Engine Mechanical - 5.3L: Removal & Installation Saab 9-7X I

Installation Procedure

1. Route the drive belt around all the pulleys except the generator pulley.
2. Install the breaker bar with hex-head socket to the belt tensioner bolt.
3. Rotate the belt tensioner clockwise in order to relieve the tension on the belt.
4. Install the drive belt on the generator pulley.
5. Slowly release the tension on the belt tensioner.
6. Remove the breaker bar and socket from the belt tensioner bolt.
7. Inspect the drive belt for proper installation and alignment.
8. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268122-S06780068422007101800000) .

Scheme 354

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
3. Install a ratchet into the square opening of the air conditioning (A/C) belt tensioner.
4. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
5. Remove the A/C belt from the pulleys.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the ratchet from the A/C belt tensioner.
8. Clean and inspect the belt surfaces of all the pulleys.

1. Install the A/C belt around the crankshaft balancer.
2. Install a ratchet into the square opening of the A/C drive belt tensioner.
3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
4. Install the A/C belt over the idler pulley.
5. Install the A/C belt around the A/C compressor pulley.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the ratchet from the A/C belt tensioner.
8. Inspect the A/C belt for proper installation and alignment.
9. Lower the vehicle.
10. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .

Scheme 355

1. Remove the accessory drive belt. Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
2. Remove the drive belt idler pulley and bolt.

1. Install the drive belt idler pulley and bolt to the generator bracket. Tighten: Tighten the bolt to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .

Scheme 356

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
2. Remove the drive belt tensioner bolts.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolts. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Tighten the drive belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .

Scheme 357

1. Remove the air conditioning (A/C) drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-268156-S20432445342007101800000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
3. Remove the A/C belt tensioner bolts.
4. Remove the A/C belt tensioner.

1. Install the A/C belt tensioner. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the A/C belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Lower the vehicle.
4. Install the A/C drive belt. Refer to «Drive Belt Replacement - Air Conditioning»(ref-268156-S20432445342007101800000) .

Scheme 358

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 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
5. Remove the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
6. Remove the front differential carrier. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
9. Remove the 3 retaining bolts to the frame engine mount bracket.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Remove the engine mount frame bracket from the frame.
14. Remove the engine mount with the upper engine mount bracket as an assembly.
15. Separate the engine mount from the upper engine mount bracket.
16. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft). IMPORTANT: Verify that the cut out side of the engine mount shield is positioned away from the engine.
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Install the left side engine mount frame bracket.
7. Install the left side engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
8. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
12. Install the front differential carrier. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
13. Install the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
14. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
15. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
16. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .

Removal Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
5. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
6. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
7. Remove the 3 frame engine mount bracket retaining bolts.
8. Install a pole jack underneath the oil pan.
9. Insert a block of wood between the oil pan and the pole jack.
10. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
11. Remove the engine mount frame bracket from the frame.
12. Remove the engine mount with the upper engine mount bracket as an assembly.
13. Separate the engine mount from the upper engine mount bracket.
14. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft). IMPORTANT: Verify that the cut out side of the engine mount shield is positioned away from the engine.
3. Install the engine mount to the engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the retaining bolts to the engine mount frame bracket.
6. Install the left side engine mount frame bracket.
7. Install the retaining bolts to the left side engine mount frame bracket. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
8. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
9. Remove the pole jack and block of wood.
10. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
11. Install the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
12. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
13. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
14. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
5. Remove the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
6. Remove the front differential carrier. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
7. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
8. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
9. Remove the 3 retaining bolts from the frame engine mount bracket.
10. Install a pole jack underneath the oil pan.
11. Insert a block of wood between the oil pan and the pole jack.
12. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
13. Shift the engine towards the left side of the frame.
14. Remove the engine mount frame bracket from the frame.
15. Remove the engine mount with the upper engine mount bracket as an assembly.
16. Separate the engine mount from the upper engine mount bracket.
17. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if necessary. Tighten: Tighten the spacer bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft). IMPORTANT: Verify that the cut out side of the engine mount shield is positioned away from the engine.
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Shift the engine back towards the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the left side engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
9. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
10. Remove the pole jack and block of wood.
11. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
13. Install the front differential carrier. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
14. Install the left side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
15. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
16. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
17. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
4. Remove the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
5. Remove the lower engine mount retaining nuts from the engine mount frame bracket.
6. Remove the 3 mounting bolts that secure the upper engine mount bracket to the engine block bracket.
7. Remove the 3 bracket retaining bolts from the frame engine mount.
8. Install a pole jack underneath the oil pan.
9. Insert a block of wood between the oil pan and the pole jack.
10. Raise the engine 21/4 inches measuring from the bottom of the oil pan to the front edge of the transmission support crossmember.
11. Shift the engine towards the left side of the frame.
12. Remove the engine mount frame bracket from the frame.
13. Remove the engine mount with the upper engine mount bracket as an assembly.
14. Separate the engine mount from the upper engine mount bracket.
15. Remove the engine mount bracket spacer if damaged.

1. Install the engine mount bracket spacer if it has been replaced. Tighten: Tighten the bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the engine mount to the upper engine mount bracket. Tighten: Tighten the engine mount nuts to 50 N.m (37 lb ft). IMPORTANT: Make sure that the cut out side of the engine mount shield is positioned away from the engine.
3. Install the engine mount to engine. Tighten: Tighten the engine mount bolts to 50 N.m (37 lb ft).
4. Install the engine mount frame bracket to the frame.
5. Install the engine mount frame bracket retaining bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
6. Shift engine back to the right side of the frame.
7. Install the left side engine mount frame bracket.
8. Install the retaining bolts to the left side of the engine mount frame bracket. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
9. Lower the engine, aligning the engine mount studs with the holes in the frame bracket.
10. Remove the pole jack and the block of wood.
11. Tighten the engine mount nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
12. Install the shock module. Refer to «Shock Module Replacement»(ref-268128-S01910808972007101800000) .
13. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
14. Install the front tire and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-268106-S04195407242007101800000) .
15. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .

Scheme 365

Scheme 366

1. Loosen intake manifold sight shield wing nut.
2. Gently lift up in order to disengage the sight shield from the ball stud.
3. Remove the sight shield from the sight shield retainer.
4. Remove the sight shield retainer bolts and the retainer, if required.
5. Remove the sight shield ball stud, if required.

1. Install the sight shield ball stud, if required. Tighten: Tighten the stud to 5 N.m (44 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Position the sight shield retainer to the intake manifold and install the bolts, if required. Tighten: Tighten the bolts to 5 N.m (44 lb in).
3. Install the sight shield to the sight shield retainer. NOTE: Use care when installing the engine sight shield to avoid contacting the manifold absolute pressure (MAP) sensor wire harness connector. Loss of engine performance or engine damage may result.
4. Seat the sight shield onto the ball stud and press down over the stud in order to secure the sight shield.
5. Tighten intake manifold sight shield wing nut until snug.

Scheme 367

Scheme 368

1. Remove the positive crankcase ventilation (PCV) dirty air hose from the intake manifold and valve rocker arm cover.
2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268122-S06780068422007101800000) .
3. Remove the PCV fresh air hose (2) from the valve rocker arm cover (1).

1. Install the PCV fresh air hose (2) to the valve rocker arm cover (1).
2. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268122-S06780068422007101800000) .
3. Install the PCV dirty air hose to the intake manifold and valve rocker arm cover.

Scheme 369

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
2. Disconnect the electrical connector from the oil pressure sensor.
3. Remove the oil pressure sensor (1) and washer (2). IMPORTANT: Do not allow dirt or debris to enter the passages of the manifold. Plug as required.
4. Remove the oil filter (3).
5. Inspect the O-ring (4) for cuts or damage. If the filter is plugged or the O-ring is cut or damaged, replace the filter and O-ring as an assembly.

1. Install a NEW oil filter (3) and O-ring (4) assembly. IMPORTANT: Do not allow dirt or debris to enter the passages of the manifold. Plug as required.
2. Apply sealant to the threads of the sensor. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number.
3. Install the oil pressure sensor (1) and washer (2). Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Connect the electrical connector to the oil pressure sensor.
5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268122-S06780068422007101800000) . IMPORTANT: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
3. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-268122-S16114962052007101800000) .
4. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
5. Remove the harness clip (1) from the cylinder head.
6. Disconnect the electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
7. Remove the harness clips from the fuel rail.
8. Perform the following steps in order to disconnect the fuel injector electrical connectors. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up one click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
9. Disconnect the following electrical connectors: Evaporative emission (EVAP) purge solenoid (3) Throttle body harness (5) Manifold absolute pressure (MAP) sensor (2) Main coil (1) Generator (4)
10. Remove the electrical harness clips from the fuel rail.
11. Remove the positive crankcase ventilation (PCV) hose.
12. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
13. Remove the EVAP purge solenoid vent tubes (1, 2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-268122-S04514937072007101800000) .
14. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to «Metal Collar Quick Connect Fitting Service»(ref-268122-S09525584282007101800000) .
15. Remove the vacuum brake booster hose from the rear of the intake manifold.
16. Remove the upper engine wire harness retainer nut (1).
17. Reposition the upper engine wire harness aside.
18. Remove the intake manifold bolts.
19. Remove the intake manifold.
20. Remove the intake manifold gaskets (1) from the intake manifold.
21. Discard the old intake manifold gaskets.
22. If necessary, clean and inspect the intake manifold. Refer to «Intake Manifold Cleaning and Inspection»(ref-268156-S29353995662007101800000) .

