Engine Mechanical - 3.5L: 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. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301532-S34449277472008101700000) .
2. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-301513-S10500297292008101700000) .
3. Install a breaker bar to the drive belt tensioner.
4. Rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.

1. Install a breaker bar to the drive belt tensioner.
2. Rotate the drive belt tensioner counterclockwise to release the spring tension.
3. Route and install the drive belt.
4. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(ref-301513-S10500297292008101700000) .
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301532-S34449277472008101700000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .
2. Loosen the appropriate drive belt idler pulley bolt (1, 2).
3. Remove the appropriate drive belt idler pulley.

1. Install the appropriate drive belt idler pulley.
2. Tighten the appropriate drive belt idler pulley bolt (1,2). Tighten: Tighten the bolt (1) to 50 N.m (37 lb ft). Tighten the bolt (2) to 30 N.m (22 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .

Installation

1. Raise the hood.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .
3. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
4. Install the thread support nuts J 28467-33A onto the strut attaching studs.
5. Install the strut tower support assemblies J 28467-5A over the thread support nuts J 28467-33A.
6. Install the T-bolts J 28467-5 with 5/16 inch washers through the strut tower support assemblies J 28467-5A into the thread support nuts J 28467-33A. Hand tighten the bolts.
7. Install the 2 cross bracket assemblies J 28467-1A over the strut tower tube J 28467-3.
8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
9. Install the 1/2 inch x 2.5 inch quick release pin J 28467-10 through the strut tower support assemblies J 28467-5A and the strut tower tube J 28467-3 on one side only.
10. Install the radiator shelf tube J 28467-2A through the driver side cross bracket assembly J 28467-1A on the top of the strut tower tube J 28467-3.
11. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
12. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
13. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
14. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
15. Install the assembled lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
16. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket.
17. Hand tighten the driver side cross bracket assembly J 28467-1A wing nuts.
18. Install the second radiator shelf tube J 28467-2A through the passenger side cross bracket assembly (J 28467-1A) on the top of the strut tower tube J 28467-3.
19. Place the rubber padded foot of the front support assembly J 28467-4A on the vehicle radiator shelf. The foot position used in the front support assembly J 28467-4A depends on the vehicle application.
20. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. The hole used in the front support assembly J 28467-4A depends on the vehicle application.
21. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
22. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
23. Install the assemblage lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
24. Adjust the radiator shelf tube J 28467-2A and the assemblage lift hook bracket J 28467-6A in order to align the hook with the right rear and front of engine.
25. Install the J 36857lift hook bracket (1).
26. Hand tighten the passenger side cross bracket assembly J 28467-1A wing nuts.
27. Hand tighten the lift hook wing nuts J 28467-34 securely in order to remove all slack from the engine support fixture assembly.

1. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .
2. Remove the engine splash shield. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
3. Remove the engine mount to fame nuts.
4. Remove the engine mount to engine mount bracket nuts (1).
5. Using a suitable jackstand, raise the engine.
6. Remove the engine mount.

1. Position the motor mount onto the frame.
2. Use the jackstand to lower the engine mount bracket on to the engine mount.
3. Install the engine mount to engine mount bracket nuts (1). Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Install the engine splash shield. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-301513-S38167725912008101700000) .
2. Remove the engine mount bracket bolts (1, 3) from the engine.
3. Remove the engine mount bracket (2).

1. Position the engine mount bracket to the engine.
2. Loosely install the engine mount bracket bolts.
3. Hold the engine mount bracket firmly to the front of the engine and snug the oil pan bolts (3) so that the bracket is just seated to the oil pan.
4. Tighten the engine mount bracket to engine bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
5. Tighten the engine mount bracket to oil pan bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
6. Install the engine mount. Refer to «Engine Mount Replacement»(ref-301513-S38167725912008101700000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301532-S34449277472008101700000) .
2. Remove the engine mount strut to engine mount strut bracket bolts (1).
3. Rotate the engine mount strut (2) to the vertical position in order to access the lower bolt.
4. Remove the engine mount strut bolt (1).
5. Remove the engine mount strut.

1. Install the engine mount strut (2) in to the engine compartment side rail. Ensure that the tab on the strut is inserted into the hole in the side rail.
2. Install the engine mount strut bolt (1). Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Rotate the engine mount strut to the horizontal position.
4. Install the engine mount strut to engine mount strut bracket bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301532-S34449277472008101700000) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(ref-301513-S14766557742008101700000) .
2. Remove the engine mount strut bracket to engine bolts.
3. Remove the engine mount strut bracket.

1. Position the engine mount strut bracket to the engine. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
2. Install the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(ref-301513-S14766557742008101700000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
2. Remove the oil filter adapter heat shield nuts.
3. Remove the oil filter adapter heat shield (2).
4. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
5. Remove the oil filter.
6. Remove the oil filter adapter bolts and stud.
7. Remove the oil filter adapter and gasket.
8. Insert a flat bladed tool into the oil filter bypass hole and remove the oil filter bypass valve.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Install the oil filter bypass valve. Seat the valve fully below the bypass valve hole chamfer.
2. Position the oil filter adapter and gasket to the engine.
3. Apply threadlock to the bolt/stud threads, if required. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Install the oil filter adapter bolts and stud. Tighten: Tighten the bolts/stud to 25 N.m (18 lb ft).
5. Install the oil filter.
6. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
7. Install the oil filter adapter heat shield (2).
8. Install the oil filter adapter heat shield nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
9. Lower the vehicle.
10. Check and fill the crankcase, if necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the heated oxygen sensor (HO2S) electrical connector (3) clip from the indicator tube tab.
3. Remove the oil level indicator.
4. Remove the oil level indicator tube bracket bolt.
5. Remove the oil level indicator tube.
6. Inspect the oil level indicator tube O-ring seal for damage, replace as necessary.

