Engine Mechanical - 2.4L: Removal & Installation Saturn Aura I

Removal Procedure

1. Remove the engine oil fill cap.
2. Pull up on the cover in order to disengage the cover from the studs.

Installation Procedure

1. Align the cover to the studs on the engine, push down on the cover above the studs in order to engage the cover to the studs.
2. Install the engine oil fill cap.

1. Install and position the drive belt around all of the pulleys except for the middle idler pulley.
2. Install a box wrench to the drive belt tensioner (2) and rotate the tensioner counterclockwise in order to release the tensioner.
3. Install the drive belt under the middle idler pulley.
4. Slowly rotate the tensioner counterclockwise in order to allow the tensioner to rest against the drive belt.
5. Loosen the forcing bolt on the EN-48079 (1) and remove from the drive belt tensioner spring. See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Ensure that the drive belt tensioner idler is fully seated against the drive belt.
7. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement»(ref-301512-S37422183092008101700000) .
8. 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) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .
2. Remove the right side engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-301500-S42272808122008101700000) .
3. Remove the air conditioning (A/C) lines from the A/C compressor. Refer to «Compressor Replacement (LAT)»(ref-301492-S23678067222008101700000) or «Compressor Replacement (LE5)»(ref-301492-S39198958172008101700000) .
4. Remove the tensioner spring bolts (1) from the tensioner.
5. Remove the tensioner spring from the tensioner.
6. Loosen engine mount-to-bracket bolts (2).
7. Insert a suitable tool between the engine mount bracket and the frame in order to reposition the engine and remove the tensioner assembly.
8. Loosen the drive belt tensioner bolt (1).
9. Raise and support vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
10. Remove the drive belt tensioner (2) with drive belt tensioner bolt (1).

1. Install the lower tensioner bolt into the tensioner.
2. Position the tensioner assembly in place.
3. Lower the vehicle.
4. Insert a suitable tool between the engine mount bracket and the frame in order to reposition the engine and install the tensioner assembly.
5. Install but do not tighten the drive belt tensioner bolt (1).
6. Position the tensioner spring to the tensioner.
7. Install the tensioner spring bolts (1) to the tensioner. Tighten: Tighten the tensioner spring bolts to 22 N.m (16 lb ft). Tighten the lower tensioner bolt to 58 N.m (43 lb ft).
8. Install the engine mount to bracket bolts (2).
9. Tighten the engine mount to bracket bolts in the following sequence. Middle Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
10. Install A/C lines to the A/C compressor. Refer to «Compressor Replacement (LAT)»(ref-301492-S23678067222008101700000) or «Compressor Replacement (LE5)»(ref-301492-S39198958172008101700000) .
11. Install the right side engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-301500-S42272808122008101700000) .
12. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .
13. Using a 6 point socket on the hex boss on the drive belt tensioner, release the tension and remove the shipping clip by hand. Discard the clip.

1. Remove the starter. Refer to «Starter Motor Replacement (LAT)»(ref-301498-S23683722422008101700000) .
2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
3. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
3. Install the starter. Refer to «Starter Motor Replacement (LAT)»(ref-301498-S23683722422008101700000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement (First Design)»(ref-301512-S34422971912008101700000) .
2. Remove the engine mount bracket to engine bolts (1).
3. Remove the engine mount bracket (2).

1. Position the engine mount bracket (2) to the engine.
2. Install the engine mount bracket bolts (1).
3. Tighten the engine mount bracket bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement (First Design)»(ref-301512-S34422971912008101700000) .

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. Support the engine with a hydraulic floor jack. Use a piece of wood between the floor jack and the oil pan.
3. Remove the engine mount to bracket bolts (1).
4. Remove the engine mount to side rail bolts (2).
5. Remove the engine mount from the engine compartment.

1. Place the engine mount onto the side rail studs.
2. Install the engine mount to side rail bolts (2). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the engine mount to bracket bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Remove the hydraulic floor jack from under the oil pan.
5. 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) .

Tools Required

1. J 28467-B Universal Engine Support Fixture
2. J-28467-13 Engine Support Fixture Adapters
3. J 36462-A Engine Support Adapter Leg Set
4. J 28467-7A Bolt Hook
5. J 28467-34 Lift Hook Wing Nut & Washer

1. Pull each end of the hood rear seal away from the cowl panel flange near both strut towers.
2. Install three J-28467-13 (1) and two J 28467-5 strut tower adapters (2) to the top of the left and right strut tower.
3. Install a 127 cm (50 in) engine support fixture cross bar J 28467-B (3) transversely across the vehicle between both J 28467-5 strut tower adapters (2).
4. Insert safety pins J-28467-10 (4) through the J 28467-5 strut tower adapters (2) and the cross bar (3) to prevent movement.
5. Position two 58 cm (23 in) engine support fixture cross bars (1) longitudinally with two J 36462-A leg assembly (2).
6. Install two J 28467-1A clamp (3) to secure the longitudinal mounted cross bar to the transverse mounted cross bar.
7. Assemble the lift hook wing nut J 28467-34 , lift hook bracket J-28467-6A and lift hook J 28467-7A to the engine lift bracket on the engine.
8. Install the lift hook and bracket assembly (1) to the longitudinal mounted cross bar (2).
9. Position the J 28467-7A lift hook to the rear engine lift bracket.
10. Assemble the lift hook wing nut J 28467-34 and the lift hook bracket J-28467-6A to the lift hook J 28467-7A .
11. Install the lift hook and bracket assembly (1) to the longitudinal mounted cross bar (2).
12. Position the J 28467-7A bolt hook (1) to the front engine lift bracket.
13. Evenly tighten both wing nuts J 28467-34 (1) until the engine weight is supported by the engine support fixture and no longer carried by the engine mounts.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .
2. Remove the oil level indicator.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
4. Remove the engine wiring harness clip (1) from the oil level indicator tube bracket (2).
5. Remove the knock sensor electrical connector lead (1) from the oil level indicator tube bracket (2).
6. Lower the vehicle.
7. Remove the oil level indicator tube bolt.
8. Remove the oil level indicator tube.
9. Remove the oil level indicator tube O-ring seals, if necessary.

