Engine Mechanical - 4.2L: Other Saab 9-7X I

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 158

Engine Block - Top View

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Engine Block - Bottom View

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Engine Block - Left Side View

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Engine Block - Right Side View

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Engine Block - Front View

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Engine Block - Rear View

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Cylinder Head - Top View

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Cylinder Head - End View (Front)

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Cylinder Head - End View (Rear)

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Cylinder Head - Intake Manifold Deck View

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Cylinder Head - Exhaust Manifold Deck View

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Oil Pan - Top View

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Oil Pan - Left Side View

Scheme 171

Oil Pan - Right Side View

Scheme 172

Oil Pan - Rear View

Scheme 173

Engine Front Cover

Scheme 174

Crankshaft Rear Oil Seal Housing

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Intermittent

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

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

J 38722 Compression Tester. See Special Tools .

A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket.

Scheme 183

1. Remove the air duct from the throttle control module.
2. Remove the ignition control modules.
3. Disable the fuel system.
4. Remove the spark plugs.
5. Measure the engine compression, using the following procedure: Firmly install J 38722 to the spark plug hole. See «Special Tools»(ref-268132-S26120190452007101800000) . Have an assistant crank the engine through at least four compression strokes in the testing cylinder. Check and record the readings on J 38722 at each stroke. See «Special Tools»(ref-268132-S26120190452007101800000) . Disconnect J 38722 . See «Special Tools»(ref-268132-S26120190452007101800000) . Repeat the compression test for each cylinder.
6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading.
7. The following are examples of the possible measurements: When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
8. Install the air duct to the throttle body.
9. Install the spark plugs.
10. Enable the fuel system.
11. Install the ignition control modules.

J 35667-A Cylinder Head Leakdown Tester. See Special Tools .

Scheme 184

1. Disconnect the battery ground negative cable. CAUTION: Refer to «Battery Disconnect Caution»(ref-268087-S29574741592007101800000) in Cautions and Notices. IMPORTANT: A leakage test may be performed to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate one or more of the following: Worn or burnt valves Broken valve springs Stuck valve lash adjuster Damaged piston Worn piston rings Worn or scored cylinder bore Damaged cylinder head gasket Cracked or damaged cylinder head Cracked or damaged engine block
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-268121-S41190456062007101800000) in Engine Control.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke.
4. Install J 35667-A . See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to prevent the engine from rotating.
5. Apply shop air pressure to J 35667-A and adjust according to the manufacturers instructions. See «Special Tools»(ref-268132-S26120190452007101800000) .
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 sounds at the throttle control module or air inlet hose may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube 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.

J 36660-A Torque Angle Meter

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Scheme 190

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (4.2L Engine)»(ref-268155-S25356465982007101800000) .
3. Remove the front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .
4. Remove the cylinder head access hole plugs.
5. Remove the timing chain tensioner shoe bolt.
6. Remove the timing chain tensioner shoe.
7. Remove the timing chain tensioner guide bolts.
8. Remove the timing chain tensioner guide.
9. Remove the timing chain and the sprockets. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-268132-S28263440172007101800000) .
10. Loosen and remove the cylinder head bolts. IMPORTANT: Rap on the head of each bolt using an appropriate size punch and hammer. The vibration produced by this procedure assists in successful removal. If a bolt breaks during engine disassembly, EN-47702 is available to assist in removal of the remaining bolt segment. See «Special Tools»(ref-268132-S26120190452007101800000) .
11. Remove the cylinder head.
12. Remove the cylinder head gasket.
13. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
14. If replacing cylinder head refer to «Cylinder Head Disassemble»(ref-268132-S37636133892007101800000) .
15. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-268132-S17674850072007101800000) .

J 44218 Seal Installer

Scheme 191

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-268132-S32598277812007101800000) . IMPORTANT: Do not damage the engine front cover or the crankshaft.
2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal.

Scheme 192

1. Apply the engine oil to the outside diameter of the crankshaft front oil seal.
2. Use the J 44218 to install the front oil seal.
3. Remove the J 44218 .
4. Install the crank balancer shaft. Refer to «Crankshaft Balancer Replacement»(ref-268132-S32598277812007101800000) .

J 44219 Cover Alignment Pins. See Special Tools .

J 44227 Rear Seal Installer. See Special Tools .

Scheme 193

1. Remove the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .
2. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-268132-S23229626302007101800000) .
3. Pry the crankshaft rear oil seal out of the rear oil seal housing using a suitable tool. IMPORTANT: Do not damage the crankshaft or seal bore.

Scheme 194

1. Use J 44227 to install the crankshaft rear oil seal. See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: Use the plastic installation sleeve supplied with the new seal when installing a new seal.
2. Remove the J 44227 . See «Special Tools»(ref-268132-S26120190452007101800000) .
3. Remove the seal installation sleeve after the seal is installed. Discard the sleeve.
4. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-268132-S23229626302007101800000) .
5. Install the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .

J 36660-A Torque Angle Meter

J 44220 Engine Lift Bracket

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1. Remove the hood. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
3. Drain engine coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
4. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
5. Remove the oil pan drain plug and drain the oil. IMPORTANT: Keep drain plug removed during engine removal and installation.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
7. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-268121-S41476428912007101800000) .
8. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-268121-S25535864052007101800000) .
9. Remove the manifold absolute pressure (MAP) sensor. Refer to «Manifold Absolute Pressure Sensor Replacement»(ref-268121-S25199606752007101800000) .
10. Remove the washer solvent container. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
11. Remove the grille. Refer to «Grille Replacement»(ref-268086-S31050323502007101800000) .
12. Remove the headlamp housing. Refer to «Headlamp Housing Panel Replacement»(ref-268090-S02626798062007101800000) .
13. Remove the radiator support brace. Refer to «Radiator Support Diagonal Brace Replacement»(ref-268102-S15556797092007101800000) .
14. Remove the hood latch. Refer to «Hood Latch Support Replacement»(ref-268102-S17882657912007101800000) .
15. Disconnect A/C lines at the condenser.
16. Disconnect the transmission cooler lines at the engine, not the radiator.
17. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
18. Remove the radiator with condenser and transmission cooler lines. Refer to «Radiator Replacement (LH6)»(ref-268147-S00841803912007101800000) or «Radiator Replacement (LL8)»(ref-268147-S02575017782007101800000) .
19. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
20. Remove the power steering pump bolts and lay the pump aside.
21. Ensure the heater hoses (1, 2) at the heater core are disconnected.
22. Remove the secondary air injection (AIR) reaction solenoid valve. Refer to «Secondary Air Injection Solenoid Valve Replacement»(ref-268121-S34923269412007101800000) .
23. Install the lift hook J 44220 to the AIR port on the engine head.
24. Disconnect the oxygen sensor electrical connector.
25. Disconnect the A/C line at the accumulator.
26. Disconnect the front axle actuator electrical connector.
27. Disconnect the camshaft phaser actuator valve electrical connector.
28. Unclip the transmission cooler lines from right side of the engine block.
29. Disconnect the ignition coil harness connectors.
30. Carefully disconnect harness retainer at clips (1) and remove.
31. Remove power brake hose at booster.
32. Remove the powertrain control module (PCM). Refer to «Powertrain Control Module Replacement»(ref-268121-S28727246682007101800000) .
33. Remove all harnesses from the engine harness bracket.
34. Disconnect the front differential vent hose from the engine harness bracket.
35. Remove the engine harness bracket bolt and remove bracket.
36. Disconnect starter electrical connections (1).
37. Disconnect the A/C pressure sensor and clutch electrical connector.
38. Disconnect generator electrical connector and battery lead (1).
39. Disconnect the knock sensor electrical connector.
40. Disconnect the crankshaft sensor electrical connector.
41. Disconnect the camshaft sensor electrical connector.
42. Remove 4 grounds on the left side of the block (1).
43. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
44. Remove the wheel drive shafts, left and right. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
45. Remove the propeller shaft from the front axle pinion yoke. Refer to «Front Propeller Shaft Replacement»(ref-268134-S01108098002007101800000) .
46. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
47. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
48. Remove the fuel tank shield, if equipped. Refer to «Fuel Tank Shield Replacement»(ref-268103-S31874767492007101800000) .
49. Disconnect the AIR pipes from the AIR pump.
50. Remove the torque converter bolt access cover.
51. Remove the torque converter bolts.
52. Place a jack on the transmission oil pan for support.
53. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-268103-S27156480052007101800000) .
54. Lower the transmission enough to reach the top bell housing bolts.
55. Remove the top 4 bell housing bolts. There may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
56. Raise the transmission.
57. Reinstall the transmission support using only 2 through bolts.
58. Remove the remaining bell housing bolts, for a total of 11 bolts.
59. Remove the left and right engine lower mount nuts.
60. Disconnect the oil pressure switch electrical connector.
61. Lower the vehicle.
62. Remove the left upper engine mount nut (1).
63. Remove the right upper engine mount nut (1).
64. Install the engine hoist.
65. Raise the engine out of the compartment slowly keeping the transmission supported.
66. Remove both engine mounts for clearance.
67. Remove the fasteners securing the AIR pipes to the back of the engine head.
68. Remove the AIR pipes from the vehicle.
69. Continue raising the engine out of the vehicle.
70. Install the engine to the engine stand.