Scheme 381

1. Install NEW intake manifold gaskets (1) to the intake manifold.
2. Install the intake manifold.
3. Apply a 5 mm (0.2 in) bead of threadlock to the threads of the intake manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number.
4. Install the intake manifold bolts. Tighten: Tighten the bolts a first pass in sequence to 5 N.m (44 lb in). Tighten the bolts a final pass in sequence to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . Use maifg
5. Route the electrical harness into position over the engine.
6. Install the engine harness bracket nut (1). Tighten: Tighten the nut to 10 N.m (89 lb in).
7. Install the vacuum brake booster hose to the rear of the intake manifold.
8. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to «Metal Collar Quick Connect Fitting Service»(ref-268122-S09525584282007101800000) .
9. Install the EVAP purge solenoid vent tubes (1, 2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-268122-S04514937072007101800000) .
10. Install the heater water shutoff valve actuator inlet hose to the intake manifold.
11. Install the PCV hose.
12. Connect the electrical harness clips to the fuel rail.
13. Connect the following electrical connectors: EVAP purge solenoid (3) Throttle body harness (5) MAP sensor (2) Main coil (1) Generator (4)
14. Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) on the connector in one click. Repeat the steps for each injector electrical connector.
15. Install the electrical harness clips to the fuel rail.
16. Connect the A/C compressor pressure switch electrical connector (2).
17. Install the harness clip (1) to the cylinder head.
18. Connect the MAF/IAT sensor electrical connector (1).
19. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268122-S06780068422007101800000) .
20. Install the fuel fill cap.
21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
22. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 382

Scheme 383

Scheme 384

Scheme 385

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
2. Disconnect the electrical connector from the oil pressure sensor.
3. Remove the valve lifter oil manifold bolts (2).
4. Remove the valve lifter oil manifold (1). IMPORTANT: Do not allow dirt or debris to enter the oil passages of the manifold. Plug as required.
5. Do not lift the manifold by the electrical lead frame.
6. Identify the 8 gasket retaining strap locations (1-8). IMPORTANT: Remove only the outer gasket from the manifold. Do not disassemble any of the internal components of the manifold in an attempt to remove the 8 inner sealing gaskets. If the inner gaskets are cut or damaged, replace the manifold as an assembly. Only use a wire-cutter type tool in order to minimize the amount of debris. Do not use a rotary-type cutting tool on the retaining straps.
7. Using a wire-cutter type tool, cut the 8 retaining straps of the outer gasket.
8. Remove the outer gasket (1) from the manifold.

1. Install the service gasket (1) onto the manifold. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. Do not allow dirt or debris to enter the manifold. Plug as required.
2. Install the manifold (2) with gasket. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the manifold bolts (1). Tighten: Tighten the manifold bolts to 25 N.m (18 lb ft).
4. Connect the electrical connector to the oil pressure sensor.
5. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .

Scheme 386

Scheme 387

Scheme 388

Scheme 389

1. Remove the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .
2. Remove the connector position assurance (CPA) lock.
3. Disconnect the main electrical connector (5) to the ignition coil wire harness.
4. Remove the harness clips.
5. Reposition the engine harness, if necessary.
6. Remove the spark plug wires from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
7. If necessary, remove the ignition coil bracket studs from the rocker arm cover.
8. If necessary, remove the ignition coils and bracket from the rocker arm cover.
9. Remove the positive crankcase ventilation (PCV) hose from the rocker arm cover.
10. Remove the valve rocker arm cover bolts.
11. Remove the valve rocker arm cover.
12. Remove the gasket (1) from the rocker cover.
13. Discard the OLD gasket.

1. Install a NEW rocker cover gasket (1) into the groove of the valve rocker arm cover. IMPORTANT: All gasket surfaces should be free of oil an/or other foreign material during assembly. DO NOT reuse the valve rocker arm cover gasket. The valve rocker arm cover bolt grommets may be reused. If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the rocker arm cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Install the PCV hose to the rocker arm cover.
6. Apply threadlock to the threads of the bracket bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
7. If necessary, install the ignition coils and bracket to the rocker arm cover.
8. If necessary, install the ignition coil bracket studs to the rocker arm cover. Tighten: Tighten the studs to 12 N.m (106 lb in).
9. Install the spark plug wires to the ignition coils.
10. Position the engine harness, if necessary.
11. Install the harness clips.
12. Connect the main electrical connector (5) to the ignition coil wire harness.
13. Install the CPA lock.
14. Install the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .

Scheme 390

Scheme 391

Scheme 392

Scheme 393

1. Remove the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .
2. Remove the air conditioning (A/C) compressor hose. Refer to «Compressor Hose Assembly Replacement (LH6)»(ref-268096-S15574468532007101800000) or «Compressor Hose Assembly Replacement (LL8)»(ref-268096-S24271056052007101800000) .
3. Remove the connector position assurance (CPA) lock.
4. Disconnect the main electrical connector (1) to the ignition coil wire harness.
5. Remove the harness clips.
6. Reposition the engine harness, if necessary.
7. Remove the spark plug wires from the ignition coils. Twist each plug wire 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
8. If necessary, remove the ignition coil bracket studs from the rocker arm cover.
9. If necessary, remove the ignition coils and bracket from the rocker cover.
10. Remove the vent hose (2) from the valve rocker arm cover (1).
11. Remove the valve rocker arm cover bolts.
12. Remove the valve rocker arm cover.
13. Remove the gasket (1) from the rocker cover.
14. Discard the OLD gasket.
15. Remove the oil fill cap from the oil fill tube.
16. Remove the oil fill tube from the rocker cover, if required.
17. Discard the oil fill tube.

1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT reuse the valve rocker arm cover gasket. The valve rocker arm cover bolt grommets may be reused. If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly.
2. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position.
4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover.
5. Install the valve rocker arm cover onto the cylinder head.
6. Install new rocker arm cover grommets, if necessary. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the rocker arm cover bolts and grommets. Tighten: Tighten the bolts to 12 N.m (106 lb in).
8. Install the vent hose (2) to the valve rocker arm cover (1).
9. Apply threadlock to the threads of the bracket bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
10. If necessary, install the ignition coils and bracket to the rocker arm cover.
11. If necessary, install the ignition coil bracket studs to the rocker cover. Tighten: Tighten the studs to 12 N.m (106 lb in).
12. Install the spark plug wires to the ignition coils.
13. Position the engine harness, if necessary.
14. Install the harness clips.
15. Connect the main electrical connector (1) feeding the ignition coils.
16. Install the CPA lock.
17. Install the A/C compressor hose. Refer to «Compressor Hose Assembly Replacement (LH6)»(ref-268096-S15574468532007101800000) or «Compressor Hose Assembly Replacement (LL8)»(ref-268096-S24271056052007101800000) .
18. Install the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .

Scheme 394

Scheme 395

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-268156-S20399691482007101800000) or to «Valve Rocker Arm Cover Replacement - Right Side»(ref-268156-S01480394812007101800000) .
2. Remove the valve rocker arm bolts.
3. Remove the valve rocker arms.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrods.
6. Clean and inspect the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(ref-268156-S19991600332007101800000) .

Scheme 396

Scheme 397

1. Lubricate the valve rocker arms and pushrods with clean engine oil. IMPORTANT: When reusing the valve train components, always install the components to the original location and position. The valve lash is net build, no valve adjustment is required.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.
3. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
4. Install the valve rocker arm pivot support.
5. Install the pushrods. IMPORTANT: Make sure that the pushrods seat properly to the valve lifter sockets.
6. Install the rocker arms and bolts. IMPORTANT: Verify that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time.
7. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinder 2, 4, 6 and 8 are the right bank. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. With the engine in the number one firing position, tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
9. Rotate the crankshaft 360 degrees.
10. Tighten the following valve rocker arm bolts: Tighten: Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft). Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
11. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-268156-S20399691482007101800000) or to «Valve Rocker Arm Cover Replacement - Right Side»(ref-268156-S01480394812007101800000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 38606 Valve Spring Compressor. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

1. Remove the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-268156-S03305123772007101800000) .
2. Disconnect the spark plug wire at the spark plug. Twist each plug wire boot 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
3. Loosen the spark plug 1-2 turns. IMPORTANT: Remove the spark plugs from the cylinder head with the engine at room temperature.
4. Brush or air blast away any dirt or debris from around the spark plug.
5. Remove the spark plug.
6. Install J 22794 into the spark plug hole. See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Attach an air hose to J 22794 . See «Special Tools»(ref-268156-S11321246192007101800000) .
8. Apply compressed air to J 22794 in order to hold the valves in place. See «Special Tools»(ref-268156-S11321246192007101800000) .
9. Use J 38606 in order to compress the valve spring. See «Special Tools»(ref-268156-S11321246192007101800000) .
10. Remove the valve stem keys (2).
11. Carefully release the valve spring tension.
12. Remove J 38606 . See «Special Tools»(ref-268156-S11321246192007101800000) .
13. Remove the valve spring cap (3).
14. Remove the valve spring (4).
15. Remove the valve stem oil seal/shim assembly (1, 5).

Scheme 403

1. Clean the cylinder head valve spring seat and/or shim area.
2. Lubricate the valve guide and valve stem oil seal with clean engine oil.
3. Install the valve stem oil seal/shim assembly (1, 5).
4. Install the valve spring (4).
5. Install the valve spring cap (3).
6. Compress the valve spring using the J 38606 . See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Install the valve keys. Use grease in order to hold the valve keys in place. Make sure the keys seat properly in the groove of the valve stem. Carefully release the valve spring pressure, making sure the valve keys stay in place. Remove J 38606 . See «Special Tools»(ref-268156-S11321246192007101800000) . Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary).
8. Remove J 22794 from the spark plug port. See «Special Tools»(ref-268156-S11321246192007101800000) .
9. Hand start the spark plug. Tighten: Tighten the spark plug to 15 N.m (11 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
10. Install the spark plug wires at the ignition coil.
11. Install the spark plug wire to the spark plug.
12. Inspect the wires for proper installation: Push sideways on each boot in order to check for proper installation. Reinstall any loose boot.
13. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-268156-S03305123772007101800000) .

Scheme 404

1. Remove the cylinder number 2 spark plug and wire. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
2. Remove the oil level indicator from the tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube from the engine block. IMPORTANT: The O-ring seal may be reused if not cut or damaged.
5. Inspect the O-ring seal for cuts or damage.
6. Remove the O-ring seal from the tube, if required.

