Engine Mechanical - 4.2L: Removal & Installation Saab 9-7X I

Installation Procedure

1. Route the drive belt over all the pulleys except the drive belt tensioner pulley.
2. Install the 3/8 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise.
3. Install the drive belt over the drive belt tensioner pulley.
4. Slowly release the tension to the drive belt tensioner arm.
5. Inspect for proper installation of the drive belt on the pulleys.

Scheme 21

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .

Scheme 22

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
2. Remove the left front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
3. Remove the drive belt idler pulley bracket bolts from inside the left wheel house opening.
4. Lower the vehicle.
5. Remove forward bolt of the drive belt idler pulley bracket from inside the engine compartment.
6. Remove the drive belt pulley from the vehicle.

1. Install the drive belt pulley bracket and the forward bolt of the idler pulley bracket from inside the engine compartment.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
3. Install the drive belt idler pulley bracket bolts from inside the left wheelhouse opening. Tighten: Tighten the drive belt idler pulley bracket bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the left front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
5. Lower the vehicle.
6. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .

Scheme 23

1. Install a pole jack underneath the oil pan. NOTE: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses.
2. Insert a block of wood between the engine oil pan and the pole jack.
3. Raise the jack until the wooden block contacts the engine oil pan.
4. Raise the engine in order to place a slight tension on the rubber cushion. Observe both mounts while raising the engine.
5. Replace the mounts if any of the following conditions exist: Hard rubber surface covered with heat check cracks The rubber cushion separated from the metal plate of the mount The rubber cushion is split through the center The mount is leaking
6. If there is movement between a metal plate of the mount and its attaching points, lower the engine and tighten the bolts or nuts attaching the mount to the engine, the frame or the bracket.

Scheme 24

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Scheme 29

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
3. Remove the manifold absolute pressure (MAP) sensor electrical connector and the retainer (1).
4. Remove the MAP sensor (2).
5. Remove the left shock module, if frame mount is being removed. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
6. Remove the right and the left upper engine mount nuts (1).
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) . IMPORTANT: When placing jack onto the oil pan, pay close attention to not damage the oil level sender.
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
11. Raise the engine with the jack just enough to clear the engine mount stud.
12. Remove the left engine mount from the bracket.
13. Remove the left engine mount bracket bolts (1).
14. Remove the left engine mount bracket.
15. Remove the left frame engine mount bracket bolts.
16. Remove the left frame engine mount bracket, if required.

1. Install the left frame engine mount bracket, if removed.
2. Install the left frame engine mount bracket bolts, if removed. Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the left engine mount bracket and secure the bracket with the bolts (1). Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the left engine mount onto the bracket.
5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts (1). Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the jack from under the vehicle.
8. Install the engine protection shield and secure the shield with the bolts. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
9. Install the right and the left lower engine mount nuts. Tighten: Torque the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the left shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Removal Procedure

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
3. Remove the manifold absolute pressure (MAP) sensor electrical connector and retainer (1).
4. Remove the MAP sensor (2).
5. Remove the right shock module, if frame engine mount is being removed. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
6. Remove the right and the left upper engine mount nuts (1).
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood. IMPORTANT: When placing jack onto the oil pan, pay close attention to not damaging the oil level sender.
11. Raise the engine with the jack just enough to clear the engine mount studs.
12. Remove the right engine mount from the bracket. Note the location of the heat shield for installation.
13. Graphic shows left, right is similar. Remove the right engine mount bracket bolts.
14. Remove the right engine mount bracket.
15. Graphic shows left, right is similar. Remove the right frame engine mount bracket bolts, if required.
16. Remove the right frame engine mount bracket, if required.

1. Graphic shows left, right is similar. Install the right frame engine mount bracket, if removed.
2. Install the right frame engine mount bracket bolts, if removed. Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Graphic shows left, right is similar. Install the right engine mount bracket and secure with the bolts (1). Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
4. Install the right engine mount.
5. Lower the engine onto the engine mounts. IMPORTANT: Ensure that the heat shield is located properly over the anti-rotation feature - right side only.
6. Install the right and the left upper engine mount nuts (1). Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the floor jack from under the vehicle.
8. Install the engine protection shield and secure with the bolts. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
9. Install the right and the left lower engine mount nuts. Tighten: Tighten the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.
11. Install the right shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
12. Install the MAP sensor (2).
13. Install the MAP sensor retainer (1) and the electrical connector.
14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 30

Scheme 31

1. Disconnect the crankcase dirty air hose from the intake manifold.
2. Disconnect the crankcase dirty air hose from the positive crankcase ventilation (PCV) orifice tube.
3. Loosen the throttle body clamps (2).
4. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator.
5. Remove the 2 resonator to engine bolts (4) from the air cleaner outlet resonator (5).
6. Lift up the front of the air cleaner outlet resonator (2).
7. Disconnect the crankcase clean air hose from the valve cover port.
8. Disconnect the crankcase clean air hose from the air cleaner outlet resonator (2).

