Engine Mechanical - 2.0L: Removal & Installation Saturn Sky I

Removal Procedure

1. Grasp the intake manifold cover in the middle of the right side and pull up in order to disengage the cover from the studs.
2. Grasp the intake manifold cover in the middle of the left side and pull up in order to disengage the cover from the studs.
3. Remove the intake manifold cover.
4. Remove the oil fill cap.
5. Remove the insulator.
6. Reinstall the oil fill cap.

Installation Procedure

1. Remove the oil fill cap.
2. Install the insulator.
3. Reinstall the oil fill cap.
4. Place the intake manifold cover onto the engine over the studs.
5. Push down on the intake manifold cover directly over the left side studs in order to engage the cover to the studs.
6. Push down on the intake manifold cover directly over the right side studs in order to engage the cover to the studs.

Scheme 2

Drive Belt Replacement

Scheme 3

Drive Belt Tensioner Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
2. Disconnect the engine wiring harness electrical connector (2) from the engine oil pressure sensor.
3. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the engine oil pressure sensor.
3. Lower the vehicle.

1. Loosen the charge air cooler (CAC) outlet hose clamp (2) at the CAC outlet pipe.
2. Loosen the CAC outlet hose clamp (1) at the throttle body.
3. Remove the CAC outlet hose from the CAC outlet pipe and throttle body.
4. Remove the left engine mount upper nut.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
6. Remove the left engine mount lower nut.
7. Remove the right engine mount lower nut.
8. Position an adjustable jack below the oil pan. Place a block of wood between the oil pan and the jack.
9. Raise the engine using the adjustable jack until the engine mount can be removed.
10. Remove the left engine mount.

1. Install the left engine mount.
2. Lower the engine using the adjustable jack until the engine is resting on the mount.
3. Remove the adjustable jack from below the oil pan.
4. Install the right engine mount lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
5. Install the left engine mount lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
6. Lower the vehicle.
7. Install the left engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
8. Install the CAC outlet hose to the CAC outlet pipe and throttle body.
9. Tighten the CAC outlet hose clamp (1) at the throttle body.
10. Tighten the CAC outlet hose clamp (2) at the CAC outlet pipe. Tighten: Tighten the clamps to 5 N.m (44 lb in).

1. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .
2. Remove the right engine mount upper nut.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
4. Remove the right engine mount lower nut.
5. Remove the left engine mount lower nut.
6. Remove the right brake hose bracket bolt.
7. Remove the right brake line clip at the crossmember.
8. Position an adjustable jack below the oil pan. Place a block of wood between the oil pan and the jack.
9. Raise the engine using the adjustable jack until the engine mount can be removed.
10. Remove the right engine mount.

1. Install the right engine mount.
2. Lower the engine using the adjustable jack until the engine is resting on the mount.
3. Remove the adjustable jack from below the oil pan.
4. Install the right brake line clip at the crossmember.
5. Install the right brake hose bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the left engine mount lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
7. Install the right engine mount lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
8. Lower the vehicle.
9. Install the right engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
2. Remove the power brake booster pump. Refer to «Power Brake Booster Pump Replacement»(ref-269803-S15486187982007110200000) .
3. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .
4. Remove the left engine mount. Refer to «Engine Mount Replacement - Left Side»(ref-269812-S19891489192007110200000) .
5. Remove the positive battery cable starter solenoid nut (2) from the starter.
6. Remove the positive battery cable terminal (3) from the starter.
7. Reposition the engine wiring harness boot (2) at the generator stud.
8. Remove the engine wiring harness nut (1) from the generator.
9. Remove the engine wiring harness terminal (3) from the generator.
10. Remove the engine mount bracket bolts and bracket.