1. Install NEW oil level indicator tube O-ring seals, if necessary.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Raise and support the vehicle.
5. Install the knock sensor electrical connector lead (1) to the oil level indicator tube bracket (2).
6. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2).
7. Lower the vehicle.
8. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2).
9. Install the oil level indicator.
10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the camshaft cover.
3. Remove the PCV hose (2) from the camshaft cover.

1. Install the PCV hose (2) to the camshaft cover.
2. Position the PCV hose clamp (1) at the camshaft cover.
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .
2. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(ref-301507-S39262997152008101700000) or «Radiator Inlet Hose Replacement (LE5)»(ref-301507-S10295693522008101700000) .
3. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC).
4. Disconnect the engine wiring harness electrical connector (2) from the generator starter.
5. Disconnect the engine wiring harness electrical connector (4) from the generator starter.
6. Remove the fuel injector wiring harness electrical connector retainer (6) from the generator starter.
7. Disconnect the fuel injector wiring harness electrical connector (7) from the engine wiring harness electrical connector (8).
8. Remove the engine wiring harness clips (5) from the intake manifold.
9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose (2) from the intake manifold.
11. Remove the throttle body bolts.
12. Remove the throttle body and seal.
13. Remove and inspect the throttle body seal.
14. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
15. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301531-S18963178012008101700000) .
16. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301512-S15879365052008101700000) .
17. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-301531-S02283219202008101700000) .
18. Remove the 3-phase voltage cable bracket bolt at the tie bar.
19. Remove the generator starter bolts.
20. Reposition and secure the generator starter out of the way.
21. Remove the intake manifold lower bolts (1).
22. Remove the intake manifold upper bolt and nuts.
23. Remove the intake manifold.
24. Remove and inspect the intake manifold gasket.

1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
2. Install the intake manifold.
3. Install the intake manifold upper bolt and nuts.
4. Install the intake manifold lower bolts. Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
5. Position the starter/generator to the bracket.
6. Install the starter/generator bolts until snug.
7. Tighten the starter generator bolts in the following sequence. Front Bottom Tighten: Tighten the bolts to 58 N.m (43 lb ft).
8. Install the 3-phase voltage cable bracket to the tie bar.
9. Install the 3-phase voltage cable bracket bolt at the tie bar. Tighten: Tighten the bolt to 10 N.m (89 lb in).
10. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-301531-S02283219202008101700000) .
11. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301512-S15879365052008101700000) .
12. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301531-S18963178012008101700000) .
13. Connect the engine wiring harness electrical connector to the MAP sensor.
14. Install a NEW throttle body seal if necessary, otherwise install the old seal.
15. Position the throttle body.
16. Install the throttle body bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
17. Install the vacuum brake booster hose (2) to the intake manifold.
18. Position the vacuum brake booster hose clamp (1) at the intake manifold.
19. Install the engine wiring harness clips (5) to the intake manifold.
20. Connect the fuel injector wiring harness electrical connector (7) to the engine wiring harness electrical connector (8).
21. Install the fuel injector wiring harness electrical connector retainer (6) to the generator starter.
22. Connect the engine wiring harness electrical connector (4) to the generator starter.
23. Connect the engine wiring harness electrical connector (2) to the generator starter.
24. Connect the engine wiring harness electrical connector (1) to the TAC.
25. Install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(ref-301507-S39262997152008101700000) or «Radiator Inlet Hose Replacement (LE5)»(ref-301507-S10295693522008101700000) .
26. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .

Crankshaft Balancer Replacement

Tools Required

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

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .
2. Remove the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side (LAT)»(ref-301500-S00217843532008101700000) .
3. Install the J 38122-A (1), and a breaker bar to the balancer in order to prevent the balancer from rotating when loosening the balancer bolt. See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Remove the J 38122-A (1) and breaker bar. See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Remove and discard the crankshaft balancer bolt.
6. Remove the crankshaft balancer.

1. Position the crankshaft balancer.
2. Install a NEW crankshaft balancer bolt.
3. Install the J 38122-A (1), and a breaker bar to the balancer in order to prevent the balancer from rotating while tightening the bolt. See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Tighten the crankshaft balancer bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Install the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side (LAT)»(ref-301500-S00217843532008101700000) .
6. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301512-S27017467882008101700000) .
2. Use a flat-bladed tool to remove the seal from the front cover.

1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301512-S27017467882008101700000) .

1. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-301512-S23398002852008101700000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301512-S27017467882008101700000) .
3. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-301512-S41347681902008101700000) .
4. Remove the engine mount to bracket bolts (2).
5. Remove the engine mount to side rail nuts (1).
6. Remove the engine mount from the engine compartment.
7. Remove the engine mount bracket to engine bolts.
8. Remove the engine mount bracket.
9. Remove the engine front cover to water pump bolt.
10. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
11. Remove the engine front cover bolts.
12. Remove the engine front cover.
13. Remove and discard the engine front cover gasket.

1. Install a NEW engine front cover gasket to the dowel pins.
2. Install the engine front cover.
3. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Install the engine front cover to water pump bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Position the engine mount bracket to the engine.
7. Install the engine mount bracket bolts in the following locations. The long bolts in the forward and lower rear holes The short bolt in the upper rear hole
8. Tighten the engine mount bracket bolts in the following sequence. Upper left Lower left Right Tighten: Tighten the bolts to 100 N.m (74 lb ft).
9. Install the engine mount to the engine compartment.
10. Install the engine mount to side rail nuts (1). Tighten: Tighten the nuts to 100 N.m (74 lb ft).
11. Install the engine mount to bracket bolts (2).
12. Tighten the engine mount to bracket bolts in the following sequence. Middle Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-301512-S41347681902008101700000) .
14. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301512-S27017467882008101700000) .
15. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-301512-S23398002852008101700000) .

Camshaft Timing Chain, Sprocket, and Tensioner Replacement

Special Tools

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

1. Remove the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-301531-S28901255452008101700000) .
2. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
3. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-301512-S06687082912008101700000) .
5. Remove the upper timing chain guide bolts and guide.
6. Remove the timing chain tensioner.
7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
8. Remove and discard the exhaust camshaft actuator bolt (2).
9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
10. Remove the timing chain tensioner guide bolt and guide.
11. Remove the fixed timing chain guide access plug.
12. Remove the fixed timing chain guide bolts and guide.
13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
14. Remove and discard the intake camshaft actuator bolt (2).
15. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head.
16. Remove the timing chain crankshaft sprocket.
17. If replacing the balance shaft timing chain and sprocket, perform the following steps, if not proceed to step 10 in the installation procedure.
18. Remove the balance shaft drive chain tensioner bolts and tensioner.
19. Remove the adjustable balance shaft chain guide bolt and guide.
20. Remove the small balance shaft drive chain guide bolts and guide.
21. Remove the upper balance shaft drive chain guide bolts and guide.
22. Remove the balance shaft drive chain (7).
23. Remove the balance shaft drive sprocket.