1. Lubricate the oil level indicator tube O-ring seal with clean engine oil.
2. Install the oil level indicator tube into the engine block.
3. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the oil level indicator.
5. Install the HO2S electrical connector (3) to from the indicator tube tab.
6. Install the spark plug wire to the number 6 cylinder spark plug.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
2. Disconnect the fuel feed pipe quick connect fitting (3) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-301532-S00470716272008101700000) .
3. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (2) from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
4. Remove the fuel line clip (1) from the manifold absolute pressure (MAP) sensor bracket.
5. Reposition the fuel/EVAP lines out of the way.
6. 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) .
7. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
8. Remove the positive crankcase ventilation (PCV) fresh air tube from the rocker cover.
9. Remove the PCV foul air tube quick connect fitting from the rocker cover. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
10. Remove the PCV foul air tube from the intake manifold.
11. Reposition the brake booster vacuum hose clamp (2) at the intake manifold.
12. Remove the brake booster vacuum hose (1) from the intake manifold.
13. Reposition the radiator surge tank inlet hose clamp (1).
14. Remove the radiator surge tank inlet hose from the inlet pipe.
15. Remove the radiator surge tank inlet pipe bolts (2).
16. Remove the radiator surge tank inlet pipe.
17. Remove and discard the O-ring seal (1).
18. Disconnect the engine wiring harness electrical connector (1) from the MAP sensor.
19. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
20. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
21. Disconnect the left side spark plug wires from the spark plugs.
22. Disconnect the left side spark plug wires from the ignition coil.
23. Disengage the spark plug wire retainer clips from the heater inlet and outlet pipe bracket and the MAP sensor bracket.
24. Remove the left side spark plug wires.
25. Remove the heater inlet and outlet pipe nuts (1) from the throttle body studs.
26. Reposition the heater inlet and outlet hose clamps (2) from the pipes.
27. Remove the heater inlet and outlet hoses from the heater inlet and outlet pipes.
28. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the inlet and outlet pipe out of the way.
29. Remove the ignition coil bracket bolts (1).
30. Remove the generator rear brace upper nut (1).
31. Remove the generator through bolt (3).
32. Remove the generator rear brace (2).
33. Remove the upper intake manifold bolts (1, 2) and stud (3).
34. Separate and remove the upper intake manifold from the lower intake manifold.
35. Remove the upper to lower intake manifold gaskets.
36. If replacing the upper intake manifold, perform the following steps otherwise proceed to step 8 in the Installation Procedure.
37. Remove the EVAP canister purge solenoid valve bolt (1), valve (2).
38. Remove and discard the EVAP canister purge solenoid O-ring seal (3).
39. Remove the intake manifold cover ball stud (4).
40. Remove the MAP sensor bracket (5) and MAP sensor (6).
41. Remove the throttle body bolts (9) and nuts (10).
42. Remove the throttle body (8) and throttle body O-ring seal (7).

1. If replacing the upper intake manifold, perform the following steps otherwise proceed to step 8.
2. Install a NEW throttle body O-ring seal (7) into the groove on the throttle body and install the throttle body (8).
3. Install the throttle body bolts (9) and nuts (10). Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
4. Lubricate the MAP sensor seal and install the MAP sensor (6), place the bracket (5) into position.
5. Install the intake manifold cover ball stud (4). Tighten: Tighten the ball stud to 10 N.m (89 lb in).
6. Lubricate and install a NEW EVAP canister purge solenoid O-ring seal (3) onto the solenoid.
7. Install the EVAP canister purge solenoid valve (2) and bolt (1). Tighten: Tighten the bolt to 12 N.m (106 lb in).
8. Install the NEW upper to lower intake manifold gaskets.
9. Set the upper intake manifold onto the lower intake manifold.
10. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
11. Install the upper intake manifold bolts (1, 2) and stud (3). Tighten: Tighten the bolts/stud to 25 N.m (18 lb ft).
12. Place the generator rear brace (2) onto the stud.
13. Install the generator through bolt (3) until snug.
14. Install the generator rear brace upper nut (1) until snug. Tighten: Tighten the generator through bolt to 50 N.m (37 lb ft). Tighten the generator rear brace upper nut to 25 N.m (18 lb ft).
15. Install the ignition coil bracket bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
16. Position the inlet and outlet pipe and install the heater inlet and outlet pipe bracket to the throttle body studs.
17. Install the heater inlet and outlet hoses to the heater inlet and outlet pipes.
18. Position the heater inlet and outlet hose clamps (2) to the pipes.
19. Install the heater inlet and outlet pipe nuts (1) to the throttle body studs. Tighten: Tighten the nuts to 10 N.m (89 lb in).
20. Install the left side spark plug wires.
21. Connect the left side spark plug wires to the spark plugs.
22. Connect the left side spark plug wires to the ignition coil.
23. Engage the spark plug wire retainer clips to the heater inlet and outlet pipe bracket and the MAP sensor bracket.
24. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
25. Connect the engine wiring harness electrical connector (2) to the ETC.
26. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
27. Install a NEW O-ring seal (1) to the inlet pipe.
28. Install the radiator surge tank inlet pipe.
29. Install the radiator surge tank inlet pipe bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
30. Install the radiator surge tank inlet hose to the inlet pipe.
31. Position the radiator surge tank inlet hose clamp (1).
32. Install the brake booster vacuum hose (1) to the intake manifold.
33. Position the brake booster vacuum hose clamp (2) at the intake manifold.
34. Install the PCV foul air tube to the intake manifold.
35. Install the PCV foul air tube quick connect fitting to the rocker cover. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
36. Install the PCV fresh air tube to the rocker cover.
37. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
38. 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) .
39. Position the fuel/EVAP lines.
40. Install the fuel line clip (1) to the MAP sensor bracket.
41. Connect the fuel feed pipe quick connect fitting (3) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-301532-S00470716272008101700000) .
42. Connect the EVAP pipe quick connect fitting (2) to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
43. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
44. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .

1. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(ref-301513-S37153713632008101700000) .
2. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-301513-S20526923152008101700000) and «Valve Rocker Arm Cover Replacement - Right Side»(ref-301513-S04523699782008101700000) .
3. Remove the coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(ref-301507-S28195212112008101700000) .
4. Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
5. Disconnect the engine wiring harness electrical connector (2) from the fuel injector inline electrical connector.
6. Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
7. Remove the fuel injector wiring harness connector bracket bolt from the intake manifold.
8. Remove the fuel rail bolts and rail (1).
9. Remove the lower intake manifold bolts.
10. Remove the lower intake manifold.
11. Loosen the rocker arm bolts.
12. Remove the rocker arms.
13. Remove the push rods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).
14. Remove the lower intake manifold gaskets and seals.
15. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
16. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
17. Remove all the loose room temperature vulcanizing (RTV) sealer.

1. Install the lower intake manifold gaskets and seals.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Install push rods in their original location. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with green stripes.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the rocker arms in their original locations.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (0.31-0.39 in) of RTV sealer to the 4 corners of the intake manifold to block joints (1). Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
8. Install the lower intake manifold.
9. Apply sealer to the lower intake manifold bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
10. Install the lower intake manifold bolts.
11. Tighten the lower intake manifold bolts in the sequence shown. Tighten: Tighten the bolts (1, 2, 3, 4) in sequence to 16 N.m (12 lb ft). Tighten the bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft).
12. Inspect the fuel rail, fuel injectors for damage and replace as necessary.
13. Lubricate and install NEW injector lower O-rings seals onto the injectors. Lubricate the NEW O-rings seals with GM P/N 12345616 (Canadian P/N 993182).
14. Install the injector nozzles into the lower intake manifold injector bores.
15. Press on the injector rail using the palms of both hands until the injectors are fully seated.
16. Install the fuel injector rail bolts. Tighten: Tighten the bolts to 14 N.m (10 lb ft).
17. Position the fuel injector wiring harness electrical connector bracket to the intake manifold and install the bolt. Tighten: Tighten the bolt to 14 N.m (10 lb ft).
18. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
19. Connect the engine wiring harness electrical connector (2) to the fuel injector inline electrical connector.
20. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
21. Install the coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(ref-301507-S28195212112008101700000) .
22. Install the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-301513-S20526923152008101700000) and «Valve Rocker Arm Cover Replacement - Right Side»(ref-301513-S04523699782008101700000) .
23. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(ref-301513-S37153713632008101700000) .

