Engine Mechanical - 2.4L: Other Saturn Aura I

Sealers, Adhesives, and Lubricants

Scheme 36

Engine Block - Front View

Scheme 37

Engine Block - Back View

Scheme 38

Engine Block - Left Side View

Scheme 39

Engine Block - Bottom View

Scheme 40

Engine Block - Right Side View

Scheme 41

Engine Block - Top View

Scheme 42

Lower Crankcase - Front View

Scheme 43

Lower Crankcase - Back View

Scheme 44

Lower Crankcase - Bottom View

Scheme 45

Lower Crankcase - Left View

Scheme 46

Lower Crankcase - Right View

Scheme 47

Cylinder Head - Top View

Scheme 48

Cylinder Head - Intake Manifold Deck View

Scheme 49

Cylinder Head - Exhaust Manifold Deck View

Scheme 50

Cylinder Head - Front View

Scheme 51

Cylinder Head - Back View

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Identification can be made through the use of the Broadcast Code label on the engine front cover (1) and the use of the partial VIN etched on the oil filter bowl (2).

1. Barcode (1)
2. Sequence Number (2)
3. Day (3)
4. Month (4)
5. Year (5)
6. Engine Assembly Plant (6)
7. Broadcast Code (7)
8. Part Designation (8)
9. Engine Assembly Number (9)
10. Broadcast Code (10)

The partial VIN identifies the specific vehicle by sequence number.

Intermittent

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

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Engine Oil

Tools Required

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

1. Worn or burnt valves
2. Broken valve springs
3. Stuck valve lifters
4. Incorrect valve lash/adjustment
5. Damaged piston
6. Worn piston rings
7. Worn or scored cylinder bore
8. Damaged cylinder head gasket
9. Cracked or damaged cylinder head
10. Cracked or damaged engine block

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-301531-S28901255452008101700000) .
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke.
4. Install the J 35667-A or equivalent. See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

J-21867-850 Oil Pressure Gage Adapter

1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
2. Run the engine, and verify low, or no oil pressure on the vehicle gage or light. Listen for a noisy valve train or a knocking noise.
3. Inspect for the following: Oil diluted by moisture or unburned fuel mixtures Improper oil viscosity for the expected temperature Incorrect or malfunctioning oil pressure sender Incorrect or malfunctioning oil pressure gage Plugged oil filter Malfunctioning oil bypass valve
4. Remove the oil pressure sender or another engine block oil gallery plug.
5. Install J-21867-850 and an oil pressure gage and measure the engine oil pressure.
6. Compare the readings to specifications. Refer to «Engine Mechanical Specifications»(ref-301512-S27176441102008101700000) .
7. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: Oil pump worn or dirty Refer to «Oil Pump Disassemble»(ref-301512-S37530746692008101700000) . Oil pump-to-engine front cover bolts loose Refer to «Engine Front Cover and Oil Pump Installation»(ref-301512-S14654857942008101700000) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Refer to «Crankshaft and Bearing Cleaning and Inspection»(ref-301512-S28225145502008101700000) . Cracked, porous or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Assemble»(ref-301512-S12834754622008101700000) . Broken lash adjusters

Engine and Transmission Mount Balancing - All Mounts

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (1st Design)»(ref-301531-S06136972482008101700000) or «Air Cleaner Assembly Replacement (2nd Design)»(ref-301531-S41446438742008101700000) .
2. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
4. Loosen the front transaxle mount through bolt.
5. Loosen the rear transaxle mount through bolt.
6. Lower the vehicle.
7. Position two floor jacks with wood blocks under the engine and transaxle in order to support the powertrain assembly.
8. Loosen the transaxle mount bolts (1).
9. Loosen the engine mount to bracket bolts (1).
10. Reposition both floor jacks in order to allow a 1/8 inch gap between the mount and bracket.
11. Tighten the transaxle mount bolts (1) in the following sequence. Rear Front Middle Tighten: Tighten the bolts to 45 N.m (33 lb ft).
12. Tighten the engine mount to bracket bolts (1) in the following sequence. Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Remove the floor jacks from under the oil pan.
14. Shake the powertrain vigorously from front to rear and allow the powertrain to settle.
15. Raise the vehicle.
16. Tighten the rear transaxle mount through bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft).
17. Tighten the front transaxle mount through bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft).
18. Lower the vehicle.
19. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) .
20. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement (1st Design)»(ref-301531-S06136972482008101700000) or «Air Cleaner Assembly Replacement (2nd Design)»(ref-301531-S41446438742008101700000) .

