Engine Mechanical - 2.0L: Overhaul Pontiac Solstice I

Disassembly Procedure

1. Remove the exhaust (1) and intake (2) camshaft position actuator solenoid valve bolts and valves.
2. Remove the fuel pump bolts (5), pump (4), and gasket (3).
3. Remove the intake camshaft position sensor (CMP) bolt (6) and sensor (7).
4. Remove the front engine lift bracket bolt (9) and bracket (8).
5. Remove the exhaust CMP sensor bolt (1) and sensor (2).
6. Remove the rear engine lift bracket bolt (3) and bracket (4).
7. Remove the intake camshaft, follower, and adjuster. Refer to «Intake Camshaft, Follower, and Adjuster Removal»(ref-267961-S09916642832007101700000) .
8. Remove the exhaust camshaft, follower, and adjuster. Refer to «Exhaust Camshaft, Follower, and Adjuster Removal»(ref-267961-S21778240612007101700000) .
9. Disassemble the cylinder head. Refer to «Cylinder Head Disassemble»(ref-267961-S36196264432007101700000) .

Assembly Procedure

1. Assemble the cylinder head. Refer to «Cylinder Head Assemble»(ref-267961-S20272782822007101700000) .
2. Install the exhaust camshaft, follower, and adjuster. Refer to «Exhaust Camshaft, Follower, and Adjuster Removal»(ref-267961-S21778240612007101700000) .
3. Install the intake camshaft, follower, and adjuster. Refer to «Intake Camshaft, Follower, and Adjuster Removal»(ref-267961-S09916642832007101700000) .
4. Position the rear engine lift bracket (4) and install the bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Inspect the exhaust CMP sensor O-ring seal and replace if necessary.
6. Install the exhaust CMP sensor (2) and bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Position the front engine lift bracket (8) and install the bolt (9). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Inspect the intake CMP sensor O-ring seal and replace if necessary.
9. Install the intake CMP (7) and bolt (6). Tighten: Tighten the bolt to 10 N.m (89 lb in).
10. Position the fuel pump gasket (3), and install the fuel pump (4) and bolts (5). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
11. Install the exhaust (1) and intake (2) camshaft position actuator solenoid valves and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).

Engine Block Disassemble

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plug.
4. Remove the 6 oil passage plugs on the sides of the block.
5. Remove the 2 water passage plugs on the top of the block.
6. Remove the 2 front oil passage plugs.
7. Remove the knock sensors.
8. Remove the oil pressure switch.
9. Remove the crankshaft position (CKP) sensor and bolt.
10. Remove the piston oil squirter bolt.
11. Remove the piston oil squirter.

Piston and Connecting Rod Disassemble

Tools Required

EN-46745 Piston Clip Retainer Remover/Installer. See Special Tools .

1. Disassemble the piston rings. Use a suitable tool to expand the rings. The piston rings must not be reused.
2. Remove the piston pin retainers using the EN-46745 and the EN-46745-4 piston pin retainer remover and installer tip. See «Special Tools»(ref-267961-S27586171862007101700000) .
3. Remove the piston pin.

Piston and Connecting Rod Assemble

Tools Required

EN-46745 Piston Pin Clip Remover/Installer. See Special Tools .

1. Assemble the connecting rod and the piston.
2. Use the following procedure to assemble the piston pin and the retainer: Coat the piston pin with oil. Using the EN-46745 and the EN-46745-4 piston pin retainer remover and installer tip, install one side of one piston pin retainer into the retaining groove. See «Special Tools»(ref-267961-S27586171862007101700000) . Rotate the retainer until it is fully seated in the groove. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Using the EN-46745 and the EN-46745-4, install the second piston pin retainer. See «Special Tools»(ref-267961-S27586171862007101700000) . Ensure that the piston moves freely.
3. Install the following components of the oil control ring assembly - bottom ring: The expander The lower oil control ring The upper control ring
4. Install the lower compression ring - second ring. Place the manufacturer's mark facing up.
5. Install the upper compression ring - top ring.

Cylinder Head Disassemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(ref-267961-S27586171862007101700000) .
2. J 36017 Valve Seal Remover. See «Special Tools»(ref-267961-S27586171862007101700000) .
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(ref-267961-S27586171862007101700000) .