1. Position the engine mount bracket to the engine block.
2. Install the engine mount bracket bolts until snug.
3. Tighten the engine mount bracket bolts in the following sequence. Lower Upper front Upper Rear Tighten: Tighten the bolts to 55 N.m (41 lb ft).
4. Install the engine wiring harness terminal (3) to the generator.
5. Install the engine wiring harness nut (1) to the generator. Tighten: Tighten the nut to 20 N.m (15 lb ft).
6. Position the engine wiring harness boot (2).
7. Install the positive battery cable terminal (3) to the starter.
8. Install the positive battery cable starter solenoid nut (2) to the starter. Tighten: Tighten the nut to 10 N.m (89 lb in).
9. Install the left engine mount. Refer to «Engine Mount Replacement - Left Side»(ref-269813-S42415595082007110200000) .
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .
11. Install the power brake booster pump. Refer to «Power Brake Booster Pump Replacement»(ref-269803-S15486187982007110200000) .
12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .

1. Remove the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-269812-S15485582402007110200000) .
2. Remove the engine mount bracket bolts and bracket.

1. Position the right engine mount bracket to the engine block.
2. Install the engine mount bracket bolts until snug.
3. Tighten the right engine mount bracket bolts in the following sequence. Tighten: Tighten the bolts to 55 N.m (41 lb ft). Lower rear Upper front Lower front Upper rear
4. Install the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-269812-S15485582402007110200000) .

1. Loosen the charge air cooler (CAC) outlet hose clamp (2) at the CAC outlet pipe.
2. Loosen the CAC outlet hose clamp (1) at the throttle body.
3. Remove the CAC outlet hose from the CAC outlet pipe and throttle body.
4. Remove the engine wiring harness clip (1) from the oil level indicator tube bracket.
5. Remove the number 1 knock sensor (2) clip from the oil level indicator tube bracket.
6. Remove the engine wiring harness clip (4) from the oil level indicator tube bracket.
7. Remove the oil level indicator tube bolt.
8. Remove the oil level indicator tube and indicator.

1. Lubricate the oil level indicator tube O-ring seal with lubricant. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
2. Install the oil level indicator tube to the engine block.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the engine wiring harness clip (4) to the oil level indicator tube bracket.
5. Install the number 1 knock sensor (2) clip to the oil level indicator tube bracket.
6. Install the engine wiring harness clip (1) to the oil level indicator tube bracket.
7. Install the CAC outlet hose to the CAC outlet pipe and throttle body.
8. Tighten the CAC outlet hose clamp (1) at the throttle body.
9. Tighten the CAC outlet hose clamp (2) at the CAC outlet pipe. Tighten: Tighten the clamps to 5 N.m (44 lb in).

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .
2. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) .
3. Remove the charge air cooler pipe bolts (1) at the turbocharger.
4. Remove the charge air cooler pipe from the turbocharger.
5. Remove the turbocharger heat shield bolts (1) and shield.
6. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-269792-S42797936102007110200000) .
7. Remove the catalytic converter bracket bolt, nut, and bracket.
8. Lower the vehicle.
9. Remove the turbocharger brace nut and brace.
10. Disconnect the engine wiring harness electrical connector from the turbocharger boost sensor.
11. Reposition the vacuum hose clamp (5) at the turbocharger.
12. Remove the vacuum hose from the turbocharger.
13. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.
14. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
15. Remove and discard the turbocharger coolant feed pipe gasket.
16. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
17. Reposition the turbocharger coolant feed pipe out of the way.
18. Remove the positive crankcase ventilation (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
19. Remove the turbocharger coolant return pipe bolts and pipe.
20. Remove and discard the turbocharger coolant return pipe gaskets.
21. Remove the turbocharger oil feed pipe bolts and pipe.
22. Remove and discard the turbocharger oil feed pipe gaskets.
23. Remove the turbocharger nuts (2).
24. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
25. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).
26. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the installation procedure.
27. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
28. Remove and discard the turbocharger oil return hose gasket (1).
29. Reposition the vacuum hose clamps (1, 2, and 3) at the boost sensor.
30. Remove the vacuum hoses from the boost sensor.
31. Gently push back the boost sensor retainer (4) and remove the boost sensor from the bracket.