1. Partially 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 intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
4. Disconnect the left side spark plug wires from the spark plugs.
5. Disengage the spark plug wire retainer clips from the heater inlet and outlet pipe bracket and the MAP sensor bracket.
6. Remove the heater inlet and outlet pipe. Refer to «Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement»(ref-301492-S06965465822008101700000) .
7. Disconnect the positive crankcase ventilation (PCV) foul air tube quick connect fitting from the PCV fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
8. Loosen the rocker arm cover bolts.
9. Remove the rocker arm cover (2). If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
10. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head, and rocker cover meet with a suitable tool.
11. Remove the rocker arm cover gasket.

1. All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian 10953463) or equivalent to clean the surfaces.
2. Install the rocker arm cover gasket into the rocker arm cover.
3. Apply sealer to the surfaces where the cylinder head and the intake manifold meet (1). Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Place the rocker arm cover (2) onto the cylinder head.
5. Tighten the rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Connect the PCV foul air tube quick connect fitting to the PCV fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
7. Install the heater inlet and outlet pipe. Refer to «Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement»(ref-301492-S06965465822008101700000) .
8. Engage the spark plug wire retainer clips to the heater inlet and outlet pipe bracket and the MAP sensor bracket.
9. Connect the left side spark plug wires to the spark plugs.
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
12. 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 generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) .
2. Remove the engine coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(ref-301507-S28195212112008101700000) .
3. Disconnect the positive crankcase ventilation (PCV) fresh air tube (1) from the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
4. Remove the PCV fresh air tube from the right rocker arm cover.
5. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
6. Disconnect the engine wiring harness electrical connector (2) from the fuel injector wiring harness electrical connector.
7. Remove the ignition coil assembly. Refer to «Ignition Coil Replacement»(ref-301532-S26548622882008101700000)
8. Loosen the rocker arm cover bolts.
9. Remove the rocker arm cover (2). If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
10. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head, and rocker cover meet with a suitable tool.
11. Remove the rocker arm cover gasket.

1. All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean the surfaces.
2. Install the rocker arm cover gasket into the rocker arm cover.
3. Apply sealer to the surfaces where the cylinder head and the intake manifold meet (1). Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Place the rocker arm cover (2) onto the cylinder head.
5. Tighten the rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the ignition coil assembly. Refer to «Ignition Coil Replacement»(ref-301532-S26548622882008101700000) .
7. Connect the engine wiring harness electrical connector (2) to the fuel injector wiring harness electrical connector.
8. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
9. Install the PCV fresh air tube to the right rocker arm cover.
10. Connect the PCV fresh air tube (1) to the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-301532-S15900271342008101700000) .
11. Install the engine coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(ref-301507-S28195212112008101700000) .
12. Install the generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) .

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-301513-S20526923152008101700000) or «Valve Rocker Arm Cover Replacement - Right Side»(ref-301513-S04523699782008101700000) .
2. Remove the rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).

1. Coat the ends of the pushrods using prelube. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Install the pushrods. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with green stripes.
3. Ensure that the pushrods seat in the lifter bore.
4. Coat the rocker arm friction surfaces using prelube. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
5. Install the rocker arms.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 32 N.m (24 lb ft).
7. Install the valve rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(ref-301513-S20526923152008101700000) or «Valve Rocker Arm Cover Replacement - Right Side»(ref-301513-S04523699782008101700000) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
3. Install the J 22794 into the spark plug port. See «Special Tools»(ref-301513-S24222073032008101700000) . Apply compressed air in order to hold the valve in place.
4. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(ref-301513-S24222073032008101700000) .
5. Remove the valve spring cap keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Remove the valve stem oil seal.

1. Lubricate the valve stem with clean engine oil.
2. Install the valve stem oil seal, ensuring the proper seals (intake - black seal and exhaust - brown seal), are installed.
3. Install the valve spring.
4. Install the valve cap.
5. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(ref-301513-S24222073032008101700000) .
6. Install the valve cap keys. If necessary, use grease in order to hold the valve cap keys in place.
7. Ensure the valve cap keys are seated.
8. Remove the compressed air and remove the J 22794 from the spark plug port. See «Special Tools»(ref-301513-S24222073032008101700000) .
9. Install the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .

1. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
3. Remove the valve lifter guide bolts.
4. Remove the valve lifter guides.
5. Remove the valve lifters.

1. Coat the valve lifters with prelube. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Install the valve lifters.
3. Apply threadlock to the valve lifter guide bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Install the valve lifter guides and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
6. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .

Note. The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .
3. Remove the right engine splash shield. Refer to «Radiator Air Side Baffle and Deflector Replacement»(ref-301507-S23838148402008101700000) .
4. Install adjustable jack stands under the frame.
5. Loosen the left frame bolts and remove the right side frame bolts.
6. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
7. Remove the torque converter covers.
8. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(ref-301513-S24222073032008101700000) .
9. Remove the crankshaft balancer bolt and the washer.
10. Remove the crankshaft balancer using the J 41816 and EN 46359 . See «Special Tools»(ref-301513-S24222073032008101700000) .

1. Apply sealant to the keyway of the crankshaft balancer. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Thread the J 29113 into the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
4. Rotate the hex nut on the J 29113 in order to install the crankshaft balancer onto the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
5. Remove the J 29113 from the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
6. Install the crankshaft balancer washer and the bolt.
7. Install the used crankshaft balancer bolt. Tighten: Tighten the used crankshaft balancer bolt to 125 N.m (92 lb ft).
8. Remove the used crankshaft balancer bolt.
9. Install the NEW crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 125 N.m (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059 .
10. Remove the J 37096 from the flywheel. See «Special Tools»(ref-301513-S24222073032008101700000) .
11. Install the torque converter covers.
12. Raise the frame to the original position.
13. Install and tighten the right and left side frame bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft) plus an additional 90 degrees using the J 45059 .
14. Install the right engine splash shield. Refer to «Radiator Air Side Baffle and Deflector Replacement»(ref-301507-S23838148402008101700000) .
15. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-301506-S12164306992008101700000) .
16. Lower the vehicle.
17. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-301513-S13537661392008101700000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
4. Place a suitable drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug and drain the engine oil from the crankcase.
6. Reinstall the oil pan drain plug until snug.
7. Remove the starter. Refer to «Starter Motor Replacement (LZ4)»(ref-301498-S25208722742008101700000) .
8. Remove the oil filter adapter. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(ref-301513-S23192926532008101700000) .
9. Remove the air conditioning (A/C) compressor bolts/nut and position the compressor aside.
10. Remove the engine mount bracket bolts and bracket.
11. Remove the transaxle brace bolts (5 and 6) and remove the brace (7).
12. Remove the transaxle to oil pan brace bolts and brace.
13. Remove the flexplate to torque converter bolts.
14. Lower the vehicle.
15. Remove the engine harness ground nut (3) from the transaxle stud.
16. Remove the engine wiring harness ground (2) and the negative battery cable ground (1) from the transaxle stud.
17. Remove the engine wiring harness clip nut (5) from the transaxle stud.
18. Remove the engine wiring harness clip (6) from the transaxle stud.
19. Remove the engine wiring harness clips (2, 3) from the oil pan.
20. Loosen, DO NOT REMOVE the transaxle studs and bolts.
21. Using the engine support fixture, raise the engine and transaxle slightly.
22. Raise and support the vehicle.
23. Remove the oil pan bolts (1 and 2).
24. Separate the engine and transaxle approximately 13 mm (1/2 inch).
25. Ensure that when removing the oil pan, the pan clears the boss (1) on the transaxle.
26. Remove the oil pan, if the oil pan cannot be removed, lower the vehicle and perform steps 21 and 23 again until the pan can be removed.
27. Remove and discard the oil pan gasket.
28. Clean the oil pan sealing surfaces.

