ridge. Turn the crankshaft so the piston is at the top of the stroke. Remove the cloth. Remove the cutting debris from the cylinder and piston.
2. Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction. A stamping mark on the side of the connecting rod, at the crankshaft journal, may affect component geometry. Mark the top of the piston to the specific cylinder bore.
3. Remove the connecting rod bolt (102), cap (103) and bearing (104).
4. Install the J 41556 to the connecting rod. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Using a hammer, tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
6. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolt onto the matching connecting rod.

Crankshaft and Bearings Removal

Tools Required

1. J 6125-1B Slide Hammer with Adapter
2. J 41818 Crankshaft Bearing Cap Remover. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Remove the crankshaft position (CKP) sensor bolt (702).
2. Remove the CKP sensor (701).
3. Remove the O-ring (750) from the sensor, as required.
4. Remove the crankshaft bearing cap M8 bolts (127).
5. Remove the crankshaft bearing cap M10 bolts (129) and studs (128).
6. Install the J 41818 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the J 41818 bolts to 11 N. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .m (100 lb in).
7. Install the J 6125-1B to the J 41818 in order to remove the crankshaft bearing caps. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Remove the bearing caps.
9. Remove the crankshaft.
10. Lay the crankshaft onto wooden V-blocks or other protective surface.
11. Remove the crankshaft bearings from the bearing caps and the engine block.
12. Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location. Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .

Engine Block Plug Removal

1. Remove the engine block coolant heater (114).
2. Remove the engine block coolant drain hole plug.
3. Remove the engine block left front oil gallery plug.
4. Remove the engine block left rear oil gallery plug.
5. Inspect the block plug sealing washers. If the block plug and heater sealing washers are not damaged, they may be used during assembly.
6. Remove the engine block rear oil gallery plug.
7. Inspect the O-ring seal of the rear oil gallery plug. If the O-ring seal is not cut or damaged, the plug and O-ring seal may be used during assembly.
8. Remove the engine block front oil gallery plug.
9. Remove the left side knock sensor (718) and bolt (739).
10. Remove the right side knock sensor (718) and bolt (739).

Engine Block Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gage
2. J 42385-100 Head/Main Bolt Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Scheme 49

Note. Do not use a caustic solution to clean the aluminum engine block.

Clean the following components

1. Remove all sludge, dirt, or debris using a cleaning solvent or thermal type oven. Refer to «Cleanliness and Care»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cleanliness-and-care) .
2. Gasket surfaces Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Coolant passages
4. Oil galleries
5. Main bearing caps
6. Cylinder head bolt holes to remove threadlocking material Thread repair driver tool J 42385-107 may be used to clean the threads of old threadlocking material.

1. Inspect the following components: Cylinder walls for excessive scratches, gouging, or ring ridge Cylinder bores for excessive ring ridge at the top of the cylinder Coolant jacket for cracks Valve lifter bores for excessive scoring or wear Crankshaft bearing webs for cracks Gasket sealing surfaces for excessive scratches or gouging Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) . Oil galleries for restrictions Threaded bolt holes for damaged threads Scoring or damage to the displacement on demand oil passages or sealing surfaces
2. Measure the cylinder bores for excessive ring ridge at the top of the cylinder.

Measuring the Cylinder for Oversize

1. Adjust the micrometer to a dimension slightly smaller than the bore size. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
2. Insert the J 8087 bore gage into the micrometer and zero the bore gage dial.
3. Using the J 8087 , measure the cylinder bore for oversize. Slide the bore gage up and down throughout the length of the cylinder bore. Measure the bore both parallel and perpendicular to the centerline of the crankshaft at the top, center, and bottom of the bore. A cylinder bore that exceeds the maximum diameter must be serviced with an oversized piston. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Boring Procedure

1. Measure all pistons with a micrometer to determine the cylinder bore diameter.
2. Before you use any type of boring bar, use a fine file and clean the top of the cylinder block, removing any dirt or burrs. If you do not check the cylinder block, the boring bar may be improperly positioned or tilted and the cylinder bore could be bored at an incorrect angle.
3. Carefully follow the instructions furnished by the manufacturer regarding use of the equipment.
4. When you bore the cylinders, ensure all the crankshaft bearing caps are in place. Tighten the crankshaft bearing caps to the proper torque in order to avoid distortion of the cylinder bores during final assembly.
5. When you take the final cut with a boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for the finish honing and fit of the piston.

Honing Procedure

1. When honing the cylinders, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean, sharp stones of the proper grade for the amount of material you remove. Dull, dirty stones cut unevenly and generate excessive heat. Do not hone to final clearance with a coarse or medium-grade stone. Leave sufficient metal so that all stone marks may be removed with fine-grade stones. Perform final honing with a fine-grade stone, honing the cylinder to the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Repeatedly check the cylinder bore for fit with the selected piston. All measurements of the piston or the cylinder bore should be made with the components at normal room temperature.
3. When honing a cylinder for fit to an oversize piston, first perform the preliminary honing with a 100 grit stone.
4. Perform final cylinder honing with a 240 grit stone and obtain a 45 degree cross hatch pattern. A 240 grit stone is preferred for final honing. If a 240 grit stone is not available, a 220 grit stone may be used as a substitute.
5. The finish marks should be clean but not sharp. The finish marks should also be free from imbedded particles and torn or folded metal.
6. By measuring the selected piston at the sizing point and by adding the average of the clearance specification, you can determine the final cylinder honing dimension required.
7. After final honing and before the piston is checked for fit, clean the cylinder bores with hot water and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will also contaminate the engine oil and may cause premature wear of the bearings. After washing the cylinder bore, dry the bore with a clean rag.
8. Perform final measurements of the piston and the cylinder bore.
9. Permanently mark the top of the piston for the specific cylinder to which it has been fitted.
10. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Scheme 50

Using a ball type or self centering honing tool, deglaze the cylinder bore lightly. Deglazing should be done only to remove any deposits that may have formed. Use a 240 grit stone of silicone carbide, or equivalent, material when preforming the deglazing procedure.

A 240 grit stone is preferred for final honing. If a 240 grit stone is not available, a 220 grit stone may be used as a substitute.

Crankshaft and Bearings Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator Set
2. J 43690 Rod Bearing Checking Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 43690-100 Rod Bearing Checking Tool - Adapter Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Cleaning Procedure

1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages (2) and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air.

1. Perform a visual inspection of the crankshaft for damage.
2. Inspect the CKP reluctor ring teeth (1) for damage.
3. Inspect the crankshaft journals for wear (1). Journals should be smooth with no signs of scoring, wear, or damage.
4. Inspect the crankshaft journals for grooves or scoring (2).
5. Inspect the crankshaft journals for scratches or wear (3).
6. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
7. Inspect the crankshaft rear oil seal surface (5) for grooves or scoring.
8. Inspect the crankshaft key (122), keyway (1), and threaded hole (2) for damage.
9. Measure the crankpins for the out-of-round.
10. Measure the crankpins for taper.
11. Measure the crankshaft thrust wall width (a). A crankshaft with a thrust wall width in excess of 26.2 mm (1.0315 in) must be replaced.
12. Measure the crankshaft runout. Use wooden V-blocks or a fixture to support the crankshaft on the front and rear journals.
13. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals.
14. Use the J 7872 in order to measure the runout of the crankshaft rear flange.
15. Use the J 7872 in order to measure the runout of the crankshaft position reluctor ring. Reluctor ring runout should be measured 1.0 mm (0.04 in) below the ring teeth. If the reluctor ring has runout in excess of 0.7 mm (0.028 in), replace the crankshaft.
16. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
17. Inspect the crankshaft bearings for excessive scoring or discoloration.
18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing. If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

Measuring Main Bearing Clearance - Gaging Plastic Method

1. Remove the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-and-bearings-removal) .
2. Install gaging plastic onto the crankshaft journal. Install the gaging plastic the full width of the crankshaft bearing journal.
3. Install the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-and-bearings-installation) .
4. Remove the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__crankshaft-and-bearings-removal) .
5. Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit. If the gaging plastic shows irregularity in the journal exceeding 0.025 mm (0.001 in), remove the crankshaft and measure the journal with a micrometer. If clearance cannot be brought to specifications, replace the crankshaft or engine block, as required. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Measuring Connecting Rod Bearing Clearance - Gaging Plastic Method

1. Remove the bearing cap, bearing half and bolts. Refer to «Piston, Connecting Rod, and Bearing Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__piston-connecting-rod-and-bearing-removal) .
2. Install the gaging plastic onto the connecting rod bearing journal. Install the gaging plastic the full width of the journal.
3. Install the bearing cap, bearing half, and bolts. Refer to «Piston, Connecting Rod, and Bearing Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__piston-connecting-rod-and-bearing-installation) .
4. Remove the bearing cap, bearing half and bolts. Refer to «Piston, Connecting Rod, and Bearing Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__piston-connecting-rod-and-bearing-removal) .
5. Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

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

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

Scheme 51

J 43690 Rod Bearing Checking Tool. See Special Tools .

1. J 43690-20 Swivel Base (1)
2. J 43690-19 Dial Indicator (2)
3. J 43690-2 Base (3)
4. J 43690-5, -6 Handle (4)
5. J 43690-10, -11 Foot (5)
6. 280307 Screw (6)
7. J 43690-1 Pivot Arm Assembly (7)
8. J 43690-3, -7, -8 Screws (8)
9. 280319 Screw (9)
10. 280311 Screw (10)
11. J 43690-17, -18 Adapter (11)
12. 280310 Pin (12)

Scheme 52

J 43690-100 Rod Bearing Checking Tool - Adapter Kit. See Special Tools .

1. J 43690-104 Spacer (1)
2. J 43690-105 Retainer Plate (2)
3. 505478 Bolt (3)
4. 511341 Bolt (4)
5. J 43690-106 Retainer Plate (5)
6. J 43690-107 Cap (6)
7. J 43690-102 Foot (7)
8. J 43690-101 Pivot Arm Assembly (8)
9. J 43690-103 Adapter (9)
10. 505439 Adapter (10)

1. Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position.
2. Remove a bearing cap and bolts (1).
3. Remove the bearing half (2).
4. Insert a piece of paper card stock onto the crankshaft journal.
5. Install the bearing half (2) and cap and bolts (1). Refer to «Fastener Tightening Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__fastener-tightening-specifications) .
6. Install the following: J 43690-2 (5) J 43690-3 (4) J 43690-101 (2) 280310 (3) J 43690-5 (1)
7. Install the swivel base (1) and dial indicator (2).
8. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. A connecting rod with a clearance in excess of 0.076 mm (0.003 in) is considered excessive. Service components, as required.