J 35268-A Camshaft/Front Main Seal Installer

J 45027 Tensioner Tool. See Special Tools .

1. J 44217 Timing Chain Tensioner Tool. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. J 44217 Timing Chain Tensioner Tool. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 45027 Tensioner Tool. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. J 43649 Valve Spring Compressor. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. J 43653 Flywheel Holding Tool. See «Special Tools»(ref-301512-S32698523102008101700000) .
4. J 43655 Sprocket Holding Tool. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. J 38185 Hose Clamp Pliers
2. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. EN-47836 Piston Ring Compressor. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J-43966-1 Connecting Rod Guides. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

J 42067 Rear Main Seal Installer. See Special Tools .

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

EN 45680-850 Cylinder Sleeve Removal and Installation Kit. See Special Tools .

1. J 38185 Hose Clamp Pliers
2. J 43828 Ball Joint Remover
3. J 44015 Steering Linkage Installer
4. J 44015 Tie Rod Installer
5. SA91100C Tie Rod Separator

J 44887 Oil Filter Wrench. See Special Tools .

1. Use J 44887 to remove the oil filter cap. See «Special Tools»(ref-301512-S32698523102008101700000) . Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

J 38122-A Crankshaft Balancer Holder. See Special Tools .

1. Install the J 38122-A . See «Special Tools»(ref-301512-S32698523102008101700000) .
2. Remove the balancer retaining bolt and washer. Use the J 38122-A and a breaker bar to prevent the crankshaft from rotating when loosening the bolt. See «Special Tools»(ref-301512-S32698523102008101700000) . Discard the bolt.
3. Remove the crankshaft balancer assembly.
4. Remove and discard the friction washer.

J 43650 Balancer Shaft Bearing Remover and Installer. See Special Tools .

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools»(ref-301512-S32698523102008101700000) . Insert the tool with the foot parallel to the shaft.
4. When the J 43650 is inserted in the block turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(ref-301512-S32698523102008101700000) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4. See «Special Tools»(ref-301512-S32698523102008101700000) .6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4. See «Special Tools»(ref-301512-S32698523102008101700000) .5 in) (a), recheck the tool alignment.
7. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(ref-301512-S32698523102008101700000) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(ref-301512-S32698523102008101700000) .

J 38188 Cylinder Head Broken Bolt Extractor Kit. See Special Tools .

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Clean all of the gasket surfaces.
5. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. IMPORTANT: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
6. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the bolt holes with a nylon bristle brush.
8. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools»(ref-301512-S32698523102008101700000) .

J-43966-1 Connecting Rod Guides. See Special Tools .

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install J-43966-1 on the connecting rod bolts before removing the piston and connecting rod assembly. See «Special Tools»(ref-301512-S32698523102008101700000) .
7. Remove the piston and connecting rod assembly.

J 8087 Cylinder Bore Gage. See Special Tools .

1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasket surface.
3. Measure the cylinder bores by setting the J 8087 dial at zero in the cylinder at the point of the desired measurement. See «Special Tools»(ref-301512-S32698523102008101700000) . Lock the dial indicator at zero before removing the dial from the cylinder. Measure across the gage contact points with an outside micrometer, with the gage at the same zero setting as when the gage was removed from the cylinder.
4. Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do not hone the cylinder in order to remove these scratches.
5. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings. Refer to «Piston, Connecting Rod, and Bearing Installation»(ref-301512-S36977884322008101700000) . The honing stones must be clean, sharp, and straight. Move the hone slowly up and down to produce a 45 degree cross-hatch pattern. Clean the bore thoroughly with soap and water. Dry the bore. Rub clean engine oil in the bore. Remeasure the bore.
6. If the cylinder bore is out of specification, replace the block.
7. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing and drying the bore.