1. Apply sealer to both sides of the front cover/block mating area. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Apply sealer to both sides of the crankcase rear main bearing cap. Press the sealer into the gap using a putty knife. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
3. Install a NEW oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts (1 and 2). Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolts (2) to 25 N.m (18 lb ft).
6. Lower the vehicle.
7. Using the engine support fixture, lower the engine and transaxle.
8. Tighten the transaxle studs and bolts. Tighten: Tighten the bolts/studs to 75 N.m (55 lb ft).
9. Install the engine wiring harness clips (2, 3) to the oil pan.
10. Install the engine wiring harness clip (6) to the transaxle stud.
11. Install the engine wiring harness clip nut (5) to the transaxle stud. Tighten: Tighten the nut to 25 N.m (18 lb ft).
12. Install the negative battery cable ground (1) and the engine wiring harness ground (2) to the transaxle stud.
13. Install the engine harness ground nut (3) to the transaxle stud. Tighten: Tighten the nut to 25 N.m (18 lb ft).
14. Raise and support the vehicle.
15. Install the flexplate to torque converter bolts. Tighten: Tighten the bolts to 62 N.m (46 lb ft).
16. Position the transaxle to oil pan brace and install the bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
17. Position the transaxle brace (7) to the transaxle and install the bolts (5 and 6) until snug.
18. Install the engine wiring harness clip to the rear of the transaxle brace.
19. Position the engine mount bracket to the engine and install the bolts until snug.
20. Tighten the engine mount bracket bolts and transaxle brace bolts. Tighten: Tighten the engine mount bracket upper bolt to 90 N.m (66 lb ft). Tighten the engine mount bracket lower bolts to 50 N.m (37 lb ft). Tighten the transaxle brace bolts to 72 N.m (53 lb ft).
21. Position the A/C compressor and install the bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
22. Install the oil filter adapter. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(ref-301513-S23192926532008101700000) .
23. Install the starter. Refer to «Starter Motor Replacement (LZ4)»(ref-301498-S25208722742008101700000) .
24. Ensure that the oil pan drain plug is tighten. Tighten: Tighten the drain plug to 26 N.m (19 lb ft).
25. Lower the vehicle.
26. Remove the engine support fixture.
27. Fill the crankcase with oil.
28. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .
29. Start the vehicle and inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
2. Remove the oil pressure sensor heat shield bolts and shield.
3. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
4. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 16 N.m (12 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
3. Install the oil pressure sensor heat shield and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Lower the vehicle.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-301513-S19469343582008101700000) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.

1. Install the oil pump drive shaft and the oil pump.
2. Install the oil pump bolt. Tighten: Tighten the bolt to 41 N.m (30 lb ft).
3. Install the oil pan. Refer to «Oil Pan Replacement»(ref-301513-S19469343582008101700000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000)
3. Remove the oil pump drive bolt.
4. Remove the oil pump drive.

1. Coat the drive gear on the oil pump drive with prelube. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Install the oil pump drive.
3. Install the oil pump drive bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301513-S30376090032008101700000) .
2. Remove the crankshaft key from the keyway.
3. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

1. Lubricate the NEW oil seal with clean engine oil.
2. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
3. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(ref-301513-S24222073032008101700000) .
4. Install the crankshaft key into the keyway.
5. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301513-S30376090032008101700000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
2. Remove the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement»(ref-301513-S14766557742008101700000) .
3. Disconnect the engine wiring harness electrical connector (2) from the camshaft position actuator magnet.
4. Remove the camshaft position actuator magnet bolts.
5. Remove the camshaft position actuator magnet and O-ring seal.

1. Install the camshaft position actuator magnet O-ring seal and magnet.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (2) to the camshaft position actuator magnet.
4. Install the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement»(ref-301513-S14766557742008101700000) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .

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 drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-301513-S41249848712008101700000) .
3. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-301513-S19469343582008101700000) .
4. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301513-S30376090032008101700000) .
5. Remove the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-301513-S41456553142008101700000) .
6. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LZ4)»(ref-301507-S09942977082008101700000) .
7. Remove the water pump. Refer to «Water Pump Replacement (LZ4)»(ref-301507-S15360534232008101700000) .
8. Remove the engine front cover bolts (1).
9. Remove the engine front cover.
10. Remove the engine front cover gasket.

1. Install the engine front cover gasket.
2. Install the engine front cover.
3. Apply sealant to the bolts in the locations pointed out (1) in the graphic. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Install the water pump. Refer to «Water Pump Replacement (LZ4)»(ref-301507-S15360534232008101700000) .
6. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LZ4)»(ref-301507-S09942977082008101700000) .
7. Install the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(ref-301513-S41456553142008101700000) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-301513-S30376090032008101700000) .
9. Install the oil pan. Refer to «Oil Pan Replacement»(ref-301513-S19469343582008101700000) .
10. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-301513-S41249848712008101700000) .
11. 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 engine front cover. Refer to «Engine Front Cover Replacement»(ref-301513-S27396160782008101700000) .
2. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
3. Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3).
4. Remove the camshaft position actuator bolts.
5. Remove the timing chain, camshaft position actuator, and crankshaft sprockets.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.
8. Remove the crankshaft sprocket.
9. Remove the timing chain dampener bolts.
10. Remove the timing chain dampener.
11. Remove and discard the camshaft position actuator filter (1) from the end of the camshaft.

1. Install a NEW the camshaft position actuator filter (1) to the end of the camshaft.
2. Install the crankshaft sprocket.
3. Apply prelube to the crankshaft sprocket thrust surface. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
4. Install the timing chain tensioner.
5. Install the timing chain tensioner bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
6. Using the EN-47719 , fully collapse the tensioner, and place he tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-301513-S24222073032008101700000) .
7. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
8. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
9. Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3).
10. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
11. Install the camshaft position actuator bolts.
12. Draw the camshaft actuator onto the camshaft using the bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
13. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
14. Coat the crankshaft and camshaft sprockets with clean engine oil.
15. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-301513-S27396160782008101700000) .