1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2).
2. Connect the crankcase clean air hose to the valve cover port.
3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5). Tighten: Tighten the bolts to 6 N.m (53 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Tighten the throttle body clamps (2). Tighten: Tighten the clamps to 4 N.m (35 lb in).
5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator.
6. Lubricate the inner diameter of the crankcase ventilation hose. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
7. Connect the crankcase dirty air hose to the intake manifold.
8. Connect the crankcase dirty air hose to the PCV orifice tube.

Scheme 32

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Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Relieve the fuel pressure. Refer to «Fuel Pressure Relief»(ref-268121-S13553312372007101800000) .
3. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-268121-S25535864052007101800000) .
4. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
5. Remove the PCM mounting studs (5) and position the PCM out of the way.
6. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
7. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-268121-S15832797132007101800000) . NOTE: Refer to «Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice»(ref-268087-S37206853432007101800000) .
8. Disconnect the integral clip (3) from the wire harness bracket.
9. Remove the engine wire harness bracket bolt.
10. Position the engine electrical wire harness bracket with wires attached out of the way.
11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
12. Disconnect the crankcase ventilation hose from the intake manifold.
13. Disconnect the vacuum brake booster hose at the intake manifold.
14. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .
15. Loosen the intake manifold bolts. IMPORTANT: The intake manifold bolts are captured within the intake manifold. Do not attempt to remove the bolts from the intake manifold.
16. Remove the intake manifold.

1. Install a new intake manifold gasket to the intake manifold.
2. Install the intake manifold onto the engine and secure the manifold with the bolts. Tighten: Tighten the intake manifold bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .
4. Install the vacuum brake booster hose to the intake manifold.
5. Lubricate the inner diameter of the crankcase ventilation hose. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
6. Install the crankcase ventilation hose.
7. Connect the MAP sensor electrical connector.
8. Properly position the engine electrical harness bracket to the intake manifold.
9. Install the engine electrical harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
10. Connect the integral clip (3) to the wire harness bracket.
11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-268121-S15832797132007101800000) .
12. Connect the ECT sensor electrical connector (1).
13. Install the PCM mounting studs (5) to the intake manifold. Tighten: Tighten the studs to 6 N.m (53 lb in).
14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
16. Install the PCM retaining nuts (6). Tighten: Tighten the nuts to 8 N.m (71 lb in).
17. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-268121-S25535864052007101800000) .
18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
19. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

Scheme 39

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Scheme 44

Scheme 45

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-268132-S29218769952007101800000) .
2. Remove the A/C line at the oil level indicator tube bracket nut.
3. Remove the A/C bracket bolt from the engine lift hook.
4. Position the A/C line out of the way.
5. Remove the engine lift bracket.
6. Disconnect the ignition control module electrical connectors.
7. Loosen the ignition control module bolts.
8. Remove the ignition control module.
9. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage the clips that hold the housing in place.
10. Disconnect the fuel injection harness electrical connector.
11. Loosen and remove the camshaft cover bolts.
12. Remove the camshaft cover.
13. Clean and inspect the camshaft cover. Refer to «Camshaft Cover Cleaning and Inspection»(ref-268132-S19605961692007101800000) .

1. Install a new camshaft cover seal.
2. Install new rubber ignition control module seals.
3. Install the camshaft cover and secure with the cam cover bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the ignition control modules and secure the modules with bolts. Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
5. Connect the ignition control module electrical connectors.
6. Install the fuel injector electrical connectors.
7. Install the engine electrical harness housing (1).
8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. Tighten: Tighten the A/C line bracket nut to 7 N.m (62 lb in).
9. Install the engine lift bracket and secure the lift hook with the bolts. Tighten: Tighten the lift bracket bolts to 50 N.m (37 lb ft).
10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten: Tighten the A/C bracket bolt to 10 N.m (89 lb in).
11. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268132-S29218769952007101800000) .

Valve Rocker Arm and Valve Lash Adjuster Replacement

Tools Required

1. J 36660-A Torque Angle Meter «Special Tools»(ref-268132-S26120190452007101800000)
2. J 44222 Camshaft Sprocket Holding Tool «Special Tools»(ref-268132-S26120190452007101800000)

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
2. Remove the exhaust and the intake sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components.
4. Carefully move the sprockets with the timing chain off of the camshafts.
5. Remove the camshaft cap bolts. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
6. Remove the camshaft caps.
7. Remove the camshafts.
8. Remove the valve rocker arms. IMPORTANT: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations.
9. Remove the valve lash adjusters.