1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
2. Install the boost sensor to the bracket until the retainer (4) clips into place.
3. Install the vacuum hoses to the boost sensor.
4. Position the vacuum hose clamps (1, 2, and 3) at the boost sensor.
5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.
6. Install the turbocharger oil return hose and bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
8. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
9. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
10. Install the turbocharger nuts (2). Tighten: Tighten the nuts to 35 N.m (26 lb ft).
11. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
12. Install the turbocharger oil feed pipe and bolts. Tighten: Tighten the bolts to 32 N.m (24 lb ft).
13. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
14. Install the turbocharger coolant return pipe and bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
15. Install a NEW O-ring seal to the PCV fitting.
16. Position the PCV pipe (with fitting) and install the PCV fitting bolt to the turbocharger. Tighten: Tighten the bolt to 10 N.m (89 lb in).
17. Position the turbocharger coolant feed pipe to the turbocharger.
18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.
22. Install the vacuum hose to the turbocharger.
23. Position the vacuum hose clamp (5) at the turbocharger.
24. Connect the engine wiring harness electrical connector to the turbocharger boost sensor.
25. Install the turbocharger brace bolt and nut. Tighten: Tighten the nut to 58 N.m (43 lb ft).
26. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
27. Position the catalytic converter bracket to the engine.
28. Install the catalytic converter bracket bolt, and nut until snug.
29. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-269792-S42797936102007110200000) .
30. Tighten the catalytic converter bracket bolt and nut. Tighten: Tighten the bolt/nut to 58 N.m (43 lb ft).
31. Lower the vehicle.
32. Install the turbocharger heat shield and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
33. Install the charge air cooler pipe and gasket (2) to the turbocharger.
34. Install the charge air cooler pipe bolts (1) at the turbocharger. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
35. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) .
36. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .

1. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-269792-S42797936102007110200000) .
2. Remove the turbocharger oil feed pipe bolts and pipe.
3. Remove and discard the turbocharger oil feed pipe gaskets.

1. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
2. Install the turbocharger oil feed pipe and bolts. Tighten: Tighten the bolts to 32 N.m (24 lb ft).
3. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-269792-S42797936102007110200000) .

1. Remove the turbocharger. Refer to «Turbocharger Replacement»(ref-269812-S19231563702007110200000) .
2. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
3. Remove and discard the turbocharger oil return hose gasket (1).

1. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
2. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.
3. Install the turbocharger oil return hose and bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the turbocharger. Refer to «Turbocharger Replacement»(ref-269812-S19231563702007110200000) .

Note. Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269813-S28128464812007110200000) .
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-269812-S05630433712007110200000) .
3. Disconnect the fuel feed line quick connect fitting (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
4. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
5. Reposition the brake booster vacuum hose clamp at the intake manifold.
6. Remove the brake booster hose from the intake manifold.
7. Remove the knock sensor electrical connector (1) clip from the intake manifold brace.
8. Remove the knock sensor electrical connector (2) clip from the oil level indicator tube bracket.
9. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
10. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
11. Disconnect the engine wiring harness electrical connector from the charge air bypass vale solenoid.
12. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC) module.
13. Remove the engine wiring harness clip (3) from the intake manifold brace.
14. Reposition the surge tank air bleed hose clamp at the engine (1).
15. Remove the surge tank air bleed hose from the engine.
16. Remove the surge tank air bleed hose clip (2) from the surge tank bracket.
17. Reposition the surge tank air bleed hose out of the way.
18. Reposition the charge air bypass valve vacuum hose clamp at the intake manifold.
19. Remove the charge air bypass valve vacuum hose from the intake manifold.
20. Remove the charge air bypass valve solenoid bolts.
21. Reposition the charge air bypass valve solenoid assembly out of the way.
22. Remove the surge tank bracket bolt (1) and stud (2).
23. Remove the surge tank bracket (3).
24. Disconnect the fuel feed pipe fitting from the fuel pump.
25. Remove the fuel feed pipe bolts.
26. Remove the fuel feed pipe.
27. Inspect the fuel feed pipe nut for damaged threads.
28. Inspect the fuel feed pipe sealing bail for damage or debris.
29. Replace the fuel feed pipe if any damage is found.
30. Unbolt and reposition the power brake booster pump. Refer to «Power Brake Booster Pump Replacement»(ref-269803-S15486187982007110200000) .
31. Remove the intake manifold brace bolt.
32. Remove the intake manifold brace.
33. Remove the intake manifold bolts and nuts.
34. Remove the intake manifold and place on a clean work surface.
35. Remove the intake manifold gasket, if necessary.
36. If replacing the intake manifold perform the following steps, otherwise proceed to step 11 in the installation procedure.
37. Remove the MAP sensor bolts (1).
38. Remove the MAP sensor (2), ensure that the O-ring seal (3) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
39. Remove the EVAP purge solenoid bolt (6).
40. Remove the EVAP purge solenoid (5), ensure that the O-ring seal (4) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
41. Turn the intake manifold up side down.
42. Remove the throttle body bolts.
43. Remove the throttle body and seal.