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301513-S15716934472008101700000) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .
4. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (LZ4)»(ref-301511-S33533898962008101700000) .
6. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301513-S42222429712008101700000) .
7. Remove the left spark plugs. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder head locator dowel pins, if necessary.
12. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-301513-S37397965412008101700000) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head and bolts.
5. Install the NEW small hex cylinder head bolts (5 and 8).
6. Install the NEW large hex cylinder head bolts (1, 2, 3, 4, 6 and 7). Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 140 degrees using the J 45059 .
7. Install the left spark plugs. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .
8. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-301513-S42222429712008101700000) .
9. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (LZ4)»(ref-301511-S33533898962008101700000) .
10. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
11. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .
12. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301513-S15716934472008101700000) .
13. Inspect for leaks.

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301513-S15716934472008101700000) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .
4. Remove the valve rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LZ4)»(ref-301511-S06548359282008101700000) .
6. Remove the right spark plugs. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .
7. Remove the generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder locator dowel pins, if necessary.
12. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(ref-301513-S37397965412008101700000) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head and bolts.
5. Install the NEW small hex cylinder head bolts (5 and 8).
6. Install the NEW large hex cylinder head bolts (1, 2, 3, 4, 6 and 7). Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 140 degrees using the J 45059 .
7. Install the generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) .
8. Install the right spark plugs. Refer to «Spark Plug Replacement»(ref-301532-S40080333592008101700000) .
9. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LZ4)»(ref-301511-S06548359282008101700000) .
10. Install the valve rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(ref-301513-S03188972242008101700000) .
11. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(ref-301513-S31825151912008101700000) .
12. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301513-S15716934472008101700000) .
13. Inspect for leaks.

1. Remove the automatic transaxle. Refer to «Transmission Replacement (3.5L (LZ4) W/MN5)»(ref-301483-S04988576292008101700000) .
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-301513-S24222073032008101700000) .
3. Loosen the flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Position the flywheel to the crankshaft.
2. Install the flywheel bolts finger tight.
3. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(ref-301513-S24222073032008101700000) .
4. Install the engine flywheel bolts. Tighten: Tighten the bolts to 70 N.m (52 lb ft).
5. Install the automatic transaxle. Refer to «Transmission Replacement (3.5L (LZ4) W/MN5)»(ref-301483-S04988576292008101700000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
2. Remove the crankshaft rear main oil seal. Refer to «Crankshaft Rear Oil Seal Removal»(ref-301513-S07543725862008101700000) .

1. Install the rear main seal. Refer to «Crankshaft Rear Oil Seal Installation»(ref-301513-S06682949612008101700000) .
2. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer. Refer to «Sealers, Adhesives, and Lubricants»(ref-301513-S21287040512008101700000) .
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .
2. Remove the intake manifold cover. Refer to «Fuel Injector Sight Shield Replacement»(ref-301505-S03191417602008101700000) .
3. 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) .
4. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301560-S02807742292008101700000) .
5. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301503-S06572343432008101700000) .
6. Remove the hood. Refer to «Hood Replacement»(ref-301493-S09192208852008101700000) .
7. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement - Right Side»(ref-301505-S14839397312008101700000) .
8. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301505-S42749017972008101700000) .
9. Disconnect the front knock sensor (KS) (1).
10. Disconnect the rear knock sensor (KS) (2).
11. Disconnect the camshaft position (CMP) sensor (4, 5), crankshaft position (CKP) sensor and the oil control valves.
12. Disconnect the manifold absolute pressure (MAP) sensor (1).
13. Disconnect the evaporative emission (EVAP) canister purge solenoid (2).
14. Disconnect the front and rear ignition coils (2).
15. Disconnect the A/C compressor (1).
16. Disconnect the coolant temperature sensor (1).
17. Disconnect the following electrical connectors: The heated oxygen sensor (HO2S) The exhaust gas recirculation (EGR) valve The electronic throttle control The body wiring harness-to-engine harness
18. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
19. Remove the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (LZ4)»(ref-301511-S18521475702008101700000) and «Catalytic Converter Replacement - Right Side (LZ4)»(ref-301511-S11465940882008101700000) .
20. Remove the engine wiring harness grounds from the transaxle.
21. Remove the engine mount lower bolts (2).
22. Remove the torque converter covers.
23. Remove the starter motor. Refer to «Starter Motor Replacement (LZ4)»(ref-301498-S25208722742008101700000) .
24. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor. Refer to «Compressor Replacement (LZ4)»(ref-301492-S03579280282008101700000) .
25. Remove the torque converter bolts.
26. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-301505-S30816786062008101700000) .
27. Remove the transaxle to oil pan brace bolts and brace.
28. Remove the lower transaxle-to-engine bolt (6) and the stud (1).
29. Remove the radiator outlet hose from the engine. Refer to «Radiator Outlet Hose Replacement (LZ4)»(ref-301507-S42287877592008101700000) .
30. Lower the vehicle and support the transaxle.
31. Remove the heater outlet and inlet hoses from the engine.
32. Remove the vacuum hoses from the upper intake manifold.
33. Remove the brake booster vacuum hose from the upper intake manifold.
34. Remove the fuel lines from the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-301532-S41233111492008101700000) .
35. Remove the radiator inlet hose from the engine. Refer to «Radiator Inlet Hose Replacement (LZ4)»(ref-301507-S02877261192008101700000) .
36. Install the engine lifting device to the engine.
37. Remove the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).
38. Remove the engine from the vehicle.
39. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
40. Install the engine to the engine stand.