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer in solvent.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following conditions: Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade emery cloth. IMPORTANT: In order for the belt to track properly, the belt grooves should be free of all dirt or debris. Dirty or damaged belt grooves (2) The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. Minor imperfections may be removed with a fine file. Worn, chunking, or deteriorated rubber (1) between the hub and pulley

Engine Flywheel Cleaning and Inspection

1. Clean the flex plate in solvent.
2. Dry the flex plate with compressed air.
3. Inspect the flex plate for the following conditions: Damaged ring gear teeth (1) Stress cracks around the flex plate-to-crankshaft bolt hole locations (2) IMPORTANT: Do not attempt to repair the welded areas that retain the ring gear to the flex plate plate. Install a new flex plate. Welded areas (3) that retain the ring gear onto the flex plate for cracking

Piston and Connecting Rod Disassemble

1. Remove the connecting rod bearings from the rod and cap.
2. Using piston ring pliers, remove the piston rings from the piston.
3. Rotate the piston pin retainers until the ring end gaps are positioned in the cutout area (1) of the pin bore.
4. Remove the retainers starting in the cutout area of the pin bore.
5. Remove the pin from the piston and connecting rod.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort, or organize the piston and the matching piston pin.

Piston, Pin, and Piston Rings

1. Clean the varnish and carbon from the piston (107) using cleaning solvent.
2. Dry the components with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the oil lubrication holes and slots.
5. Inspect the piston for the following conditions: Cracks in the piston ring lands, the piston skirt, or pin bosses Piston ring grooves for nicks, burrs, or warpage which may cause the piston ring to bind MINOR imperfections may be removed from the piston with a fine file. Scuffed or damaged skirts (2) Eroded areas at the top of the piston (1) Scoring to the full-floating design piston pin bore (3) or piston pin
6. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston. If binding is caused by distorted ring groove, MINOR imperfections may be removed with a fine file. If binding is caused by a distorted piston ring, replace the rings, as required.
7. Measure the piston ring side clearance with a feeler gauge. If side clearance is not within specifications, try another piston ring. If the proper ring-to- groove clearance cannot be obtained, replace the piston, pin, and connecting rod assembly. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
8. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin outside diameter (OD).
9. To determine the piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore inside diameter (ID).
10. Subtract the piston pin OD measurement from the piston pin bore ID measurement to determine pin-to-bore clearance. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Measuring Piston Ring End Gap

1. Place the piston ring into the cylinder bore 6.5 mm (0.25 in) below the top of the ring travel area.
2. Insert a feeler gage and measure the piston ring end gap. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Connecting Rod and Bearings

1. Clean the connecting rod (105) and cap (103) in solvent.
2. Dry the components with compressed air.
3. Inspect the connecting rod for the following conditions: Twisting (1) Proper fit of the connecting rod and cap mating surfaces (2) Nicks or gouges in the bearing bore (3) Damage to the bearing locating slots (4)
4. Measure the connecting rod bearing bore for an out-of-round condition. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
5. To determine full-floating piston pin-to-connecting rod bore clearance, use a micrometer and measure the piston pin outside diameter (OD).
6. To determine the full-floating piston pin-to-connecting rod bore clearance, use a micrometer and measure the connecting rod pin bore (1) inside diameter (ID).
7. Subtract the piston pin OD measurement from the connecting rod pin bore ID measurement to determine pin-to-bore clearance. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
8. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the bearing halves indicate fatigue.
9. Inspect the connecting rod bearings for excessive scoring or discoloration.
10. Inspect the connecting rod bearings for dirt or debris imbedded into the bearing material.
11. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearing surface.

Piston and Connecting Rod Assemble

1. Assemble the piston and connecting rod with the lug (1) on the bottom of the piston and the tab (2) on the side of the connecting rod facing the same direction. When installing the piston and connecting rod assembly, the mark on the top of the piston and the tab (2) on the side of the connecting rod should face the front of the engine.
2. Install the retainer. The retainer should be seated in the groove of the pin bore.
3. Install the piston pin to the piston and connecting rod.
4. Install the retainer. The retainer should be seated in the groove of the pin bore.
5. Using piston ring pliers, install the piston rings onto the piston. Install the compression rings with the orientation mark facing the top of the piston.
6. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other.
7. Position the compression ring end gaps 180 degrees opposite each other.
8. Install the connecting rod bearings to the rod and cap.

Camshaft Bearing Removal

Tools Required

J 33049 Camshaft Bearing Service Set

1. Prior to bearing removal, inspect the camshaft bearings for loose fit in the engine block bearing bores. Refer to «Camshaft and Bearings Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__camshaft-and-bearings-cleaning-and-inspection) .
2. Repair or replace the components, as required.
3. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 .
4. Assemble the tool.
5. Insert the tool through the front of the engine block and into the bearing.
6. Tighten the expander assembly (15) nut until snug.
7. Push the guide cone (1) into the front camshaft bearing location in order to align the tool.
8. Drive the bearing from the block bore.
9. Repeat the above procedures in order to remove the remaining bearings.

Tool Usage Information

Bearing, Expander, and Expander Driver Information

1. The tool consists of a guide cone (1), driving washers (2 or 3), expander bearing drivers (4-8), driver bars (9 or 10), expander jaws (11), expander sleeve (12), expander cone (13), expander shaft (14), and expander assembly (15).
2. Expander bearing driver number 1 inside diameter is 28.575-37.465 mm (1.125-1.475 in) and is used with the expander assembly and the small washer.
3. Expander bearing driver number 2 inside diameter is 37.465-43.18 mm (1.475-1.7 in) and is used with number 1 expanding driver and the small washer.
4. Expander bearing driver number 3 inside diameter is 43.18-48.895 mm (1.7-1.925 in) and is used with number 2 expanding driver and the large washer.
5. Expander bearing driver number 4 inside diameter is 48.895-54.61 mm (1.925-2.15 in) and is used with number 3 expanding driver and the large washer.
6. Expander bearing driver number 5 inside diameter is 54.61-60.325 mm (2.150-2.375 in) and is used with number 4 expanding driver and the large washer.
7. Expander bearing driver number 6 inside diameter is 60.325-68.326 mm (2.375-2.69 in) and is used with number 5 expanding driver and the large washer.

Tool Assembly and Operation

1. Select the proper expanding driver and washer from the expanding driver and washer information.
2. Place the expanding driver onto the expander assembly.
3. Ensure the separation lines between the segments of the expanding driver align with the separation lines of the expander assembly.
4. With the small end of the cone (2) facing the driver assembly, place the guide cone over the driving bar.
5. Place the driving washer over the threaded portion of the expander assembly.
6. Screw the expander assembly, with driving washer, onto the driving bar. For removal of the inner bearings, it may be necessary to install the driver bar extension.
7. Insert the tool into an inner camshaft bearing and tighten until snug. Operate the tool from the front or rear of the engine block. On some engine blocks, the nut on the expander assembly is inaccessible, except from either end. In this case, you must use a socket and extension to enlarge and reduce the expander assembly.
8. Slide the cone (2) into the front or rear camshaft bearing location. This will properly align the tool.
9. Drive the bearing out of the engine block.
10. Repeat the procedure for the additional inner bearings.
11. For the 2 end bearings, front and rear, remove the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.

Camshaft and Bearings Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator Set
2. J 8520 Camshaft Lobe Lift Indicator. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Clean the components in solvent.
2. Dry the components with compressed air.
3. Inspect the camshaft bearing journals (1) for scoring or excessive wear.
4. Inspect the camshaft valve lifter lobes (2) for scoring or excessive wear.
5. Inspect the threaded bolt holes (3) in the front of the camshaft for damaged threads or debris.
6. Inspect the camshaft sprocket pin (204) for damage.
7. Inspect the camshaft retainer plate (203) for wear or a damaged sealing gasket. If the camshaft retainer plate sealing gasket is not cut or damaged, it may be used again.
8. Inspect the camshaft bearings for proper fit in the engine block. Camshaft bearings have an interference fit to the engine block and should not be loose in their engine block bearing bores.
9. Inspect the camshaft bearings for excessive wear or scoring. Bearings with excessive scoring or wear must be replaced.
10. Measure the camshaft journals for wear and out-of-round with a micrometer. If the camshaft bearing journals measure greater than 0.025 mm (0.001 in) out-of-round, replace the camshaft. If the camshaft bearing journal diameter measures less than 54.99 mm (2.164 in), replace the camshaft.
11. Using a micrometer, measure the camshaft lobes for wear. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
12. Measure the camshaft runout. Mount the camshaft in wooden V-blocks or between centers on a fixture. Using the J 7872 , measure the runout of the intermediate camshaft bearing journals. If camshaft runout exceeds 0.05 mm (0.002 in), the camshaft is bent and should be replaced.

Measuring Camshaft Lobe Lift

1. Measure camshaft lobe lift using J 8520 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Remove the valve rocker arms and bolts.
3. Install the dial indicator mounting stud into the valve rocker arm bolt hole.
4. Assemble the components of the J 8520 and position onto the stud. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Position the shaft of the dial indicator onto the end of the pushrod.
6. Rotate the face of the dial indicator to zero.
7. Slowly rotate the crankshaft clockwise until the dial indicator obtains its highest and lowest readings.
8. Compare the total to specifications. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Camshaft Bearing Installation

Tools Required

J 33049 Camshaft Bearing Service Set

1. Measure the engine block camshaft bearing bores (1-5) in order to identify the correct OD size bearing for each position. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
2. Select the expanding driver (4-8) and washer (2 or 3) from the J 33049 . Refer to «Piston and Connecting Rod Assemble»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__piston-and-connecting-rod-assemble) .
3. Assemble the tool.
4. Insert the tool through the front of the engine block and into the bearing.
5. Tighten the expander assembly nut until snug.
6. Push the cone (2) into the front camshaft bearing location in order to align the tool.
7. Drive the bearing into the block bore.
8. Install the front and rear bearings to the block.

Timing Chain and Sprockets Cleaning and Inspection

1. Clean the components with cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the timing chain (1) for binding or wear.
4. Inspect the camshaft position (CMP) sensor raised area (2) for nicks or damage.
5. Inspect for worn, damaged, or chipped teeth (3).
6. Inspect for a damaged keyway (4).
7. Inspect for worn oil pump drive splines (5).