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm roller.
4. Install the valve rocker arms in their original locations.
5. Coat the camshaft journals with engine oil.
6. Install the camshafts to their original position.
7. Install the camshaft caps onto their original journal. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 .
9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 38820 Valve Stem Seal Remover and Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 44222 Camshaft Sprocket Holding Tool
3. J-44228-A Valve Spring Compressor. See «Special Tools»(ref-268132-S26120190452007101800000) .
4. J 44226 Crankshaft Balancer Remover

Scheme 51

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Scheme 54

Scheme 55

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) . IMPORTANT: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components, as previously installed. Regulate the air pressure to 50 psi before pressurizing the cylinder to help prevent the crankshaft from turning.
2. Remove the torque converter access plug.
3. Use the J 44226-3A 15 mm holding bar on a torque converter bolt to prevent the crankshaft from turning.
4. Lower the vehicle.
5. Remove and discard the timing gear bolts.
6. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components.
7. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension.
8. Carefully move the sprockets with the timing chain, off of the camshafts.
9. Remove the camshaft cap bolts.
10. Remove the camshaft caps. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
11. Remove the camshafts.
12. Using a suitable adapter, apply air pressure to the cylinder.
13. Install the J-44228-A and compress the valve springs. See «Special Tools»(ref-268132-S26120190452007101800000) .
14. Remove the valve keys.
15. Remove the J-44228-A . See «Special Tools»(ref-268132-S26120190452007101800000) .
16. Remove the valve spring retainer and the valve spring.
17. Use the J 38820 and remove the seals. See «Special Tools»(ref-268132-S26120190452007101800000) .
18. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-268132-S17674850072007101800000) .

1. Use the J 38820 to install the valve seals. See «Special Tools»(ref-268132-S26120190452007101800000) . There is only one size seal.
2. Install the valve spring and the valve spring retainer.
3. Use the J-44228-A and compress the valve springs. See «Special Tools»(ref-268132-S26120190452007101800000) .
4. Install the valve keys.
5. Remove the J-44228-A . See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Remove the air pressure to the cylinder.
7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil.
8. Install the camshafts to their original position.
9. Install the camshaft caps onto their original journal. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 .
11. Install a NEW intake camshaft sprocket washer and bolt, and a NEW exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
12. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-268121-S41190456062007101800000) .
13. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
14. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
15. Remove the J 44226-3A from the torque converter bolt.
16. Install the torque converter access plug.
17. Lower the vehicle.

Scheme 56

1. Remove the A/C line bracket nut.
2. Remove the A/C line bracket from the oil level indicator tube stud.
3. Disconnect the oxygen (O2) sensor electrical connector from the oil level indicator bracket.
4. Remove the oil level indicator tube stud.
5. Pull the indicator out of the tube.
6. Pull the tube out of the block.

1. Install the oil level indicator tube into the engine block.
2. Add sealant to the oil level indicator tube stud threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
3. Install the oil level indicator tube stud. Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the A/C line bracket to oil level indicator tube and secure with the nut. Tighten: Tighten the A/C line bracket nut to 7 N.m (6 lb in).
5. Connect the O2 sensor electrical connector.
6. Install the oil level indicator into the tube.

Cylinder Head Replacement

Scheme 57

1. If installing new cylinder head, refer to «Cylinder Head Assemble»(ref-268132-S02107966402007101800000) .
2. Install the dowel pins, cylinder head locator, if necessary.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
5. Install new cylinder head bolts.
6. Tighten the new cylinder head bolts in the following sequence: Tighten: Tighten the cylinder head bolts (1-14) in sequence to 30 N.m (22 lb ft). Use J 36660-A to tighten the cylinder head bolts in sequence an additional 155 degrees. Tighten the (2 Short) end bolts to 7 N.m (62 lb in). Use J 36660-A to tighten the short cylinder head end bolts an additional 60 degrees. Tighten the (1 Long) end bolt to 7 N.m (62 lb in). Use J 36660-A to tighten the long cylinder head end bolt an additional 120 degrees. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the cylinder head access hole plugs. Tighten: Tighten the plugs to 5 N.m (44 lb in).
8. Install the timing chain and sprockets. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-268132-S28263440172007101800000) .
9. Install the front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
11. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (4.2L Engine)»(ref-268155-S25356465982007101800000) .

Crankshaft Balancer Replacement

Tools Required

1. J 36660-A Torque Angle Meter «Special Tools»(ref-268132-S26120190452007101800000)
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-268132-S26120190452007101800000) .
4. J 44226 Crankshaft Balancer Remover/Holder «Special Tools»(ref-268132-S26120190452007101800000)

Scheme 58

Scheme 59

1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
3. Carefully loosen and remove the balancer bolt.
4. Install J 41816-2 into the end of the crankshaft. See «Special Tools»(ref-268132-S26120190452007101800000) .
5. Use a 3 jaw puller to remove the crankshaft balancer. IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
6. Remove the 3 jaw puller and the J 41816-2 . See «Special Tools»(ref-268132-S26120190452007101800000) .
7. Remove the crankshaft balancer shim from the crankshaft snout.
8. Clean and inspect the crankshaft balancer. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-268132-S26217799392007101800000) .