1. Remove the engine from the engine stand.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
3. Install the engine to the vehicle.
4. Install the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2). Tighten: Tighten the bolts (3, 4, 5) and the stud (2) to 75 N.m (55 lb ft).
5. Remove the engine lifting device.
6. Install the radiator inlet hose to the engine. Refer to «Radiator Inlet Hose Replacement (LZ4)»(ref-301507-S02877261192008101700000) .
7. Install the fuel lines to the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(ref-301532-S41233111492008101700000) .
8. Install the brake booster vacuum hose to the upper intake manifold.
9. Install the vacuum hoses to the upper intake manifold.
10. Install the heater inlet and outlet hoses to the engine.
11. Raise the vehicle and remove the transaxle support.
12. Install the radiator outlet hose to the engine. Refer to «Radiator Outlet Hose Replacement (LZ4)»(ref-301507-S42287877592008101700000) .
13. Install the lower transaxle-to-engine bolt (6) and the stud (1). Tighten: Tighten the bolt (6) and the stud (1) to 75 N.m (55 lb ft).
14. Position the transaxle to oil pan brace and install the bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
15. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-301505-S30816786062008101700000) .
16. Install the torque converter bolts.
17. Install the A/C compressor. Refer to «Compressor Replacement (LZ4)»(ref-301492-S03579280282008101700000) .
18. Install the starter motor. Refer to «Starter Motor Replacement (LZ4)»(ref-301498-S25208722742008101700000) .
19. Install the torque converter covers.
20. Install the engine mount lower bolts (2). Tighten: Tighten the bolts to 50 N.m (38 lb ft).
21. Install the engine wiring harness grounds to the transaxle.
22. Install the engine wiring harness ground nut to the transaxle stud. Tighten: Tighten the nut to 35 N.m (26 lb ft).
23. Install the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (LZ4)»(ref-301511-S18521475702008101700000) and «Catalytic Converter Replacement - Right Side (LZ4)»(ref-301511-S11465940882008101700000) .
24. Lower the vehicle.
25. Connect the following electrical connectors: The body wiring harness-to-engine harness The electronic throttle control The exhaust gas recirculation (EGR) valve The heated oxygen sensor (HO2S)
26. Connect the coolant temperature sensor (1).
27. Connect the A/C compressor (1).
28. Connect the front and rear ignition coils (2).
29. Connect the evaporative emission (EVAP) canister purge solenoid (2).
30. Connect the manifold absolute pressure (MAP) sensor (1).
31. Connect the camshaft position (CMP) sensor (4, 5), crankshaft position (CKP) sensor and the oil control valves.
32. Connect the rear knock sensor (KS) (2).
33. Connect the front knock sensor (KS) (1).
34. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301505-S42749017972008101700000) .
35. Install the engine mount strut. Refer to «Engine Mount Strut Replacement - Right Side»(ref-301505-S14839397312008101700000) .
36. Install the hood. Refer to «Hood Replacement»(ref-301493-S09192208852008101700000) .
37. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-301503-S06572343432008101700000) .
38. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LZ4/LY7)»(ref-301498-S23733685642008101700000) .
39. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-301560-S02807742292008101700000) .
40. Fill 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) .
41. Perform a CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(ref-301532-S35056917632008101700000) .
42. Install the intake manifold cover. Refer to «Fuel Injector Sight Shield Replacement»(ref-301505-S03191417602008101700000) .
43. Inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
2. Position a suitable drain pan under the oil pan drain plug.
3. Remove the oil pan plug.
4. Allow the engine oil to drain completely.
5. Clean and inspect the oil pan drain plug sealing surface. Replace the oil pan if necessary.
6. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
7. Position a suitable drain pan under the oil filter.
8. Remove the oil filter.
9. Ensure that the oil filter gasket is still on the old filter. If not remove the oil filter gasket from the adapter.

1. Apply clean engine oil to the NEW oil filter gasket.
2. Install the NEW oil filter Tighten: Tighten the new filter to 3/4 to 1 full turn, after the oil filter gasket contacts the adapter.
3. Tighten the oil pan drain plug. Tighten: Tighten the plug to 26 N.m (19 lb ft).
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «Approximate Fluid Capacities (BAS/Hybrid)»(ref-301561-S38679594442008101700000) or «Approximate Fluid Capacities (AURA)»(ref-301561-S02810998062008101700000) and «Fluid and Lubricant Recommendations»(ref-301561-S18551700982008101700000) .
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn OFF the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil level indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level if the engine oil on the oil level indicator.
15. If necessary, adjust the oil level by adding or draining oil.
16. Check for oil leaks.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the coolant drain plug from the left side.
5. If equipped with an oil cooler (RPO-KC4), reposition the upper inlet hose clamp (1).
6. Remove the oil cooler inlet hose from the block outlet.
7. If not equipped with an oil cooler (RPO-KC4), remove the coolant drain plug from the right side.
8. Drain the coolant.

Crankshaft Balancer Removal

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. EN 46359 Puller End Protector. See «Special Tools»(ref-301513-S24222073032008101700000) .

Removal

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816 along with EN 46359 . See «Special Tools»(ref-301513-S24222073032008101700000) .

Engine Flywheel Removal (Automatic Transmission)

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

Engine Flywheel Removal (Manual Transmission)

1. Remove the flywheel/pressure plate bolts.
2. Remove the flywheel/pressure plate.
3. Remove the clutch pilot bearing.

Drive Belt Tensioner Removal

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

Coolant Crossover Pipe Removal

1. Loosen thermal bypass hose clamp (3) and remove hose from the coolant crossover pipe.
2. Remove the heater inlet/outlet pipe bolt (1) and remove the heater inlet/outlet pipe.
3. Remove the coolant vent pipe bolt (2) and the coolant vent pipe.
4. Remove the idler pulley bolts and pulleys (1, 2).
5. Remove the coolant crossover pipe bolts (2, 3), engine lift bracket (1), and the coolant crossover pipe assembly.

Engine Lift Rear Bracket Removal

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

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator tube bolt.
2. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter adapter heat shield nuts.
2. Remove the oil filter adapter heat shield (2).
3. Remove the oil filter adapter bolts.
4. Remove the oil filter adapter (1) and gasket.

Exhaust Manifold Removal - Left Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires from the spark plugs and set aside.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

Exhaust Manifold Removal - Right Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shields.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

Water Outlet and Thermostat Removal

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

Valve Rocker Arm Cover Removal - Left Side

1. Remove the positive crankcase ventilation (PCV) tube.
2. Remove and discard both PCV tube O-rings.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
6. Remove the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right Side

1. Remove any remaining spark plug wires from their retainers.
2. Remove the ignition coil assembly bolts and nuts.
3. Remove the ignition coil assembly.
4. Remove the ignition coil assembly studs, if necessary.
5. Remove the fresh air tube from the valve rocker arm cover.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover.
8. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
9. Remove the valve rocker arm cover gasket.

Upper Intake Manifold Removal

1. Remove the upper intake manifold bolts and stud.
2. Remove the manifold absolute pressure (MAP) sensor bracket.
3. Remove the upper intake manifold and gaskets.

Lower Intake Manifold Removal

1. Disconnect the coolant temperature sensor (1).
2. Disconnect the camshaft position (CMP) sensor (2).
3. Remove the fuel injector rail bolts.
4. Remove the fuel rail assembly.
5. Remove the lower intake manifold bolts and discard.
6. Remove the lower intake manifold.

Valve Rocker Arm and Push Rod Removal

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 147.51 mm (5.81 in). The exhaust push rods measure 154.87 mm (6.1 in).
4. Remove the intake manifold gaskets.

Valve Lifter Removal

1. Remove the valve lifter guide bolts.
2. Remove the valve lifter guides.
3. Remove the valve lifters.

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gasket.

Cylinder Head Removal - Left Side

1. Remove the cylinder head bolt and discards.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Cylinder Head Removal - Right Side

1. Remove the cylinder head bolts and discard.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Oil Pan Removal

1. Remove the oil pan support bracket bolts and brackets as needed
2. Remove the oil pan side bolts.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Remove the oil pan gasket.

Oil Pump Removal

1. Remove the oil pump bolt.
2. Remove the oil pump and oil pump drive shaft.
3. Remove the crankshaft oil deflector nuts.
4. Remove the crankshaft oil deflector.

Camshaft Position Actuator Magnet Removal

1. Remove the camshaft position actuator magnet bolts.
2. Remove the camshaft position actuator magnet and O-ring seal.

Oil Pump Drive Removal

1. Remove the oil pump drive clamp bolt.
2. Remove the oil pump drive clamp.
3. Remove the oil pump drive.

Scheme 60

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

Engine Front Cover Removal

1. Remove the engine front cover bolts.
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

1. Using the EN-47719 fully collapse the tensioner and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-301513-S24222073032008101700000) .
2. Remove the camshaft sprocket bolts.
3. Remove the timing chain and sprockets.
4. Remove the timing chain tensioner bolts.
5. Remove the timing chain tensioner.