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

1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air.
4. Perform a visual inspection of the crankshaft for damage.
5. The crankshaft position reluctor ring may be replaced if damaged. Tighten: Tighten the crankshaft position reluctor ring bolts to 15 N.m (11 lb ft).
6. Inspect the crankshaft journals for wear (1). The journals should be smooth, with no signs of scoring, wear, or damage.
7. Inspect the crankshaft journals for grooves or scoring (2).
8. Inspect the crankshaft journals for scratches or wear (3).
9. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
10. Measure the crankshaft journals for out-of-round.
11. Measure the crankshaft journals for taper.
12. Measure the crankshaft runout. Using wooden V-blocks, support the crankshaft on the front and rear journals.
13. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. See «Special Tools»(ref-301512-S32698523102008101700000) .
14. Use the J 7872 in order to measure the runout of the crankshaft rear flange. See «Special Tools»(ref-301512-S32698523102008101700000) .
15. Replace the crankshaft if the measurements are not within specifications.
16. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
17. Inspect the crankshaft bearings for excessive scoring or discoloration.
18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing. If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

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

1. Disassemble the piston rings. Use a suitable tool to expand the rings. The piston rings must not be reused.
2. Remove the piston pin retainers using the EN-46745 . See «Special Tools»(ref-301512-S32698523102008101700000) .
3. Remove the piston pin.

Connecting Rod Measurement

1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rods for the following: Signs of being twisted, bent, nicked, or cracked Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure: Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. Using an inside micrometer, measure the connecting rod piston pin bore. Subtract the piston pin diameter from the piston pin bore diameter. The clearance should not be more than 0.021 mm (0.0008 in).
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.

Piston Measurement

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston (1) Scuffed or damaged skirts (2) Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure: Piston pin bores and pins must be free of varnish or scuffing. Use an outside micrometer to measure the piston pin in the piston contact areas. Using an inside micrometer, measure the piston pin bore. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). If the clearance is excessive, determine which component is out of specification.
6. Measure the piston ring end gap using the following procedure: Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm or 1 inch down from the deck surface). Be sure the ring is square with the cylinder bore by positioning the ring with the piston head. Measure the end gap of the piston ring with feeler gages. Compare the measurements with those provided below: The top compression ring end gap should be 0.20-0.40 mm (0.0060-0.015 in). The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in). The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). If the clearance exceeds the provided specifications, the piston rings must be replaced. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure: Roll the piston ring entirely around the piston ring groove. If any binding is caused by a distorted piston ring, replace the ring. With the piston ring on the piston, use feeler gages to check clearance at multiple locations. The clearance between the surface of the top piston ring and the ring land should be no greater than 0.075 mm (0.0030 in). If the clearance is greater than specifications, replace the piston ring. If the new ring does not reduce the top ring side clearance to 0.075 mm (0.0030 in) or less, install a new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the 2nd compression ring near the end for identification of the top side. Install the 2nd compression ring with the dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than 0.069 mm (0.0026 in).
10. If the new ring does not reduce the clearance to 0.069 mm (0.0026 in) or less, install a new piston.
11. Measure piston width using the following procedure: Using an outside micrometer, measure the width of the piston 14.5 mm (0.570 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. The proper clearance specification for the piston is 0.010-0.041 mm (0.0006-0.0016 in).
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replace the piston.

Piston Selection

1. Inspect the engine block cylinder bore. Refer to «Engine Block Cleaning and Inspection»(ref-301512-S37304689562008101700000) .
2. Inspect the piston and the piston pin. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection»(ref-301512-S29061842762008101700000) .
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge with a micrometer and record the reading.
5. With a micrometer or caliper at a right angle to the piston, measure the piston 14 mm (0.570 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(ref-301512-S27176441102008101700000) .
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «Separating Parts»(ref-301512-S04925656742008101700000) .

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

1. The cast boss (1), on the underside of the piston, must go to the rear of the block.
2. The larger feature (1), at the split line located on one side of the connecting rod, must go to the front of the block.
3. Assemble the connecting rod and the piston.
4. Use the following procedure to assemble the piston pin and the retainer: Coat the piston pin with oil. Install one side of one piston pin retainer into the retaining groove using EN-46745 . See «Special Tools»(ref-301512-S32698523102008101700000) . Rotate the retainer until it is fully seated in the groove. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Install the second piston pin retainer, using EN-46745 . See «Special Tools»(ref-301512-S32698523102008101700000) . Ensure that the piston moves freely.
5. Install the following components of the oil control ring assembly (bottom ring): The expander The lower oil control ring The upper control ring
6. Install the lower compression ring (second ring). Place the manufacturer's mark facing up.
7. Install the upper compression ring (top ring).