Scheme 60

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) . IMPORTANT: The crankshaft balancer does not have a key-way; so the crankshaft could turn when tightening, causing an improper torque. Make sure to follow the installation procedure to prevent damage.
2. Remove the torque converter access plug in the dry part of the oil pan.
3. Use the torque converter holding tool from the J 44226 kit and secure the torque converter while tightening the crankshaft balancer.
4. Install a new crankshaft balancer shim GM P/N 12573950 over the crankshaft snout, against the crankshaft gear.
5. Using the J 41478 install and seat the crankshaft balancer. See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Remove the J 41478 . See «Special Tools»(ref-268132-S26120190452007101800000) .
7. While still holding the flywheel, install the balancer washer and the bolt. Tighten: Tighten the crankshaft balancer bolt to 150 N.m (110 lb ft). Use the J 36660-A in order to tighten the balancer bolt an additional 180 degrees. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Remove the torque converter holding tool.
9. Install the torque converter access plug into the oil pan.
10. Lower the vehicle.
11. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
12. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .
2. Remove the cooling fan and the shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
4. Remove the water pump. Refer to «Water Pump Replacement (LH6)»(ref-268147-S28059382942007101800000) or «Water Pump Replacement (LL8)»(ref-268147-S03777892412007101800000) .
5. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-268132-S32598277812007101800000) .
6. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-268130-S06939904192007101800000) or «Power Steering Pump Replacement (Except 4.2L)»(ref-268130-S22765424012007101800000) .
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
8. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-268132-S00330239472007101800000) .
9. Lower the vehicle.
10. Remove the 7 mm center bolt (1).
11. Loosen and remove the remaining engine front cover bolts.
12. Place 2 of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to release the front cover from the engine.
13. Remove the 2 bolts from the front cover.
14. Remove the oil pump. Refer to «Oil Pump Replacement»(ref-268132-S07366258722007101800000) .
15. Clean and inspect the front cover. Refer to «Engine Front Cover Cleaning and Inspection»(ref-268132-S05520268312007101800000) .

Scheme 61

Scheme 62

Scheme 63

1. Install the J 44219 onto the engine. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Apply a 3 mm (0.12 in) bead of sealer to the trace grooves on back side of the engine front cover (1). Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number. IMPORTANT: The engine front cover must be installed within 10 minutes from when the sealer was applied.
3. Also apply sealant on the inside 3 bolt hole bosses on the cover.
4. Align the oil pump to the crankshaft sprocket splines.
5. Install the front cover.
6. Install the front cover bolts, tightening the center bolt (1) last. Tighten: Tighten the front cover bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Remove the J 44219 . See «Special Tools»(ref-268132-S26120190452007101800000) .
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
9. Install the oil pan. Refer to «Oil Pan Replacement»(ref-268132-S00330239472007101800000) .
10. Lower the vehicle.
11. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-268130-S06939904192007101800000) or «Power Steering Pump Replacement (Except 4.2L)»(ref-268130-S22765424012007101800000) .
12. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-268132-S32598277812007101800000) .
13. Install the water pump. Refer to «Water Pump Replacement (LH6)»(ref-268147-S28059382942007101800000) or «Water Pump Replacement (LL8)»(ref-268147-S03777892412007101800000) .
14. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
15. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
16. Fill the engine with coolant. Refer to «Draining and Filling Cooling System (LH6)»(ref-268147-S30426788732007101800000) or «Draining and Filling Cooling System (LL8)»(ref-268147-S34710564872007101800000) .

Camshaft Position Exhaust Actuator Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44217 Timing Chain Retention Tool

Scheme 64

Scheme 65

Scheme 66

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with the cylinder head to cam cover mating surface.
3. Remove the top chain guide bolts.
4. Remove the top chain guide.
5. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link across from it.
6. Install the J-44217 (1). Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. Tighten the wingnuts. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on the edge of the head.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.

Scheme 67

Scheme 68

1. Install the exhaust camshaft actuator into the timing chain.
2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator sprocket (1).
3. Install the exhaust camshaft actuator onto the exhaust camshaft. IMPORTANT: Ensure the alignment pin is engaged between the camshaft and the exhaust camshaft position actuator.
4. Install the exhaust camshaft actuator bolt. Tighten: Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Ensure the camshaft actuator is rotated clockwise relative to the camshaft prior to tightening the bolt. Do not force the camshaft actuator to rotate clockwise. If it does not move easily, it is already fully advanced. New camshaft actuators are already packaged in the fully advanced (clockwise) position.
5. Remove the J-44217 .
6. Install the top chain guide.
7. Add threadlocker to the top chain guide bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
8. Install the top chain guide bolts. Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 36660-A Torque Angle Meter «Special Tools»(ref-268132-S26120190452007101800000)
2. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .
3. Release the tension on the timing chain by moving the tensioner shoe in.
4. Place the tee into the tensioner to hold the shoe in place.
5. Remove the top chain guide bolts.
6. Remove the top chain guide.
7. Remove the exhaust camshaft position actuator bolt.
8. Remove the exhaust camshaft position actuator.
9. Remove the intake camshaft sprocket bolt.
10. Remove the intake camshaft sprocket.
11. Remove the timing chain.
12. Remove the crankshaft sprocket.
13. Remove the cylinder head access hole plugs.
14. Remove the timing chain tensioner shoe bolt.
15. Remove the timing chain tensioner shoe.
16. Remove the timing chain tensioner guide bolts.
17. Remove the timing chain tensioner guide.
18. Remove the timing chain tensioner bolts.
19. Remove the timing chain tensioner.