1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10.
2. Install the balance shaft drive sprocket.
3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and 1 is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
4. Install the upper balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
5. Install the small balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
6. Install the adjustable balance shaft chain guide and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
8. Install the balance shaft drive chain tensioner and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.
10. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
11. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
12. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
13. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
14. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
15. Hand tighten the new intake camshaft actuator bolt.
16. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
17. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
18. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
19. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
20. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
21. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
22. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
23. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
24. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
25. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
26. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
27. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
28. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
29. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
30. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
31. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
32. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
33. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
34. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
35. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).
36. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-301512-S06687082912008101700000) .
37. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
38. Install the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-301531-S28901255452008101700000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .
2. Remove the battery box cover.
3. Disconnect the engine wiring harness electrical connectors (2, 3) from the intake and exhaust camshaft position actuator solenoid valves.
4. Remove the ignition coils. Refer to «Ignition Coil Replacement»(ref-301531-S00643363462008101700000) .
5. Remove the engine harness clips (4) from the cover.
6. Reposition the engine wiring harness out of the way.
7. Remove the fuel feed line retainers (1, 2) from the engine brackets.
8. Remove the camshaft cover bolts.
9. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Install the feed line retainers (1, 2) to the engine brackets.
3. Install the ignition coils. Refer to «Ignition Coil Replacement»(ref-301531-S00643363462008101700000) .
4. Position the engine wiring harness and install the clips (4) to the cover.
5. Connect the engine wiring harness electrical connectors (2, 3) to the intake and exhaust camshaft position actuator solenoid valves.
6. Install the battery box cover.
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LAT)»(ref-301498-S16025379472008101700000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LAT)»(ref-301498-S16025379472008101700000) .

1. Remove the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-301512-S22406789672008101700000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the intake camshaft (1).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers with GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the intake camshaft (1). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-301512-S22406789672008101700000) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-301512-S31645954002008101700000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the exhaust camshaft (3).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Apply lubricate GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the exhaust camshaft (3). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-301512-S31645954002008101700000) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
2. Remove the upper timing chain guide bolts and guide.
3. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
4. Loosen, but DO NOT remove the intake camshaft actuator bolt.
5. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-301512-S32698523102008101700000) . Firmly tighten the nuts.
6. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-301512-S32698523102008101700000) . Firmly tighten the nuts.
7. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
8. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
9. Remove and discard the intake camshaft actuator bolt (2).
10. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW intake camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
8. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .
2. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
3. Remove the upper timing chain guide bolts and guide.
4. Remove the timing chain tensioner.
5. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
6. Loosen, but DO NOT remove the exhaust camshaft actuator bolt.
7. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-301512-S32698523102008101700000) . Firmly tighten the nuts.
8. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-301512-S32698523102008101700000) . Firmly tighten the nuts.
9. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
10. Remove and discard the exhaust camshaft actuator bolt (2).
11. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
8. Remove the old oil from the timing chain tensioner.
9. Inspect the timing chain tensioner for scoring or free movement.
10. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
11. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 in) from end to end (a).
12. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
13. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
14. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
15. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1- 8.4.
16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.
19. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
20. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-301512-S19429119172008101700000) .