J 42385-850 Thread Repair Kit. See Special Tools .

Scheme 58

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

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

Cylinder Head Bolt Hole Thread Repair

1. The cylinder head bolt hole thread repair kit consists of the following items: Drill (1) Tap (2) Installer (3) Sleeve (4) Alignment Pin (5) Bushing (6) Bolts (7) Fixture Plate (8)
2. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck. Position the fixture plate and bushing over the hole that is to be repaired (4).
3. Position the alignment pin (1) through the bushing and into the hole.
4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6. Install the sleeve (2) onto the drill (1), if required.
7. Drill out the threads of the damaged hole. Drill the hole until the stop collar of the drill bit or the sleeve contacts the bushing.
8. Using compressed air, clean out any chips.
9. Using a tap wrench, tap the threads of the drilled hole.
10. Using a TAP wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap align with the top of the drill bushing (2).
11. Remove the fixture plate (1), bushing (2), and bolts.
12. Using compressed air, clean out any chips.
13. Spray cleaner GM P/N 12346139 or GM P/N 1237798 (Canadian P/N 10953463), or equivalent, into the hole.
14. Using compressed air, clean any cutting oil and chips out of the hole.
15. Lubricate the threads of the installer tool (2) with the driver oil (1).
16. Install the insert (2) onto the driver tool (1).
17. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
18. Install the insert and driver (1) into the hole. Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

Main Cap Bolt Hole Thread Repair

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

J 45059 Angle Meter. See Special Tools .

1. Install the upper crankshaft bearings and lubricate bearing surfaces with engine oil.
2. Install the crankshaft on the journals.
3. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) to the surfaces of the engine block to bedplate mating surfaces.
5. Install the lower crankcase. Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) . Tighten: Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
7. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).

J 42067 Rear Main Seal Installer. See Special Tools .

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools»(ref-301512-S32698523102008101700000) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools»(ref-301512-S32698523102008101700000) .

J 45059 Angle Meter. See Special Tools .

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence. Use the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).

J 43650 Balance Shaft Bushing Remover/Installer. See Special Tools .

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(ref-301512-S32698523102008101700000) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Place the number one piston at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts into their bores.
7. Install the balance shaft retaining bolts. Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).

Balance Shaft to Engine Timing

1. Install the balance shaft drive sprocket.
2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. There are three colored links on the chain. Two links are of matching colors, and one link is of a unique color. Use the following procedure to line up the links with the sprockets: Orient the chain so that the colored links are visible.
3. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
4. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 6 o'clock position on the crank sprocket)
5. Place the chain (3) on the water pump drive sprocket. The alignment is not critical.
6. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.

J 35268-A Camshaft/Front Main Seal Installer. See Special Tools .

1. Install the seal into the front cover using the J 35268-A . See «Special Tools»(ref-301512-S32698523102008101700000) .
2. Ensure that the engine front cover is properly supported when installing the seal.

J 44887 Oil Filter Wrench. See Special Tools .

1. Install a new oil filter on the oil filter cap.
2. Lubricate the O-ring on the oil filter cap with 5W30 engine oil.
3. Use J 44887 to install the oil filter adapter. See «Special Tools»(ref-301512-S32698523102008101700000) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

J 45299 Engine Preluber. See Special Tools .

1. Remove the oil pressure switch.
2. Install the M12 x 1.75 adapter P/N 509376.
3. Install the flexible hose to the adapter and open the valve.
4. Pump the handle on the J 45299 in order to flow a minimum of 1-1. See «Special Tools»(ref-301512-S32698523102008101700000) .9 liters (1-2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
5. Close the valve and remove the flexible hose and adapter from the engine.
6. Install the oil pressure switch to the engine. Tighten: Tighten the oil pressure switch to 22 N.m (16 lb ft).
7. Top-off the engine oil to the proper level.

Cylinder Block

The cylinder block is lost foam cast aluminum with 4 cylinders arranged in-line. The cylinders have pressed in place iron liners. The block has 5 crankshaft bearings with the thrust bearing located on the second bearing from the front of the engine. The cylinder block incorporates a bedplate design that forms an upper and lower crankcase. This design promotes cylinder block rigidity and reduced noise and vibration.