Scheme 73

Scheme 74

Scheme 75

1. Install the timing chain tensioner and secure the tensioner with the bolts. Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Every seventh link of the timing chain is darkened to aid in aligning the timing marks.
2. Install the timing chain tensioner guide and secure the guide with the bolts. Tighten: Tighten the timing chain tensioner guide to 10 N.m (89 lb in).
3. Install the timing chain tensioner shoe and secure the shoe with the bolt. Tighten: Tighten the timing chain tensioner shoe bolt to 26 N.m (19 lb ft).
4. Install the cylinder head access hole plugs. Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).
5. Install the J 44221 with the camshaft flats up and the number 1 piston at top dead center. See «Special Tools»(ref-268132-S26120190452007101800000) . The crank pin will be at 12 o'clock when the number 1 piston is at top dead center.
6. Install the crankshaft sprocket (1).
7. Install the intake camshaft sprocket into the timing chain. Refer to «Camshaft Position Actuator Diagnosis»(ref-268132-S06997279632007101800000) .
8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1).
9. Feed the timing chain down through the opening in the head.
10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing mark on to the crankshaft sprocket. IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. See «Special Tools»(ref-268132-S26120190452007101800000) .
11. Install the intake camshaft sprocket onto the intake camshaft.
12. Install the intake camshaft sprocket washer and bolt.
13. Install the exhaust camshaft actuator into the timing chain.
14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1). IMPORTANT: It may be necessary to remove the J 44221 to rotate and hold the camshaft hex to align the pin to the camshaft sprocket. See «Special Tools»(ref-268132-S26120190452007101800000) .
15. Install the exhaust camshaft actuator onto the exhaust camshaft.
16. Install the exhaust camshaft actuator bolt. Tighten: Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.
17. Install the intake camshaft sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 ft lb). Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
18. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
19. Remove the J 44221 . See «Special Tools»(ref-268132-S26120190452007101800000) .
20. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown.
21. Install the top chain guide.
22. Add threadlock on the top chain guide bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
23. Install the top chain guide bolts. Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
24. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .
25. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .

Camshaft Replacement

Tools Required

1. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 44222 Camshaft Sprocket Holding Tool
3. J 36660-A Torque/Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .
2. Remove the intake and the exhaust camshaft sprocket bolts.
3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components.
4. Carefully move the sprockets with the timing chain, off of the camshafts.
5. Remove the camshaft cap bolts.
6. Remove the camshaft caps and store. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
7. Remove the camshafts.

1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the intake and exhaust camshafts to their original positions.
3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See «Special Tools»(ref-268132-S26120190452007101800000) .
4. Install the camshaft caps and bolts. Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Install the camshaft caps onto their original locations. The camshaft caps are pin stamped for direction and numerical order.
5. Remove the J 44221 . See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Carefully move the sprockets back onto the camshafts and remove the J 44222 .
7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt. Tighten: Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees. Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135 degrees.
8. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-268132-S38151007752007101800000) .

Scheme 76

Scheme 77

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-268132-S10492551202007101800000) .
2. Remove the oil filter adapter.
3. Remove the oil filter bypass valve.

1. Install the oil filter bypass valve.
2. Install the oil filter adapter. Tighten: Tighten the oil filter adapter to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-268132-S10492551202007101800000) .

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3).
3. Remove the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-268132-S29487714212007101800000) .
4. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(ref-268128-S39209003642007101800000) .
5. Remove the front differential and secure to the frame. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
6. Remove the front drive axle intermediate shaft bearing assembly. Refer to «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (A4WD)»(ref-268154-S32184986692007101800000) or «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (S4WD)»(ref-268154-S04668881692007101800000) .
7. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-268132-S10492551202007101800000) .
8. Unclip the transmission cooler lines from the engine block.
9. Remove 4 transmission bell housing bolts that are attached to the oil pan.
10. Remove the remaining oil pan bolts.
11. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine (1).
12. Clean and inspect the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-268132-S21225279492007101800000) .

Scheme 82

Scheme 83

1. Apply a 3 mm (0.12 in) bead of sealer to the block, rather than the oil pan. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number. IMPORTANT: The oil pan must be installed within 10 minutes from when sealer was applied.
2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly. IMPORTANT: When you install the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block.
3. Install the oil pan bolts.
4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission mounting surface. Tighten: Tighten the oil pan side bolts to 25 N.m (18 lb ft). Tighten the oil pan end bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
5. Install the 4 transmission bell housing bolts that attach to the oil pan. Tighten: Tighten bolts to 47 N.m (35 lb ft).
6. Clip transmission cooler lines to the engine block.
7. Install the front drive axle intermediate shaft bearing assembly. Refer to «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (A4WD)»(ref-268154-S32184986692007101800000) or «Intermediate Shaft Bearing Assembly Replacement - Front Drive Axle (S4WD)»(ref-268154-S04668881692007101800000) .
8. Install the oil drain plug and filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-268132-S10492551202007101800000) .
9. Install the front differential to the engine. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
10. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(ref-268128-S39209003642007101800000) .
11. Install the A/C compressor 2 bottom bolts (4). Tighten: Tighten all 4 bolts (2, 3, 4) to 50 N.m (37 lb ft).
12. Install the oil level indicator and tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-268132-S29487714212007101800000) .
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
14. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-268132-S10492551202007101800000) . IMPORTANT: Inspect the engine for oil leaks in order to ensure all sealing surfaces are sealed.