Valve Rocker Arm and Push Rods Cleaning and Inspection

1. Mark, sort, or organize the components for assembly. Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .
2. Clean the components with cleaning solvent.
3. Dry the components with compressed air.
4. Inspect the valve rocker arms bearings (2) for binding or roughness.
5. Inspect the valve rocker arm pushrod sockets (3) and valve stem mating surfaces (1). These surfaces should be smooth with no scoring or exceptional wear.
6. Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
7. Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
8. Inspect the pushrod oil passages for restrictions.
9. Inspect the rocker arm pivot supports for cracks, wear, or other damage.

Non Displacement on Demand Valve Lifters

1. Clean the components in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the valve lifters for the following conditions: Bent or broken clip (1) Worn pushrod socket (2) Scuffed or worn sides (3) If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage. Flat spots on the roller (4) Loose or damaged pin (5) Plugged oil hole (6) Worn or damaged roller bearing The roller should rotate freely with no binding or roughness.

Displacement on Demand Valve Lifters

1. Clean the components in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the valve lifters for the following conditions: Broken or collapsed spring (1) Worn pushrod socket (2) Plugged lubrication hole (3) Plugged lifter oil-switching hole (4) Flat spots on the roller (5) Worn or damaged roller bearing (6) The roller should rotate freely with no binding or roughness. Scuffed or worn sides (7)

Valve Guides

Inspect the valve lifter guides for the following conditions

1. Cracks or damage
2. Excessive wear in the lifter mounting bores

Cylinder Head Disassemble

Tools Required

J 8062 Valve Spring Compressor - Head Off. See Special Tools .

1. Remove the spark plugs from the cylinder heads.
2. Use the J 8062 in order to compress the valve spring. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. Remove the valve stem keys (225).
4. Remove the valve spring cap (224).
5. Remove the valve spring (223).
6. Remove the valves (227 and 228).
7. Remove the valve stem oil seal (222). Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .
8. Remove the cylinder head core hole plugs (226), as required.
9. Remove the coolant temperature sensor from the left cylinder head.
10. Remove the coolant plug (229) from the right cylinder head.

Cylinder Head Cleaning and Inspection

Tools Required

1. J 8089 Carbon Removal Brush. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 9666 Valve Spring Tester

1. Clean the following components: Use the J 8089 in order to remove the carbon from the combustion chambers. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Gasket surfaces Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) . Valve stems and heads on a buffing wheel Bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
2. Inspect the cylinder head for the following conditions: Cracks in the exhaust ports and combustion chambers External cracks in the water chambers Gasket surfaces for excessive scratches or gouging Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) . Bolt hole threads for debris or damaged threads Refer to «Thread Repair»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__thread-repair) or «Thread Repair Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Inspect the cylinder head for warpage. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
4. Use the J 9666 in order to measure the valve spring tension. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

J 37378-1 Valve Guide Reamer. See Special Tools .

Valve Guide Reaming

1. Measure the valve stem-to-guide clearance using a dial indicator. Position the tip of the dial indicator at the top of the valve guide. Valve stem-to-guide clearance may also be obtained by using a micrometer to measure the valve stem diameter and a ball type measuring gage to measure the guide bore.
2. A valve stem (1) and guide (2) with excessive clearance must be replaced or the components replaced. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
3. Inspect the valve stems for excessive scoring, wear, or warpage. A valve stem that has excessive scoring (3 or 4) or wear (4 or 6) must be replaced. A valve guide that is worn and has excessive stem-to-guide clearance should be reamed and valves with oversize stems installed.
4. Measure the valve stem diameter. A valve stem with a diameter less than 7.95 mm (0.313 in) must be replaced. If the valve stem diameter is within specifications, and the stem-to-guide clearance is excessive, the cylinder head must be replaced.

Valve and Seat Grinding

1. Inspect the valve for the following conditions: Burnt or eroded areas (1) A worn margin (2) A bent stem (3) A worn or scored stem (4) A worn key groove (5) A worn stem tip (6)
2. Inspect the valve face for the following conditions: Worn or no margin (1 or 4) Pitted surfaces (2) Burnt or eroded areas (3)
3. Inspect the valve margin. The exhaust valve may be refaced if the margin is greater than 1.25 mm (0.05 in) thick before grinding.
4. Reface pitted exhaust valves on a suitable valve refacing machine.
5. Replace the valve if the margin is less than 1.25 mm (0.05 in) thick after grinding.
6. If the valve face has been ground, it may be necessary to shim the valve spring to obtain the proper spring installed height. Refer to «Cylinder Head Disassemble»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-disassemble) .
7. Inspect for a loose valve seat in the cylinder head. The valve seat has an interference fit to the cylinder head.
8. Clean the valve guide bores with a suitable tool. Remove all carbon or dirt from the bores. The valve guide must be clean for the seat grinding tool to obtain proper results.
9. Grind the valve seat. The recommendations of the manufacturer of the equipment should be followed carefully to obtain the proper results. Regardless of what type of equipment is used, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the tool pilot in the guide.
10. Inspect the valve seats. The valve seats should be concentric to within 0.05 mm (0.0021 in) total indicator reading. If the valve seat has been ground, it may be necessary to shim the valve spring to attain the proper spring installed height. Refer to «Cylinder Head Disassemble»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cylinder-head-disassemble) .

Cylinder Head Assemble

Tools Required

J 8062 Valve Spring Compressor - Head Off. See Special Tools .

1. Clean the cylinder head valve spring shim area.
2. Install the valves (228) into the proper location. Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .
3. Install the valve stem oil seal (222).
4. Install the valve spring (223).
5. Install the valve spring cap (224).
6. Compress the valve spring using the J 8062 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Install the valve stem keys. Use grease to hold the keys in place and remove the J 8062 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Ensure the keys seat properly in the groove of the valve stem. Tap the end to the valve stem with a plastic faced hammer to seat the keys, if necessary.
8. Measure the valve spring installed height using a ruler. Measure from the base of the valve spring to the top of the valve spring. Specification: If the installed height exceeds 46.25 mm (1.82 in), install a valve spring shim of approximately 0.5 mm (0.02 in) thick. Do not shim the valve spring to obtain less than the specified height. Do not assemble the components without a spring shim on the cylinder head.
9. Install the remaining valves, springs, and other components.
10. Install sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the coolant sensor.
11. Install the coolant temperature sensor (725) into the left cylinder head. Tighten: Tighten the coolant temperature sensor to 20 N.m (15 lb ft).
12. Install threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the plug (229).
13. Install the coolant plug to the right cylinder head. Tighten: Tighten the coolant plug to 20 N.m (15 lb ft).
14. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the sides of the cylinder head core hole plugs (216).
15. Install the core hole plugs into the cylinder head. A properly installed plug should be installed 2.5 mm (0.1 in) below the end face of the head.

Oil Pump Disassemble

1. Remove the oil pump cover bolts (408).
2. Remove the oil pump cover (409).
3. Remove the drive gear (410).
4. Remove the driven gear (412).
5. Remove the pressure relief valve plug (416).
6. Remove the pressure relief valve spring (415).
7. Remove the pressure relief valve (414).
8. Inspect the oil pump components. Refer to «Oil Pump Cleaning and Inspection»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-pump-cleaning-and-inspection) .

Oil Pump Cleaning and Inspection

1. Clean the parts in solvent.
2. Dry the parts with compressed air.
3. Inspect the oil pump housing (413) and the cover (409) for cracks, excessive wear, scoring, or casting imperfections.
4. Inspect the oil pump housing-to-engine block oil gallery surface for scratches or gouging.
5. Inspect the oil pump housing for damaged bolt hole threads.
6. Inspect the relief valve plug (416) and plug bore for damaged threads.
7. Inspect the oil pump internal oil passages for restrictions.
8. Inspect the drive gear (410) and driven gear (412) for chipping, galling or wear. Minor burrs or imperfections on the gears may be removed with a fine oil stone.
9. Inspect the drive gear splines for excessive wear.
10. Inspect the pressure relief valve (414) and bore for scoring or wear. The valve must move freely in the bore with no restrictions.
11. Inspect the oil pump screen for debris or restrictions.
12. Inspect the oil pump screen for broken or loose wire mesh.

Oil Pump Assemble

1. Install the driven gear (412) into the pump housing (413). Install the driven gear with the orientation mark facing the pump cover.
2. Install the drive gear (410) into the pump housing.
3. Install the oil pump cover (409).
4. Install the pump cover bolts (408). Tighten: Tighten the oil pump cover bolts to 12 N.m (106 lb in).
5. Install the relief valve (414).
6. Install a NEW relief valve spring (415).
7. Install the pressure relief valve plug (416). Tighten: Tighten the pressure relief valve plug to 12 N.m (106 lb in).
8. Inspect the oil pump for smooth operation by rotating the drive gear.

Engine Front Cover Cleaning and Inspection

1. Remove the crankshaft oil seal (140) from the front cover.
2. Clean the cover in solvent. Remove the sealant from the cover oil pan surface. Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Dry the cover with compressed air.
4. Inspect the gasket sealing surfaces for excessive scratches or gouging.
5. Inspect the threaded bolt holes for damaged threads or debris.
6. Inspect the crankshaft oil seal and camshaft position (CMP) sensor mounting bores for damage.

Crankshaft Rear Oil Seal Housing Cleaning and Inspection

1. Remove the crankshaft oil seal (141) from the rear housing.
2. Clean the housing in solvent. Remove the sealant from the housing oil pan surface. Refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Dry the housing with compressed air.
4. Inspect the gasket sealing surfaces for excessive scratches or gouging.
5. Inspect the housing-to-oil pan threaded bolt holes for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for damage.

Valve Lifter Oil Manifold Cleaning and Inspection

1. Do not lift the manifold assembly by the electrical lead frame.
2. Remove the oil pressure sensor (706) and washer (707).
3. Remove the oil screen (452) with O-ring (454).
4. Clean the manifold with compressed air.
5. Inspect for loose electrical solenoids (1-4) or loose or missing bolts.
6. Inspect for damage to the electrical lead frame (5).
7. Inspect for a damaged electrical connector, for bent or corroded pins.
8. Inspect for damaged interior sealing gaskets (1-8). If the interior sealing gaskets are damaged, the manifold must be replaced as an assembly.
9. Inspect for a damaged exterior sealing gasket (9) or scored gasket surfaces.
10. Inspect for debris or restrictions within the oil passages of the manifold.