Scheme 206

Scheme 207

1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. Install the AIR pipes to the engine.
4. Install the fasteners securing the AIR pipes to the back of the engine head.
5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.
6. Lower the engine onto the mounts and install the upper engine mount nuts (1). Tighten: Tighten the nuts to 70 N.m (51 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Remove the engine hoist.
8. Lay the radiator into the radiator support, but do not install the radiator completely.
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
10. Install all of the lower bell housing bolts, excluding the top 4.
11. Remove the 2 through bolts securing the transmission support.
12. Lower the transmission.
13. Install the top 4 bell housing bolts. Tighten: Tighten all 11 bell housing bolts to 50 N.m (37 lb ft).
14. Raise the transmission.
15. Install the transmission support. Refer to «Transmission Support Replacement»(ref-268103-S27156480052007101800000) .
16. Install the 3 torque converter bolts. Tighten: Tighten the torque converter bolts to 60 N.m (44 lb ft).
17. Install the torque converter bolt cover.
18. Install the fuel tank shield, if removed. Refer to «Fuel Tank Shield Replacement»(ref-268103-S31874767492007101800000) .
19. Connect the AIR pipes to the AIR pump.
20. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
21. Install the propeller shaft to the front axle pinion yoke. Refer to «Front Propeller Shaft Replacement»(ref-268134-S01108098002007101800000) .
22. Connect the exhaust pipe to the manifold and secure the pipe with the bolts. Tighten: Tighten the exhaust pipe bolts to 50 N.m (37 lb ft).
23. Connect the oil pressure sensor electrical connector.
24. Install the oil pan drain plug. Tighten: Tighten the plug to 26 N.m (19 lb ft).
25. Install the lower radiator hose (1).
26. Install the left and right wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
27. Lower the vehicle.
28. Install the 4 grounds on the left side of the block (1).
29. Install the camshaft sensor electrical connectors.
30. Install the crankshaft sensor electrical connector.
31. Install the knock sensor electrical connector.
32. Install the generator electrical connector and battery lead (1). Tighten: Tighten the generator battery lead nut to 9 N.m (80 lb in).
33. Install the A/C pressure sensor and clutch electrical connector.
34. Install starter electrical connectors and battery lead (1). Tighten: Tighten the starter battery lead to 9 N.m (80 lb in).
35. Install the engine harness bracket and bolt. Tighten: Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
36. Install the front differential vent hose, to the engine harness bracket.
37. Install all the harnesses to the engine harness bracket.
38. Install the PCM. Refer to «Powertrain Control Module Replacement»(ref-268121-S28727246682007101800000) .
39. Install the power brake hose at booster.
40. Install the harness retainer (1) to the original location.
41. Install the ignition coil harness electrical connectors.
42. Clip the transmission cooler lines to the right side of the engine block.
43. Connect the camshaft phaser actuator valve electrical connector.
44. Connect the front axle actuator electrical connector.
45. Connect the A/C line at the accumulator.
46. Install the oxygen sensor electrical connector.
47. Remove the lift hook J 44220 .
48. Install the secondary AIR solenoid valve. Refer to «Secondary Air Injection Solenoid Valve Replacement»(ref-268121-S34923269412007101800000) .
49. Install the heater hoses to the heater core. Refer to «Heater Inlet Hose Replacement (LL8)»(ref-268096-S30877658262007101800000) or «Heater Inlet Hose Replacement (LH6)»(ref-268096-S26675446392007101800000) and «Heater Hose Replacement - Outlet (LH6)»(ref-268096-S28417121532007101800000) or «Heater Hose Replacement - Outlet (LL8)»(ref-268096-S06323324822007101800000) .
50. Install the power steering pump.
51. Install the power steering pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
52. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator. Refer to «Radiator Replacement (LH6)»(ref-268147-S00841803912007101800000) or «Radiator Replacement (LL8)»(ref-268147-S02575017782007101800000) .
55. Install transmission cooler lines together.
56. Install the MAP sensor. Refer to «Manifold Absolute Pressure Sensor Replacement»(ref-268121-S25199606752007101800000) .
57. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-268121-S25535864052007101800000) .
58. Install the hood latch. Refer to «Hood Latch Support Replacement»(ref-268102-S17882657912007101800000) .
59. Install the head lamp housing. Refer to «Headlamp Housing Panel Replacement»(ref-268090-S02626798062007101800000) .
60. Install the grill. Refer to «Grille Replacement»(ref-268086-S31050323502007101800000) .
61. Install the washer solvent container. Refer to «Washer Solvent Container Replacement»(ref-268104-S07078591782007101800000) .
62. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-268121-S41476428912007101800000) .
63. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
64. Install the hood. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) .
65. Service the engine oil.
66. Fill the cooling system. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
67. Recharge the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
68. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-268121-S42850641212007101800000) . Disable the ignition system. IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle. Crank the engine several times. Listen for unusual noises or evidence that parts are binding. Enable the ignition system. Start the engine and listen for unusual noises. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature. Listen for a sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Perform a final inspection for the proper engine oil and coolant levels.
69. Install the hood. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) .

Scheme 208

1. Remove the oil fill cap.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
3. Remove the oil pan drain plug and drain the oil into a suitable container.
4. Remove the oil filter using a suitable wrench.
5. Inspect the old oil filter to ensure the filter seal is not left on the engine block.

Tool Required

J 41240 Fan Clutch Remover and Installer

Scheme 209

Scheme 210

1. Install J 41240 to hold the pulley.
2. Remove the water pump pulley bolts.
3. Remove J 41240 .
4. Remove the water pump pulley
5. Remove the water pump bolts.
6. Remove the water pump.
7. Remove the water pump gasket.

Scheme 211

1. Remove the thermostat housing bolts.
2. Remove the thermostat housing.

Scheme 212

1. Remove the throttle control module bolts.
2. Remove the throttle control module.
3. Remove the throttle control module gasket.
4. Remove the crankcase ventilation hose.
5. Remove the intake manifold and bolts.

Scheme 213

1. Remove the fuel injector rail bolts.
2. Remove the fuel injector rail.

Scheme 214

1. Remove the camshaft position actuator valve bolt.
2. Remove the camshaft position actuator valve.

Scheme 215

1. Remove the ignition control modules and bolts.
2. Remove the camshaft cover and bolts.

Scheme 216

1. Remove the oil level sensor. NOTE: Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first.
2. Remove the oil pan bolts and nuts.
3. Install two of the oil pan bolts into the threaded holes (jack bolts) to break the seal of oil pan (1).
4. Remove the oil pan.

Scheme 217

1. Remove the oil pump pipe bolts.
2. Remove the oil pump pipe.
3. Discard the gasket.

J 41816-2 Crankshaft End Protector. See Special Tools .

Scheme 218

1. Remove the crankshaft balancer bolt.
2. Install J 41816-2 into the end of the crankshaft. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. Use a three jaw puller to remove the crankshaft balancer. IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
4. Remove J 41816-2 . See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 219

Scheme 220

1. Remove the 7 mm center bolt (1) first.
2. Loosen the engine front cover bolts.
3. Remove the engine front cover and bolts.
4. Remove the spacer bolt.
5. Remove the crankshaft balancer friction washer from the crankshaft snout. IMPORTANT: The friction washer may have come off with the crankshaft balancer.

EN-47702 Bolt Extractor Kit. See Special Tools .

1. Remove the cylinder head bolts. IMPORTANT: Rap on the head of each bolt using an appropriate size punch and hammer. The vibration produced by this procedure assists in successful removal. If a bolt breaks during engine disassembly, a broken bolt extractor kit EN-47702 is available to assist in removal of the remaining bolt segment. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Remove the cylinder head.
3. Remove the cylinder head gasket.

J 41556 Connecting Rod Guides. See Special Tools .