Scheme 84

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the engine shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
3. Remove the electrical connector from the oil pressure switch.
4. Remove the oil pressure switch.

1. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 20 N.m (15 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the electrical connector to the oil pressure switch.
3. Install the engine shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
4. Lower the vehicle.

Scheme 85

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .
2. Remove the oil pump cover bolts.
3. Remove the oil pump cover.
4. Mark the inner and the outer gears in relation to the oil pump housing.
5. Remove the inner and the outer oil pump gears.
6. Remove the oil pump pressure relief valve plug.
7. Remove the oil pump pressure relief valve and the spring.

1. Install the oil pump pressure relief valve and the spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the oil pump pressure relief valve to 14 N.m (124 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
6. Install the front cover. Refer to «Engine Front Cover Replacement»(ref-268132-S26783927722007101800000) .

Crankshaft Rear Oil Seal and Housing Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 44219 Cover Alignment Pins. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. J 44227 Rear Seal Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 86

Scheme 87

1. Remove the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .
2. Remove the flywheel bolts and remove the flywheel.
3. Remove the crankshaft rear oil seal housing bolts.
4. Install 2 bolts into the jackscrew holes (1) to release the cover from the block.
5. Remove the crankshaft and rear oil seal housing.
6. Remove the oil seal from the crankshaft snout.

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. Use the J 44227 to install the crankshaft rear oil seal. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Remove the J 44227 . See «Special Tools»(ref-268132-S26120190452007101800000) .
3. Apply a 3 mm (0.12 in) bead of sealant to the rear oil seal housing (1). Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
4. Install the J 44219 guide pins (1) into the block. See «Special Tools»(ref-268132-S26120190452007101800000) .
5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft. See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: When installing a new seal, use the plastic installation sleeve supplied with the new seal. The seal installation sleeve should come off after the seal is installed. Discard the sleeve.
6. Install the crankshaft rear oil seal housing bolts, except the 2 in place of the guide pins.
7. Remove the J 44219 guide pins. See «Special Tools»(ref-268132-S26120190452007101800000) .
8. Install the remaining 2 crankshaft rear oil seal housing bolts. Tighten: Tighten all the oil seal housing bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
9. Wipe off any excess material from the bottom of the oil pan sealing area (1).
10. Install the flywheel and secure with the bolts. Tighten: Tighten the flywheel bolts in sequence to 25 N.m (18 lb ft).
11. Use the J 36660-A to tighten the bolts an additional 50 degrees.
12. Install the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .

1. Remove the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .
2. Remove the flywheel bolts. IMPORTANT: Note the position and the direction of the engine flywheel before removal.
3. Remove the flywheel.
4. Clean and Inspect the flywheel. Refer to «Engine Flywheel Cleaning and Inspection»(ref-268132-S10140598982007101800000) .

1. Add threadlock to the new flywheel bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268132-S34241285802007101800000) for the correct part number.
2. Install the flywheel and secure the flywheel with the new bolts. Tighten: Tighten the bolts in sequence to 25 N.m (18 lb ft). Use the J 36660-A in order to tighten the bolts an additional 50 degrees. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .

1. Wipe the excess oil from the oil filter housing.
2. Lubricate the oil filter seal with clean engine oil.
3. Install the new oil filter. Tighten: Tighten the oil filter to 17 N.m (22 lb ft) plus 150 degrees. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 26 N.m (19 lb ft).
5. Lower the vehicle.
6. Fill the crankcase with the proper quantity of engine oil. Refer to «Capacities - Approximate Fluid»(ref-268159-S19539682002007101800000) and «Fluid and Lubricant Recommendations»(ref-268159-S32137604382007101800000) .
7. Remove the oil level indicator.
8. Wipe the indicator with a clean cloth.
9. Install the oil level indicator.
10. Remove the oil level indicator and check the oil level.
11. Add oil if necessary.
12. Check for any oil leaks.

Engine Flywheel Removal

1. Remove the flywheel bolts.
2. Remove the flywheel.

Scheme 92

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.

Scheme 93

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

Scheme 94

1. Remove the power steering pump bracket bolts.
2. Remove the power steering pump bracket.

Drive Belt Idler Pulley Removal

1. Remove the drive belt idler pulley bolts.
2. Remove the drive belt idler pulley.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator.
2. Remove the oil level indicator tube stud.
3. Remove the oil level indicator tube.

Scheme 95

Scheme 96

Scheme 97

Scheme 98

1. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
3. Remove the exhaust manifold studs.(if needed)
4. Remove the exhaust manifold bolts.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.

Scheme 99

Scheme 100

1. Remove the oil filter adapter.
2. Remove the oil filter bypass valve.

Scheme 101

1. Remove the heater inlet pipe bolt.
2. Remove the heater inlet pipe.

Scheme 102

Remove the heater outlet hose fitting.