1. If equipped, with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set.
2. If equipped, with an automatic transmission, remove the starter. Refer to «Starter Motor Replacement (LAT)»(ref-301498-S23683722422008101700000) .
3. Install J 43653 . See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Remove the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-301512-S05776254062008101700000) or «Exhaust Camshaft and Valve Lifter Replacement»(ref-301512-S42892931502008101700000) .
5. Remove the camshaft roller followers.
6. Install the front section of the J 43649 to the second camshaft cover bolt hole. See «Special Tools»(ref-301512-S32698523102008101700000) .
7. Install the remaining parts of the J 43649 to the cylinder head. See «Special Tools»(ref-301512-S32698523102008101700000) .
8. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-301531-S28901255452008101700000) .
9. Install an air hose adapter into the spark plug hole.
10. Attach an air hose to the adapter
11. Using the compressed air, pressurize the cylinder to 690 kPa (100 psi).
12. Compress the valve spring using the J 43649 . See «Special Tools»(ref-301512-S32698523102008101700000) .
13. Remove the valve spring keepers.
14. Remove the valve spring retainer.
15. Remove the valve spring.
16. Using the J 36017 remove the valve seal. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. Using the J 36017 install the NEW valve seal. See «Special Tools»(ref-301512-S32698523102008101700000) . Fully seat the seal onto the valve guide.
2. Install the valve spring.
3. Install the valve spring retainer.
4. Compress the valve spring using the J 43649 . See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Install the valve spring keepers.
6. Disconnect the air hose from the adapter.
7. Remove the air hose adapter from the spark plug hole.
8. Remove the J 43649 from the cylinder head. See «Special Tools»(ref-301512-S32698523102008101700000) .
9. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-301531-S28901255452008101700000) .
10. Install the camshaft roller followers.
11. Install the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(ref-301512-S05776254062008101700000) or «Exhaust Camshaft and Valve Lifter Replacement»(ref-301512-S42892931502008101700000) .
12. If used, remove the J 43653 . See «Special Tools»(ref-301512-S32698523102008101700000) .
13. If removed, install the starter. Refer to «Starter Motor Replacement (LAT)»(ref-301498-S23683722422008101700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LAT)»(ref-301511-S19249739342008101700000) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-301512-S24307277002008101700000) .
4. Reposition the coolant recovery inlet hose clamp (2).
5. Remove the coolant recovery inlet hose (1) from the cylinder head.
6. Reposition the radiator inlet hose clamp using the J 38185 .
7. Remove the radiator inlet hose from the cylinder head.
8. Remove the timing chain. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-301512-S21026046552008101700000) .
9. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
10. Remove the cylinder head.
11. Remove the cylinder head gasket.
12. Clean all of the gasket surfaces.
13. Use the following steps 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 either surface. IMPORTANT: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the 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.
14. Clean the old sealer/lube and any dirt from around the bolt holes.
15. Clean the bolts holes with a nylon bristle brush.
16. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.
5. Install and tighten the cylinder head bolts in the sequence shown. Tighten: Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Install the NEW front cylinder head bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
7. Install the timing chain. Refer to «Camshaft Timing Chain, Sprocket, and Tensioner Replacement»(ref-301512-S21026046552008101700000) .
8. Install the radiator inlet hose to the cylinder head.
9. Position the radiator inlet hose clamp using the J 38185 .
10. Install the coolant recovery inlet hose (1) to the cylinder head.
11. Position the coolant recovery inlet hose clamp (2).
12. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LAT)»(ref-301511-S19249739342008101700000) .
13. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-301512-S24307277002008101700000) .
14. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301512-S15879365052008101700000) .
3. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-301512-S41347681902008101700000) .
4. Remove engine mount. Refer to «Engine Mount Replacement (First Design)»(ref-301512-S34422971912008101700000) .
5. Using the engine support fixture, raise the engine approximately 3 inches.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
7. Loosen the upper air conditioning (A/C) compressor bolts.
8. Remove the lower A/C compressor bolt.
9. Place a suitable drain pan under the oil pan drain plug.
10. Remove the oil pan drain plug.
11. Drain the engine oil.
12. Reinstall the oil pan drain plug until snug.
13. Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump (2).
14. Remove the generator control module coolant pump bolt (3).
15. Remove the generator control module coolant pump from the oil pan.
16. Remove the 4 oil pan to transaxle bolts.
17. Remove the oil pan bolts.
18. Remove the oil pan
19. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required. Refer to «Sealers, Adhesives, and Lubricants»(ref-301512-S04824426002008101700000) .
3. Install the oil pan.
4. Install the oil pan bolts.
5. Install the 4 oil pan to transaxle bolts. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
6. Tighten the oil pan bolts in the sequence shown. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the generator control module coolant pump to the oil pan. Ensure that the anti-rotation tab is inserted into the hole in the oil pan.
8. Install the generator control module coolant pump bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
9. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump (2).
10. Lower the vehicle.
11. Using the engine support fixture, lower the engine.
12. Install the engine mount. Refer to «Engine Mount Replacement (First Design)»(ref-301512-S34422971912008101700000) .
13. Remove the engine support fixture.
14. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301512-S15879365052008101700000) .
15. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301512-S17898609722008101700000) .
16. Fill the engine oil to the proper level.

1. Remove the engine oil pan. Refer to «Oil Pan Replacement»(ref-301512-S42770129712008101700000) .
2. Rotate the crankshaft so that cylinders 1 and 4 are at top dead center (TDC).
3. Remove the piston oil nozzles from cylinders 1 and 4 using a 3/8 inch wobble extension drive with a 6 mm hex drive bit. Remove the piston oil nozzles. (Crankshaft removed for illustrative purposes.)
4. Rotate the crankshaft so that cylinders 2 and 3 are at TDC. Remove the piston oil nozzles.

1. Install new piston oil nozzles. Turn the extension by hand to ensure that the threads are aligned. Use a long screwdriver to ensure that the nozzle does not rotate and make sure that the locating pin is properly indexed in its hole. Tighten: Tighten the piston oil nozzle bolts to 15 N.m (11 lb ft).
2. Install the engine oil pan. Refer to «Oil Pan Replacement»(ref-301512-S42770129712008101700000) .
3. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
4. Replace the oil filter and fill the engine with new engine oil. Refer to «Engine Mechanical Specifications»(ref-301512-S27176441102008101700000) .
5. Reset the engine oil life monitor. Refer to «GM Oil Life System Resetting»(ref-301561-S10803613852008101700000) .

1. Remove the engine from the vehicle. Refer to «Engine Replacement»(ref-301512-S35551031842008101700000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Removal»(ref-301512-S02052844232008101700000) .
3. Remove the front cover. Refer to «Camshaft Cover Removal»(ref-301512-S42093734742008101700000) .
4. Remove the engine oil pan. Refer to «Oil Pan Removal»(ref-301512-S22818714812008101700000) .
5. Remove the crankshaft position sensor.
6. Remove the 3 perimeter bolts.
7. Remove and discard the crankshaft bearing bolts.
8. Using the pry points and an appropriate prying tool, gently separate the upper and lower crankcase.
9. Clean the sealing material from the engine block and lower the crankcase.

1. Apply oil to the crankshaft bearing surfaces.
2. Apply a 2-5 mm (0.08-0.20 in) bead (a) of sealer GM P/N 12378521 (Canadian P/N 88901148) to the surface of the engine block-to-lower crankcase mating surface.
3. Install the lower crankcase. Tap gently into place with a suitable tool, if necessary. Ensure it is aligned properly on the dowels.
4. 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 to 70 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).
6. Install the crankcase position sensor.
7. Install the front cover. Refer to «Engine Front Cover and Oil Pump Installation»(ref-301512-S14654857942008101700000) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Installation»(ref-301512-S28406754392008101700000) .
9. Install the engine oil pan. Refer to «Oil Pan Installation»(ref-301512-S19093149122008101700000) .
10. Install the engine. Refer to «Engine Replacement»(ref-301512-S35551031842008101700000) .

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-301512-S42770129712008101700000) .
2. Remove the cylinder head. Refer to «Cylinder Head Replacement»(ref-301512-S25500450742008101700000) .
3. If a ring ridge is present, remove the ring ridge as follows: Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use a ridge reamer to remove the ring ridge. Turn the crankshaft so the piston is at top of the stroke. Remove the cloth and cutting debris.
4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts.
5. Remove the connecting rod and the piston out of the top of the engine block using the J-43966-1 . See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

1. Coat the following parts with engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the piston into its original bore using the J-43966-1 . See «Special Tools»(ref-301512-S32698523102008101700000) .
3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the EN-47836 firmly against the engine block until all the piston rings have entered the cylinder bore. See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.
8. Install the new connecting rod bolts and nuts. Tighten: On the first pass, tighten the nuts evenly to 25 N.m (18 lb ft). On the final pass, use the J 45059 in order to tighten the nuts an additional 100 degrees. See «Special Tools»(ref-301512-S32698523102008101700000) .
9. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to «Cylinder Head Replacement»(ref-301512-S25500450742008101700000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-301512-S42770129712008101700000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-301512-S42424648882008101700000) .
2. Pry out the crankshaft rear oil seal using a flat-bladed tool.