1. If replacing the intake manifold perform the following steps, otherwise proceed to step 11.
2. Inspect the throttle body seal and replace if necessary.
3. Install the throttle body seal and position the throttle body.
4. Install the throttle body bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Turn the intake manifold right side up.
6. Inspect the EVAP purge solenoid and MAP sensor O-ring seals, replace if necessary.
7. Ensure that the EVAP purge solenoid O-ring seal (4) is installed on the EVAP purge solenoid (5).
8. Install the EVAP purge solenoid (5) and bolt (6). Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Ensure that the MAP sensor O-ring seal (3) is installed on the MAP sensor (2).
10. Install the MAP sensor (2) and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
11. Install the intake manifold gasket, if necessary.
12. Install the intake manifold to the studs.
13. Install the intake manifold bolts and nuts. Tighten: Tighten the bolts/nuts to 22 N.m (16 lb ft).
14. Install the intake manifold brace.
15. Loosely install the intake manifold brace bolt.
16. Position and install the power brake booster pump. Refer to «Power Brake Booster Pump Replacement»(ref-269803-S15486187982007110200000) .
17. Tighten the intake manifold brace bolt. Tighten: Tighten the bolt to 22 N.m (16 lb ft).
18. Lubricate the high pressure fuel pump fuel feed pipe connection threads with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
19. Place the fuel feed pipe on top of the intake manifold.
20. Connect the fuel feed pipe fitting to the high pressure fuel pump.
21. Install the fuel feed pipe bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). Tighten the fitting to 30 N.m (22 lb ft).
22. Position the surge tank bracket (3) to the intake manifold.
23. Install the surge tank bracket bolt (1) and stud (2). Tighten: Tighten the bolt/stud to 9 N.m (80 lb in).
24. Position the charge air bypass valve solenoid assembly to the intake manifold.
25. Install the charge air bypass valve solenoid bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
26. Install the charge air bypass valve vacuum hose to the intake manifold.
27. Position the charge air bypass valve vacuum hose clamp at the intake manifold.
28. Position the surge tank air bleed hose to the engine.
29. Install the surge tank air bleed hose to the engine.
30. Position the surge tank air bleed hose clamp at the engine (1).
31. Install the surge tank air bleed hose clip (2) to the surge tank bracket.
32. Connect the engine wiring harness electrical connector (1) to the TAC module.
33. Install the engine wiring harness clip (3) to the intake manifold brace.
34. Connect the engine wiring harness electrical connector to the charge air bypass vale solenoid.
35. Connect the engine wiring harness electrical connector (2) to the MAP sensor.
36. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
37. Install the knock sensor electrical connector (1) clip to the intake manifold brace.
38. Install the knock sensor electrical connector (2) clip to the oil level indicator tube bracket.
39. Install the brake booster hose to the intake manifold.
40. Position the brake booster vacuum hose clamp at the intake manifold.
41. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
42. Connect the fuel feed line quick connect fitting (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
43. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-269812-S05630433712007110200000) .
44. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269813-S28128464812007110200000) .