Scheme 103

1. Remove the water outlet bolts.
2. Remove the water outlet.

Oil Pump Removal

1. Remove the oil pump cover bolts.
2. Remove the oil pump cover.
3. Mark the inner and outer gears in relation to the oil pump housing.
4. Remove the inner and outer oil pump gears.
5. Remove the oil pump pressure relief valve plug.
6. Remove the oil pump pressure relief valve and spring.

Crankshaft Front Oil Seal Removal

Pry out the crankshaft front oil seal using a suitable tool.

Scheme 104

1. Remove the exhaust camshaft position actuator bolt.
2. Remove the exhaust camshaft position actuator.
3. Remove the intake camshaft sprocket bolt.
4. Remove the intake camshaft sprocket.
5. Remove the timing chain.
6. Remove the crankshaft sprocket.

Scheme 105

1. Remove the crankshaft rear oil seal housing bolts.
2. Install two bolts (Jack Screws) into the threaded holes (1) to break the seal of the housing.
3. Remove the crankshaft rear oil seal housing.

Crankshaft Rear Oil Seal Removal

Remove the crankshaft rear oil seal.

Scheme 106

1. Remove the cylinder head access hole plugs.
2. Remove the timing chain tensioner shoe bolt.
3. Remove the timing chain tensioner shoe.
4. Remove the timing chain tensioner guide bolts.
5. Remove the timing chain tensioner guide.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.

Scheme 107

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

Camshaft Removal

1. Remove the camshaft cap bolts.
2. Remove the camshaft caps. IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed.
3. Remove the camshafts.

Valve Rocker Arm and Valve Lash Adjuster Removal

1. Remove the valve rocker arms. IMPORTANT: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations.
2. Remove the valve lash adjusters.

Cylinder Head Removal

Crankshaft and Bearings Removal

Crankshaft and Bearings Installation

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. EN-47701 Piston Ring Compressor. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. J 41556 Connecting Rod Guide. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at bottom dead center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Install EN-47701 onto the piston and ring assembly to compress the rings. See «Special Tools»(ref-268132-S26120190452007101800000) .
6. Install the connecting rod bearings into the connecting rods and caps (1).
7. Lubricate the connecting rod bearing contact surfaces with engine oil.
8. Install the J 41556 into the connecting rod. See «Special Tools»(ref-268132-S26120190452007101800000) .
9. Install the connecting rod and piston into the proper cylinder bore. IMPORTANT: The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and connecting rod assembly into the proper cylinder bore. The piston alignment mark MUST face the front of the engine block (1) or the flat casting boss (2).
10. Make sure to install the connecting rod facing the right direction. IMPORTANT: The oil hole, in the connecting rod, should be facing the exhaust side of the block.
11. Hold the EN-47701 firmly against the engine block. See «Special Tools»(ref-268132-S26120190452007101800000) . Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
12. Guide the connecting rod end onto the crankshaft journal. Use J 41556 to pull the connecting rod into place. See «Special Tools»(ref-268132-S26120190452007101800000) .
13. Install the connecting rod bearing, cap, and bolts. Tighten: Tighten the connecting rod bearing cap bolts on the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the connecting rod bearing cap bolts on the second pass an additional 110 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
14. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankshaft.
15. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be between 0.05-0.35 mm (0.0019-0.0137 in).

Cylinder Head Installation

Valve Rocker Arm and Valve Lash Adjuster Installation

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
3. Lubricate the valve rocker arm roller, needle bearings, valve pallet, and lash adjuster pocket.
4. Install the valve rocker arms in their original locations.

Timing Chain and Sprockets Installation

Tools Required

1. J 44221 Camshaft Holding Tool. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 113

Scheme 114

Scheme 115

Scheme 116

1. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See «Special Tools»(ref-268132-S26120190452007101800000) . The crankshaft pin should be at 12 o'clock when the number 1 piston is at top dead center.
2. Compress the tensioner and lock in place.
3. Install the crankshaft sprocket.
4. Install the intake camshaft sprocket into the timing chain.
5. Align the - dark link of the timing chain with the timing mark on the intake camshaft sprocket (1).
6. Feed the timing chain down through the opening in the head.
7. Install the timing chain onto the crankshaft sprocket. Align the - dark link of the timing chain with the timing mark on the crankshaft sprocket (2).
8. Install the intake camshaft sprocket onto the intake camshaft. IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. See «Special Tools»(ref-268132-S26120190452007101800000) .
9. Install the intake camshaft sprocket washer and new bolt. Tighten: Tighten the new intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft). Use J 45059 to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
10. Install the exhaust camshaft actuator into the timing chain.
11. Align the - dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1).
12. Install the exhaust camshaft actuator onto the exhaust camshaft. IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. See «Special Tools»(ref-268132-S26120190452007101800000) .
13. Install the new exhaust camshaft actuator bolt. Tighten: Tighten the new exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft). Use J 45059 to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.
14. Unlock the tensioner.
15. Remove J 44221 . See «Special Tools»(ref-268132-S26120190452007101800000) .
16. Rotate the camshaft actuator clockwise - as seen from the front of the vehicle. IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.
17. The dark links (1) on the chain should be aligned with marks on sprockets as shown.