1. Using the J 42067 , install a NEW crankshaft real oil seal. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-301512-S42424648882008101700000) .

1. Remove the transaxle. Refer to «Transmission Replacement (2.4L (LAT) W/ME7)»(ref-301483-S22566553722008101700000) and «Transmission Replacement»(ref-301510-S30157785642008101700000) .
2. Have an assistant install the J 38122-A , and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when loosening the flywheel bolts. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. Loosen, remove and discard the flywheel bolts.
4. Remove the flywheel.
5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Position the flywheel to the crankshaft.
2. Install the NEW flywheel bolts until snug.
3. Have an assistant install the J 38122-A , and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when tightening the flywheel bolts. See «Special Tools»(ref-301512-S32698523102008101700000) .
4. Tighten the flywheel bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Remove the J 38122-A and breaker bar. See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Install the transaxle. Refer to «Transmission Replacement (2.4L (LAT) W/ME7)»(ref-301483-S22566553722008101700000) and «Transmission Replacement»(ref-301510-S30157785642008101700000) .

1. Remove the piston and connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement»(ref-301512-S17457309172008101700000) .
2. Inspect the condition of the piston. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection»(ref-301512-S29061842762008101700000) .
3. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
4. Install the EN 45680-852 cylinder bore sleeve puller (1) through the cylinder bore.
5. Align the shoe (1) of the EN 45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2).
6. Hold the threaded shaft of the EN 45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
7. Install the EN 456850-851 fixture (4) onto the threaded shaft of the EN 456850-852 cylinder bore sleeve puller and the engine block.
8. Install the bearing (3) and the nut (1).
9. Tighten the nut (1) to the bearing (3).
10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
11. Rotate the nut clockwise in order to remove the cylinder bore liner.
12. Remove EN 45680-851 fixture, EN 45680-852 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block.
13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.

1. Place the NEW cylinder bore sleeve onto the cylinder block.
2. Install EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
3. Insert the 4 attachment bolts into the legs of the EN 45680-851 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
6. Align the pusher block (2) of EN 45680-853 cylinder bore sleeve installer into the groove of EN 45680-851 fixture (1).
7. Using a ratchet, rotate the threaded shaft of EN 45680-85 fixture and EN 45680-853 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block.
8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
9. Using a torque wrench, tighten the threaded shaft of the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface.
10. Remove the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly (1) from the cylinder block (2).

Scheme 2

1. EN 45680-865 Debris Collector (3)
2. EN 45680-861 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction

Scheme 3

1. Trim Tool Preloader (1)
2. EN 45680-862 Set Gage Ring (2)
3. EN 45680-863 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-864 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the EN 45680-863 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional EN 45680-863 metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the EN 45680-863 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the EN 45680-862 set gage ring (1) should be positioned upward on a flat surface.
6. Carefully position EN 45680-861 trim tool assembly onto the EN 45680-862 set gage ring.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place the EN 45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
11. Install the EN 45680-864 4 bolts into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten the drive adapter EN 45680-866 into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-861 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place the EN 45680-866 drive adapter and the drill assembly vertically onto the EN 45680-861 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove the EN 45680-866 drive adapter (1) and the drill assembly from the EN 45680-861 trim tool assembly.
16. Turn OFF the compressed air valve.
17. Remove the EN 45680-861 trim tool assembly from the engine block.
18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-863 metal shaving catch plug.
19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
20. Using a light, illuminate the backside of the straight edge.
21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary.
24. Install the piston and the connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement»(ref-301512-S17457309172008101700000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027-100)»(ref-301531-S14857657392008101700000) or «Fuel Pressure Relief (Without CH 48027-100)»(ref-301531-S09824082922008101700000) .
2. 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) .
3. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-301531-S42820319642008101700000) .
4. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301531-S18963178012008101700000) .
5. Remove the fuel feed pipe clip (2) from the fuel line bracket.
6. Remove the transaxle shift cable clip (1) from the fuel line bracket.
7. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) .
8. Remove the generator starter. Refer to «Generator with Starter Replacement»(ref-301533-S35996312512008101700000) .
9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.
11. Remove the coolant recovery inlet hose clamp (2) at the cylinder head.
12. Remove the coolant recovery inlet pipe clip from the fuel rail.
13. Remove the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.
14. Reposition the radiator inlet hose clamp using the J 38185 .
15. Remove the radiator inlet hose from the cylinder head.
16. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(ref-301507-S23621310922008101700000) or «Radiator Outlet Hose Replacement (LE5)»(ref-301507-S14537066042008101700000) .
17. Reposition the generator control module coolant hose clamp (1) at the generator control module.
18. Remove the generator control module coolant hose from the generator control module.
19. Disconnect the engine wiring harness electrical connector (1) from the transaxle auxiliary pump module.
20. Reposition the heater inlet hose clamp (1) at the thermostat housing.
21. Remove the heater inlet hose (2) from the thermostat housing.
22. Reposition the coolant recovery reservoir/heater inlet hose (3) clamp at the thermostat housing.
23. Remove the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
24. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
25. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301512-S30148696362008101700000) .
26. Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump.
27. Disconnect the engine wiring harness electrical connector (2) from the air conditioning (A/C) compressor.
28. Remove the generator control module coolant pump bolt (3) and pump (2).
29. Unbolt the A/C compressor and reposition out of the way.
30. Remove the positive battery cable to starter motor nut (4).
31. Remove the positive battery cable lead (1) from the starter motor.
32. Remove the positive battery cable from in between the starter and the engine. Reposition the positive battery cable out of the way.
33. Disconnect the engine wiring harness electrical connector (2) from the auxiliary heater water pump.
34. Remove the auxiliary heater water pump bolt and pump.
35. Lower the vehicle.
36. Remove the transaxle shift cable from the range select lever.
37. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
38. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
39. Raise the vehicle.
40. Remove the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .
41. Remove the front fender liners. Refer to «Front Fender Liner Replacement»(ref-301500-S02566820132008101700000) .
42. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the engine cradle.
43. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the engine cradle.
44. Drain the transaxle fluid.
45. Remove the transaxle oil cooler line to transaxle nut (1).
46. Remove the transaxle oil cooler lines from the transaxle.
47. Remove the catalytic converter. Refer to «Exhaust Manifold Pipe Replacement (LAT)»(ref-301511-S14665565812008101700000) .
48. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.
49. Remove and discard both outer tie rod to steering knuckle nuts.
50. Using the SA91100C , separate the tie rods from the steering knuckles.
51. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.
52. Remove and discard both of the lower control arm ball stud cotter pins.
53. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.
54. Using the J 43828 , separate the lower control arms from the steering knuckles.
55. Remove the ball stud nuts.
56. Remove the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-301528-S25162625692008101700000) .
57. Lower the vehicle.
58. Remove the engine mount to bracket bolts (1).
59. Remove the transaxle mount to transaxle bolts.
60. Raise the vehicle.
61. Position a engine support table under the powertrain assembly.
62. With the table positioned, fully raise the table to contact with the powertrain assembly.
63. Remove the cradle to body bolts. Discard the bolts.
64. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle.
65. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
66. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
67. Remove the engine wiring harness clip (3) from the oil level indicator tube bracket.
68. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
69. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.
70. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
71. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
72. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.
73. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
74. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.
75. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.
76. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
77. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
78. Remove the engine wiring harness clip (5) from the stud.
79. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
80. Gather all branches of the engine wiring harness and reposition the harness out of the way.
81. Remove the starter motor bolts and starter.
82. Remove the torque converter to flexplate bolts (1).
83. Install a suitable lifting devise to the engine.
84. Remove the transaxle bolts from the engine.
85. Separate the engine from the transaxle.
86. Install the engine to a suitable engine stand.