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Scheme 223

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap with the cylinder position. Also mark the orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap and bearing half.
5. Install J 41556 on the connecting rod. See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Remove the connecting rod and piston assembly. Push out the assembly.
7. Remove J 41556 . See «Special Tools»(ref-268132-S26120190452007101800000) .

EN-47702 Bolt Extractor Kit. See Special Tools .

Scheme 224

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Scheme 228

1. Remove the crankshaft main bearing cap bolts. IMPORTANT: Rap on the head of each bolt using an appropriate size punch and hammer. The vibration produced by this procedure assists in successful removal. If a bolt breaks during engine disassembly, a broken bolt extractor kit EN-47702 is available to assist in removal of the remaining bolt segment. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Remove the crankshaft main bearing cap stiffener.
3. Remove the crankshaft main bearing caps and lower bearings.
4. Remove the crankshaft.
5. Remove the upper crankshaft main bearing halves.

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1. Remove the engine block oil gallery plugs.
2. Remove the engine block oil gallery plug from rear of block.
3. Remove the crankshaft position sensor.
4. Remove the knock sensors.
5. Remove the EVAP solenoid.
6. Remove the coolant temperature sensor.

EN-46745 Piston Pin Retainer Remover and Installer. See Special Tools .

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Scheme 237

1. Remove the piston rings using a piston ring expander. CAUTION: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. IMPORTANT: Do not reuse the piston rings.
2. Remove the piston pin retainers using EN-46745 . See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: Two retainers hold the piston pins in place. Reuse the retainers if they are not damaged during removal.
3. Remove the piston pin.

J 8087 Cylinder Bore Gage. See Special Tools .

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1. Clean and soak the following components in a carburetor cleaning solution to remove carbon, sludge, and varnish: Piston Piston pin Connecting rod
2. Install the connecting rod cap.
3. Place the connecting rod assembly on a checking fixture.
4. Inspect the connecting rod assembly for bending or twisting.
5. Replace any bent or twisted connecting rods.
6. If the connecting rod large bore contains minor scratches or abrasions, clean the bore in a circular direction with light emery paper. DO NOT scrape the connecting rod or cap.
7. Measure the piston pin to connecting rod bore using the following procedure: Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. Using an inside micrometer, measure the connecting rod piston pin bore. Subtract the piston pin diameter from the piston pin bore diameter. The clearance should not be more than 0.018 mm (0.0007 in).
8. If there is excessive clearance, replace the piston pin.
9. If there is still excessive clearance, replace the connecting rod.
10. If there is evidence of pin bore or pin scoring, replace the rod and pin assembly.
11. Inspect the connecting rod bearings for the following conditions: Craters or pockets Flattened sections Excessive scoring or discoloration. Imbedded debris Bright, polished sections
12. Inspect the inside of the connecting rod bearing and outside diameter of the connecting rod bearing journal for wear. This indicates high spots.
13. Inspect the connecting rod bearing bore for taper and out-of-round.
14. Inspect the connecting rod bolts for stretching (compare to new or known good bolt). The callout (1) is a stretched bolt, (2) is a new or good bolt.
15. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
16. Clean the piston ring grooves. Ensure that the oil ring holes and slots are clean.
17. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston Scuffed or damaged skirts Worn piston pin bores
18. Replace pistons that show any signs or damage or excessive wear.
19. Measure the piston diameter for size with a micrometer or caliper at a right angle to the pin center line, across the skirts, 38 mm (1.50 in) from the top of the piston. IMPORTANT: When fitting pistons, consider both the piston and the cylinder bore conditions together. Production and service pistons have the same nominal weight and may be intermixed without affecting engine balance. If necessary, used pistons may be fitted selectively to any cylinder of the engine, providing the pistons are in good condition and the same weight. Do not cut oversize pistons down or the engine balance may be affected. Finish hone when selecting the piston.
20. Replace the piston if worn beyond specifications or if damaged.
21. Use J 8087 to measure the cylinder bore. See «Special Tools»(ref-268132-S26120190452007101800000) .
22. Hone to size if necessary. Use the following procedure to hone the cylinder bore to the correct size. Select a piston. Hone the cylinder bore to obtain the recommended clearance. Clean the piston and cylinder bore with soap and water. Dry the cylinder bore and piston. Lubricate the cylinder bore with clean engine oil.
23. Use the following procedure to measure the piston-to-cylinder bore clearance. Subtract the piston diameter from the cylinder bore diameter to determine the piston-to-bore clearance. Compare the piston-to-bore clearance using the specifications to determine if the clearance is in the acceptable range. If the used piston is not acceptable, a new service piston may be selected.
24. When a piston has been selected, mark the piston to identify the cylinder for which the piston was fitted.
25. Select a set of new piston rings.
26. Install each ring, one at a time, into the corresponding cylinder.
27. Install the piston for that cylinder, upside down (top of piston pushing on the ring) and push the ring to approximately 25 mm (1 in) down from the deck surface.
28. Remove the piston.
29. Measure the ring end gap with a feeler gage.
30. If the ring gap is not within the specification range, replace the rings.
31. Measure the piston ring side clearance - compression rings.
32. Use the following procedure to measure the compression ring side clearance. Roll the piston ring around the groove. Measure the side clearance with a feeler gage. If the ring is too tight, inspect the piston ring groove for nicks, burrs, or damage. Use emery cloth to remove any minor burrs. If the ring side clearance is greater than the specification, replace the piston. NOTE: The piston ring groove must only be cleaned with a ring groove cleaning tool. Proper engine performance and durability depends on the straightness and smoothness of the ring groove. Cleaning the piston ring groove with an improper tool can damage the piston ring groove and effect the performance and durability of the engine.

EN-46745 Piston Pin Retainer Remover and Installer. See Special Tools .