Valve Rocker Arm Cover Cleaning and Inspection

1. Inspect the oil fill tube (423) for a loose fit or damage.
2. Inspect the covers for the following conditions: Scoring or damage to the gasket surfaces (1) Ventilation system passages (2, 3) for restrictions Threaded bolt holes (4) for damage or debris

Oil Pan Cleaning and Inspection

1. Remove the oil filter fitting and bypass valve, as required. Refer to «Oil Filter and Adapter Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__oil-filter-and-adapter-removal) .
2. Remove the drain plug (430) and O-ring (429).
3. Remove the oil level sensor (727), bolt (751), and O-ring (728).
4. Clean the oil pan in solvent. Be sure to thoroughly clean all of the oil passages and recesses of the pan.
5. Dry the oil pan with compressed air.
6. Inspect the oil pan for the following conditions: Damaged gasket surfaces Restrictions within the oil passages of the pan Threaded bolt holes for damage
7. Inspect the displacement on demand oil pressure relief valve for proper operation. Lightly depress the valve (2). The valve spring (1) should seat the valve to the proper closed position.
8. The valve (455) is press-fit in the oil pan and is serviceable separately.

1. Remove and discard the intake manifold-to-cylinder head gaskets (514).
2. Remove the manifold absolute pressure (MAP) sensor (714). Refer to «Intake Manifold Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__intake-manifold-removal) .
3. Remove the evaporative emission (EVAP) canister purge solenoid valve (730), EVAP tube (729), and fuel rail with injectors. Refer to «Fuel Rail and Injectors Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__fuel-rail-and-injectors-removal) .
4. Remove the throttle body and gasket. Refer to «Throttle Body Removal»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__throttle-body-removal) .
5. Clean the intake manifold in solvent.
6. Dry the intake manifold with compressed air.

1. Inspect the manifold for the following conditions: Damaged gasket or sealing surfaces (1, 5) Loose threaded inserts or studs (2, 4) Debris or restrictions within the passages of the manifold Damaged or broken hose fittings (3, 6) Inspect the composite intake manifold assembly for cracks or other damage.
2. Inspect the intake manifold cylinder head deck for warpage. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of 2 runner port openings. Insert a feeler gage between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold (600) and heat shield (603) in solvent.
2. Dry the exhaust manifold with compressed air.
3. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging.
4. Inspect for a loose, damaged, or cracked heat shield (603).
5. Inspect the studs (605) for damaged threads.
6. Use a straight edge and a feeler gage and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the 2 front or 2 rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.

Coolant Air Bleed Pipe Cleaning and Inspection

1. Remove the seals (308) from the pipe and covers.
2. Clean the pipe (307) and covers in solvent.
3. Dry the pipe (307) and covers with compressed air.
4. Inspect the pipe and covers for damaged sealing surfaces or restrictions within the pipe.
5. Inspect the hose (311) for wear, restrictions, or damage.

Water Pump Cleaning and Inspection

1. Clean all excess dirt and debris from the water pump housing.
2. Inspect the water pump for the following conditions: Gasket sealing surfaces for excessive scratches or gouging Excessive side-to-side play in the pulley shaft Leakage at the water pump vent hole A stain around the vent hole is acceptable. If leakage, dripping, occurs with the engine running and the cooling system pressurized, replace the water pump. Wear or damage in the belt tracking area of the pulley (1)
3. Inspect the water manifold for the following conditions: Damage to threaded bolt holes (1) Restrictions within the internal passages (2, 3) Gasket sealing surfaces (4) for excessive scratches or gouging

Thread Repair

Tools Required

1. J 42385-100 Head/Main Bolt Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 42385-200 Common Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 42385-300 Fixtures and Hardware Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Scheme 53

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

1. Drill out the threads of the damaged hole (1). M6 inserts require a minimum drill depth of 15 mm (0.59 in). M8 inserts require a minimum drill depth of 20 mm (0.79 in). M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
2. Using compressed air, clean out any chips.
3. Counterbore the hole to the full depth permitted by the tool (1).
4. Using compressed air, clean out any chips.
5. Using a tap wrench (2), tap the threads of the drilled hole. M6 inserts require a minimum tap depth of 15 mm (0.59 in). M8 inserts require a minimum tap depth of 20 mm (0.79 in). M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
6. Using compressed air, clean out any chips.
7. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
8. Using compressed air, clean any cutting oil and chips out of the hole.
9. Lubricate the threads of the installer tool (2) with the driver oil (1).
10. Install the insert (2) onto the driver tool (1).
11. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent, to the insert OD threads (2).
12. Install the insert (2) into the hole. Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
13. Inspect the insert for proper installation into the hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).

Cylinder Head Bolt Hole Thread Repair

1. The cylinder head bolt hole thread repair kit consists of the following items: The drill (1) The tap (2) The installer (3) The sleeve (4) The alignment pin (5) The bushing (6) The bolts (7) The fixture plate (8)
2. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck. Position the fixture plate and bushing over the hole that is to be repaired (4).
3. Position the alignment pin (1) through the bushing and into the hole.
4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6. Install the sleeve (2) onto the drill (1).
7. Drill out the threads of the damaged hole. Drill the hole until the stop collar of the drill bit or the sleeve contacts the bushing.
8. Using compressed air, clean out any chips.
9. Using a tap wrench, tap the threads of the drilled hole.
10. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (1) on the tap aligns with the top of the drill bushing (3).
11. Remove the fixture plate (2), bushing (3), and bolts.
12. Using compressed air, clean out any chips.
13. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
14. Using compressed air, clean any cutting oil and chips out of the hole.
15. Lubricate the threads of the installer tool (2) with the driver oil (1).
16. Install the insert (2) onto the driver tool (1).
17. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent, to the insert OD threads (2).
18. Install the insert and driver (1) into the hole. Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

Main Cap Bolt Hole Thread Repair

1. The main cap bolt hole thread repair kit consists of the following items: The drill (1) The tap (2) The installer (3) The fixture plate (4) The long bolts (5) The short bolts (6) The alignment pin (7) The bushing (8)
2. Install the fixture plate, bolt, and bushing onto the engine block. Position the fixture plate and bushing over the hole that is to be repaired.
3. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
4. Drill out the damaged hole. The outer bolt hole locations 11-20 have the shallower counterbores. Use sleeve J 42385-316 with the drill. Drill until the stop collar of the drill bit or the sleeve contacts the bushing.
5. Using compressed air, clean out any chips.
6. Using a tap wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark on the tap aligns with the top of the bushing. For the deeper main cap holes 1-10, rotate the tap until the upper mark (4) on the tap aligns with the top of the bushing (3). For the shallower main cap holes 11-20, rotate the tap until the lower mark (1) on the tap aligns with top of the bushing (3).
7. Using compressed air, clean out any chips.
8. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), or equivalent, into the hole.
9. Using compressed air, clean any cutting oil and chips out of the hole.
10. Lubricate the threads of the installer tool (2) with the driver oil (1).
11. Install the insert (2) onto the driver tool (1).
12. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent, to the insert OD threads (2).
13. Install the insert and driver (1) through the fixture plate and bushing and into the hole. Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2). The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

Service Prior to Assembly

1. Dirt or debris will cause premature wear of the rebuilt engine. Clean all components. Refer to «Cleanliness and Care»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__cleanliness-and-care) .
2. Use the proper tools to measure components when inspecting for excessive wear. Components that are not within the manufacturers specifications must be repaired or replaced.
3. When the components are installed into an engine, return the components to their original location, position and direction. Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .
4. During assembly, lubricate all moving parts with clean engine oil. This provides initial lubrication when the engine is first started.

Engine Block Plug Installation

1. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block coolant heater sealing washer, if applicable. Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
2. Install the engine block coolant heater to the engine block. Tighten: Tighten the block coolant heater to 50 N.m (37 lb ft).
3. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block coolant drain hole plug sealing washer.
4. Install the engine block coolant drain hole plug. Tighten: Tighten the coolant drain hole plug to 60 N.m (44 lb ft).
5. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block left front oil gallery plug sealing washer (117).
6. Install the engine block left front oil gallery plug (116). Tighten: Tighten the block left front oil gallery plug to 60 N.m (44 lb ft).
7. Apply a 3.175 mm (0.125 in) bead of sealant GM P/N 12346004 (Canadian P/N 10953480) to the engine block left rear oil gallery plug sealing washer (113).
8. Install the engine block left rear oil gallery plug (112). Tighten: Tighten the block left rear oil gallery plug to 60 N.m (44 lb ft).
9. Inspect the engine block rear oil gallery plug and O-ring seal. If the O-ring seal on the plug is not cut or damaged, the rear oil gallery plug may be used again.
10. Lubricate the O-ring seal with clean engine oil.
11. Install the O-ring seal onto the plug.
12. Install the engine block rear oil gallery plug into the oil gallery bore. A properly installed block plug will protrude 0.8-1.4 mm (0.0315-0.055 in) beyond the rear face of the block.
13. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the sides of the NEW front oil gallery plug (101).
14. Install a NEW engine block front oil gallery plug. Install the plug into the oil gallery bore 2.2-2.8 mm (0.0086-0.011 in) below flush.
15. Install the left side knock sensor (718) and bolt (739). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
16. Install the right side knock sensor (718) and bolt (739). Tighten: Tighten the bolt to 20 N.m (15 lb ft).