1. Lubricate the O-ring seal with clean engine oil.
2. Install the O-ring seal onto the oil level indicator tube.
3. Install the oil level indicator tube behind the exhaust manifold.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
5. Install the oil level indicator tube into the block. Install the tube with the collar flush to the block.
6. Lower the vehicle. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the oil level indicator to the tube.
9. Install the cylinder number 2 spark plug and wire. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .

1. Install the cylinder head. Refer to «Cylinder Head Installation - Left Side»(ref-268156-S39358500982007101800000) .
2. If equipped, install the auxiliary A/C bracket bolt (5). Tighten: Tighten the bolt to 20 N.m (15 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-268156-S03305123772007101800000) .
4. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side»(ref-268155-S38907835402007101800000) .
5. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-268147-S36260957382007101800000) .
6. Install the generator bracket. Refer to «Generator Bracket Replacement (5.3L Engine)»(ref-268108-S07306319122007101800000) .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
2. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-268156-S20272525282007101800000) .
3. Remove the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-268147-S36260957382007101800000) .
4. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side»(ref-268155-S04758142222007101800000) .
5. Remove the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-268156-S03305123772007101800000) .
6. If equipped, remove the auxiliary air conditioning (A/C) bracket nut (2).
7. Remove the cylinder head. Refer to «Cylinder Head Removal - Right Side»(ref-268156-S42096883412007101800000) .
8. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-268156-S22891410842007101800000) .

1. Install the cylinder head. Refer to «Cylinder Head Installation - Right Side»(ref-268156-S01587181752007101800000) .
2. If equipped, install the auxiliary A/C bracket nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-268156-S03305123772007101800000) .
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
5. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side»(ref-268155-S04758142222007101800000) .
6. Install the coolant air bleed pipe. Refer to «Coolant Air Bleed Pipe Assembly Replacement (5.3L Engine)»(ref-268147-S36260957382007101800000) .
7. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-268156-S20272525282007101800000) .

1. Install the valve lifter. Refer to «Valve Lifter Installation»(ref-268156-S13453614912007101800000) .
2. Install the cylinder head and gasket. Refer to «Cylinder Head Replacement - Left Side»(ref-268156-S36618334172007101800000) or to «Cylinder Head Replacement - Right Side»(ref-268156-S04378438912007101800000) .

Crankshaft Balancer Replacement

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
5. J 45059 Angle Meter. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 405

Scheme 406

Scheme 407

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
2. Remove the air conditioning (A/C) drive belt, if equipped. Refer to «Drive Belt Replacement - Air Conditioning»(ref-268156-S20432445342007101800000) .
3. Remove the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
4. Remove the starter motor. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
5. Install J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten J 42386-A bolts to 50 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (37 lb ft). IMPORTANT: Ensure that the teeth of J 42386-A mesh with the teeth of the engine flywheel. See «Special Tools»(ref-268156-S11321246192007101800000) . The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
6. Remove the crankshaft balancer bolt. Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
7. Use J 41816 and J 41816-2 in order to remove the crankshaft balancer.
8. Remove J 41816 and J 41816-2 from the crankshaft balancer.
9. Clean and inspect the crankshaft balancer. Refer to «Crankshaft Balancer Cleaning and Inspection»(ref-268156-S40419361722007101800000) .

Scheme 408

Scheme 409

1. Install the crankshaft balancer onto the end of the crankshaft. IMPORTANT: Ensure that the teeth of J 42386-A mesh with the teeth of the engine flywheel. See «Special Tools»(ref-268156-S11321246192007101800000) . The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second pass of the balancer bolt tightening procedure. The crankshaft balancer installation and bolt tightening involves a 4-stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque. IMPORTANT: Position the balancer onto the end of the crankshaft as straight as possible prior to tool installation.
2. Use J 41665 in order to install the crankshaft balancer. See «Special Tools»(ref-268156-S11321246192007101800000) . Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tool.
3. Install the used crankshaft balancer bolt. Tighten: Tighten the USED bolt to 330 N.m (240 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Remove the used crankshaft balancer bolt. IMPORTANT: Recess the nose of the crankshaft 2.4-4.48 mm (0.094-0.176 in) into the balancer bore.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install J 41665 and repeat the installation procedure. See «Special Tools»(ref-268156-S11321246192007101800000) .
6. Install a NEW crankshaft balancer bolt. Tighten: Tighten the bolt a first pass to 50 N.m (37 lb ft). Tighten the bolt a final pass to 140 degrees using J 45059 .
7. Remove J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) .
8. Install the starter motor. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
9. Install the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-268147-S12673307262007101800000) .
10. Install the A/C drive belt, if equipped. Refer to «Drive Belt Replacement - Air Conditioning»(ref-268156-S20432445342007101800000) .
11. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
12. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-268121-S42850641212007101800000) .

Scheme 410

1. Lubricate the outer edge of the oil seal (1) with clean engine oil.
2. Lubricate the front cover oil seal bore with clean engine oil.
3. Install the crankshaft front oil seal onto the J 41478 guide.
4. Install J 41478 threaded rod with nut, washer, guide, and oil seal into the end of the crankshaft.
5. Use J 41478 in order to install the oil seal into the cover bore. Use a wrench and hold the hex on the installer bolt. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. Remove J 41478 . Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore.
6. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-268156-S29573806542007101800000) .
7. Install the radiator. Refer to «Radiator Replacement (LH6)»(ref-268147-S00841803912007101800000) or «Radiator Replacement (LL8)»(ref-268147-S02575017782007101800000) .

Scheme 411

1. Lubricate the outside diameter of the oil seal (1) with clean engine oil. DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
3. Install J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore.
6. Thread J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Align the oil seal into the tool (1).
8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore.
9. Remove J 41479 . See «Special Tools»(ref-268156-S11321246192007101800000) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-268156-S36105362232007101800000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-268156-S36105362232007101800000) .
2. Remove the crankshaft rear oil seal housing bolts (1).
3. Remove the crankshaft rear oil seal housing bolts.
4. Remove the crankshaft rear oil seal housing and gasket.
5. Discard the crankshaft rear oil seal housing and gasket.
6. Clean and inspect the crankshaft rear oil seal housing. Refer to «Crankshaft Rear Oil Seal Housing Cleaning and Inspection»(ref-268156-S34081045022007101800000) .

Scheme 412

Scheme 413

Scheme 414

Scheme 415

1. Apply a 5 mm (0.2 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) long to the oil pan to engine block junction. IMPORTANT: Do not reuse the crankshaft oil seal or rear cover gasket. Do not apply any type of sealant to the rear cover gasket unless specified. The special tool in this procedure is used to properly center the crankshaft rear oil seal. Install the crankshaft rear oil seal after the rear cover has been installed and aligned. Install the rear cover without the crankshaft oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. Center the crankshaft rear oil seal in relation to the crankshaft. An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks.
2. Install the crankshaft rear oil seal housing gasket and cover.
3. Install the crankshaft rear oil seal housing bolts until snug. Do NOT over tighten.
4. Install the crankshaft rear oil seal housing bolts (1) until snug. Do not over tighten.
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface. IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
6. Install J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Tighten J 41476 mounting bolts until snug. See «Special Tools»(ref-268156-S11321246192007101800000) . Do not overtighten. Tighten: Tighten the oil pan-to-crankshaft rear oil seal housing bolts to 12 N.m (106 lb in). Tighten the engine crankshaft rear oil seal housing bolts to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Remove J 41476 . See «Special Tools»(ref-268156-S11321246192007101800000) .
9. Install a NEW crankshaft rear oil seal. Refer to «Crankshaft Rear Oil Seal Replacement»(ref-268156-S36762848842007101800000) .
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-268156-S36105362232007101800000) .

Scheme 416

Scheme 417

1. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-268156-S26628680202007101800000) .
2. Remove the oil filter adapter (1).

1. Install the oil filter adapter (1). Tighten: Tighten the adapter to 55 N.m (40 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-268156-S26628680202007101800000) .

1. Remove the oil filter.
2. Remove the oil filter adapter (1).
3. Remove the oil filter bypass valve (2).

1. Install the oil filter bypass valve (2). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the oil filter adapter (1). Tighten: Tighten the adapter to 55 N.m (40 lb ft).
3. Install the oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft).
4. Refill the engine oil if necessary. Refer to «Capacities - Approximate Fluid»(ref-268159-S19539682002007101800000) or to «Fluid and Lubricant Recommendations»(ref-268159-S32137604382007101800000) .

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-268156-S20272525282007101800000) .
3. 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) .
4. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-268156-S26628680202007101800000) .
5. Remove the transmission oil cooler lines (1) from the retainer (2).
6. Remove the transmission oil cooler line retaining bracket bolt and bracket.
7. Remove the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
8. Remove the flywheel inspection cover from the left side of the transmission.
9. Remove the battery cable channel bolt from the front of the oil pan.
10. Remove the battery cable channel from the oil pan.
11. Loosen the 2 upper air conditioning (A/C) compressor bracket bolts (4).
12. Remove the 2 lower A/C compressor bracket bolts (3).
13. Remove the 2 lower bellhousing bolts.
14. Remove the oil pan bolts.
15. Remove the oil pan by tilting the rear of the oil pan down to clear the transmission, pull the oil pan rearward past the front wire harness, then lower the oil pan clear of the vehicle.
16. Drill out the oil pan gasket retaining rivets (2), if required. IMPORTANT: The oil pan gasket is reusable. It is NOT necessary to remove the oil pan gasket unless damaged. DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required.
17. Remove the gasket (1) from the pan.
18. Discard the gasket and rivets.
19. Clean and inspect the oil pan. Refer to «Oil Pan Cleaning and Inspection»(ref-268156-S17851175972007101800000) .