Scheme 243

Scheme 244

Scheme 245

1. Lubricate the piston pin with clean engine oil.
2. Install one of the piston pin retainers into the retainer groove using EN-46745 . See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: The oil hole, in the connecting rod, should be facing the exhaust side of the block.
3. Install the connecting rod and piston pin. Push the piston pin in until it bottoms against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Install the following components of the bottom ring assembly (oil control ring). The expander The lower oil control ring The upper oil control ring NOTE: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. IMPORTANT: The piston ring end gaps must be staggered 90 degrees apart.
6. Install the middle ring (compression ring) with the napier groove facing down.
7. Install the top ring.

J 7872 Magnetic Base Dial Indicator Set. See Special Tools .

Scheme 246

Scheme 247

1. Clean the camshafts with cleaning solvent.
2. Inspect the camshafts for the following conditions: Scored camshaft journals Damaged camshaft lobes Damaged camshaft sprocket locator pin slots Damaged threads
3. Measure the camshaft lobes using a micrometer. The intake camshaft lobes should be a minimum of 41.5 mm (1.635 in). The exhaust camshaft lobes should be a minimum of 41 mm (1.615 in).
4. Use J 7872 to measure the camshaft runout. See «Special Tools»(ref-268132-S26120190452007101800000) . Set the camshaft in V-blocks between the centers. Measure the intermediate camshaft journal.
5. Use J 7872 to measure the camshaft lobe lift. See «Special Tools»(ref-268132-S26120190452007101800000) . Lubricate the camshaft to V-block contact areas with engine oil. Set the camshaft on V-blocks. Measure the camshaft lobe lift.
6. If the runout or camshaft lobe lift is not within specifications, replace the camshaft.

Scheme 248

1. Inspect the timing chain sprockets for cracks or teeth that are worn, broken, or chipped.
2. Inspect the timing chain for binding or stretching.
3. Inspect the dowel pins for wear or damage
4. Inspect the crankshaft sprocket keyway and the locating dowel pins in the crankshaft for damage.
5. Inspect the timing chain shoe and guide for excessive wear or cracks.
6. Inspect the timing chain tensioner for damage.
7. Replace the timing chain and sprockets if damaged.

Scheme 249

Scheme 250

1. Clean the valve rocker arms and valve lash adjusters in cleaning solvent.
2. Dry the valve rocker arms and valve lash adjusters with compressed air.
3. Inspect the valve rocker arms for the following conditions: Excessive wear at the valve contact or valve lash adjuster socket area A loose or damaged pin A worn or damaged roller. The roller should rotate freely with no binding or roughness.
4. Inspect the valve lash adjusters for the following conditions: Excessive wear Clogging of the oil passage Damage Collapsed or spongy IMPORTANT: Keep the valve rocker arms and valve lash adjusters in the order from where they where removed.

J 9666 Valve Spring Tester

Scheme 251

Scheme 252

Scheme 253

1. Inspect the cylinder head gasket and the mating surface. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure: Improper installation Warped cylinder head Missing or not fully seated dowel pins Low torque on the cylinder head bolts Incorrect length cylinder head bolts A warped engine block surface Scratched surfaces Foreign material Cracked engine block threaded holes
3. Clean the following components: The gasket surfaces Do not use a motorized brush on the head gasket sealing surface. Valve stems and valve heads The bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
4. Inspect the cylinder head mating surfaces for flatness. Use a feeler gauge and a straight edge.
5. Replace the cylinder head if warped more than 0.08 mm (0.003 in).
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. IMPORTANT: Do not attempt to weld the cylinder head. If the cylinder head is damaged, replace the cylinder head. Minor nicks may be repaired with a fine flat file or emery cloth.
8. Inspect the valve springs for squareness.
9. Use J 9666 to measure the valve spring tension. Replace the valve spring if the tension is not within specification.
10. Inspect the valve guides for wear. The valve guides may be reamed oversized 0.075 mm (0.003 in) and oversized steamed valves may be installed. The same size valve seal should be used.
11. Inspect the valve seats for excessive wear, damage, or hot spots.
12. Use the following procedure to measure the valve seat concentricity: Lift the valve off the valve seat. Apply a dab of blue dye to the valve face. Seat and rotate the valve. The blue dye traces transferred to the valve seat are an indication of concentricity of the valve seat.
13. Use the following procedure to measure the valve runout: Clean off the blue dye. Apply blue dye to the valve seat. Seat and rotate the valve. The traces of blue dye transferred to the valve indicates valve runout.
14. Replace the head if the valve seats are damaged.
15. Inspect the valves for the following damage: Grooving (1, 2) Bent valve stem (3). Replace any bent valve. Burrs or scratches (4). Minor burrs or scratches may be removed with a fine oil stone. Chipped or worn key grooves (5). Replace if damaged. Valve tip wear (6). Replace if worn.

Thread Repair

Tools Required

1. J 42385-400 Thread Repair Kit. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 43965 Extension Kit. See «Special Tools»(ref-268132-S26120190452007101800000) .

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external threads of the insert into the base material. This action mechanically locks the insert into place.

Scheme 254

The tool kit J 42385-400 is designed for use with either a suitable tap wrench or drill motor. See Special Tools . Limited access and larger hole repair may process better using a tap wrench. An extension J 43965 may also be necessary to drive the thread repair tooling dependent on access to the hole being repaired. See Special Tools .

Scheme 255

It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as the original hole.

Scheme 256

During the drilling and tapping of the hole being repaired ensure the tooling is consistently machining perpendicular to the surface of the base material.

Scheme 257

If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are available to aid in tapping the hole.

Thread Repair

Scheme 258

When installed to the proper depth, the flange (1) of the insert will be seated against the counterbore of the drilled/tapped hole and just below the surface (2) of the base material.