1. Install a suitable lifting devise to the engine.
2. Using the lifting devise, position and install the engine to the transaxle.
3. Install the transaxle bolts to the engine. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
4. Install the torque converter to flexplate bolts (1). Tighten: Tighten the bolts to 60 N.m (44 lb ft).
5. Remove the engine lifting devise.
6. Install the starter motor and bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
7. Gather all branches of the engine wiring harness and position the harness to the engine.
8. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
9. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
10. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
11. Install the engine wiring harness clip (5) to the stud.
12. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.
13. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
14. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.
15. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
16. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
17. Connect the engine wiring harness electrical connector (3) to the knock sensor.
18. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
19. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.
20. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
21. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
22. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.
23. Position the powertrain and support table under the vehicle.
24. Raise the powertrain into position under the vehicle.
25. With the table positioned, if required, lower the vehicle over the powertrain.
26. Align the lower radiator pins with the cradle. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
27. Install the NEW cradle to body bolts. Tighten: Tighten the bolts to 155 N.m (114 lb ft).
28. Lower the vehicle.
29. Install the transaxle mount to transaxle bolts. Tighten: Tighten the bolts to 55 N.m (41 lb ft).
30. Install the engine mount to bracket bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
31. Raise and support the vehicle.
32. Install the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(ref-301528-S25162625692008101700000) .
33. Install the control arm ball studs into the steering knuckles.
34. Install the ball stud nuts Tighten: Tighten the nuts to 40 N.m (30 lb ft).
35. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.
36. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts. Tighten: Tighten the nuts to 65 N.m (48 lb ft).
37. Connect the outer tie rods to the steering knuckles.
38. Use the J 44015 in order to seat the ball stud taper to 40 N.m (30 lb ft).
39. Remove the J 44015 .
40. Install NEW outer tie rod to steering knuckle nuts. Tighten: Tighten the nuts to 25 N.m (48 lb ft) plus 90 degrees.
41. Position the intermediate shaft to the steering gear and install a NEW pinch bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
42. Install the catalytic converter. Refer to «Exhaust Manifold Pipe Replacement (LAT)»(ref-301511-S14665565812008101700000) .
43. Install the transaxle oil cooler lines to the transaxle.
44. Install the transaxle oil cooler line to transaxle nut (1). Tighten: Tighten the nut to 4 N.m (27 lb in).
45. Remove the wood from between the oil pan and the engine cradle.
46. Remove the wood from between the transaxle and the engine cradle.
47. Install the front fender liners. Refer to «Front Fender Liner Replacement»(ref-301500-S02566820132008101700000) .
48. Install the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .
49. Lower the vehicle.
50. Unsecure and position the radiator/condenser/fan assembly.
51. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
52. Install the transaxle shift cable to the range select lever.
53. Raise and support the vehicle.
54. Install the auxiliary heater water pump and bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
55. Connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.
56. Position and install the positive battery cable between the starter and the engine.
57. Install the positive battery cable lead (1) to the starter motor.
58. Install the positive battery cable to starter motor nut (4). Tighten: Tighten the nut to 9 N.m (80 lb in).
59. Position the A/C compressor and install the bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
60. Install the generator control module coolant pump (2) and bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
61. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
62. Connect the engine wiring harness electrical connector (2) to the A/C compressor.
63. Lower the vehicle.
64. Install the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
65. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
66. Install the heater inlet hose (3) to the thermostat housing.
67. Position the heater inlet hose clamp (1) at the thermostat housing.
68. Connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.
69. Install the generator control module coolant hose to the generator control module.
70. Position the generator control module coolant hose clamp (1) at the generator control module.
71. Reposition the radiator inlet hose clamp using the J 38185 .
72. Remove the radiator inlet hose from the cylinder head.
73. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(ref-301507-S23621310922008101700000) or «Radiator Outlet Hose Replacement (LE5)»(ref-301507-S14537066042008101700000) .
74. Position and install the coolant recovery inlet hose (1) to the cylinder head.
75. Install the coolant recovery inlet pipe clip to the fuel rail.
76. Install the coolant recovery inlet hose clamp (2) at the cylinder head.
77. Position and install the vacuum brake booster hose (2) to the intake manifold.
78. Position the vacuum brake booster hose clamp (1) at the intake manifold.
79. Install the generator starter. Refer to «Generator with Starter Replacement»(ref-301533-S35996312512008101700000) .
80. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) .
81. Install the transaxle shift cable clip (1) to the fuel line bracket.
82. Install the fuel feed pipe clip (2) to the fuel line bracket.
83. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301531-S18963178012008101700000) .
84. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-301531-S42820319642008101700000) .
85. 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) .
86. Fill the transaxle with fluid.
87. Refill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301512-S30148696362008101700000) .
88. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-301531-S28039219932008101700000) .
89. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Allow the oil to drain completely.
5. Install the oil pan drain plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
6. Lower the vehicle.
7. Use a 32 mm (1 1/4 in) socket on the hex on top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap.
8. Remove the oil filter cap and filter.
9. Remove the filter from the cap.