Scheme 423

Scheme 424

Scheme 425

Scheme 426

1. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.
2. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.
3. Pre-assemble the oil pan gasket and bolts to the pan. Install the gasket onto the pan. Install the oil pan bolts to the pan and through the gasket.
4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly.
5. Hand thread the oil pan bolts into the engine block until snug. Do not tighten at this time.
6. Install the 2 lower bellhousing bolts. Tighten: Tighten the lower bellhousing bolts to 50 N.m (37 lb ft). Tighten the 2 rear oil pan to rear cover bolts to 12 N.m (106 lb in). Tighten the remaining oil pan bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the 2 lower A/C compressor bracket bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. Tighten the 2 upper A/C compressor bracket bolts (4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Install the battery cable channel to the oil pan.
10. Install the battery cable channel bolt to the oil pan. Tighten: Tighten the bolt to 12 N.m (106 lb in).
11. Install the flywheel inspection cover to the left side of the transmission.
12. Install the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
13. Install the inner axle shaft. Refer to «Inner Axle Shaft Replacement - Front Drive Axle»(ref-268154-S09350652672007101800000) .
14. Install the transmission oil cooler line retaining bracket and bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
15. Install the transmission oil cooler lines (1) to the retainer (2).
16. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-268156-S20272525282007101800000) .
17. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-268156-S26628680202007101800000) .
18. Install the front differential. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
19. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 427

Scheme 428

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-268156-S20312910052007101800000) .
2. Remove the oil filter tube bolts (435, 446) and gaskets (445, 448).
3. Remove the oil filter tube (447).
4. Remove the displacement on demand oil pressure relief valve (455) by pushing downward.

1. Install the displacement on demand oil pressure relief valve (455) by pushing upward until fully seated.
2. Install the oil filter tube (447).
3. Install the oil filter tube bolts (435, 446) and gaskets (445, 448). Tighten: Tighten the bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the oil pan. Refer to «Oil Pan Replacement»(ref-268156-S20312910052007101800000) .

1. Apply sealant to the threads of the oil pressure sensor. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Using J 41712 or equivalent, install the oil pressure sensor. See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (1).
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .

Scheme 429

Scheme 430

Scheme 431

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-268156-S20312910052007101800000) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-268156-S42154919782007101800000) .
3. Remove the oil pump screen bolt and nuts.
4. Remove the oil pump screen with O-ring seal.
5. Remove the O-ring seal from the pump screen.
6. Discard the O-ring seal.
7. Remove the remaining crankshaft oil deflector nuts.
8. Remove the crankshaft oil deflector.
9. Remove the oil pump bolts.
10. Remove the oil pump. IMPORTANT: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary.
11. Clean and inspect the oil pump. Refer to «Oil Pump Cleaning and Inspection»(ref-268156-S39014939872007101800000) .

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump.
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the crankshaft oil deflector and nuts until snug.
5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen.
7. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump.
8. Install the oil pump screen.
9. Install the oil pump screen bolt and nuts. Tighten: Tighten the bolt to 12 N.m (106 lb in). Tighten the nuts to 25 N.m (18 lb ft).
10. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-268156-S42154919782007101800000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-268156-S20312910052007101800000) .

Timing Chain and Sprockets Replacement

Tools Required

1. J 8433-1 Puller Bar. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
5. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 432

Scheme 433

Scheme 434

Scheme 435

1. Remove the oil pump. Refer to «Oil Pump, Screen, and Crankshaft Oil Deflector Replacement»(ref-268156-S03960908212007101800000) .
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
3. Remove the camshaft sprocket bolts (1).
4. Remove the camshaft sprocket (2) and timing chain (3).
5. Use J 8433-1 , J 41816-2 and J 41558 in order to remove the crankshaft sprocket. See «Special Tools»(ref-268156-S11321246192007101800000) .
6. Remove the crankshaft sprocket.
7. Remove the crankshaft sprocket key, if required.
8. Clean and inspect the timing chain and sprockets. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(ref-268156-S01646711962007101800000) .

Scheme 436

Scheme 437

Scheme 438

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use J 41665 and J 41478 in order to install the crankshaft sprocket. See «Special Tools»(ref-268156-S11321246192007101800000) . Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Install the camshaft sprocket (2) and timing chain (3). IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position.
7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Install the camshaft sprocket bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
9. Install the oil pump. Refer to «Oil Pump, Screen, and Crankshaft Oil Deflector Replacement»(ref-268156-S03960908212007101800000) .

Scheme 439

Scheme 440

Scheme 441

Scheme 442

1. Remove the condenser. Refer to «Condenser Replacement (LL8)»(ref-268096-S20830882912007101800000) .
2. Remove the valve lifters from both cylinder heads. Refer to «Valve Lifter Replacement»(ref-268156-S41892789692007101800000) .
3. Remove the camshaft sensor bolt and sensor.
4. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned.
5. Remove the camshaft sprocket bolts.
6. Remove the camshaft sprocket and reposition the timing chain. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
7. Remove the camshaft retainer bolts and retainer.
8. Remove the camshaft. Install three 8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the 3 bolts from the camshaft. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
9. Clean and inspect the camshaft and bearings. Refer to «Camshaft and Bearings Cleaning and Inspection»(ref-268156-S10729583092007101800000) .

1. Lubricate the camshaft journals and the bearings with clean engine oil. IMPORTANT: If camshaft replacement is required, the valve lifters must also be replaced.
2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
3. Using the bolts as a handle, carefully install the camshaft into the engine block.
4. Remove the 3 bolts from the front of the camshaft.
5. Install the camshaft retainer and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft). IMPORTANT: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
6. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. IMPORTANT: Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Locate the camshaft sprocket alignment mark in the 6 o'clock position.
7. Install the camshaft sprocket and the timing chain.
8. Install the camshaft sprocket bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
9. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused.
10. Lubricate the O-ring seal with clean engine oil.
11. Install the camshaft sensor and bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
12. Install the valve lifters. Refer to «Valve Lifter Replacement»(ref-268156-S41892789692007101800000) .
13. Install the condenser. Refer to «Condenser Replacement (LL8)»(ref-268096-S20830882912007101800000) .

Scheme 443

1. Remove the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) . IMPORTANT: Note the position and direction of the engine flywheel before removal.
2. Remove the engine flywheel bolts.
3. Remove the engine flywheel.
4. Clean and inspect the engine flywheel. Refer to «Engine Flywheel Cleaning and Inspection»(ref-268156-S15183448592007101800000) .

Scheme 444

1. Install the engine flywheel to the crankshaft.
2. Apply threadlock to the threads of the flywheel bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) for the correct part number.
3. Install the engine flywheel bolts. Tighten: Tighten the bolts a first pass in sequence to 20 N.m (15 lb ft). Tighten the bolts a second pass in sequence to 50 N.m (37 lb ft). Tighten the bolts a final pass in sequence to 100 N.m (74 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the transmission. Refer to «Transmission Replacement (LL8)»(ref-268097-S42661221372007101800000) or «Transmission Replacement (LM4)»(ref-268097-S27748498692007101800000) .

Engine Replacement

Tools Required

1. J 41798 Engine Lift Bracket. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 21366 Converter Holding Strap. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 38185 Hose Clamp Pliers. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

1. Remove the hood. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) .
2. Place fender covers over both fenders.
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
4. Remove the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .
5. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
6. Remove the radiator. Refer to «Radiator Replacement (LH6)»(ref-268147-S00841803912007101800000) or «Radiator Replacement (LL8)»(ref-268147-S02575017782007101800000) .
7. Remove the radiator support brace. Refer to «Radiator Support Diagonal Brace Replacement»(ref-268102-S15556797092007101800000) .
8. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD). Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
9. Remove the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
10. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
11. Disconnect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
12. Remove the air conditioning (A/C) compressor hose. Refer to «Compressor Hose Assembly Replacement (LH6)»(ref-268096-S15574468532007101800000) or «Compressor Hose Assembly Replacement (LL8)»(ref-268096-S24271056052007101800000) .
13. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
14. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
15. Tie the pipe assembly out of the way.
16. Disconnect the engine coolant temperature (ECT) sensor (1).
17. Remove the ground terminal bolt (2).
18. Remove the retaining clips from the brackets.
19. Disconnect the A/C pressure switch electrical connector (2).
20. Remove the retaining clip (1) from the cylinder head.
21. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
22. Remove the ground terminal bolts (2, 4).
23. Remove the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
24. Remove the battery cable channel bolt.
25. Remove the battery cable channel from the oil pan.
26. Disconnect the A/C compressor electrical connector.
27. Lower the vehicle.
28. Gather all branches of the engine wiring harness and reposition the harness off to the side.
29. Remove the generator cable from the generator. Perform the following: Slide the boot down revealing the terminal stud. Remove the generator cable nut from the terminal stud. Remove the generator cable.
30. Remove the generator bracket bolts.
31. Position the bracket with generator aside.
32. Using J 38185
33. Remove the inlet hose from the water outlet.
34. Using J 38185
35. Remove the outlet hose from the water outlet.
36. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.
37. Using J 38185
38. Remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.
39. Remove the ignition coils as required for the proper fit of J 41798 . Refer to «Ignition Coil Replacement»(ref-268122-S26409434032007101800000) .
40. Install J 41798 . Tighten: Tighten the M8 bolts to 25 N.m (18 lb ft). Tighten the M10 bolts to 50 N.m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
41. Raise the vehicle.
42. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-268155-S37156285252007101800000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-268155-S27803118402007101800000) .
43. Remove the 3 bracket bolts from both the right and the left sides of the frame engine mount.
44. Remove the torque converter bolts.
45. Remove the transmission oil level indicator tube nut.
46. Remove the transmission oil level indicator tube.
47. Remove the transmission bolt and stud on the right side.
48. Remove the lower transmission bolt/studs.
49. Lower the vehicle.
50. Remove the 3 upper transmission bolts/studs.
51. Install an engine hoist to J 41798 .
52. Install a floor jack under the transmission for support.
53. Separate the engine from the transmission.
54. Remove the engine.
55. Install the engine to an engine stand.
56. Install J 21366 . See «Special Tools»(ref-268156-S11321246192007101800000) .