Crankshaft

The crankshaft is cast nodular iron with 8 counterweights. The number 8 counterweight is also the ignition system reluctor wheel. The main bearing journals are cross-drilled, and the upper bearings are grooved. The crankshaft has a slip fit balance shaft drove sprocket. Number 2 main bearing is the thrust bearing. A harmonic damper is used to control torsional vibration.

Connecting Rod and Piston

The connecting rods are powdered metal. The connecting rod incorporates the floating piston pin. The pistons are cast aluminum. The piston rings are of a low tension type to reduce friction. The top compression ring is ductile iron with a molybdenum facing and phosphate coated sides. The second compression ring is gray iron. The oil ring is a 3-piece spring construction with chromium plating.

Oil Pan

The oil pan is die cast aluminum. The oil pan includes an attachment to the transmission to provide additional structural support.

Cylinder Head

The cylinder head is a lost foam aluminum casting. Pressed-in powdered metal valve guides and valve seat insets are used. The fuel injection nozzle is located in the intake port. The cylinder head incorporates camshaft journals and camshaft caps.

Valves

There are 2 intake and 2 exhaust valves per cylinder. Rotators are used on all of the intake valves. The rotators are located at the bottom of the valve spring to reduce valve train reciprocating mass. Positive valve stem seals are used on all valves.

Camshaft

Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron.

Valve Lifters

The valve train uses a roller finger follower acted on by a hydraulic lash adjuster. The roller finger follower reduces friction and noise.

Camshaft Cover

The camshaft cover has a steel crankcase ventilation baffling incorporated. The camshaft cover has mounting locations for the ignition system.

Camshaft Drive

A roller chain is used for camshaft drive. There is a tensioner and active guide used on the slack side of the chain to control chain motion and noise. The chain drive promotes long valve train life and low maintenance.

Intake and Exhaust Manifold

The intake manifold is made of composite plastic. The exhaust manifold is cast iron. The intake manifold incorporates a distribution and control system for positive crankcase ventilation (PCV) gases. The exhaust manifold is a dual plane design that promotes good low end torque and performance.

Scheme 59

Oil is applied under pressure to the crankshaft, connecting rods, balance shaft assembly, camshaft bearing surfaces, valve lifters and timing chain hydraulic tensioner. All other moving parts are lubricated by gravity flow or splash. Oil enters the gerotor type oil pump through a fixed inlet screen. The oil pump is driven by the crankshaft. The oil pump body is within the engine front cover. The pressurized oil from the pump passes through the oil filter. The oil filter is located on the right (front) side of the engine block. The oil filter is housed in a casting that is integrated with the engine block. The oil filter is a disposable cartridge type. A by-pass valve in the filter cap allows continuous oil flow in case the oil filter should become restricted. Oil then enters the gallery where it is distributed to the balance shafts, crankshaft, camshafts and camshaft timing chain oiler nozzle. The connecting rod bearings are oiled by constant oil flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each upper main bearing furnishes oil to the drilled crankshaft passages. The pressurized oil passes through the cylinder head restrictor orifice into the cylinder head and then into each camshaft feed gallery. Cast passages feed each hydraulic element adjuster and drilled passages feed each camshaft bearing surface. An engine oil pressure switch or sensor is installed at the end. Oil returns to the oil pan through passages cast into the cylinder head. The timing chain lubrication drains directly into the oil pan.

Cleanliness and Care

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

When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

Separating Parts

Separate, mark, or organize the following components

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

J 28410 Gasket Remover

Gasket Reuse and Applying Sealants

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

Separating Components

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

Cleaning Gasket Surfaces

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

Pipe Joint Compound

1. Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2 non-rigid parts, such as the oil pan and the engine block, are assembled together.
2. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(ref-301512-S36605858062008101700000) .
4. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the bolt is tightened.
5. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
6. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. Room temperature vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used where 2 rigid parts, such as the lower crankcase and the engine block, are assembled together.
2. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(ref-301512-S36605858062008101700000) .
4. Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened.
5. Assemble components while RTV is still wet, within 3 minutes. Do not wait for RTV to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Tools and Equipment

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

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

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