1. Install the NEW oil filter to the cap.
2. Install the oil filter cap and filter.
3. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap. Tighten: Tighten the oil filter cap until fully seated. DO NOT exceed 25 N.m (18 lb ft).
4. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(ref-301561-S18551700982008101700000) .

Engine Flywheel Removal

1. Remove the flywheel attaching bolts.
2. Remove the flywheel, if the vehicle has a manual transmission.
3. Remove the flywheel retainer for vehicles with automatic transmission.
4. Remove the flywheel, if the vehicle has an automatic transmission.
5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

1. Remove knock sensor connector from the oil level indicator tube.
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator and the oil level indicator tube from the oil pan.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield.
2. Remove the block heater if equipped.
3. Remove the oxygen sensor.
4. Remove and discard the exhaust manifold to cylinder head retaining nuts.
5. Remove the exhaust manifold.
6. Clean all of the sealing surfaces.
7. If the exhaust manifold is being replaced, transfer the following parts: The exhaust manifold heat shield The oxygen sensor

Intake Manifold Removal

1. Remove the evaporative emission (EVAP) canister valve tube (1).
2. Remove the EVAP canister valve (2).
3. Remove the throttle body bolts.
4. Remove the throttle body.
5. Remove fuel pipes and clip. Remove the fuel rail assembly.
6. Remove the fuel injector tip insulators and discard.
7. Remove the intake manifold retaining nuts and bolts.
8. Remove the intake manifold.
9. Remove the intake manifold gasket, if necessary. The gasket can be used again if it is not damaged.
10. If the intake manifold needs to be replaced, transfer the throttle body to the new intake manifold.

Camshaft Cover Removal

1. Remove the bolt and coil.
2. Remove the camshaft position actuator solenoid valve bolts.
3. Remove the camshaft position actuator solenoid valves.
4. Remove the camshaft cover assembly.

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner bolts.
2. Remove the accessory drive belt tensioner.
3. Remove the drive belt tensioner bracket bolts.
4. Remove the drive belt tensioner bracket.
5. Remove the engine front cover bolts.
6. Remove the long water pump bolt.
7. Remove the engine front cover and gaskets.
8. Remove the crankshaft front cover oil seal with an appropriate tool.

Timing Chain and Tensioner Removal

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide.
3. Remove the timing chain tensioner plunger.
4. Locate hex on the exhaust camshaft and hold with a wrench.
5. Remove the exhaust cam bolt and the exhaust cam actuator. Discard the bolt.
6. Remove the adjustable timing chain guide bolt.
7. Remove the adjustable timing chain guide.
8. Remove the plug to gain access to the fixed timing chain guide bolt.
9. Remove the fixed timing chain guide bolts.
10. Remove the fixed timing chain guide.
11. Locate hex on the intake camshaft and hold with a wrench.
12. Remove the intake cam sprocket bolt, the intake cam sprocket and the timing chain through the top of the cylinder head. Discard the bolt.
13. Remove the crankshaft sprocket.
14. Remove the timing chain oil nozzle bolt.
15. Remove the timing chain oil nozzle.

Intake Camshaft, Bearing Cap, and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the intake camshaft cap bolts.
3. Remove the camshaft caps.
4. Remove the intake camshaft.
5. Remove the intake camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Exhaust Camshaft, Bearing Cap, and Lash Adjuster Removal

1. Mark camshaft caps to ensure they are installed in the same position.
2. Remove the exhaust camshaft cap bolts.
3. Remove the camshaft caps ensuring they are marked and refitted in same position on assembly.
4. Remove the exhaust camshaft.
5. Remove the exhaust camshaft roller finger followers.
6. Remove the hydraulic lash adjusters.

Water Pump and Balance Shaft Chain and Tensioner Removal

1. Remove the balance shaft drive chain tensioner bolts.
2. Remove the balance shaft drive chain tensioner.
3. Remove the adjustable balance shaft chain guide bolt.
4. Remove the adjustable balance shaft chain guide.
5. Remove the small balance shaft drive chain guide bolts.
6. Remove the small balance shaft drive chain guide.
7. Remove the upper balance shaft drive chain guide bolts.
8. Remove the upper balance shaft drive chain guide.
9. Remove the balance shaft drive chain.
10. Remove the balance shaft drive sprocket.

Water Pump Removal

1. Remove the engine coolant temperature sensor.
2. Remove the thermostat and water feed pipe retaining bolts.
3. Remove the thermostat housing and water feed pipe from the water pump cover.
4. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
5. Remove the water pump assembly.

Oil Pan Removal

1. Remove the oil pan bolts.
2. Remove the oil pan at pry points.

Lower Crankcase Removal

1. Remove the crankshaft position sensor.
2. Inspect the crankshaft position sensor for damage and replace, if necessary.
3. Remove the bedplate perimeter bolts.
4. Remove and discard the crankshaft bearing bolts.
5. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase.