Crankshaft Balancer Replacement

Tools Required

1. J 43653 Flywheel Holding Tool
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-269813-S08456875012007110200000) .
2. Remove the starter motor. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
4. Install the J 43653 (1) to the engine block, in order to hold the flywheel.
5. Remove the crankshaft balancer bolt. Discard the bolt.
6. Remove the balancer using a universal removal tool.

1. Install the crankshaft balancer onto the crankshaft indexing keyway. Use care to properly align the keyway and the flats on the balancer with the oil pump drive.
2. Install the crankshaft balancer using a universal balancer installer. NOTE: Refer to «Fastener Notice»(ref-269768-S31088373702007110200000) .
3. Install a NEW crankshaft balancer bolt. Prevent the crankshaft from rotating when tightening the bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
4. Remove the J 43653 (1) from the engine block.
5. Lower the vehicle.
6. Install the starter motor. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
7. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-269813-S08456875012007110200000) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-269812-S30806078132007110200000) .
2. Using a flat-bladed tool, remove the oil seal from the front cover.

1. Use the J 35268-A in order to install the oil seal to the front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-269812-S30806078132007110200000) .

1. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-269813-S30806608142007110200000) .
3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-269813-S20842056102007110200000) .
4. Remove the engine front cover bolts.
5. Remove the engine front cover to water pump bolt.
6. Remove and discard the engine front cover gasket.
7. Remove the crankshaft front cover oil seal with an appropriate tool.
8. Remove and discard the friction washer.

1. Install a NEW crankshaft front oil seal. Refer to «Crankshaft Front Oil Seal Installation»(ref-269812-S08119361882007110200000) .
2. Install a NEW friction washer.
3. Position and install a NEW engine front cover gasket to the dowel pins.
4. Position and install the engine front cover.
5. Install the engine front cover to water pump bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-269813-S20842056102007110200000) .
8. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-269813-S30806608142007110200000) .
9. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 45027 Tensioner Tool. See «Special Tools»(ref-269812-S12310610572007110200000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
2. Remove the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-269808-S29635203392007110200000) .
3. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
4. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269812-S09610205822007110200000) .
5. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-269812-S30757656542007110200000) .
6. Remove the upper timing chain guide bolts and guide.
7. Remove the timing chain tensioner.
8. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
9. Remove and discard the exhaust camshaft actuator bolt (2).
10. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
11. Remove the timing chain tensioner guide bolt and guide.
12. Remove the fixed timing chain guide access plug.
13. Remove the fixed timing chain guide bolts and guide.
14. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
15. Remove and discard the intake camshaft actuator bolt (2).
16. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head.
17. Remove the timing chain crankshaft sprocket.
18. If replacing the balance shaft timing chain and sprocket, perform the following steps: if not proceed the step 10 in the installation procedure.
19. Remove the balance shaft drive chain tensioner bolts and tensioner.
20. Remove the adjustable balance shaft chain guide bolt and guide.
21. Remove the small balance shaft drive chain guide bolts and guide.
22. Remove the upper balance shaft drive chain guide bolts and guide.
23. Remove the balance shaft drive chain (7).
24. Remove the balance shaft drive sprocket.

1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10.
2. Install the balance shaft drive sprocket.
3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are three colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
4. Install the upper balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
5. Install the small balance shaft drive chain guide and bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
6. Install the adjustable balance shaft chain guide and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
8. Install the balance shaft drive chain tensioner and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.
10. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
11. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
12. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
13. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
14. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
15. Hand tighten the new intake camshaft actuator bolt.
16. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
17. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
18. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
19. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
20. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
21. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
22. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
23. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
24. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
25. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
26. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
27. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
28. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
29. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
30. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
31. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the.
32. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the.
33. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
34. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
35. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).
36. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-269812-S30757656542007110200000) .
37. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269812-S09610205822007110200000) .
38. Install the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-269808-S29635203392007110200000) .
39. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .

1. Remove the timing chain, sprocket and tensioner. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .
2. Remove the right (intake) balance shaft bolt (1).
3. Remove the right (intake) balance shaft.
4. Install the J 43650 into the balance shaft hole. See «Special Tools»(ref-269812-S12310610572007110200000) . Insert the tool with the foot parallel to the shaft.
5. When the J 43650 is inserted in the block, turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(ref-269812-S12310610572007110200000) .
6. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) .
7. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(ref-269812-S12310610572007110200000) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
8. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(ref-269812-S12310610572007110200000) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(ref-269812-S12310610572007110200000) .
2. Seat the balance shaft busing into the bore using the J 43650 and a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
4. Place the number one cylinder at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the right (intake) balance shaft.
7. Install the right (intake) balance shaft bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
8. Install the timing chain, sprocket and tensioner. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .

1. Remove the timing chain, sprocket and tensioner. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .
2. Remove the left (exhaust) balance shaft bolt (2).
3. Remove the left (exhaust) balance shaft.
4. Install the J 43650 into the balance shaft hole. See «Special Tools»(ref-269812-S12310610572007110200000) . Insert the tool with the foot parallel to the shaft (right side shown, left side similar).
5. When the J 43650 is inserted in the block, turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(ref-269812-S12310610572007110200000) .
6. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) .
7. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(ref-269812-S12310610572007110200000) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
8. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(ref-269812-S12310610572007110200000) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) (right side shown, left side similar).

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(ref-269812-S12310610572007110200000) (right side shown, left side similar).
2. Seat the balance shaft busing into the bore using the J 43650 and a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
4. Place the number one cylinder at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the left (exhaust) balance shaft.
7. Install the left (exhaust) balance shaft bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
8. Install the timing chain, sprocket and tensioner. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .
2. Remove the intake manifold cover studs (1).
3. Remove the air cleaner outlet. Refer to «Air Cleaner Outlet Duct Replacement»(ref-269808-S15294799362007110200000) .
4. Disconnect the engine wiring harness intake (2) and exhaust (1) electrical connectors from the camshaft position actuator solenoid valves.
5. Remove the engine wiring harness clip (1) from the camshaft cover.
6. Remove the engine wiring harness clips (1, 2) from the camshaft cover.
7. Disconnect the engine wiring harness electrical connector from the evaporative emission (EVAP) canister purge solenoid valve.
8. Remove the ignition coils. Refer to «Ignition Coil Replacement»(ref-269808-S39885185432007110200000) .
9. Remove the heated oxygen sensor (HO2S) electrical connector clip (2) from the camshaft cover.
10. Remove the positive crankcase ventilation (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
11. Remove the camshaft cover bolts.
12. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Install a NEW O-ring seal to the PCV fitting.
3. Position the PCV pipe (with fitting) and install the PCV fitting bolt to the turbocharger. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the HO2S electrical connector clip (2) to the camshaft cover.
5. Install the ignition coils. Refer to «Ignition Coil Replacement»(ref-269808-S39885185432007110200000) .
6. Disconnect the engine wiring harness electrical connector from the evaporative emission (EVAP) canister purge solenoid valve.
7. Install the engine harness clips (1, 2) to the camshaft cover.
8. Install the engine wiring harness clip (1) to the camshaft cover.
9. Connect the engine wiring harness intake (2) and exhaust (1) electrical connectors to the camshaft position actuator solenoid valves.
10. Install the air cleaner outlet. Refer to «Air Cleaner Outlet Duct Replacement»(ref-269808-S15294799362007110200000) .
11. Install the intake manifold cover studs (1). Tighten: Tighten the studs to 9 N.m (80 lb in).
12. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269812-S09610205822007110200000) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269812-S09610205822007110200000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .

1. Remove the camshaft position intake actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-269812-S18642477502007110200000) .
2. Remove the high pressure fuel pump. Refer to «High Pressure Fuel Pump Replacement»(ref-269808-S00890905172007110200000) .
3. Mark the camshaft bearing caps to ensure they are installed in the same position.
4. Remove the camshaft bearing cap bolts and caps.
5. Remove the valve lifter follower.
6. Remove the cylinder head opening plate bolts and plate.
7. Remove the rear bearing cap bolts and cap.
8. Remove the intake camshaft.
9. Remove the valve rocker arms.
10. Remove the hydraulic valve lash adjusters.