1. Remove the intake camshaft position sensor and bolt.
2. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(ref-267961-S27586171862007101700000) .
3. Remove the valve keys.
4. Slowly release the J 8062 and the J 43963 from the valve spring assembly. See «Special Tools»(ref-267961-S27586171862007101700000) .
5. Remove the retainer.
6. Remove the spring.
7. Using the J 36017 , remove the valve seal. See «Special Tools»(ref-267961-S27586171862007101700000) . Do not reuse the valve seal.
8. Remove the valve.
9. Remove the remaining valves.
10. Remove the cylinder head plugs.

Cylinder Head Assemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(ref-267961-S27586171862007101700000) .
2. J 9666 Valve Spring Tester. See «Special Tools»(ref-267961-S27586171862007101700000) .
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(ref-267961-S27586171862007101700000) .

1. Install NEW cylinder head plugs. Coat the plugs with sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent.
2. Inspect the valve springs.
3. Look for the following conditions when inspecting the valve springs: Expanded height Unparallel spring ends Spring tension using J 9666 Any distorted springs should be replaced
4. Assemble the valves.
5. Use the following steps to measure valve runout: Apply a dab of Prussian blue on the entire valve face. Seat the valve but do not rotate it. The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. Clean all traces of Prussian blue. Apply a dab of Prussian blue on the valve seat and repeat the inspection. The traces of Prussian blue transferred to the valve face indicates valve face concentricity.
6. Replace the valves, if required.
7. Install the new valve seals. Fully seat the seals on the valve guides.
8. Install the springs.
9. Install the retainer.
10. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(ref-267961-S27586171862007101700000) .
11. Install the valve keys.
12. Slowly release the J 8062 and the J 43963 from the valve/spring assembly. See «Special Tools»(ref-267961-S27586171862007101700000) .
13. Inspect for proper valve key seating.
14. Install the remaining valves, springs, and other components.
15. Lubricate the camshaft position sensor O-ring with clean engine oil.
16. Install the intake camshaft position sensor and bolt. Tighten: Tighten the intake camshaft position sensor bolt to 10 N.m (89 lb in).

Oil Pump Disassemble

1. Disassemble the pressure relief valve.
2. Remove the oil pump gerotor cover and bolts.
3. Clean all of the parts in cleaning solvent. Remove varnish, sludge, and dirt.
4. Inspect the oil pump for wear and scoring. Ensure that all components are within specifications. Refer to «Engine Mechanical Specifications»(ref-267961-S30602847122007101700000) .
5. Replace the front cover and oil pump assembly if it is out of specification or damaged.

Oil Pump Assemble

1. Lubricate all oil pump parts with engine oil.
2. Install the inner gear into the outer gear.
3. Install the gears together into the front cover with the hub of the center gear facing the front cover.
4. Install the oil pump gerotor cover and bolts. Tighten: Tighten the oil pump gerotor bolts to 6 N.m (53 lb in).
5. Install the pressure relief valve piston.
6. Install the pressure relief valve spring. Tighten: Tighten the pressure relief valve plug to 40 N.m (30 lb ft).

Service Prior to Assembly

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

Engine Block Assemble

1. Install the drain plug in the water pump.
2. Apply GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the plug before installation.
3. Install the coolant jacket plugs. Tighten: Tighten the coolant jacket plug to 35 N.m (26 lb ft).
4. Install the rear oil passage plugs.
5. Apply GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the plugs before installation. Tighten: Tighten the oil passage plug to 60 N.m (44 lb ft).
6. Install the other oil passage plugs.
7. Apply GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the plug before installation. Tighten: Tighten the oil passage plugs to 35 N.m (26 lb ft).
8. Lubricate the crankshaft position (CKP) sensor O-ring with clean engine oil.
9. Install the CKP sensor and bolt. Tighten: Tighten the CKP sensor bolt to 10 N.m (89 lb in).
10. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 26 N.m (19 lb ft).
11. Install the knock sensors and bolts. Tighten: Tighten the knock sensor bolts to 25 N.m (18 lb ft).
12. Install the piston oil squirters.
13. Install the piston oil squirter bolts. Tighten: Tighten the piston oil squirter bolts to 15 N.m (11 lb ft).

Balance Shaft Assembly

There are 2 block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the maximum effectiveness of the balance shaft system and reduces noise and vibration.

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. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened.
7. Tighten bolts to specifications. Do not overtighten.