Crankshaft and Bearing Removal

1. Remove the crankshaft from the block.
2. Remove the crankshaft rear oil seal from the block.
3. Remove the bearing inserts from the block.
4. Remove the bearing inserts from the bed plate.
5. Clean the oil, sludge, and carbon.
6. Inspect the oil passages for obstructions.
7. Inspect the threads.
8. Inspect the bearing journals and the thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating (discoloration)
9. Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists find the cause and repair it.
10. Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selection of bearing inserts. If not within limits the crankshaft must be replaced. Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

Crankshaft and Bearing Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gage. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

Scheme 4

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure

1. Tighten the bedplate to specification using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
2. Measure the bearing bore for taper and out-of-round using the J 8087 . See «Special Tools»(ref-301512-S32698523102008101700000) .
3. No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2 methods to measure bearing clearance. Method A gives more reliable results and is preferred. Method A yields measurement from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
2. To measure bearing clearance using Method A, use the following procedure: Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements. Measure the crankshaft bearing journal taper and runout. Install the lower crankcase and tighten the bearing cap bolts to specification. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing ID measurement to determine clearance. Determine whether clearance is within specification. If out of specification, choose different inserts. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer.
3. To measure bearing clearance using Method B, use the following procedure: Clean the used bearing inserts. Install the used bearing inserts. Place a piece of gaging plastic across the entire bearing width. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Install the bearing cap bolts to specification. IMPORTANT: Do not rotate the crankshaft. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package. Remove the gaging plastic.

Piston, Connecting Rod, and Bearing Installation

Tools Required

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

1. Install the connecting rod bearings. Use NEW bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. See «Special Tools»(ref-301512-S32698523102008101700000) . This protects the crankshaft journal during piston and connecting rod installation.
3. Install EN-47836 , piston, and the connecting rod to the correct bore. See «Special Tools»(ref-301512-S32698523102008101700000) . Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the EN-47836 against the engine block until all the rings have entered the cylinder bore. See «Special Tools»(ref-301512-S32698523102008101700000) . Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use new bolts. Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.07-0.37 mm (0.0027-0.0145 in).

Intake Camshaft, Bearing Cap, and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM P/N 1234550 (Canadian P/N 992704) or equivalent.
3. Lubricate the valve tips.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Set the intake camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
6. Install the camshaft caps and hand start the camshaft cap bolts.
7. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

Exhaust Camshaft, Bearing Cap, and Lash Adjuster Installation

1. Install the hydraulic lash adjusters into their bores in the cylinder head. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Lubricate the valve tips with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Position the roller followers on the tip of the valve stem and on the lash adjuster. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
4. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the camshaft caps and hand start the camshaft cap bolts.
6. Tighten the camshaft cap bolts in increments of 3 turns until they are seated, lubricate. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).

Water Pump Installation

Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1. Install the water pump assembly.
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
5. Install the water pump drain plug, if necessary. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
6. Install the water feed tube.
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing to block bolts and stud. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the engine coolant temperature sensor by hand.
11. Tighten the engine coolant temperature sensor. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

Water Pump and Balance Shaft Chain and Tensioner Installation

1. Install the upper balance shaft chain guide and bolts. Tighten: Tighten the upper balance shaft chain guide bolts to 15 N.m (11 lb ft).
2. Install the small balance shaft chain guide.
3. Install the balance shaft chain guide bolts. Tighten: Tighten the chain guide bolts to 15 N.m (11 lb ft).
4. Install the adjustable balance shaft drive chain guide.
5. Install the adjustable balance shaft drive chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
6. Reset the timing chain tensioner by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts. Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Camshaft Timing Chain, Sprocket, and Tensioner Installation

Tools Required

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

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
3. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
4. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
5. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
6. Hand tighten the new intake camshaft actuator bolt.
7. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
8. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
9. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
10. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
11. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
12. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
13. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
14. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
15. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
16. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
17. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
18. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
19. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
20. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
21. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
22. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
23. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .
24. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
25. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
26. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

Engine Front Cover and Oil Pump Installation

1. Install the engine front cover with a new gasket.
2. Install the long water pump bolt. Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).
3. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
4. Install the drive belt tensioner bracket.
5. Install the drive belt tensioner bracket bolts. Tighten: Tighten the drive belt tensioner bracket bolts to 45 N.m (33 lb ft).
6. Install the accessory drive belt tensioner.
7. Install the accessory drive belt tensioner bolt. Tighten: Tighten the bolt to 45 N.m (33 lb ft).

Camshaft Cover Installation

1. Assemble the camshaft cover and gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
2. Install the cover on the cylinder head and hand start the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install the front lift bracket.
4. Install the front lift bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the rear lift bracket.
6. Install the rear lift bracket bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
8. Install the ignition coil. Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
9. Install the camshaft position actuator solenoid valves.
10. Install the camshaft position actuator solenoid valve bolts.

Oil Pan Installation

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 3.5 mm bead of GM P/N 12378521 (Canadian P/N 88901148) or equivalent around the perimeter of the oil pan and the oil suction port opening.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

Crankshaft Balancer Installation

Tools Required

1. EN-48585 Crankshaft Balancer Guide
2. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-301512-S32698523102008101700000) .

1. Install a new friction washer.
2. Install the EN-48585 into the end of the crankshaft.
3. Install the balancer onto the EN-48585 . Use care to properly align the keyway and flats on the balancer with the oil pump drive.
4. Install the J 38122-A . See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar to prevent the crankshaft from rotating when tightening the bolt. See «Special Tools»(ref-301512-S32698523102008101700000) . Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 5 N.m (44 lb in).
2. Install a new intake manifold gasket on the intake manifold.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate the fuel injector tip insulators with engine oil.
6. Install new fuel injector tip insulators.
7. Lubricate the fuel injector oil rings with engine oil.
8. Install the fuel rail assembly.
9. Install the fuel rail stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
10. Install a new throttle body gasket.
11. Install the throttle body.
12. Install the throttle body bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
13. Install the EVAP canister valve (2). Tighten: Tighten the EVAP canister valve to 22 N.m (16 lb ft).
14. Install the EVAP canister valve tube (1).

Exhaust Manifold Installation

1. Install new exhaust manifold studs. Tighten: Tighten the studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten: Tighten the nuts a second time to 14 N.m (124 lb in).
6. Coat the threads of the oxygen sensor with antiseize P/N 12397953 or equivalent.
7. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 42 N.m (31 lb ft).
8. Install the exhaust manifold heat shield.
9. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).

Oil Level Indicator and Tube Installation

1. Lubricate the oil level indicator tube O-ring with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the oil level indicator and the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the intake manifold bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the electrical wiring harness to the oil level indicator tube.
5. Install the knock sensor wiring clip into the oil level indicator tube.

Engine Flywheel Installation

Tools Required

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

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft balancer with J 38122-A , tighten the bolts evenly. See «Special Tools»(ref-301512-S32698523102008101700000) . Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 . See «Special Tools»(ref-301512-S32698523102008101700000) .