1. Install the hydraulic valve lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
3. Lubricate the valve tips. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
4. Position the valve rocker arms on the tip of the valve stem and on the valve lash adjuster. Lubricate the rocker arms. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
5. Install the intake camshaft. Lubricate the camshaft. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
6. Apply a 3.5 mm (0.138 in) bead of sealer (1) to the cylinder head. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
7. In areas were the rear bearing cap ends on the perimeter rail, extend the bead of sealer 4.0 mm (0.1575 in) beyond the edge of the cap (2).
8. Run the bead of sealer to within 4.0 mm (0.1575 in) of end points (3).
9. Install the rear bearing cap and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the cylinder head opening plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
11. Install the valve lifter follower.
12. Position the camshaft bearing caps. Install the bearing cap bolts hand tight.
13. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
14. Install the high pressure fuel pump. Refer to «High Pressure Fuel Pump Replacement»(ref-269808-S00890905172007110200000) .
15. Install the camshaft position intake actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-269812-S18642477502007110200000) .

1. Remove the camshaft position exhaust actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-269812-S20487031832007110200000) .
2. Mark the camshaft bearing caps to ensure they are installed in the same position.
3. Remove the camshaft bearing cap bolts and cap.
4. Remove the exhaust camshaft.
5. Remove the valve rocker arms.
6. Remove the hydraulic valve lash adjusters.

1. Install the hydraulic valve lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic valve lash adjusters. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
3. Lubricate the valve tips. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
4. Position the rocker arms on the tip of the valve stem and on the valve lash adjuster. Lubricate the rocker arms. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
5. Install the exhaust camshaft. Lubricate the camshaft. Refer to «Sealers, Adhesives, and Lubricants»(ref-269812-S36933929602007110200000) .
6. Position the camshaft bearing caps. Install the bearing cap bolts hand tight.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the camshaft position exhaust actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-269812-S20487031832007110200000) .

Camshaft Position Intake Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Remove the camshaft cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .
2. Remove the upper timing chain guide bolts and guide.
3. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
4. Loosen, but DO NOT remove the intake camshaft actuator bolt.
5. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
6. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
7. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
8. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
9. Remove and discard the intake camshaft actuator bolt (2).
10. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW intake camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
8. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .

Camshaft Position Exhaust Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool
2. J 45027 Tensioner Tool. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Remove the camshaft cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .
2. Remove the upper timing chain guide bolts and guide.
3. Remove the timing chain tensioner.
4. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
5. Loosen, but DO NOT remove the exhaust camshaft actuator bolt.
6. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
7. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.
8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
9. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
10. Remove and discard the exhaust camshaft actuator bolt (2).
11. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.
5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
7. Tighten the NEW camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
8. Remove the old oil from the timing chain tensioner.
9. Inspect the timing chain tensioner for scoring or free movement.
10. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
11. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 in) from end to end (a).
12. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
13. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
14. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
15. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1 through 8.4.
16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.
19. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
20. Install the camshaft cover. Refer to «Intake Manifold Cover Replacement»(ref-269812-S02875793922007110200000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor. See «Special Tools»(ref-269812-S12310610572007110200000) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. J 43653 Flywheel Holding Tool
4. J 43655 Sprocket Holding Tool