Camshaft Removal

1. Remove the camshaft position sensor bolt.
2. Remove the camshaft position sensor.
3. Remove the camshaft thrust plate screws.
4. Remove the camshaft thrust plate.
5. Complete the following steps in order to remove the camshaft. Install a camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate and remove the camshaft from the engine block.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(ref-301513-S24222073032008101700000) .

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See «Special Tools»(ref-301513-S24222073032008101700000) . Complete the following steps: Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Remove the connecting rod bearing half.
7. Install J 41556 into the connecting rod. See «Special Tools»(ref-301513-S24222073032008101700000) .
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

Crankshaft Rear Oil Seal Removal

Tools Required

1. EN-48672 Rear Main Oil Seal Remover
2. J 23444-A Extreme Press Lubricant - 1/4 Ounce Tube. See «Special Tools»(ref-301513-S24222073032008101700000) .

Scheme 61

The EN-48672 has a unique design to allow the technician to easily remove the rear main seal without nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal, review the illustration to become familiar with the following components

1. Removal Plate (1)
2. Threaded Adjustment Pins and Jam Nuts (2)
3. Force Screw (3)
4. #2 Self Drill Screws 38 mm (1.5 in) long 8 needed (4)
5. Extreme Pressure Lubricant (5)

1. Remove the transmission. Refer to «Transmission Replacement (3.5L (LZ4) W/MN5)»(ref-301483-S04988576292008101700000) .
2. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
3. Install the removal plate (2) and both threaded adjustment pins and jam nuts (1) into the back of the crankshaft flange and secure the plate with adjustment pins and jam nuts.
4. Install the #2 self drill screws 38 mm (1.5 in) long, 8 needed (1) and tighten the screws down flush to the plate.
5. Install the force screw (1) and back off both jam nuts (2). Continue to turn the force screw (1) into the removal plate in order to remove the seal from the crankshaft.
6. Once the seal is removed from the crankshaft, remove and save all 8 screws. Discard the old seal.

Crankshaft and Bearing Removal

1. Remove the crankshaft position sensor heat shield nut and heat shield.
2. Remove the crankshaft position sensor stud.
3. Remove the crankshaft position sensor from the side of the block.
4. Remove the crankshaft main bearing cap bolt and studs.
5. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
6. Remove the crankshaft.
7. Remove the upper crankshaft main bearing halves.

Piston Oil Nozzle Removal

1. Remove the bolts retaining the piston oil nozzles to the engine block.
2. Remove the piston oil nozzles.

Engine Block Heater Installation

1. Apply sealer GM P/N 12346004 (Canadian P/N 1095380), or equivalent to the engine block heater.
2. Install the engine block heater into the engine block. Tighten: Tighten engine block heater to 50 N.m (37 lb ft).

1. Assemble the J 33049 according to the manufacturer's instructions. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. Install the camshaft bearings in the following order: Index the camshaft bearing oil holes with the engine block oil passages. Place the bearing on the J 33049 . See «Special Tools»(ref-301513-S24222073032008101700000) . Install the third camshaft bearing. Install the second camshaft bearing. Install the outer camshaft bearings.
3. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

Piston Oil Nozzle Installation

1. Position the piston oil nozzles in the engine block.
2. Install the bolts retaining the piston oil nozzles to the engine block. Tighten: Tighten the bolt to 10 N.m (89 lb in).

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N.m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-0.21 mm (0.002-0.008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor inperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).

Crankshaft Rear Oil Seal Installation

Tools Required

1. EN-48108 Rear Main Oil Seal Installer. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. J 23444-A Extreme Press Lubricant - 1/4 Ounce Tube. See «Special Tools»(ref-301513-S24222073032008101700000) .

Note. Do not remove the protective sleeve from the seal. The sleeve assures the seal is installed correctly and protects the seal from damage. If removed, the EN-48108 installation tool will not work.

Note. Clean the crankshaft sealing surface with a clean, lint free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage the rear main oil seal. Remove burrs/sharp edges with crocus cloth before proceeding.

Note. Do not remove protective nylon sleeve prior to installation. The rear main oil seal installation tool is designed to install the rear main seal with the protective sleeve in place. Never apply or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal.

A new design crankshaft rear main oil seal and installation tool, EN-48108 , has been released. See Special Tools . This seal incorporates features that improve high mileage durability. Replace the crankshaft rear main oil seal with the new design rear main oil seal, GM P/N 12592195 (Canadian P/N 12592195).

Scheme 62

The EN-48108 has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. See Special Tools . Before proceeding with installation, review the illustration to become familiar with the following components

1. Mandrel (1)
2. Drive Drum (2)
3. Drive Nut (3)
4. Washer (4)
5. Bearing (5)

1. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
2. Using a large flat-blade screwdriver, tighten the 2 mandrel screws to the crankshaft. Ensure the mandrel is snug to the crankshaft hub.
3. Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel. The seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an error proof, the seal will fit only one way onto the mandrel.
4. Install the outer drive drum onto the mandrel.
5. Install the bearing, washer, and drive nut onto the threaded shaft.
6. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block.
7. Loosen and remove the drive nut, washer, bearing, and drive drum. Discard the protective nylon sleeve.
8. Verify that the seal has seated properly.
9. Use a flat-blade screwdriver in order to remove the 2 attachment screws from the mandrel and remove the mandrel from the crankshaft hub.
10. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-301513-S03517659782008101700000) .
11. Install the transmission. Refer to «Transmission Replacement (3.5L (LZ4) W/MN5)»(ref-301483-S04988576292008101700000) .
12. Inspect for proper fluid levels.
13. Inspect for leaks.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Ring Compressor. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(ref-301513-S24222073032008101700000) .
3. J 43654 Piston Pin Clip Remover and Installer
4. J 43690 Rod Bearing Clearance Checking Tool. See «Special Tools»(ref-301513-S24222073032008101700000) .
5. J 43690-100 Rod Bearing Clearance Checking Tool-Adapter Kit. See «Special Tools»(ref-301513-S24222073032008101700000) .
6. J 45059 Angle Meter

Assembly & Installation

1. Lightly lubricate the following components with clean engine oil: The piston The piston pin The piston rings The cylinder bore The bearing surfaces
2. There are two styles of pistons in use in the LZ engine, and each piston must use the appropriate matching piston ring set. To identify which make you have, look on the bottom of the piston, in between the piston pin bores (1). If there is an "FM" marking, it is a Federal Mogul piston and must use the Federal Mogul piston rings. If there is no marking, it is a Mahle piston and must use Mahle piston rings. Failure to do so may result in engine damage.
3. Stagger the oil control ring end gaps a minimum of 90 degrees.
4. Stagger the compression ring end gaps a minimum of 25 mm (1 in).
5. Install the J 8037 onto the piston and compress the piston rings. See «Special Tools»(ref-301513-S24222073032008101700000) .
6. Align the piston pin bore with the connecting rod pin bore.
7. Slide the piston pin (4) into the piston and the connecting rod (3).
8. Install NEW piston pin retainers (1) using the J 43654 .
9. Ensure that the piston pin retainers are fully seated in their grooves.
10. Repeat these procedures for the remaining pistons.
11. Install the J 41556 into the connecting rod. See «Special Tools»(ref-301513-S24222073032008101700000) .
12. Install the piston and connecting rod assembly into the proper cylinder bore.
13. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
14. Using J 41556 , guide the connecting rod end onto the crankshaft journal. See «Special Tools»(ref-301513-S24222073032008101700000) .
15. Install the bearing, bearing cap and bolts. Tighten: Tighten the connecting rod bearing cap bolts a first pass to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts a final pass to 110 degrees using the J 45059 .
16. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
17. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting rod side clearance should be within 0.18-0.44 mm (0.007-0.017 in).