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

1. Drill out the threads of the damaged hole. 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). IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Do NOT drill any further than the original hole depth.
2. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
3. Counterbore the drilled hole to the full depth permitted by the tool (1). IMPORTANT: A properly counterbored hole will show a slight burnishing on the surface of the base material for 360 degrees around the drilled hole.
4. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
5. Using a suitable tapping wrench, 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). IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
6. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
7. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole.
8. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
9. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
10. Install the insert (2) onto the driver installation tool (1).
11. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
12. Install the insert (2) into the tapped hole.
13. Install the insert until the flange (2) of the insert contacts the counterbored surface. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface, remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
14. Continue to rotate the driver installation tool (1) through the insert (2). IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
15. Inspect the insert for proper installation into the tapped hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).
16. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Scheme 271

When installed to the proper depth, the flange of the insert (1) will be seated against the counterbore (2) of the drilled/tapped hole.

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

1. Install a stop collar (2) on the counterbore drill (1), if required.
2. Drill out the threads of the damaged hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Drill the hole until the stop collar contacts the surface of the base material.
3. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
4. Using a suitable tapping wrench, tap the threads of the drilled hole. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
5. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
6. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole.
7. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole.
12. Install the insert until the flange (2) of the insert contacts the counterbored surface. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
13. Continue to rotate the driver installation tool (1) through the insert (2). IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Tapered Pipe Thread Repair

The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

Scheme 277

When installed to the proper depth, the flange (1) of the insert will be seated against surface (2) of the base material of the drilled/tapped hole.

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

1. Drill out the threads of the damaged hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Drill the hole until the stop collar contacts the surface of the base material.
2. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
3. Using a suitable tapping wrench, tap the threads of the drilled hole. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.
5. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
6. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole.
7. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
8. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
9. Install the insert (2) onto the driver installation tool (1).
10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
11. Install the insert (2) into the tapped hole.
12. Install the insert until the flange (2) of the insert contacts the surface of the base material. IMPORTANT: If the insert will not thread down until the flange contacts the surface of the base material remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3). IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.

Cylinder Head Bolt Hole Thread Repair

The cylinder head bolt hole required tools consist of the following

1. Drill (1) J 42385-402
2. Tap (2) J 42385-403
3. Installation driver (3) J 42385-404
4. Alignment pin (4) J 42385-303
5. Bushing (5) J 42385-302
6. Bolts (6) J 42385-421
7. Fixture plate (7) J 42385-401

Scheme 283

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.
6. Drill out the threads of the damaged hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
7. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
8. Using a suitable tapping wrench, tap the threads of the drilled hole. IMPORTANT: During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt hole until the first mark (1) on the tap aligns with the top of the drill bushing (3).
10. Remove the fixture plate bolts (2). IMPORTANT: Remove the fixture plate prior to installing the insert with the installer tool.
11. Remove the fixture plate (3) and bushing (1).
12. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
13. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole.
14. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
15. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110. IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
16. Install the insert (2) onto the driver installation tool (1).
17. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2).
18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole.
20. Install the insert until the flange of the insert contacts the counterbored surface. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
21. Continue to rotate the driver installation tool through the insert. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
22. Inspect the insert for proper installation into the tapped hole.

Scheme 290

The crankshaft main bearing bolt hole required tools consist of the following

1. Drill (1) J 42385-417
2. Tap (2) J 42385-418
3. Installation driver (3) J 42385-419
4. Fixture plate (4) J 42385-401
5. Bushing (5) J 42385-307
6. Alignment pin (6) J 42385-308
7. Bolts (7) J 42385-510

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

1. Position the fixture plate (3) with the bushing (2), installed over the crankshaft main cap bolt hole to be repaired.
2. Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.
3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.
6. Drill out the threads of the damaged hole. IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).
7. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
8. Using a suitable tapping wrench, tap the threads of the drilled hole. IMPORTANT: Do not remove the fixture plate, ensure the fixture plate is installed during the machining and installation processes of the insert. During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap. Ensure the tap has created full threads at least to the depth equal to the insert length.
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
10. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
11. Spray cleaner GM P/N United States 12377981, GM P/N Canada 10953463 or equivalent into the tapped hole.
12. Using compressed air, clean out any chips. IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
13. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110. IMPORTANT: Do not remove the fixture plate, ensure the fixture plate is installed during the installation process of the insert. Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
14. Install the insert (2) onto the driver installation tool (1).
15. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
16. Install the insert and installation driver (1) into the tapped hole.
17. Start the insert into the threaded hole.
18. Install the insert until the flange of the insert contacts the counterbored surface. IMPORTANT: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
19. Continue to rotate the driver installation tool through the insert. IMPORTANT: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
21. Inspect the insert for proper installation into the tapped hole.
22. Remove the fixture plate bolts (1).
23. Remove the fixture plate (3) and bushing (2).

J 45059 Angle Meter. See Special Tools .

Scheme 296

Scheme 297

1. Install the upper crankshaft main bearings into the block.
2. Lubricate the upper crankshaft main bearing surface with clean engine oil.
3. Install the crankshaft.
4. Install the lower crankshaft main bearings into the main bearing caps. IMPORTANT: Refer to the pin stamp on the crankshaft main bearing caps for sequence and direction of installation. The pin stamp arrow points to the front of the engine.
5. Lubricate the lower crankshaft main bearing surface with clean engine oil.
6. Install the crankshaft main bearing caps.
7. Install the crankshaft main bearing cap stiffener. IMPORTANT: The crankshaft main bearing cap stiffener is directional. The end marked front goes to the front.
8. Install new crankshaft main bearing bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the block surface.
9. Tighten the crankshaft main bearing cap bolts in equal increments. Tighten: Tighten the crankshaft main bearing cap bolts to 25 N.m (18 lb ft) in sequence. Use J 45059 to tighten the crankshaft main bearing cap bolts an additional 180 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
10. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the thrust crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. Refer to «Engine Mechanical Specifications»(ref-268132-S23912727782007101800000) for the proper clearance. 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.