1. Remove J 21366 . See «Special Tools»(ref-268156-S11321246192007101800000) .
2. Install an engine hoist to J 41798 .
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.
7. Install the 3 upper transmission bolts/studs. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
10. Install the transmission bolt and stud on the right side. Tighten: Tighten the bolts/studs to 50 N.m (37 lb ft).
11. Install the transmission oil level indicator tube.
12. Install the transmission oil level indicator tube nut. Tighten: Tighten the nut to 10 N.m (89 lb ft).
13. Install the torque converter bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the 3 bracket bolts to both the right and the left sides of the frame engine mount. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
15. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.2L Engine)»(ref-268155-S37156285252007101800000) or «Catalytic Converter Replacement (5.3L Engine)»(ref-268155-S27803118402007101800000) .
16. Lower the vehicle.
17. Remove J 41798 .
18. Install the ignition coil(s) (as required). Tighten: Tighten the bolts to 8 N.m (71 lb in).
19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump.
20. Using J 38185
21. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.
22. Install the outlet hose to the water outlet.
23. Using J 38185
24. Install the inlet hose to the water outlet.
25. Using J 38185
26. Position the bracket with generator to the engine.
27. Install the generator bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
28. Install the generator cable to the generator, perform the following procedure: Install the generator cable. Install the generator cable nut to the terminal stud. Tighten: Tighten the nut to 9 N.m (80 lb in). Slide the boot down covering the terminal stud.
29. Gather all branches of the engine wiring harness and position the harness over the engine.
30. Raise the vehicle.
31. Connect the A/C compressor electrical connector.
32. Install the battery cable channel to the oil pan.
33. Install the battery cable channel bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
34. Install the starter. Refer to «Starter Motor Replacement (4.2L Engine)»(ref-268108-S33676684972007101800000) or «Starter Motor Replacement (5.3L Engine)»(ref-268108-S09695333912007101800000) .
35. Install the ground terminal bolts (2, 4). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
36. Lower the vehicle.
37. Install the retaining clip (1) to the cylinder head.
38. Connect the A/C pressure switch electrical connector (2).
39. Install the retaining clips to the brackets.
40. Install the ground terminal bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
41. Connect the ECT sensor (1).
42. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5). Tighten: Tighten the nut/bolt to 20 N.m (15 lb ft).
43. Connect the rear auxiliary A/C compressor pipe fitting (7). Tighten: Tighten the nut to 16 N.m (12 lb ft).
44. Install the A/C compressor hose. Refer to «Compressor Hose Assembly Replacement (LH6)»(ref-268096-S15574468532007101800000) or «Compressor Hose Assembly Replacement (LL8)»(ref-268096-S24271056052007101800000) .
45. Connect the following electrical connectors: Oil pressure sensor (1) Oxygen sensors (2, 3) Camshaft position (CMP) sensor (4)
46. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-268156-S20821663172007101800000) .
47. Install the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-268131-S39569648442007101800000) .
48. Install the front differential drive axle, if equipped with 4WD. Refer to «Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)»(ref-268154-S11482693632007101800000) or «Differential Carrier Assembly Replacement (V8)»(ref-268154-S06485419242007101800000) .
49. Install the radiator support brace. Refer to «Radiator Support Diagonal Brace Replacement»(ref-268102-S15556797092007101800000) .
50. Install the radiator. Refer to «Radiator Replacement (LH6)»(ref-268147-S00841803912007101800000) or «Radiator Replacement (LL8)»(ref-268147-S02575017782007101800000) .
51. Recharge the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-268096-S34829348672007101800000) .
52. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
53. Remove the fender covers from both fenders.
54. Prelube the engine. Refer to «Engine Prelubing»(ref-268156-S35055995502007101800000) .
55. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-268121-S42850641212007101800000) .
56. Install the hood. Refer to «Hood Replacement»(ref-268102-S04771574792007101800000) . IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
57. Test the vehicle using the following procedure: Disable the ignition system. Crank the engine several times. Listen for any 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 gauge or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. Listen for sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Close the hood.
58. Install the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .

Scheme 460

1. Open the hood. IMPORTANT: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure.
2. Remove the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .
3. Remove the oil fill cap.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
5. Position a suitable drain pan under the oil pan drain plug.
6. Remove the oil pan drain plug.
7. Allow the oil to drain completely.
8. Clean and inspect the oil pan drain plug. Replace if necessary.
9. Clean and inspect the oil pan drain plug sealing surface. Replace the oil pan if necessary.
10. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
11. Position a suitable drain pan under the oil filter.
12. Remove the oil filter.
13. Ensure that the oil filter gasket is still on the oil filter. If not, remove the oil filter gasket from the oil pan.

1. Apply clean engine oil to the NEW oil filter gasket.
2. Install the NEW oil filter. Tighten: Tighten the filter to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Tighten the oil drain plug. Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the crankcase with NEW engine oil. Refer to «Capacities - Approximate Fluid»(ref-268159-S19539682002007101800000) and to «Fluid and Lubricant Recommendations»(ref-268159-S32137604382007101800000) .
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn OFF the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level of the engine oil on the oil level indicator.
15. If necessary, adjust the oil level by adding or draining oil.
16. Check for oil leaks.
17. Install the intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-268156-S26702613292007101800000) .
18. Close the hood.

Scheme 461

Scheme 462

Scheme 463

Scheme 464

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

Crankshaft Balancer Removal

Tools Required

1. J 41816-A Crankshaft Balancer Remover. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 465

Scheme 466

Scheme 467

1. Install the J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Use 1 M10 - 1.5 x 120 mm and 1 M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten the J 42386-A bolts to 50 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Do not use the crankshaft balancer bolt again. Install a NEW crankshaft balancer bolt during final assembly.
2. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure.
3. Use the J 41816-A (1) and the J 41816-2 (2) in order to remove the crankshaft balancer. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. Remove the balancer (1).
5. Remove the J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 468

1. Remove the engine flex plate bolts. IMPORTANT: The flex plate does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flex plate bolts. This procedure requires a 3 stage tightening process.
2. Remove the flex plate.

Scheme 469

1. Remove the oil level indicator (418) from the tube.
2. Remove the oil level indicator tube bolt (419).
3. Remove the oil level indicator tube (420) from the engine block.
4. Remove the O-ring (421) from the tube, as required. IMPORTANT: Inspect the O-ring for cuts or damage. The O-ring seal may be used again if it is not cut or damaged.

Scheme 470

Scheme 471

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

Scheme 472

Scheme 473

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

Scheme 474

1. Remove the water pump bolts (3).
2. Remove the water pump (1) and gaskets (2).
3. Discard the water pump gaskets.

Scheme 475

1. Remove the electrical wire harness connectors from the throttle body. IMPORTANT: The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.
2. Remove the throttle body nuts (507) and bolts (538).
3. Remove the throttle body (508).
4. Remove the throttle body gasket (509).
5. Discard the gasket.

Scheme 476

Scheme 477

Scheme 478

Scheme 479

1. Remove the fuel rail stop bracket and bolt, as required. CAUTION: Refer to «Fuel Rail Stop Bracket Installation Caution»(ref-268087-S42661314352007101800000) in Cautions and Notices. IMPORTANT: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the intake manifold as a complete assembly.
2. Remove the evaporative emission (EVAP) canister purge solenoid valve (730) and tubes (729, 735).
3. Remove the fuel rail bolts (511).
4. Remove the fuel rail (510) with injectors. Lift evenly on both sides of the fuel rail until all the injectors have left their bores. IMPORTANT: Do not separate the fuel injectors from the fuel rail, unless component service is required. Use cleanliness and care when handling the fuel system components. Do not allow dirt or debris to enter the fuel injectors or fuel rail components. Cap ends, as necessary.
5. Remove the fuel injector retainers (521) and fuel injectors (533), as required.
6. Remove the O-rings (532, 534) from the injectors, as required.

Scheme 480

Scheme 481

Scheme 482

Scheme 483

1. Remove the positive crankcase ventilation (PCV) hose - dirty air (716).
2. Remove the PCV hose - fresh air. IMPORTANT: The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. DO NOT use the intake manifold-to-cylinder head gaskets again.
3. Remove the manifold absolute pressure (MAP) sensor (714) and retainer (736), as required.
4. Remove the O-ring (715) from the sensor, as required.
5. Remove the intake manifold bolts (512).
6. Remove the intake manifold (500) with gaskets.
7. Remove the intake manifold gaskets (514).
8. Discard the intake manifold gaskets.

Scheme 484

Scheme 485

Scheme 486

1. Remove the engine coolant air bleed pipe bolts (309).
2. Remove the pipe (307) with seals (308).
3. Remove the engine coolant air bleed cover bolts (312).
4. Remove the covers (313) with seals (308).
5. Remove the seals (308) from the pipe and covers.
6. Discard the seals.

Scheme 487

Scheme 488

1. Do not lift the manifold by the electrical lead frame.
2. Remove the valve lifter oil manifold bolts (506).
3. Remove the valve lifter oil manifold (451). IMPORTANT: Do not allow dirt or debris to enter the oil passages of the manifold. Plug, as required.
4. Identify the 8 gasket retaining strap locations (1-8). IMPORTANT: Remove only the outer gasket from the manifold. Do not disassemble any of the internal components of the manifold in an attempt to remove the 8 inner sealing gaskets. If the inner gaskets are cut or damaged, replace the manifold as an assembly. Only use a wire-cutter type tool in order to minimize the amount of debris. Do not use a rotary-type cutting tool on the retaining straps.
5. Using a wire-cutter type tool, cut the 8 retaining straps.
6. Remove the outer gasket (556) from the manifold.

Valve Lifter Oil Filter Removal

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

Scheme 489

Scheme 490

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

Valve Rocker Arm Cover Removal - Right Side

1. Remove the spark plug wires (724). IMPORTANT: Do not remove the oil fill tube from the cover, unless service is required. If the oil fill tube has been removed from the cover, install a NEW tube during assembly.
2. Remove the ignition coil bracket studs (720).
3. Remove the ignition coil and bracket assembly (719).
4. Disconnect the ignition coil electrical connectors.
5. Remove the bolts (723), coils (722), and wire harness (721) from the bracket (719), as required.
6. Remove the valve rocker arm cover bolts and cover.
7. Remove the gasket (504) from the cover.
8. Remove the oil fill cap (424) from the oil fill tube (423).
9. Remove the oil fill tube, as required.
10. Discard the oil fill tube.