Camshaft Cover Installation

1. Install a new camshaft cover seal.
2. Install the camshaft cover and bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
3. Install new ignition control module seals.
4. Install the ignition control modules and bolts. Tighten: Tighten the ignition control module bolts to 10 N.m (89 lb in).

Camshaft Position Actuator Solenoid Valve Installation

1. Apply clean engine oil to the camshaft position actuator valve hole.
2. Install the camshaft position actuator valve.
3. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the camshaft position actuator valve bolt threads.
4. Install the camshaft position actuator valve bolt. Tighten: Tighten the camshaft position actuator valve bolt to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Oil Pump Installation

1. Install the oil pump pressure relief valve and spring.
2. Install the oil pump pressure relief valve plug. Tighten: Tighten the oil pump pressure relief valve plug to 14 N.m (124 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
3. Install the oil pump outer and inner gears as removed.
4. Install the oil pump cover.
5. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).

Oil Pump Pipe and Screen Assembly Installation

1. Install a new oil pump pipe gasket.
2. Install the oil pump pipe and screen assembly.
3. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil pump pipe bolt threads.
4. Install the oil pump pipe and screen assembly bolts. Tighten: Tighten the oil pump pipe and screen assembly bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Scheme 117

1. Apply a 3 mm (0.12 in) bead of sealer GM P/N United States 12378521, GM P/N Canada 88901148 to the block.
2. Install the oil pan. IMPORTANT: The oil pan must be installed within 10 minutes from when the sealer was applied.
3. Install the oil pan bolts.
4. Check the oil pan alignment. Use a straight edge on the back of the block and oil pan - transmission mounting surface. IMPORTANT: When installing the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block.
5. Tighten the oil pan bolts. Tighten: Tighten the - side oil pan bolts to 25 N.m (18 lb ft). Tighten the - end oil pan bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
6. Install the oil level sensor.
7. Install the oil level sensor bolt. Tighten: Tighten the oil level sensor bolt to 10 N.m (89 lb in).

Crankshaft Balancer Installation

Tools Required

1. J 45059 Angle Meter. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .

1. Install the crankshaft balancer using J 41478 . See «Special Tools»(ref-268132-S26120190452007101800000) .
2. Remove J 41478 . See «Special Tools»(ref-268132-S26120190452007101800000) .
3. Hold the flywheel or back of the crankshaft. The crankshaft balancer does not have a keyway so the crankshaft could turn when tightening, causing an improper torque.
4. Install the crankshaft balancer washer and new bolt. Tighten: Tighten the new crankshaft balancer bolt while holding the back to 150 N.m (110 lb ft). Use J 45059 to tighten the crankshaft balancer bolt an additional 180 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices. IMPORTANT: Be sure the crankshaft balancer friction washer, GM P/N 12573950, was installed prior to the engine front cover installation.

Fuel Rail and Injectors Installation

1. Lubricate the lower injector O-rings with mineral oil GM P/N 9981704.
2. Install the fuel injector rail.
3. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Intake Manifold Installation

1. Install a new intake manifold gasket.
2. Install the intake manifold and bolts. Tighten: Tighten the intake manifold bolts from the inside out to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
3. Lubricate the inner diameter of the ends of PCV hose with GM P/N 12345884, (Canadian P/N 5728223) or equivalent.
4. Install the PCV hose.
5. Install a new throttle control module gasket.
6. Install the throttle control module.
7. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the throttle control module bolt threads.
8. Install the throttle control module bolts. Tighten: Tighten the throttle control module bolts to 10 N.m (89 lb in).

Engine Coolant Thermostat Housing Installation

1. Install the thermostat housing.
2. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Heater Inlet Pipe Installation

1. Install the heater inlet pipe.
2. Install the heater inlet pipe bolt. Tighten: Tighten the heater inlet pipe bolt to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Heater Outlet Hose Fitting Installation

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the heater outlet hose fitting threads.
2. Install the heater outlet hose fitting. Tighten: Tighten the heater outlet hose fitting to 45 N.m (33 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Water Outlet Installation

1. Install the water outlet.
2. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter adapter. Tighten: Tighten the oil filter adapter to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Scheme 118

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Add threadlock GM P/N United States 12345493, GM P/N Canada 10953488 to the exhaust manifold bolt threads.
4. Install the exhaust manifold bolts.
5. Tighten the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts a first pass in sequence to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts a second pass in sequence to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts a final pass in sequence to 20 N.m (15 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
6. Install the exhaust manifold heat shield studs (if required). Tighten: Tighten the exhaust manifold heat shield studs to 10 N.m (89 lb in).
7. Install the exhaust manifold heat shield.
8. Add anti-seize GM P/N United States 12371386, GM P/N Canada 993128 to the exhaust manifold heat shield nuts.
9. Install the exhaust manifold heat shield nuts. Tighten: Tighten the exhaust manifold heat shield nuts to 10 N.m (89 lb in).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.
2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads.
3. Install the oil level indicator tube stud. Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
4. Install the oil level indicator.

Power Steering Pump Bracket Installation

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

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Drive Belt Idler Pulley Installation

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolts. Tighten: Tighten the drive belt idler pulley bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.