J 45059 Angle Meter. See Special Tools .

1. Install the dowel pins - cylinder head locator, if necessary.
2. Install a new cylinder head gasket.
3. Install the cylinder head.
4. Install new cylinder head bolts.
5. Tighten the new cylinder head bolts in the following sequence: Tighten: Tighten the (14) long cylinder head bolts in sequence to 30 N.m (22 lb ft). Use J 45059 to tighten the cylinder head bolts in sequence an additional 155 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 45059 to tighten the short cylinder head end bolts an additional 60 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . Tighten the (1 Long) end bolt to 7 N.m (62 lb in). Use J 45059 to tighten the long cylinder head end bolt an additional 120 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

J 44221 Camshaft Holding Tool. See Special Tools .

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the exhaust camshaft.
3. Install the intake camshaft.
4. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See «Special Tools»(ref-268132-S26120190452007101800000) .
5. Install the exhaust camshaft caps. IMPORTANT: Install the same camshaft cap onto the same camshaft journal from which it was removed. The camshaft caps are pin stamped for direction and numerical order.
6. Install the intake camshaft caps.
7. Install the camshaft cap bolts. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
8. Remove J 44221 . See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 298

1. Install the engine lift bracket.
2. Install the engine lift bracket bolts in sequence. Tighten: Tighten the engine lift bracket bolts in sequence to 50 N.m (37 lb ft) NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Scheme 299

1. Install the timing chain tensioner.
2. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
3. Install the timing chain tensioner guide.
4. Install the timing chain tensioner guide bolts. Tighten: Tighten the timing chain tensioner guide bolts to 12 N.m (107 lb in).
5. Install the timing chain tensioner shoe.
6. Install the timing chain tensioner shoe bolt. Tighten: Tighten the timing chain tension shoe bolt to 25 N.m (18 lb ft).
7. Install the cylinder head access hole plugs. Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).

J 44218 Seal Installer

1. Apply engine oil to the outside diameter of the crankshaft front oil seal.
2. Use J 44218 to install the crankshaft front oil seal.
3. Remove J 44218 .

J 44219 Engine Cover Alignment Pins. See Special Tools .

Scheme 300

Scheme 301

1. Install the engine front cover spacer bolt. Tighten: Tighten the engine front cover spacer bolt to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
2. Install the crankshaft balancer friction washer GM P/N 12573950 over the crankshaft snout, up against the crankshaft gear.
3. Install J 44219 . See «Special Tools»(ref-268132-S26120190452007101800000) .
4. Apply a 3 mm (0.12 in) bead of sealer GM P/N United States 12378521, GM P/N Canada 88901148 to the back side of the engine front cover (1). IMPORTANT: The engine front cover must be installed within 10 minutes from when the sealer was applied.
5. Align the oil pump to the crankshaft sprocket splines.
6. Install the engine front cover.
7. Remove J 44219 . See «Special Tools»(ref-268132-S26120190452007101800000) .
8. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 10 N.m (89 lb in). Tighten the small center bolt (1) last to 10 N.m (89 lb in).

J 41240 Fan Clutch Remover and Installer

Scheme 302

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
4. Install the water pump pulley.
5. Install the water pump pulley bolts.
6. Install J 41240 to hold pulley.
7. Tighten the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
8. Remove J 41240 .

J 44219 Housing Alignment Pins. See Special Tools .

Scheme 303

Scheme 304

1. Apply a 3 mm (0.12 in) bead of GM P/N United States 12378521, GM P/N Canada 88901148 to the rear oil seal housing (1).
2. Install J 44219 into the block. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. Slide the crankshaft rear oil seal housing over the alignment pins ( J 44219 ) and crankshaft. See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: With the help of the plastic installation aid (supplied with the new seal), be sure the lip of the seal faces inward.
4. Install the crankshaft rear oil seal housing bolts (except the two in place of the guide pins). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
5. Remove J 44219 . See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Install the remaining two crankshaft rear oil seal housing bolts. Tighten: Tighten the crankshaft rear oil seal housing bolts to 10 N.m (89 lb in).
7. Wipe off any excess material from the bottom of the oil pan sealing area (1).

J 44227 Rear Seal Installer. See Special Tools .

1. Use the plastic installation sleeve supplied with the new seal when installing a new seal. Use J 44227 to install the crankshaft rear oil seal. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Remove J 44227 . See «Special Tools»(ref-268132-S26120190452007101800000) .

J 45059 Angle Meter. See Special Tools .

1. Install the flywheel.
2. Install new flywheel bolts. Tighten: Tighten the new flywheel bolts to 25 N.m (18 lb ft). Use J 45059 to tighten the flywheel bolts an additional 50 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

J 45299 Engine Preluber. See Special Tools .

Scheme 305

Scheme 306

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft). IMPORTANT: A constant/continuous flow of clean engine oil is required to properly prime the engine. Be sure to use an approved engine oil as specified in the owners manual. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
2. Remove the engine block oil gallery plug (1).
3. Install the M16 x 1.5 adapter P/N 509375.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. See «Special Tools»(ref-268132-S26120190452007101800000) . Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine block oil gallery plug (1). Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft).
8. Top-off the engine oil to the proper level.

Engine Block

The lost foam all aluminum engine block utilizes a deep skirt design for increased rigidity. The cylinders are positioned in a straight in-line 6 cylinder orientation. The crankshaft bearing caps have a bearing beam or "ladder" for enhanced structural rigidity and vibration reduction.