Crankshaft and Bearings Installation

Tools Required

J 45059 Angle Meter

1. Install the crankshaft bearings to the engine block and bearing caps. The thrust bearings are to be installed into center journal.
2. Lubricate the bearing surfaces and crankshaft journals with clean engine oil.
3. Install the crankshaft.
4. Install the crankshaft bearing caps, with bearings, into the engine block.
5. Install the M10 bolts (129) and M10 studs (128).
6. Tap the bearing caps into place with a plastic-face hammer.
7. Install the NEW M8 bearing cap side bolts (127).
8. Tighten the bearing cap M10 bolts (1-10). Tighten: Tighten the M10 bearing cap bolts (1-10) a first pass in sequence to 20 N.m (15 lb ft).
9. Using a plastic-face hammer, tap the crankshaft rearward, then forward to align the thrust bearings. Tighten: Tighten the M10 bolts (1-10) a final pass in sequence 80 degrees using the J 45059 . Tighten the M10 studs (11-20) a first pass in sequence to 20 N.m (15 lb ft). Tighten the M10 studs (11-20) a final pass in sequence 51 degrees using the J 45059 . Tighten the bearing cap M8 bolts to 25 N.m (18 lb ft). Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap.
10. Install the crankshaft position (CKP) sensor. Inspect the CKP sensor O-ring seal (750). If the O-ring seal is not cut or damaged, it may be used. Coat the O-ring seal with clean engine oil. Install the O-ring onto the sensor. Install the sensor (701). Rotate the sensor until the locating hole in the bracket aligns with the bolt hole in the block. Install the sensor bolt (702). Tighten: Tighten the CKP sensor bolt to 25 N.m (18 lb ft).
11. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the center crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.04-0.2 mm (0.0015-0.0078 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.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor
2. J 8087 Cylinder Bore Gage
3. J 41556 Connecting Rod Guide. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. J 45059 Angle Meter

Piston Selection

1. With a micrometer at a right angle, measure the piston outside diameter (OD). Measure the diameter 43 mm (1.69 in) from the top of the piston. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
2. Record the piston OD.
3. Adjust the micrometer to the recorded piston OD.
4. Insert the J 8087 into the micrometer and zero the gage dial.
5. Using the J 8087 , measure the cylinder bore inside diameter (ID). Measure at a point 64 mm (2.5 in) from the top of the cylinder.
6. Record the cylinder bore ID.
7. Subtract the piston OD from the cylinder bore ID to determine the piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .
8. If the proper clearance cannot be obtained, select another piston, pin, and connecting rod assembly and again measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing for an oversize piston.

Piston, Pin, and Connecting Rod Installation

1. Lightly lubricate the following components with clean engine oil: Piston Piston rings Cylinder bore Bearings and bearing surfaces
2. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other.
3. Position the compression ring end gaps 180 degrees opposite each other.
4. Install the J 41556 to the connecting rod. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Identify the proper installation direction of the piston and connecting rod assembly. When installing the piston and connecting rod assembly, the mark on the top of the piston (1) and the tab (2) on the side of the connecting rod should face the front of the engine.
6. Install the J 8037 onto the piston and compress the piston rings.
7. Install the piston, pin, and connecting rod assembly into the cylinder bore. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all the piston rings have entered the cylinder bore.
8. Use the J 41556 to guide the connecting rod onto the crankshaft journal. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
9. Remove the J 41556 from the connecting rod. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
10. Install the bearing cap (103), bearing (104), and bolts (102). Tighten: Tighten the bolts a first pass to 20 N.m (15 lb ft). Tighten the bolts a final pass to 75 degrees using the J 45059 .
11. Measure the connecting rods for the proper side clearance. Refer to «Engine Mechanical Specifications»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__engine-mechanical-specifications) .

Camshaft Installation

1. Lubricate the camshaft journals and the bearings with clean engine oil.
2. Install 3 M8 - 1.25 x 100 mm (M8 - 1.25 x 4.0 in) bolts into the camshaft front bolt holes.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the 3 bolts from the front of the camshaft.
5. Install the camshaft retainer (203) and the bolts (204). Install the retainer with the sealing gasket facing the front of the engine block.
6. Tighten the camshaft retainer bolts. Tighten: Tighten the first design hex head bolts (3) to 25 N.m (18 lb ft). Tighten the second design TORX® head bolts (4) to 15 N.m (11 lb ft).

Timing Chain and Sprockets Installation

Tools Required

1. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Install the timing chain dampener (232) and bolts (231). Tighten: Tighten the timing chain dampener bolts to 25 N.m (18 lb ft).
7. Install the camshaft sprocket (205) and timing chain (208). If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
8. Install the camshaft sprocket bolts (206). Tighten: Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).
9. Inspect for proper alignment of the camshaft and crankshaft sprocket timing marks (1, 2).

Oil Pump, Screen and Crankshaft Oil Deflector Installation

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump (413).
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts (411). Tighten: Tighten the oil pump bolts to 25 N.m (18 lb ft).
4. Install the crankshaft oil deflector.
5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen.
7. Install the oil pump screen.
8. Install the oil pump screen bolt and the deflector nuts. Tighten: Tighten the oil pump screen bolt to 12 N.m (106 lb in). Tighten the crankshaft oil deflector nut to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Housing Installation

Tools Required

1. J 41476 Front and Rear Cover Alignment Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41480 Front and Rear Cover Alignment. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Inspect the rear oil gallery plug for proper installation.
2. Install the rear housing gasket (519), rear housing (518), and bolts (517).
3. Tighten the bolts finger tight. Do not overtighten.
4. Install the J 41480 and bolts. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface.
6. Install the J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the tool mounting bolts until snug. Do not overtighten. Tighten the J 41480 tool-to-rear housing bolts evenly to 12 N. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .m (106 lb in). Tighten the rear housing bolts to 25 N.m (18 lb ft).
7. Remove the tools.
8. Measure the rear housing-to-engine block oil pan surface for flatness. Place a straight edge onto the engine block and rear housing oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the rear housing and the straight edge. The housing must be flush with the oil pan or no more than 0.5 mm (0.02 in) below flush.
9. If the rear housing-to-engine block oil pan surface alignment is not within specifications, repeat the housing alignment procedure.
10. If the correct rear housing-to-engine block alignment at the oil pan surface cannot be obtained, replace the rear housing.

Crankshaft Rear Oil Seal Installation

Tools Required

J 41479 Crankshaft Rear Oil Seal Installer. See Special Tools .

1. Lubricate the outside diameter (OD) of the oil seal (141) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear housing oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear seal bore.
6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
7. Align the oil seal onto the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear housing and bottoms into the seal bore.
9. Remove the tool.

Engine Front Cover Installation

Tools Required

1. J 41476 Front and Rear Cover Alignment Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41480 Front and Rear Cover Alignment. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

1. Install the front cover gasket (503), front cover (502), and bolts (501).
2. Tighten the cover bolts finger tight. Do not overtighten.
3. Install the J 41480 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
4. Install the J 41476 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Install the crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. Tighten the J 41480 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface, or no greater than 0.5 mm (0.02 in) (a) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
10. Inspect the camshaft position (CMP) sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be used again.
11. Lubricate the O-ring seal with clean engine oil.
12. Install the O-ring seal onto the sensor (703).
13. Install the sensor to the cover.
14. Install the bolt (705). Tighten: Tighten the bolt to 12 N.m (106 lb in).

Crankshaft Front Oil Seal Installation

Tools Required

J 41478 Crankshaft Front Oil Seal Installer. See Special Tools .

1. Lubricate the outer edge of the oil seal (140) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal (140) onto the J 41478 . See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. Install the J 41478 threaded rod, with nut, washer, guide, and oil seal, into the end of the crankshaft. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
5. Use the J 41478 in order to install the oil seal into the cover bore. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Use a wrench and hold the hex on the installer bolt. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Remove the tool. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.

Oil Pan Installation

1. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent, 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface. Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
2. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent, 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface.
3. Pre-assemble the oil pan gasket to the pan. Install the gasket onto the oil pan. Install the oil pan bolts (439, 453) to the pan and through the gasket.
4. Install the oil pan, gasket and bolts to the engine block.
5. Tighten bolts finger tight. Do not overtighten.
6. Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces.
7. Align the oil pan until the rear of engine block and rear of oil pan are flush or even. Tighten: Tighten the oil pan-to-block and oil pan-to-front cover bolts to 25 N.m (18 lb ft). Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in).
8. Measure the oil pan-to-engine block alignment. Place a straight edge across the rear of the engine block and rear of oil pan at the transmission housing mounting surfaces. IMPORTANT: The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing mounting surfaces. Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface, and inspect to ensure there is no more than a 0.25 mm (0.01 in) gap (a) between the pan and straight edge. If the oil pan alignment is not within specifications, remove the oil pan and repeat the above procedure.

Oil Filter and Adapter Installation

1. Install a new oil filter bypass valve (436) into the oil pan as required.
2. Install the oil filter fitting (438). Tighten: Tighten the oil filter fitting to 55 N.m (40 lb ft).
3. Lubricate the oil filter seal with clean engine oil.
4. Install the oil filter (437). Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
5. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides. Align the flat area (3) on the top of the non displacement on demand lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. The displacement on demand lifters are to be installed into the guide, with the notch in the guide (1) aligned with the raised area (2) of the lifter.
3. Install the valve lifters and guide assembly (210) to the engine block.
4. Install the valve lifter guide bolts (211). Tighten: Tighten the valve lifter guide bolts to 12 N.m (106 lb in).

Cylinder Head Installation - Left

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 45059 Angle Meter

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Cylinder Head Installation - Right

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 45059 Angle Meter

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Valve Rocker Arm and Push Rod Installation

1. Lubricate the valve rocker arms and pushrods with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.
3. Install the valve rocker arm pivot support.
4. Install the pushrods.
5. Install the rocker arms and bolts.
6. Rotate the crankshaft until number one piston is at top dead center of compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The camshaft and crankshaft sprocket alignment marks will be in the 12 o'clock positions. If viewing from the rear of the engine, the additional crankshaft pilot hole, non-threaded, will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank.
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten: Tighten exhaust valve rocker arm bolts 1, 2, 7, and 8 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 1, 3, 4, and 5 to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten: Tighten exhaust valve rocker arm bolts 3, 4, 5, and 6 to 30 N.m (22 lb ft). Tighten intake valve rocker arm bolts 2, 6, 7, and 8 to 30 N.m (22 lb ft).

Valve Rocker Arm Cover Installation - Left

1. Install a NEW gasket (504) into the valve rocker arm cover.
2. Install a new oil fill tube (423) and O-ring (422).
3. Install the oil fill cap (424) and O-ring (450).
4. Install the valve rocker arm cover onto the cylinder head.
5. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bolts (723).
7. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 8 N.m (71 lb in).
8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bracket studs (720).
9. Install the ignition coil and bracket assembly (719) and studs (720). Tighten: Tighten the bracket studs to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install a NEW gasket (504) into the valve rocker arm cover.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bolts (723).
5. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 8 N.m (71 lb in).
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bracket studs (720).
7. Install the ignition coil and bracket assembly (719) and studs (720). Tighten: Tighten the bracket studs to 12 N.m (106 lb in).

Valve Lifter Oil Filter Installation

1. Install a NEW oil filter (452) and O-ring (454) assembly.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the sensor.
3. Install the oil pressure sensor (706) and washer (707). Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft).

Valve Lifter Oil Manifold Installation

1. Do not lift the manifold assembly by the electrical lead frame.
2. Install the service gasket (556) onto the manifold.
3. Install the manifold (451) with gasket.
4. Install the manifold bolts (506). Tighten: Tighten the manifold bolts to 25 N.m (18 lb ft).