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm bolts. IMPORTANT: Place the valve rocker arms, valve pushrods, and pivot support, in a rack so they can be installed in the same location from which they were removed.
2. Remove the valve rocker arms.
3. Remove the valve rocker arm pivot support.
4. Remove the pushrods.

Scheme 491

Scheme 492

1. Remove the cylinder head bolts (220, 221). IMPORTANT: The cylinder head bolts are of a torque-to-yield design and are NOT to be used again. Install NEW cylinder head bolts during assembly.
2. Remove the cylinder head (218). NOTE: After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Scheme 493

Scheme 494

1. Remove the cylinder head bolts (220, 221). IMPORTANT: The cylinder head bolts are of a torque-to-yield design and are NOT to be used again. Install NEW cylinder head bolts during assembly.
2. Remove the cylinder head (218). NOTE: After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
3. Remove the gasket (217) and locating pins (230).
4. Discard the gasket and cylinder head bolts.

Scheme 495

Scheme 496

1. Remove the bolts (211).
2. Remove the guides (210) with lifters. Note the installed position of the guides. The notched area of the guide is to align with the locating tab of the block.
3. Remove the valve lifters (209, 219) from the guide (210).
4. Organize or mark the components so they can be installed in the same location from which they were removed. The active fuel management lifters (4) are installed into the guide by aligning the notched area of the guide (1) with the raised surface on the side of the lifter (2). Refer to «Separating Parts»(ref-268156-S42784542542007101800000) .

Scheme 497

1. Remove the oil filter (437).
2. Remove the oil filter fitting (1), as required.

Scheme 498

Scheme 499

Scheme 500

Scheme 501

1. Remove the left closeout cover and bolt. IMPORTANT: The original oil pan gasket is retained and aligned to the oil pan by rivets. When installing a new gasket, it is not necessary to install new oil pan gasket rivets. DO NOT use the oil pan gasket again. When installing the oil pan, install a NEW oil pan gasket.
2. Remove the right closeout cover and bolt.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Drill (2) out the oil pan gasket retaining rivets (1), if required. IMPORTANT: DO NOT allow foreign material to enter the oil passages of the oil pan. Cap or cover the openings, as required. Use care not to gouge, score, or damage the oil pan sealing surface.
6. Remove the gasket (426) from the pan.
7. Discard the gasket and rivets.
8. Remove the filter tube, baffle and other internal components, as required. Refer to «Oil Pan Cleaning and Inspection»(ref-268156-S17851175972007101800000) .

Scheme 502

Scheme 503

1. Remove the front cover bolts (1).
2. Remove the front cover (2) and gasket (3).
3. Discard the front cover gasket.
4. Remove the oil seal (4).
5. Remove the bolts (1, 6), camshaft position (CMP) sensor (2), and wire harness (5).
6. Remove the O-ring (3) from the sensor, as required.

Scheme 504

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

Scheme 505

Scheme 506

Scheme 507

1. Remove the oil pump screen bolt (405) and nut (404).
2. Remove the oil pump screen (407) with O-ring seal.
3. Remove the O-ring seal (406) from the pump screen.
4. Discard the O-ring seal.
5. Remove the crankshaft oil deflector nuts.
6. Remove the crankshaft oil deflector.
7. Remove the oil pump bolts (411).
8. Remove the oil pump (413). IMPORTANT: Do not allow dirt or debris to enter the oil pump assembly. Cap ends, as necessary.

Timing Chain and Sprockets Removal

Tools Required

1. J 8433 Two Jaw Puller. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41558 Crankshaft Sprocket Remover. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 41816-2 Crankshaft End Protector. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 508

Scheme 509

Scheme 510

Scheme 511

1. Remove and discard the camshaft sprocket bolt (206). NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
2. Remove the camshaft sprocket (205) and timing chain (208).
3. Remove the bolts (231) and timing chain tensioner (232).
4. Use the J 41816-2 (1), the J 41558 (2), bolts (3), and the J 8433 (4) in order to remove the crankshaft sprocket. See «Special Tools»(ref-268156-S11321246192007101800000) .
5. Remove the crankshaft sprocket (207).
6. Remove the crankshaft sprocket key, as required.

Scheme 512

Scheme 513

1. Remove the camshaft retainer bolts (204) and retainer (203).
2. Remove the camshaft. Install the camshaft sprocket bolt into the camshaft front bolt hole. Using the bolt as a handle, carefully rotate and pull the camshaft out of the engine block. Remove the bolt from the front of the camshaft. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

1. Use the J 24270 in order to remove the cylinder bore ring ridge, if required. See «Special Tools»(ref-268156-S11321246192007101800000) . Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use the J 24270 , or equivalent, in order to remove a cylinder ring ridge. See «Special Tools»(ref-268156-S11321246192007101800000) . Turn the crankshaft so the piston is at the top of the stroke. Remove the cloth. Remove the cutting debris from the cylinder and piston.
2. Using a paint stick or etching tool, place matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction. A stamping mark on the side of the connecting rod, at the crankshaft journal, may affect component geometry. Mark the top of the piston to the specific cylinder bore.
3. Remove the connecting rod bolts (102), cap (103) and bearing (104). IMPORTANT: Mark, sort, or organize the connecting rod bearings so they may be installed to their original position and location. The connecting rods and the bearing caps are NOT interchangeable. Refer to «Separating Parts»(ref-268156-S42784542542007101800000) .
4. Install the J 41556 to the connecting rod.
5. Using a hammer, tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore.
6. Remove the J 41556 .
7. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolts onto the matching connecting rod.

Crankshaft and Bearings Removal

Tools Required

1. J 6125-1B Slide Hammer. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41818 Crankshaft Bearing Cap Remover. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

Scheme 526

1. Remove the crankshaft position (CKP) sensor bolt (702). IMPORTANT: The crankshaft bearing caps are machined with the engine block, for the proper clearances. Mark or identify each crankshaft bearing cap location and direction before removal. The crankshaft bearing caps MUST be installed to their original position and direction. Do not use the bearing cap M8 side bolts again.
2. Remove the CKP sensor (701).
3. Remove the O-ring (750) from the sensor, as required.
4. Remove the crankshaft bearing cap M8 side bolts (127).
5. Remove the bearing cap M10 bolts (129) and studs (128).
6. Install the J 41818 (2). See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the J 41818 (2) bolts to 11 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (100 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the J 6125-1B (1) to the J 41818 (2) in order to remove the crankshaft bearing caps. See «Special Tools»(ref-268156-S11321246192007101800000) .
8. Remove the bearing caps.
9. Remove the crankshaft.
10. Lay the crankshaft onto 2 wooden V-blocks or other protective surface. IMPORTANT: Use care when handling the crankshaft. Avoid damage to the crankshaft position sensor reluctor ring teeth. Nicks, burrs or other damage to the teeth may effect on-board diagnostics (OBD) II system performance.
11. Remove the crankshaft bearings from the bearing caps and the engine block.
12. Mark, sort, or organize the crankshaft bearings so they may be installed to their original position and location. Refer to «Separating Parts»(ref-268156-S42784542542007101800000) .

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

1. Remove the engine block coolant heater (114) and seal (115).
2. Remove the engine block right rear coolant drain hole plug and seal.
3. Remove the engine block left front oil gallery plug (116) and seal (117).
4. Remove the engine block left rear oil gallery plug (112) and seal (113). If the block plug and coolant heater sealing washers are not damaged, they may be used during assembly.
5. Remove the engine block rear oil gallery plug (111) and seal.
6. Inspect the O-ring seal of the rear oil gallery plug. If the O-ring seal is not cut or damaged, the plug and O-ring seal may be used during assembly.
7. Remove the engine block front oil gallery plug (101). IMPORTANT: Remove the front oil gallery plug, only if service is required. If the front oil gallery plug is removed, a NEW oil gallery plug must be installed.
8. Remove the left side knock sensor (718) and bolt (739).
9. Remove the right side knock sensor (718) and bolt (739).

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 8087 Cylinder Bore Gage. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 41556 Connecting Rod Guide. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. J 45059 Angle Meter. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 534

1. With a micrometer at a right angle, measure the piston outside diameter (OD). Measure the diameter 43 mm (1.69 in) from the top of the piston. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) . IMPORTANT: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores must not have excessive wear or taper. A used piston, pin, and connecting rod assembly may be installed if, after inspection is within specifications.
2. Record the piston OD.
3. Adjust the micrometer to the recorded piston OD.
4. Insert the J 8087 into the micrometer and zero the gage dial.
5. Using the J 8087 , measure the cylinder bore inside diameter (ID). Measure at a point 64 mm (2.5 in) from the top of the cylinder.
6. Record the cylinder bore ID.
7. Subtract the piston OD from the cylinder bore ID in order to determine the piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .
8. If the proper clearance cannot be obtained, select another piston and pin assembly and measure the clearances again. If the proper fit cannot be obtained, the cylinder bore may require honing for an oversize piston.

Scheme 535

Scheme 536

1. Lubricate the following components with clean engine oil: Piston Piston rings Cylinder bore Bearings and bearing surfaces
2. Install the bearings to the connecting rod and cap.
3. Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other.
4. Position the compression ring end gaps 180 degrees opposite each other.
5. Install the J 41556 to the connecting rod.
6. Identify the proper installation direction of the piston and connecting rod assembly. When installing the piston and connecting rod assembly, the mark on the top of the piston (1) and the tab (2) on the side of the connecting rod should face the front of the engine.
7. Install the J 8037 onto the piston and compress the piston rings. See «Special Tools»(ref-268156-S11321246192007101800000) .
8. Install the piston, pin, and connecting rod assembly into the cylinder bore. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all piston rings have entered the cylinder bore. IMPORTANT: The piston alignment mark MUST face the front of the engine block.
9. Use the J 41556 to guide the connecting rod onto the crankshaft journal.
10. Remove the J 41556 from the connecting rod.
11. Install the bearing cap (103), bearing (104), and bolts (102). Tighten: Tighten the bolts a first pass to 20 N.m (15 lb ft). Tighten the bolts a final pass to 75 degrees using the J 45059 . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: The connecting rod and cap must be assembled with the mating surfaces properly aligned.
12. Measure the connecting rods for the proper side clearance. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .

Scheme 537

1. Lubricate the camshaft journals and the bearings with clean engine oil. IMPORTANT: If camshaft replacement is required, the valve lifters must also be replaced.
2. Install the camshaft sprocket bolt into the camshaft front bolt hole.
3. Using the bolt as a handle, carefully install the camshaft into the engine block. NOTE: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.
4. Remove the bolt from the front of the camshaft.
5. Install the camshaft retainer (203) and the bolts (204). Install the retainer with the sealing gasket facing the front of the engine block. IMPORTANT: The gasket surface on the engine block should be clean and free of dirt or debris.
6. Tighten the camshaft retainer bolts. Tighten: Tighten the first design hex head bolts (3) to 25 N.m (18 lb ft). Tighten the second design TORX® head bolts (4) to 15 N.m (11 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .

Timing Chain and Sprockets Installation

Tools Required

1. EN 46330 Timing Belt Tensioner Retaining Pin. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
5. J 45059 Angle Meter

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. See «Special Tools»(ref-268156-S11321246192007101800000) . Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Compress the timing chain tensioner guide and install the EN 46330 . See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Install the timing chain tensioner (232) and bolts (231). Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Install the camshaft sprocket (205), timing chain (208), and bolt (206). IMPORTANT: The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position.
10. Remove the EN 46330 . See «Special Tools»(ref-268156-S11321246192007101800000) .
11. Temporarily install the automatic transmission flex plate or manual transmission flywheel and bolts. Refer to «Engine Flywheel Installation»(ref-268156-S10423870942007101800000) . IMPORTANT: Do not apply threadlock to the flex plate bolts at this time.
12. Install the J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Use 1 M10-1.5 x 120 mm bolt and 1 M10-1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten the J 42386-A bolts to 50 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (37 lb ft).
13. Tighten the camshaft sprocket bolt. Tighten: Tighten the camshaft sprocket bolt a first pass to 90 N.m (66 lb ft). Tighten the camshaft sprocket bolt a final pass an additional 40 degrees using the J 45059 .
14. Remove the J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) .
15. Remove the automatic transmission flex plate or manual transmission flywheel and bolts. Refer to «Engine Flywheel Removal»(ref-268156-S18587555172007101800000) .

Oil Pump, Screen and Crankshaft Oil Deflector Installation

1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump (413). IMPORTANT: Inspect the oil pump and engine block oil gallery passages. These surfaces must be clear and free of debris or restrictions.
2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
3. Install the oil pump bolts (411). Tighten: Tighten the oil pump bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the crankshaft oil deflector.
5. Lubricate a NEW oil pump screen O-ring seal (406) with clean engine oil.
6. Install the NEW O-ring seal onto the oil pump screen.
7. Install the oil pump screen (407). IMPORTANT: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap bolt/studs.
8. Install the oil pump screen bolt (405) and the deflector nut (404). Tighten: Tighten the oil pump screen bolt to 12 N.m (106 lb in). Tighten the crankshaft oil deflector nut to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Housing Installation

Tools Required

1. J 41476 Front and Rear Cover Alignment Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41480 Front and Rear Cover Alignment. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 547

Scheme 548

Scheme 549

Scheme 550

1. Inspect the rear oil gallery plug for proper installation. IMPORTANT: Do not use the crankshaft rear oil seal or the engine rear housing gasket again. Do not apply any type of sealant to the rear housing gasket, unless specified. The special tools in this procedure are used to properly align the engine rear housing at the oil pan surface and to center the crankshaft rear oil seal. The crankshaft rear oil seal will be installed after the rear housing has been installed and aligned. Install the rear housing without the crankshaft oil seal. The crankshaft rear oil seal MUST be centered in relation to the crankshaft. The oil pan sealing surface at the rear housing and engine block MUST be aligned within specifications. An improperly aligned rear housing may cause premature rear oil seal wear and/or engine assembly oil leaks.
2. Install the rear housing gasket (519), rear housing (518), and bolts (517).
3. Tighten the bolts finger tight. Do not overtighten.
4. Install the J 41480 and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Start the J 41480 tool-to-rear housing bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Do not tighten the bolts at this time.
5. Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface. IMPORTANT: To properly align the rear housing, the J 41476 must be installed onto the rear of the crankshaft with the tool mounting bolts parallel to the oil pan surface. See «Special Tools»(ref-268156-S11321246192007101800000) .
6. Install the J 41476 and bolts onto the rear of the crankshaft. See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the tool mounting bolts until snug. Do not overtighten. Tighten the J 41480 tool-to-rear housing bolts evenly to 12 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (106 lb in). Tighten the rear housing bolts to 30 N.m (22 lb ft). IMPORTANT: The tapered legs of the alignment tool must enter the rear housing oil seal bore.
7. Remove the tools.
8. Measure the rear housing-to-engine block oil pan surface for flatness. Place a straight edge onto the engine block and rear housing oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the rear housing and the straight edge. The housing must be flush with the oil pan or no more than 0.5 mm (0.02 in) below flush.
9. If the rear housing-to-engine block oil pan surface alignment is not within specifications, repeat the housing alignment procedure.
10. If the correct rear housing-to-engine block alignment at the oil pan surface cannot be obtained, replace the rear housing.

Crankshaft Rear Oil Seal Installation

Tools Required

1. J 41479 Crankshaft Rear Oil Seal Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41479-2A Crankshaft Rear Oil Seal Installation Guide. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 551

1. Inspect the seal and identify the part number markings for proper orientation. IMPORTANT: For proper orientation, note the installation direction of the oil seal. The oil seal is a reverse-lip design. The part number is applied to the outside face of the seal, as shown.
2. Install the J 41479 or J 41479-2A cone (2) and bolts onto the rear of the crankshaft. J 41479-2A may be required for manual transmission applications. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. Tighten the bolts until snug. Do not overtighten.
4. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear seal bore. Install the oil seal with the part number markings facing away from the engine.
5. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. See «Special Tools»(ref-268156-S11321246192007101800000) .
6. Align the oil seal onto the tool (1).
7. Rotate the handle of the tool (1) clockwise until the seal enters the rear housing and bottoms into the seal bore.
8. Remove the tool.

Engine Front Cover Installation

Tools Required

1. J 41476 Front and Rear Cover Alignment Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41480 Front and Rear Cover Alignment. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 552

Scheme 553

Scheme 554

1. Install the front cover gasket (3), front cover (2), and bolts (1). IMPORTANT: Do not use the crankshaft oil seal or the engine front cover gasket again. Do not apply any type of sealant to the front cover gasket, unless specified. The special tools in this procedure are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. The crankshaft front oil seal MUST be centered in relation to the crankshaft. The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications. An improperly aligned front cover may cause premature front oil seal wear and/or engine assembly oil leaks.
2. Tighten the cover bolts finger tight. Do not overtighten.
3. Install the J 41480 . See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.
4. Install the J 41476 . See «Special Tools»(ref-268156-S11321246192007101800000) . IMPORTANT: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
5. Install the crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. Tighten the J 41480 . See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface, or no greater than 0.5 mm (0.02 in) (a) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
10. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not cut or damaged, it may be used again.
11. Lubricate the O-ring seal with clean engine oil.
12. Install the O-ring seal onto the sensor (2).
13. Install the sensor to the cover.
14. Install the CMP sensor wire harness (5) and bolts (1, 6). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Oil Filter and Adapter Installation

1. Install the oil filter fitting (1). Tighten: Tighten the oil filter fitting to 55 N.m (40 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Lubricate the oil filter seal with clean engine oil.
3. Install the oil filter (437). Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
4. Install the oil pan drain plug (430) and O-ring (429). Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil. IMPORTANT: When using the valve lifters again, install the lifters to their original locations. If camshaft replacement is required, the valve lifters must also be replaced. Each of the 4 valve guide assemblies will contain 2 active fuel management valve lifters and 2 non-active fuel management valve lifters. With the lifters and guides properly installed, cylinders 1, 4, 6, and 7 lifter bores will each contain 2 active fuel management valve lifters.
2. Insert the valve lifters into the lifter guides. Align the flat area (3) on the top of the non-active fuel management lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. The active fuel management lifters (4) are to be installed into the guide, with the notch in the guide (1) aligned with the raised area (2) of the lifter.
3. Install the valve lifters and guide assembly (210) to the engine block.
4. Install the valve lifter guide bolts (211). Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .

Cylinder Head Installation - Left Side

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 555

Scheme 556

Scheme 557

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) in Cautions and Notices. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components. IMPORTANT: Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly. Do not use any type of sealant on the cylinder head gasket, unless specified.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Cylinder Head Installation - Right Side

Tools Required

1. J 42385-100 Thread Repair Kit. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-268156-S11321246192007101800000) .