Oil Pan

A single piece cast aluminum oil pan contributes to crankshaft and block rigidity while reducing overall weight. The oil pan bolts to the bell housing as well as the block. This eliminates points of vibration and makes the complete powertrain act as a single casting. Jack screws are used to remove the oil pan.

Crankshaft

The crankshaft is a nodular iron design with seven main bearings.

Connecting Rods

The connecting rods are forged powdered metal. The connecting rods and caps are of a fractured split design to improve durability and reduce internal friction. Care must be taken to ensure the mating surfaces are not damaged during service procedures.

Pistons

The pistons are a full-floating design. The piston pins are a slip fit in the bronze bushed connecting rod and are retained in the piston by round wire retainers. There are two compression rings and one oil control ring.

Cylinder Head

The cylinder head is also made of the lost foam aluminum for lighter weight and rapid heat dissipation. There are 4 valves per cylinder and the ports are of a high swirl design for improved combustion. The cylinder head gasket consist of a steel laminated construction.

Valve Train

The engine utilizes dual overhead camshafts and roller followers for reduced friction, which results in improved gas mileage.

Fuel System

A new electronic throttle control system is used on the engine. A throttle actuator control or TAC system eliminates cable linkage from the pedal to the throttle control module. All throttle movements are controlled by the PCM.

Oil Pump

The oil pump is gear driven directly from the crankshaft. The oil pump drive gear is a slip fit to the crankshaft.

Engine Covers

There is a front engine cover and a rear engine cover, both are made of aluminum. The front engine cover and rear engine cover have "T" sealing joints and need to be removed after the oil pan. The front and rear covers need to be installed before the oil pan. Jack screws are used to remove the covers. Guide pins are used to aid in the installation of both covers.

New Product Information

The purpose of New Product Information is to highlight or indicate important new features for the service community.

Changes may include one or more of the following items

1. Torque values and/or fastener tightening strategies
2. Engine specifications
3. New sealants and/or adhesives
4. Disassembly and assembly procedure revisions
5. Engine mechanical diagnostic procedure revisions
6. Special tools required

New Sealants and/or Adhesives

1. U.S. and Canadian SPO part numbers
2. 3-Bond sealant P/N 12378521 (Canadian P/N 88901148)

New Features

1. 10.3:1 Compression
2. Vane style camshaft position actuator
3. "Bee Hive" valve springs

Engine Features

1. Powder metal connecting rods
2. Full floating piston pins
3. Lost foam casted aluminum block and head
4. Composite plastic camshaft cover
5. Electronic Throttle Control - ETC
6. Bridge/bearing beam - stiffener ladder
7. Stainless steel fuel rail
8. Coil-on-plug ignition system
9. Inlet side thermostat
10. No EGR
11. No AIR

Cleanliness and Care

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

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

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

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

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

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

Separating Parts

The components of an internal combustion engine develop wear patterns with their mating components. During disassembly of the engine, parts should be separated and kept in order so they may be reinstalled in the same location from which they were removed.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use jack screws to separate components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces. IMPORTANT: Do not use any other method or technique in order to remove the gasket material from a components. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand paper Power tools These methods of cleaning may damage the component. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure. IMPORTANT: Do not allow the sealant to enter any blind threaded holes. The sealant may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
5. Tighten the bolts to the specifications.

Sealant Types

The following 2 major types of sealant are commonly used in engines

1. Aerobic sealant (Room Temperature Vulcanizing (RTV))
2. Anaerobic sealant, which include the following: Gasket eliminator Pipe Threadlock

Aerobic Type Room Temperature Vulcanizing (RTV) Sealant

Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is used where 2 components (such as the intake manifold and the engine block) are assembled together.

Use the following information when using RTV sealant

1. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Any other surfaces where a different type of sealant is specified in the service procedure
2. Always follow all the safety recommendations and the directions that are on the RTV sealant container.
3. Use a plastic or wood scraper in order to remove all the RTV sealant from the components.
4. The surfaces to be sealed must be clean and dry. IMPORTANT: Do not allow the RTV sealant to enter any blind threaded holes, as it may prevent the fasteners from clamping properly or cause damage when the fastener is tightened.
5. Use a RTV sealant bead size as specified in the service procedure.
6. Apply the RTV sealant bead to the inside of any bolt holes areas.
7. Assemble the components while the RTV sealant is still wet to the touch. Do not wait for the RTV sealant to skin over.
8. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Anaerobic Type Threadlock Sealant

Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for threadlocking and sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when confined between 2 close fitting metal surfaces.

Use the following information when using threadlock sealant

1. Always follow all safety recommendations and directions that are on the threadlock sealant container.
2. The threaded surfaces to be sealed must be clean and dry.
3. Apply the threadlock sealant as specified on the threadlock sealant container.
4. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners. IMPORTANT: Fasteners that are partially torqued and then the threadlock sealant allowed to cure more than five minutes, may result in incorrect clamp load of assembled components.

Anaerobic Type Pipe Sealant

Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is used where 2 parts are assembled together and require a leak proof joint.

Use the following information when using pipe sealant

1. Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Surfaces where a different sealant is specified
2. Always follow all the safety recommendations and the directions that are on the pipe sealant container.
3. The surfaces to be sealed must be clean and dry.
4. Use a pipe sealant bead of the size or quantity as specified in the service procedure.
5. Apply the pipe sealant bead to the inside of any bolt hole areas. IMPORTANT: Do not allow the pipe sealant to enter any of the blind threaded holes, as the pipe sealant may prevent the fastener from clamping properly, or cause component damage when the fastener is tightened.
6. Apply a continuous bead of pipe sealant to 1 sealing surface.
7. Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.

Tools and Equipment

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

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

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