Coolant Air Bleed Pipe Installation

1. Install the seals (308) onto the engine coolant air bleed pipe and covers.
2. Install the hose (311) and clamps (322) onto the pipe (307).
3. Install the pipe (307).
4. Install the bolts (309). Tighten: Tighten the pipe bolts to 12 N.m (106 lb in).
5. Install the covers (313).
6. Install the bolts (312). Tighten: Tighten the cover bolts to 12 N.m (106 lb in).

Intake Manifold Installation

1. Install NEW intake manifold-to-cylinder head gaskets (514).
2. Install the intake manifold (500).
3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512). Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
4. Install the intake manifold bolts. Tighten: Tighten the intake manifold bolts (1-10) a first pass in sequence to 5 N.m (44 lb in). Tighten the intake manifold bolts (1-10) a final pass in sequence to 10 N.m (89 lb in).
5. Install the fuel rail. Refer to «Fuel Rail and Injectors Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__fuel-rail-and-injectors-installation) .
6. Lubricate the manifold absolute pressure (MAP) sensor grommet (715) with clean engine oil.
7. Install the grommet onto the MAP sensor (714).
8. Install the MAP sensor.
9. Install the positive crankcase ventilation (PCV) hose - dirty air (716).

Fuel Rail and Injectors Installation

1. Lubricate the NEW fuel injector O-ring seals (532, 534) with clean engine oil.
2. Install the O-ring seals to the fuel injectors.
3. Install the fuel injectors (533) and retainers (521).
4. Note the installed location of the fuel rail ground strap (557).
5. Install the fuel rail assembly (510) to the manifold. Push firmly on both sides of the rail until all injectors have entered their bores.
6. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts. Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
7. Install the fuel rail bolts (511) and ground strap (557). Tighten: Tighten the fuel rail bolts to 10 N.m (89 lb in).
8. Install the evaporative emission (EVAP) canister purge solenoid valve (730), bracket (741), and tube (729).

Throttle Body Installation

1. Install the throttle body gasket (509) to the intake manifold. Align the locating tab of the gasket with the notch in the manifold.
2. Install the throttle body (508) and bolts (538). Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).

Water Pump Installation

1. Install the thermostat (305), O-ring (304), inlet housing (303), and bolts (302). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
2. Install the water manifold (315), gaskets (306), and bolts (301). Tighten: Tighten the water manifold M8 bolts to 30 N.m (22 lb ft). Tighten the water manifold M10 bolts to 60 N.m (44 lb ft).
3. Install the water pump (300) and NEW gasket (314).
4. Install the water pump bolts (318). Tighten: Tighten the water pump bolts to 12 N.m (106 lb in).
5. Install the coolant air bleed hose and clamp (1) to the manifold.

Exhaust Manifold Installation - Left

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the bolts to 9 N.m (80 lb in).
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
4. Install the exhaust manifold, NEW gasket, and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Exhaust Manifold Installation - Right

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the bolts to 9 N.m (80 lb in).
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__sealers-adhesives-and-lubricants) .
4. Install the exhaust manifold, NEW gasket, and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Oil Level Indicator and Tube Installation

1. Inspect the O-ring seal (421) for cuts or damage. If the oil level indicator tube O-ring seal is not cut or damaged, it may be used again.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the O-ring seal onto the oil level indicator tube (420).
4. Install the oil level indicator tube into the engine and rotate into proper position.
5. Install the tube bolt (419). Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
6. Install the oil level indicator (418) into the tube.

Engine Flywheel Installation

1. Install the flex plate to the crankshaft.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the flex plate bolts.
3. Install the engine flex plate bolts. Tighten: Tighten the engine flex plate bolts (1-6) a first pass in sequence to 20 N.m (15 lb ft). Tighten the engine flex plate bolts (1-6) a second pass in sequence to 50 N.m (37 lb ft). Tighten the engine flex plate bolts (1-6) a final pass in sequence to 100 N.m (74 lb ft).

Crankshaft Balancer Installation

Tools Required

1. EN 47699 Flywheel Holding Tool. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
3. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
4. J 45059 Angle Meter

1. Install the EN 47699 (2), spacer (1), and bolt (3) to the block and flywheel. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
2. Tighten the EN 47699 bolt (1). See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Tighten: Tighten the bolt to 60 N.m (44 lb ft).
3. Position the balancer (138) onto the end of the crankshaft.
4. Use the J 41478 and the J 41665 in order to install the balancer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Assemble the J 41478 threaded rod, nut, washer and J 41665 installer. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) . Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tools.
5. Install the used crankshaft balancer bolt (139). Tighten: Tighten the crankshaft balancer bolt to 330 N.m (240 lb ft).
6. Remove the used crankshaft balancer bolt (139).
7. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .
8. Install the NEW crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). Tighten the crankshaft balancer bolt a second pass to 140 degrees using the J 45059 .
9. Remove the EN 47699 , spacer, and bolt. See «Special Tools»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__special-tools) .

Engine Prelubing

Tools Required

J 45299 Engine Preluber

1. Remove the engine oil filter and fill with clean engine oil.
2. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
3. Locate the engine block left front oil gallery plug (116).
4. Install the M16 x 1.5 adapter P/N 509375.
5. Install the flexible hose to the adapter and open the valve.
6. Pump the handle on the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
7. Close the valve and remove the flexible hose and adapter from the engine.
8. Install the gallery plug to the engine. Tighten: Tighten the oil gallery plug to 60 N.m (44 lb ft).
9. Top-off the engine oil to the proper level.

Crankcase Ventilation System Description

A closed crankcase ventilation system is used in order to provide a more complete scavenging of crankcase vapors. Fresh air from the throttle body is supplied to the crankcase, mixed with blow-by gases, and then passed through a crankcase ventilation pipe/passage into the intake manifold.

Results of Incorrect Operation

A plugged PCV Pipe/passage way may cause

1. Rough idle
2. Stalling or slow idle speed
3. Oil leaks
4. Sludge in engine

Drive Belt System Description

The drive belt system consists of the following components

1. The drive belt
2. The drive belt tensioner
3. The drive belt idler pulley
4. The crankshaft balancer pulley
5. The accessory drive component mounting brackets
6. The accessory drive components The power steering pump, if belt driven The generator The A/C compressor, if equipped The engine cooling fan, if belt driven The water pump, if belt driven The vacuum pump, if equipped The air compressor, if equipped

The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.

Scheme 54

The 5.3 Liter V8 engine is identified as RPO LS4 VIN C.

Camshaft and Drive System

A billet steel 1 piece camshaft is supported by 5 bearings pressed into the engine block. The camshaft timing sprocket is mounted to the front of the camshaft and is driven by the crankshaft sprocket through the camshaft timing chain. The camshaft position (CMP) sensor lobes are incorporated into the front face of the camshaft sprocket with the CMP sensor mounted in the engine front cover. A timing chain dampener is mounted to the front of the engine block above the crankshaft sprocket. The externally splined crankshaft sprocket is positioned to the crankshaft by a key and keyway. The crankshaft sprocket external splines drive the oil pump drive gear. A retaining plate mounted to the front of the engine block maintains camshaft location.

Crankshaft

The crankshaft is cast nodular iron. The crankshaft is supported by 5 crankshaft bearings. The bearings are retained by crankshaft bearing caps which are machined with the engine block for proper alignment and clearance. The crankshaft journals are undercut and rolled. The center main journal is the thrust journal. A crankshaft position (CKP) reluctor ring is press fit mounted at the rear of the crankshaft. The reluctor ring is not serviceable separately.

Cylinder Heads

The cylinder heads are cast aluminum and have pressed in place powdered metal valve guides and valve seats. Passages for the engine coolant air bleed system are at the front of each cylinder head. The valve rocker arm covers are retained to the cylinder heads by 4 center mounted rocker arm cover bolts.

Engine Block

The engine block is a cam-in-block deep skirt 90 degree V configuration with 5 crankshaft bearing caps. The engine block is cast aluminum. The 5 crankshaft bearing caps each have 4 vertical M10 and 2 horizontal M8 mounting bolts. The camshaft is supported by 5 camshaft bearings pressed into the block.

Exhaust Manifolds

The exhaust manifolds are a 1 piece cast iron design. The exhaust manifolds direct exhaust gasses from the combustion chambers to the exhaust system. Each manifold also has an externally mounted heat shield that is retained by bolts.

Intake Manifold

The intake manifold is a 1 piece composite design that incorporates brass threaded inserts for mounting the fuel rail and throttle body. Each side of the intake manifold is sealed to the cylinder head by 8 non-reusable silicone sealing gaskets. The electronically actuated throttle body bolts to the front of the intake manifold. The throttle body is sealed by a 1 piece push in place silicone gasket. The fuel rail assembly, with 8 separate fuel injectors, is retained to the intake by 4 bolts. The injectors are seated into their individual manifold bores with O-ring seals to provide sealing. The manifold absolute pressure (MAP) sensor is installed and retained to the top of the intake manifold and sealed by an O-ring seal. The evaporative emission (EVAP) canister purge solenoid valve is retained to the manifold by a mounting bracket. There are no coolant passages within the intake manifold. The manifold is installed with the throttle body facing the rear of the engine.

Oil Pan

The structural rear-sump oil pan is cast aluminum. Incorporated into the design is the oil filter mounting boss, the displacement on demand (DoD) oil pressure relief valve and the drain plug opening. Filtered oil is returned to the engine block through the oil filter to the engine block upper oil galleries. The press-fit oil pressure relief valve is located at the left rear of the oil pan and can be inspected by removing the oil pan cover. The alignment of the structural oil pan to the rear of the engine block and transmission bell housing is critical.

Piston and Connecting Rod Assembly

The pistons are cast aluminum. The pistons use 2 compression rings and 1 oil control ring assembly. The piston is a low friction, lightweight design with a flat or recessed top and barrel shaped skirt. The piston pins are chromium steel and are a full-floating design. The connecting rods are powdered metal. The connecting rods are fractured at the connecting rod journal and then machined for the proper clearance. All applications use a piston with a graphite coated skirt. The piston and pin are to be serviced as an assembly.

Valve Rocker Arm Cover Assemblies

The valve rocker arm covers are cast aluminum and use a pre-molded silicon gasket for sealing. Mounted to each rocker cover are the coil and bracket assemblies. Incorporated into the left cover is the oil fill tube and the positive crankcase ventilation (PCV) fresh air passage. Incorporated into the right cover is the PCV system dirty air passage.