1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) in Cautions and Notices. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components. IMPORTANT: Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly. Do not use any type of sealant on the cylinder head gasket, unless specified.
2. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463), or equivalent, into the hole.
3. Clean the cylinder head bolt holes with compressed air.
4. Install the cylinder head locating pins (230).
5. Inspect the locating pins for proper installation.
6. Inspect the displacement markings (1, 2) on the gasket for proper usage.
7. Install the NEW cylinder head gasket (217) onto the locating pins.
8. Install the cylinder head (218) onto the locating pins and the gasket.
9. Install the NEW cylinder head bolts (220, 221).
10. Tighten the cylinder head bolts. Tighten: Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N.m (22 lb ft). Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 . Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 . Tighten the M8 cylinder head bolts (11-15) to 30 N.m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Scheme 558

1. Lubricate the valve rocker arms and pushrods with clean engine oil. IMPORTANT: When using the valve train components again, always install the components to the original location and position. Valve lash is net build. No valve adjustment is required.
2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.
3. Install the valve rocker arm pivot support.
4. Install the pushrods. IMPORTANT: Ensure the pushrods seat properly to the valve lifter sockets.
5. Install the rocker arms and bolts. IMPORTANT: Ensure the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time.
6. Rotate the crankshaft until number 1 piston is at top dead center of compression stroke. In this position, cylinder number 1 rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The camshaft and crankshaft sprocket alignment marks (1, 2) will be in the 12 o'clock position. If viewing from the rear of the engine, the additional crankshaft pilot hole, non-threaded, will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank.
7. With the engine in the number 1 firing position, tighten the following valve rocker arm bolts: Tighten: Tighten the exhaust valve rocker arm bolts 1, 2, 7, and 8 to 30 N.m (22 lb ft). Tighten the intake valve rocker arm bolts 1, 3, 4, and 5 to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts: Tighten: Tighten the exhaust valve rocker arm bolts 3, 4, 5, and 6 to 30 N.m (22 lb ft). Tighten the intake valve rocker arm bolts 2, 6, 7, and 8 to 30 N.m (22 lb ft).

Valve Rocker Arm Cover Installation - Left Side

1. Install a NEW gasket (504) into the valve rocker arm cover. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT use the valve rocker arm cover gasket again. The valve rocker arm cover bolt grommets may be used again if not damaged.
2. Install the valve rocker arm cover onto the cylinder head.
3. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bolts (723).
5. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bracket studs (720).
7. Install the ignition coil and bracket assembly (719) and studs (720). Tighten: Tighten the bracket studs to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Right Side

1. Install a NEW gasket (504) into the valve rocker arm cover. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT use the valve rocker arm cover gasket again. The valve rocker arm cover bolt grommets may be used again if not damaged.
2. Install a NEW oil fill tube (423) to the valve rocker arm cover.
3. Install the oil fill cap (424).
4. Install the valve rocker arm cover onto the cylinder head.
5. Install the cover bolts with grommets. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bolts (723).
7. Install the ignition coils (722), wire harness (721), and bolts (723) to the bracket (719). Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the ignition coil bracket studs (720).
9. Install the ignition coil and bracket assembly (719) and studs (720). Tighten: Tighten the bracket studs to 12 N.m (106 lb in).

Valve Lifter Oil Filter Installation

1. Install a NEW oil filter (452) and O-ring (454) assembly. IMPORTANT: Do not allow dirt or debris to enter the oil passages of the manifold. Plug, as required.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the sensor.
3. Install the oil pressure sensor (706) and washer (707). Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .

Valve Lifter Oil Manifold Installation

1. Do not lift the manifold assembly by the electrical lead frame.
2. Install the service gasket (556) onto the manifold. IMPORTANT: All gasket surfaces should be free of oil or other foreign material during assembly. Do not allow dirt or debris to enter the manifold. Plug, as required.
3. Install the manifold (451) with gasket.
4. Install the manifold bolts (506). Tighten: Tighten the manifold bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Coolant Air Bleed Pipe Installation

1. Install the seals (308) onto the engine coolant air bleed pipe and covers. IMPORTANT: Position the O-ring seal onto the nipple portion of the pipe.
2. Install the pipe (307) and seals (308).
3. Install the bolts (309). Tighten: Tighten the bolts to 12 N.m (106 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
4. Install the covers (313) and seals (308).
5. Install the bolts (312). Tighten: Tighten the cover bolts to 12 N.m (106 lb in).

Scheme 559

1. Install NEW intake manifold-to-cylinder head gaskets (514). IMPORTANT: The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, install the intake manifold as a complete assembly. DO NOT use the intake manifold gaskets again. Install NEW intake manifold-to-cylinder head gaskets.
2. Install the intake manifold (500).
3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512). Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
4. Install the intake manifold bolts. Tighten: Tighten the intake manifold bolts (1-10) a first pass in sequence to 5 N.m (44 lb in). Tighten the intake manifold bolts (1-10) a final pass in sequence to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
5. Install the fuel rail. Refer to «Fuel Rail and Injectors Installation»(ref-268156-S06698139392007101800000) .
6. Lubricate the manifold absolute pressure (MAP) sensor grommet (715) with clean engine oil.
7. Install the grommet onto the MAP sensor (714).
8. Install the MAP sensor and retainer (736).
9. Install the positive crankcase ventilation (PCV) hose - dirty air (716).
10. Install the PCV hose - fresh air.

Fuel Rail and Injectors Installation

1. Lubricate the NEW fuel injector O-ring seals (532, 534) with clean engine oil. CAUTION: Refer to «Fuel Rail Stop Bracket Installation Caution»(ref-268087-S42661314352007101800000) . IMPORTANT: DO NOT use the fuel injector O-ring seals again. Install NEW fuel injector O-ring seals during assembly.
2. Install the O-ring seals to the fuel injectors.
3. Install the fuel injectors (533) and retainers (521).
4. Install the fuel rail assembly (510) to the manifold. Push firmly on both sides of the rail until all the injectors have entered their bores.
5. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
6. Install the fuel rail bolts (511). Tighten: Tighten the fuel rail bolts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
7. Install the evaporative emission (EVAP) canister purge solenoid valve (730) and tubes (729, 735).
8. Install the fuel rail stop bracket and bolt. Tighten: Tighten the fuel rail stop bracket bolt to 50 N.m (37 lb ft).

Throttle Body Installation

1. Install the throttle body studs, as required. Tighten: Tighten the throttle body studs to 6 N.m (53 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
2. Install the throttle body gasket (509) to the intake manifold. Align the locating tab of the gasket with the notch in the manifold. IMPORTANT: DO NOT use the throttle body gasket again. Install a NEW gasket during assembly.
3. Install the throttle body (508), bolts (538), and nuts (507). Tighten: Tighten the throttle body nuts and bolts to 10 N.m (89 lb in).

Water Pump Installation

1. Install the water pump (1) and NEW gaskets (2). NOTE: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. IMPORTANT: All gasket surfaces are to be free of oil or other foreign material during assembly.
2. Install the water pump bolts (3). Tighten: Tighten the water pump bolts a first pass to 15 N.m (11 lb ft). Tighten the water pump bolts a final pass to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .

Exhaust Manifold Installation - Left Side

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the heat shield bolts to 9 N.m (80 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or on-board diagnostic (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Do not apply sealant to the first 3 threads of the bolt.
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
4. Install the exhaust manifold, NEW gasket, and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Exhaust Manifold Installation - Right Side

1. Install the heat shield (603) and bolts (604). Tighten: Tighten the heat shield bolts to 9 N.m (80 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or on-board diagnostic (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Do not apply sealant to the first 3 threads of the bolt.
2. Install the exhaust pipe studs (605). Tighten: Tighten the studs to 20 N.m (15 lb ft).
3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the exhaust manifold bolts. Refer to «Sealers, Adhesives, and Lubricants»(ref-268156-S21759060742007101800000) .
4. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the exhaust manifold bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.

Oil Level Indicator and Tube Installation

1. Inspect the O-ring seal (421) for cuts or damage. If the oil level indicator tube O-ring seal is not cut or damaged, it may be used again.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the O-ring seal onto the oil level indicator tube (420).
4. Install the oil level indicator tube into the engine block and rotate into proper position.
5. Install the tube bolt (419). Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
6. Install the oil level indicator (418) into the tube.

Engine Flywheel Installation

1. Install the flex plate to the crankshaft. IMPORTANT: The flex plate does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flex plate bolts. This procedure requires a 3 stage tightening process.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the flex plate bolts.
3. Install the engine flex plate bolts. Tighten: Tighten the engine flex plate bolts (1-6) a first pass in sequence to 20 N.m (15 lb ft). Tighten the engine flex plate bolts (1-6) a second pass in sequence to 50 N.m (37 lb ft). Tighten the engine flex plate bolts (1-6) a final pass in sequence to 100 N.m (74 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.

Crankshaft Balancer Installation

Tools Required

1. J 41478 Crankshaft Front Oil Seal Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 41665 Crankshaft Balancer and Sprocket Installer. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 42386-A Flywheel Holding Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. J 45059 Angle Meter. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 560

1. Install the J 42386-A and bolts. See «Special Tools»(ref-268156-S11321246192007101800000) . Use 1 M10 - 1.5 x 120 mm and 1 M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten: Tighten the J 42386-A bolts to 50 N. See «Special Tools»(ref-268156-S11321246192007101800000) .m (37 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. The crankshaft balancer installation and bolt tightening involves a 4 stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third and fourth passes tighten the NEW bolt to the proper torque. The used crankshaft balancer bolt is used only during the first pass of the balancer installation procedure. Install a NEW crankshaft balancer bolt and tighten as described in the second, third and fourth passes of the balancer bolt tightening procedure. Ensure the teeth of the tool engage the engine flywheel teeth.
2. Position the balancer (1) onto the end of the crankshaft. IMPORTANT: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation.
3. Use the J 41665 and the J 41478 in order to install the balancer. See «Special Tools»(ref-268156-S11321246192007101800000) . Assemble the J 41478 threaded rod, nut, washer and the J 41665 installer. See «Special Tools»(ref-268156-S11321246192007101800000) . Insert the smaller end of the installer into the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. Use a wrench and hold the hex end of the threaded rod. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. Remove the balancer installation tools.
4. Install the used crankshaft balancer bolt (139). Tighten: Tighten the crankshaft balancer bolt to 330 N.m (240 lb ft).
5. Remove the used crankshaft balancer bolt.
6. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. See «Special Tools»(ref-268156-S11321246192007101800000) . IMPORTANT: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore.
7. Install the NEW crankshaft balancer bolt (139). Tighten: Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). Tighten the crankshaft balancer bolt a second pass to 140 degrees using the J 45059 .
8. Remove the J 42386-A . See «Special Tools»(ref-268156-S11321246192007101800000) .