Camshaft Installation

1. Coat the camshaft journals with clean engine oil.
2. Coat the camshaft lobes with prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the camshaft using the following procedure: Install a camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate the camshaft while installing the camshaft into the camshaft bearings.
4. Install the camshaft thrust plate.
5. Install the camshaft thrust plate screws. Tighten: Tighten the camshaft thrust plate screws to 10 N.m (89 lb in).
6. Install the camshaft position sensor.
7. Install the camshaft position sensor bolt. Tighten: Tighten the camshaft position sensor bolt to 10 N.m (89 lb in).

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain tensioner.
4. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 21 N.m (15 lb ft).
5. Using the EN-47719 , fully collapse the tensioner, and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(ref-301513-S24222073032008101700000) .
6. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
7. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
8. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain tensioner (3).
9. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
10. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
11. Remove the tensioner retaining pin.
12. Coat the crankshaft and camshaft sprocket with engine oil.

Engine Front Cover Installation

1. Install the front cover and the front cover gasket.
2. Install the front cover bolts. Tighten: Tighten the front cover bolts to 25 N.m (18 lb ft).

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(ref-301513-S24222073032008101700000) .

Oil Pump Drive Installation

1. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.
5. Install the oil pump drive gear clamp bolt. Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).

Camshaft Position Actuator Magnet Installation

1. Install the camshaft position actuator magnet and O-ring seal into the front cover.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the camshaft position actuator magnet bolts to 10 N.m (89 lb in).

Oil Pump Installation

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pump.
4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).

Oil Pan Installation

1. Apply sealer GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to both sides of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to both sides of the front cover/block mating area (1).
3. Install the oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
6. Install the oil pan side bolts. Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
7. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the NEW small hex cylinder head bolts (5 and 8).
6. Install the NEW large hex cylinder head bolts (1, 2, 3, 4, 6 and 7). Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 140 degrees using the J 45059 .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the NEW small hex cylinder head bolts (5 and 8).
6. Install the NEW large hex cylinder head bolts (1, 2, 3, 4, 6 and 7). Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 140 degrees using the J 45059 .

Water Pump Installation

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the threads.
4. Install the valve lifter guides and guide bolts. Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).

Valve Rocker Arm and Push Rod Installation

1. Install the lower intake manifold gaskets.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the push rods in their original location.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 34 N.m (25 lb ft).

Lower Intake Manifold Installation

1. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of room temperature vulcanizing (RTV) sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to block joints (1).
2. Install the lower intake manifold.
3. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
4. Install the new lower intake manifold bolts if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in) on the final pass. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.
5. Inspect the fuel rail, and fuel injectors for damage and replace if necessary.
6. Install NEW lower fuel injector O-rings.
7. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
8. Install the injector nozzles into the lower intake manifold injector bores.
9. Press on the injector rail using the palms of both hands until the injectors are fully seated.
10. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
11. Connect the coolant temperature sensor (1).
12. Connect the camshaft position (CMP) sensor (2).

Upper Intake Manifold Installation

1. Install the upper intake manifold gaskets and manifold.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the upper intake manifold bolt threads.
3. Install the MAP sensor bracket, upper intake manifold bolts and the upper intake manifold stud. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).

Valve Rocker Arm Cover Installation - Left Side

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install two NEW positive crankcase ventilation (PCV) tube O-rings.
6. Install the fresh air tube.

Valve Rocker Arm Cover Installation - Right Side

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the fresh air tube into the valve rocker arm cover.
6. Install the ignition coil assembly studs, if necessary. Tighten: Tighten the ignition coil assembly studs to 25 N.m (18 lb ft).
7. Install the ignition coil assembly.
8. Install the ignition coil assembly bolts and nuts. Tighten: Tighten the ignition coil assembly bolts and nuts to 25 N.m (18 lb ft).

Water Outlet and Thermostat Installation

1. Install the thermostat.
2. Install the water outlet.
3. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Exhaust Manifold Installation - Right Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N.m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Oil Filter Adapter Installation

1. Install the oil filter adapter (1) and gasket.
2. Apply threadlocker P/N 21485277 to the bolt threads if required.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N.m (18 lb ft).
4. Install the oil filter adapter heat shield (2).
5. Install the oil filter adapter heat shield nuts. Tighten: Tighten the oil filter adapter heat shield nuts to 25 N.m (18 lb ft).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube and oil level indicator.
2. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).

Engine Lift Rear Bracket Installation

1. Install the rear engine lift bracket.
2. Install the rear engine lift bracket bolts. Tighten: Tighten the rear engine lift bracket bolts to 50 N.m (37 lb ft).

Coolant Crossover Pipe Installation

1. Install the coolant crossover pipe assembly onto the engine.
2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the side coolant crossover pipe bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the idler pulleys and bolts. Tighten: Tighten the bolts (1) to 50 N.m (37 lb ft). Tighten the bolt (2) to 30 N.m (22 lb ft).
5. Install the coolant vent pipe and bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the heater inlet/outlet pipe and bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Install the thermal bypass hose and securely fasten the clamp (3).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Engine Flywheel Installation (Automatic Transmission)

1. Install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).

1. Install the clutch pilot bearing.
2. Install the flywheel/pressure plate.
3. Install the flywheel/pressure plate bolts. Tighten: Tighten the flywheel/pressure plate bolts to 50 N.m (37 lb ft) plus an additional 70 degrees using the J 45059 .

Crankshaft Balancer Installation

Tools Required

1. J 29113 Balancer and Crank Sprocket Puller. See «Special Tools»(ref-301513-S24222073032008101700000) .
2. J 45059 Angle Meter

1. Place the crankshaft balancer into position over the key in the crankshaft.
2. Install the J 29113 onto the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
3. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
4. Remove the J 29113 from the crankshaft. See «Special Tools»(ref-301513-S24222073032008101700000) .
5. Install the used crankshaft balancer bolt. Tighten: Tighten the used crankshaft balancer bolt to 125 N.m (92 lb ft).
6. Remove the used crankshaft balancer bolt.
7. Install the NEW crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 125 N.m (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059 .