Valve Train

Motion is transmitted from the camshaft through the hydraulic roller valve lifters and tubular pushrods to the roller type rocker arms. The nylon valve lifter guides position and retain the valve lifters. The valve rocker arms for each bank of cylinders are mounted on pedestals or pivot supports. Each rocker arm is retained on the pivot support and cylinder head by a bolt. Valve lash is net build. Cylinders 1, 4, 6, and 7 are displacement on demand. Refer to Displacement on Demand (DoD) System Description .

System Operation

General Motors Displacement on Demand® (DoD) engine control system has the ability, under certain light load driving conditions, to provide maximum fuel economy by deactivating 4 of the engines 8 cylinders. The engine will normally operate on 8 cylinders in V8 mode during, starting, idling, and medium or heavy throttle conditions. When commanded ON, the powertrain control module (PCM) will direct the DoD system and deactivate cylinders 1 and 7 on the left bank and cylinders 4 and 6 on the right bank, forcing V4 mode. Refer to Lubrication Description (Main Pressure Below 65 psi - DoD Off) or Lubrication Description (Main Pressure Above 65 psi - DoD Off) or Lubrication Description (Main Pressure Below 65 psi - DoD On) or Lubrication Description (Main Pressure Above 65 psi - DoD On) and Displacement on Demand (DoD) System Description in Engine Controls - 5.3L.

Scheme 55

The valve lifter oil manifold (VLOM) assembly (1) is bolted to the top of the engine block beneath the intake manifold assembly. The oil manifold consists of 4 electrically operated and normally-closed solenoids (2). Each solenoid directs the flow of pressurized engine oil to the DoD intake and exhaust valve lifters (5). The oil pressure relief valve (6), located in the left rear area of the oil pan, regulates engine oil pressure to the lubrication system and the oil manifold.

When enabling conditions are met for DoD operation, the ECM will ground each solenoid control circuit in firing order sequence, allowing current to flow through the solenoid windings. With the windings energized, the solenoid valves open and direct pressurized engine oil through the manifold into 8 vertical passages in the engine block lifter valley. The 8 vertical passages, 2 per cylinder, direct pressurized oil to the valve lifter bores of the cylinders to be deactivated. When vehicle operating conditions require a return to V8 mode, the ECM will turn OFF the ground circuit for the solenoids, allowing the solenoid valves to close. When the solenoid valves are closed, remaining oil pressure is exhausted through the bleed passages of the manifold into the engine block lifter valley. The housing of the oil manifold incorporates several oil bleed passages that continually purge trapped air from the manifold and engine block.

To help control contamination within the DoD hydraulic system, a small replaceable oil filter (4) is located in the manifold oil inlet passage. The oil pressure sensor (3) monitors engine oil pressure and provides information to the ECM.

Scheme 56

When operating in V8 mode, the DoD valve lifters function similar to the non-DoD valve lifters. The DoD oil manifold solenoids are in the closed position with no pressurized oil directed to the valve lifters. The pushrod (1) travels upward and downward to actuate the rocker arm and valve. The spring loaded locking pins (5) of the lifter are extended outward and mechanically lock the pin housing (4) to the outer body of the valve lifter (3).

When the DoD system is commanded ON, the ECM will direct the solenoids of the oil manifold to open and direct pressurized oil to the valve lifters. Oil travels through the manifold and engine block oil galleries and enters the inlet port (6) of the valve lifter.

When operating in V4 mode, pressurized oil forces the locking pins (11) inward. The pushrod (7) remains in a constant position and does not travel upward and downward. The outer body of the lifter (9) moves upward and downward independently from the pin housing (10). The valve lifter spring (8) retains tension on the valve train components to eliminate valve train noise.

When the DoD system is commanded OFF, the ECM directs the solenoids of the oil manifold to close, stopping the flow of pressurized oil to the valve lifters. The oil pressure within the lifter will decrease and the locking pins will move outward to mechanically lock the pin housing and outer body.

Scheme 57

The DoD engine block incorporates additional features to support DoD system operation. Engine oil pressure is routed to the manifold assembly from an oil gallery (2) in the rear of the cylinder block. Cylinders 1, 4, 6, and 7 each have 2 vertical, cast-in-block oil passages (1). The vertical oil passages permit oil flow from the manifold assembly to the valve lifter bores.

Powertrain Control Module (PCM)

Refer to Displacement on Demand (DoD) System Description in Engine Controls - 5.3L.

New Product Information

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

Changes may include 1 or more of the following items

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

Torque Values and/or Fastener Tightening Strategies

1. All fasteners and threaded holes on the LS4 engine utilize metric threads.
2. Certain fasteners should not be used again. Bolts, studs, or other fasteners that must be replaced, will be called out in the specific service procedure.
3. Some applications may use a second design camshaft retainer plate and bolts. Refer to «Camshaft Installation»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__camshaft-installation) .

New Sealants and/or Adhesives

Sealers and adhesives, as required, are identified within the specific service procedures. Refer to Sealers, Adhesives, and Lubricants .

Disassembly and Assembly Procedure Revisions

The piston and piston pin are to be serviced as an assembly.

Engine Mechanical Diagnostic Procedure Revisions

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Diagnostic Starting Point - Engine Mechanical .

New Special Tools Required

No new special tools have been designed for this application.

A Component Comparison from the Previous Year

Some applications may use a second design camshaft retainer plate and bolts. Refer to Camshaft Installation .

Scheme 58

Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is pressurized as it passes through the pump and is sent through the engine block lower oil gallery. Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range.

Pressurized oil is directed through the engine block lower oil gallery to the full flow oil filter where harmful contaminants are removed. A bypass valve is incorporated into the oil pan at the oil filter boss, which permits oil flow in the event the filter becomes restricted. A second valve, the displacement on demand (DoD) oil pressure relief valve is incorporated into the left rear side of the oil pan. The DoD oil pressure relief valve limits oil pressure directed to the upper oil galleries and oil manifold assembly to 448 kPa (65 psi) at 3,000 RPM and 21°C (70°F).

Oil is then directed from the filter to the upper main oil galleries and the DoD manifold assembly. Oil from the left upper oil gallery is directed to the crankshaft and camshaft bearings. Oil that has entered both the upper main oil galleries also pressurizes the valve lifter assemblies and is then pumped through the pushrods to lubricate the valve rocker arms and valve stems. Oil returning to the pan is directed by the crankshaft oil deflector. The oil pressure sensor is located at the top rear of the engine. Refer to Displacement on Demand (DoD) System Description .

Scheme 59

Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is pressurized as it passes through the pump and is sent through the engine block lower oil gallery. Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range.

Pressurized oil is directed through the engine block lower oil gallery to the full flow oil filter where harmful contaminants are removed. A bypass valve is incorporated into the oil pan at the oil filter boss, which permits oil flow in the event the filter becomes restricted. A second valve, the displacement on demand (DoD) oil pressure relief valve is incorporated into the left rear side of the oil pan. The DoD oil pressure relief valve limits oil pressure directed to the upper oil galleries and oil manifold assembly to 448 kPa (65 psi) at 3,000 RPM and 21°C (70°F). When main oil pressure exceeds 448 kPa (65 psi), the DoD oil pressure relief valve exhausts excess oil to the sump.

Oil is then directed from the filter to the upper main oil galleries and the DoD manifold assembly. Oil from the left upper oil gallery is directed to the crankshaft and camshaft bearings. Oil that has entered both the upper main oil galleries also pressurizes the valve lifter assemblies and is then pumped through the pushrods to lubricate the valve rocker arms and valve stems. Oil returning to the pan is directed by the crankshaft oil deflector. The oil pressure sensor is located at the top rear of the engine. Refer to Displacement on Demand (DoD) System Description .

Scheme 60

Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is pressurized as it passes through the pump and is sent through the engine block lower oil gallery. Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range.

Pressurized oil is directed through the engine block lower oil gallery to the full flow oil filter where harmful contaminants are removed. A bypass valve is incorporated into the oil pan at the oil filter boss, which permits oil flow in the event the filter becomes restricted. A second valve, the displacement on demand (DoD) oil pressure relief valve is incorporated into the left rear side of the oil pan. The DoD oil pressure relief valve limits oil pressure directed to the upper oil galleries and oil manifold assembly to 448 kPa (65 psi) at 3,000 RPM and 21°C (70°F).

Oil is then directed from the filter to the upper main oil galleries and the DoD manifold assembly. Oil from the left upper oil gallery is directed to the crankshaft and camshaft bearings. Oil that has entered both the upper main oil galleries also pressurizes the valve lifter assemblies and is then pumped through the pushrods to lubricate the valve rocker arms and valve stems. Oil returning to the pan is directed by the crankshaft oil deflector. The oil pressure sensor is located at the top rear of the engine.

With DoD activated, the ECM commands the 4 solenoids to open, directing oil through the engine block oil galleries to the intake and exhaust valve lifters for cylinders 1, 4, 6, and 7. Refer to Displacement on Demand (DoD) System Description .

Scheme 61

Engine lubrication is supplied by a gerotor type oil pump assembly. The pump is mounted on the front of the engine block and driven directly by the crankshaft sprocket. The pump gears rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is pressurized as it passes through the pump and is sent through the engine block lower oil gallery. Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range.

Pressurized oil is directed through the engine block lower oil gallery to the full flow oil filter where harmful contaminants are removed. A bypass valve is incorporated into the oil pan at the oil filter boss, which permits oil flow in the event the filter becomes restricted. A second valve, the displacement on demand (DoD) oil pressure relief valve is incorporated into the left rear side of the oil pan. The DoD oil pressure relief valve limits oil pressure directed to the upper oil galleries and oil manifold assembly to 448 kPa (65 psi) at 3,000 RPM and 21°C (70°F). When main oil pressure exceeds 448 kPa (65 psi), the DoD oil pressure relief valve exhausts excess oil to the sump.

Oil is then directed from the filter to the upper main oil galleries and the DoD manifold assembly. Oil from the left upper oil gallery is directed to the crankshaft and camshaft bearings. Oil that has entered both the upper main oil galleries also pressurizes the valve lifter assemblies and is then pumped through the pushrods to lubricate the valve rocker arms and valve stems. Oil returning to the pan is directed by the crankshaft oil deflector. The oil pressure sensor is located at the top rear of the engine.

With DoD activated, the ECM commands the 4 solenoids to open, directing oil through the engine block oil galleries to the intake and exhaust valve lifters for cylinders 1, 4, 6, and 7. Refer to Displacement on Demand (DoD) System Description .

Cleanliness and Care

1. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
2. When any internal engine parts are serviced, care and cleanliness is important.
3. When components are removed for service, they should be marked, organized or retained in a specific order for assembly. Refer to «Separating Parts»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l__separating-parts) .
4. At the time of installation, components should be installed in the same location and with the same mating surface as when removed.
5. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch. These surfaces should be covered or protected to avoid component damage.
6. A liberal coating of clean engine oil should be applied to friction areas during assembly.
7. Proper lubrication will protect and lubricate friction surfaces during initial operation.

Separating Parts

Separate, mark, or organize the following components

1. Piston and the piston pin
2. Piston to the specific cylinder bore
3. Piston rings to the piston
4. Connecting rod location and orientation to the crankshaft journal
5. Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
6. Crankshaft main and connecting rod bearings
7. Camshaft and valve lifters
8. Valve lifters, lifter guides, pushrods and rocker arm assemblies
9. Valve to the valve guide
10. Valve spring to the cylinder head location
11. Engine block main bearing cap location and direction
12. Oil pump drive and driven gears

J 28410 Gasket Remover

Gasket Use and Applying Sealants

1. Do not use any gasket again unless specified.
2. Gaskets that can be used again will be identified in the service procedure.
3. Do not apply sealant to any gasket or sealing surface unless called out in the service information.

Separating Components

1. Use a rubber mallet to separate components.
2. Bump the part sideways to loosen the components.
3. Bumping should be done at bends or reinforced areas to prevent distortion of parts.

Cleaning Gasket Surfaces

1. Remove all gasket and sealing material from the part using the J 28410 or equivalent.
2. Care must be used to avoid gouging or scraping the sealing surfaces.
3. Do not use any other method or technique to remove sealant or gasket material from a part.
4. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage.

Assembling Components

1. When assembling components, use only the sealant specified or equivalent in the service procedure.
2. Sealing surfaces should be clean and free of debris or oil.
3. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
4. Components requiring lubrication will be identified in the service procedure.
5. When applying sealant to a component, apply the amount specified in the service procedure.
6. Tighten bolts to specifications. Do not overtighten.

Pipe Joint Compound

1. Pipe joint compound is a pliable sealer that does not completely harden. This type of sealer is used where 2 non-rigid parts, such as the oil pan and the engine block, are assembled together.
2. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
4. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes.
5. Apply a continuous bead of pipe joint compound to 1 sealing surface. Sealing surfaces to be resealed must be clean and dry.
6. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. RTV sealant hardens when exposed to air. This type of sealer is used where 2 non-rigid parts, such as the intake manifold and the engine block, are assembled together.
2. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
4. Apply RTV sealant to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes.
5. Assemble components while the RTV sealant is still wet, within 3 minutes. Do not wait for the RTV sealant to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

1. Anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts, such as castings, are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
2. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/pontiac/grand-prix/vii-2004-2008/remont/mechanical/#engine-mechanical-53l) .
3. Apply a continuous bead of gasket eliminator to 1 flange. Surfaces to be sealed must be clean and dry.
4. Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
5. Tighten bolts to specifications. Do not overtighten.
6. After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Tools and Equipment

Special tools are listed and illustrated throughout this section, with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available

1. Approved eye protection and safety gloves
2. A clean, well lit, work area
3. A suitable parts cleaning tank
4. A compressed air supply
5. Trays or storage containers to keep parts and fasteners organized
6. An adequate set of hand tools
7. Approved engine repair stand
8. An approved engine lifting device that will adequately support the weight of the components

Special Tools

Special Tools Illustration Tool Number/Description EN-46999 Displacement on Demand Tester EN-46999-1 Displacement on Demand Tester Air Adapter EN-46999-5 Displacement on Demand Tester Harness - Small Block V8 EN-47699 Flywheel Holding Tool EN-47988 Serpentine Belt Tension Unloader J 3049-A Valve Lifter Remover J 6125-1B Slide Hammer Adapter J 7872 Magnetic Base Dial Indicator J 8037 Ring Compressor J 8062 Valve Spring Compressor - Head Off J 8087 Cylinder Bore Gage J 8089 Carbon Removal Brush J 8433 Two Jaw Puller J 8520 Cam Lobe Lift Indicator J 9666 Valve Spring Tester J 21867 Pressure Gage J 21867-16 Oil Pressure Adapter J 22794 Spark Plug Port Adapter J 24270 Cylinder Bore Ridge Reamer J 28410 Gasket Remover J 28428-E High-Intensity Black Light Kit J 28467-501 Engine Support Fixture Adapters J 28467-B Universal Engine Support Fixture J 33049 Camshaft Bearing Service Set J 35667-A Cylinder Head Leakdown Tester J 37378-1 Valve Guide Reamer J 38185 Hose Clamp Pliers J 38606 Valve Spring Compressor J 39580 Power Pack Stand Engine and Transaxle Assembly Support J 41476 Front and Rear Cover Alignment Tool J 41478 Crankshaft Front Oil Seal Installer J 41479 Crankshaft Rear Oil Seal Installer J 41480 Front and Rear Cover Alignment J 41556 Connecting Rod Guide J 41558 Crankshaft Sprocket Remover J 41665 Crankshaft Balancer and Sprocket Installer J 41712 Oil Pressure Switch Socket J 41816 Crankshaft Balancer Remover J 41816-2 Crankshaft End Protector J 41818 Crankshaft Bearing Cap Remover J 42385-100 Head/Main Bolt Thread Repair Kit J 42385-200 Common Threads Repair Kit J 42385-300 Fixtures and Hardware Kit J 42451-1 Engine Support Adapter J 42504 Engine Lift Bracket J 42640 Steering Column Anti-rotation Pin J 42907 Oil Pressure Tester J 43690 Rod Bearing Checking Tool J 43690-100 Rod Bearing Checking Tool - Adapter Kit J 45059 Angle Meter J 45299 Engine Preluber

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See also:
• Diagnostic System Check - Vehicle
• Strategy Based Diagnosis
• Checking Aftermarket Accessories
• Spark Plug Inspection
• Detonation/Spark Knock
• Battery Disconnect Caution
• Spark Plug Replacement
• Fastener Notice
• Diagnostic Starting Point - Vibration Diagnosis and Correction
• Lifting and Jacking the Vehicle
• Transmission Mount Inspection
• Exhaust Manifold Replacement - Left (RPOs L26/L32)
• Coolant Air Bleed Pipe Assembly Replacement (RPO LS4)
• Power Steering Pulley Replacement (3.8L V6)
• Power Steering Pulley Replacement (5.3L V8)
• Generator Bracket Replacement (RPO LS4)
• Steering Column Replacement
• Splash Shield Replacement - Engine
• Automatic Transmission Oil Cooler Hose Replacement
• Stabilizer Shaft Link Replacement
• Intermediate Steering Shaft Replacement
• Tire and Wheel Removal and Installation
• Frame Replacement
• CKP System Variation Learn Procedure
• Power Steering Pump Replacement (3.8L V6)
• Capacities - Approximate Fluid
• Fluid and Lubricant Recommendations
• GM Oil Life System - Resetting
• Refrigerant Recovery and Recharging
• Draining and Filling Cooling System (GE 47716 Fill)
• Fuel Pressure Relief Procedure
• Wheel Drive Shaft Replacement
• Hydraulic Brake System Bleeding (Manual)
• Transmission Fluid Checking Procedure
• Fuel Rail Stop Bracket Installation Caution
• Safety Glasses Caution
• Displacement on Demand (DoD) System Description
• Sealant Notice
• Disassembled Views
• Drive Belt System Description
• Base Engine Misfire without Internal Engine Noises
• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Upper Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Displacement on Demand (DoD) System Diagnosis
• Engine Compression Test
• Displacement on Demand (DoD) System Compression Test
• Cylinder Leakage Test
• Oil Consumption Diagnosis
• Oil Pressure Diagnosis and Testing
• Displacement on Demand (DoD) Oil Pressure Relief Valve Diagnosis and Testing
• Displacement on Demand (DoD) Valve Lifter Oil Manifold Diagnosis and Testing
• Oil Leak Diagnosis
• Crankshaft Balancer Replacement
• Diagnostic Starting Point - Engine Mechanical
• Piston, Connecting Rod, and Bearing Installation
• Cylinder Head Cleaning and Inspection
• Cylinder Head Replacement - Left
• Cylinder Head Replacement - Right
• Special Tools
• Engine Mechanical Specifications
• Oil Pump Cleaning and Inspection
• Oil Pump, Screen and Crankshaft Oil Deflector Installation
• Engine Block Plug Installation
• Fastener Tightening Specifications
• Engine Support Fixture
• Valve Rocker Arm and Push Rods Cleaning and Inspection
• Engine Front Cover Cleaning and Inspection
• Oil Pan Cleaning and Inspection
• Timing Chain and Sprockets Cleaning and Inspection
• Engine Replacement
• Crankshaft Balancer Removal
• Oil Level Indicator and Tube Removal
• Exhaust Manifold Removal - Left
• Exhaust Manifold Removal - Right
• Water Pump Removal
• Intake Manifold Removal
• Valve Lifter Oil Manifold Removal
• Coolant Air Bleed Pipe Removal
• Valve Rocker Arm Cover Removal - Left
• Valve Rocker Arm and Push Rod Removal
• Valve Lifter Removal
• Engine Front Cover Installation
• Valve Lifter Installation
• Valve Rocker Arm Cover Installation - Left
• Coolant Air Bleed Pipe Installation
• Valve Lifter Oil Manifold Installation
• Intake Manifold Installation
• Water Pump Installation
• Exhaust Manifold Installation - Left
• Exhaust Manifold Installation - Right
• Oil Level Indicator and Tube Installation
• Crankshaft Balancer Installation
• Engine Flywheel Cleaning and Inspection
• Separating Parts
• Cleanliness and Care
• Crankshaft and Bearings Removal
• Crankshaft and Bearings Installation
• Piston, Connecting Rod, and Bearing Removal
• Camshaft and Bearings Cleaning and Inspection
• Piston and Connecting Rod Assemble
• Thread Repair
• Cylinder Head Disassemble
• Oil Filter and Adapter Removal
• Fuel Rail and Injectors Removal
• Throttle Body Removal
• Sealers, Adhesives, and Lubricants
• Fuel Rail and Injectors Installation
• Camshaft Installation