1. If equipped with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set.
2. If equipped with an automatic transmission, remove the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
3. Install J 43653 .
4. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-269812-S14886339112007110200000) or «Exhaust Camshaft and Lifter Replacement»(ref-269812-S17427476942007110200000) .
5. Remove the camshaft roller followers.
6. Install the front section of the J 43649 to the second camshaft cover bolt hole. See «Special Tools»(ref-269812-S12310610572007110200000) .
7. Install the remaining parts of the J 43649 to the cylinder head. See «Special Tools»(ref-269812-S12310610572007110200000) .
8. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-269808-S29635203392007110200000) .
9. Install an air hose adapter into the spark plug hole.
10. Attach an air hose to the adapter
11. Using the compressed air, pressurize the cylinder to 690 kPa (100 psi).
12. Compress the valve spring using the J 43649 . See «Special Tools»(ref-269812-S12310610572007110200000) .
13. Remove the valve spring keepers.
14. Remove the valve spring retainer.
15. Remove the valve spring.
16. Using the J 36017 remove the valve seal. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Using the J 36017 install the NEW valve seal. See «Special Tools»(ref-269812-S12310610572007110200000) . Fully seat the seal onto the valve guide.
2. Install the valve spring.
3. Install the valve spring retainer.
4. Compress the valve spring using the J 43649 . See «Special Tools»(ref-269812-S12310610572007110200000) .
5. Install the valve spring keepers.
6. Disconnect the air hose from the adapter.
7. Remove the air hose adapter from the spark plug hole.
8. Remove the J 43649 from the cylinder head. See «Special Tools»(ref-269812-S12310610572007110200000) .
9. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-269808-S29635203392007110200000) .
10. Install the camshaft roller followers.
11. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-269812-S14886339112007110200000) or «Exhaust Camshaft and Lifter Replacement»(ref-269812-S17427476942007110200000) .
12. If used, remove the J 43653 .
13. If removed, install the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .

1. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
2. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-269808-S15640782002007110200000) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LNF)»(ref-269792-S34959777142007110200000) .
4. Remove the turbocharger coolant feed pipe. Refer to «Turbocharger Coolant Feed Pipe Replacement (LNF)»(ref-269827-S38003762592007110200000) .
5. Remove the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .
6. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .
7. Remove the fuel pump acoustic cover.
8. Remove the negative battery cable ground terminal bolt (5).
9. Remove the negative battery cable ground terminal (6) from the engine lift bracket.
10. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
11. Remove the evaporative emission (EVAP) canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269808-S18258969822007110200000) .
12. Disconnect the engine wiring harness electrical connector (4) from the exhaust CMP sensor.
13. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
14. Reposition the radiator inlet hose clamp at the engine.
15. Remove the radiator inlet hose from the cylinder head.
16. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
17. Remove the cylinder head and place on a clean work surface.
18. Remove the cylinder head gasket.
19. Clean all of the gasket surfaces.
20. Use the following steps when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface. IMPORTANT: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket. Hold the razor blade as parallel to the gasket surface as possible.
21. Clean the old sealer/lube and any dirt from around the bolt holes.
22. Clean the bolts holes with a nylon bristle brush.
23. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
4. Install NEW cylinder head bolts.
5. Install and tighten the cylinder head bolts in the sequence shown. Tighten: Tighten the bolts to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
6. Install the NEW front cylinder head bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
7. Install the radiator inlet hose to the cylinder head.
8. Position the radiator inlet hose clamp at the engine.
9. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
10. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
11. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269808-S18258969822007110200000) .
12. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
13. Position the negative battery cable ground terminal (6) to the engine lift bracket.
14. Install the negative battery cable ground terminal bolt (5). Tighten: Tighten the bolt to 10 N.m (89 lb in).
15. Install the fuel pump acoustic cover.
16. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .
17. Install the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269812-S14660407932007110200000) .
18. Install the turbocharger coolant feed pipe. Refer to «Turbocharger Coolant Feed Pipe Replacement (LNF)»(ref-269827-S38003762592007110200000) .
19. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LNF)»(ref-269792-S34959777142007110200000) .
20. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-269808-S15640782002007110200000) .
21. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .
2. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
3. Remove the intake camshaft position (CMP) sensor.
4. Remove the air inlet screen support nuts and support.
5. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
6. Remove the radiator outlet hose from the thermostat housing for access and removal of the oil cooler.
7. Reposition the radiator outlet hose clamp (1) at the oil cooler.
8. Remove the radiator outlet hose from the oil cooler.
9. Remove the radiator outlet hose clip (3) from the bracket.
10. Reposition the surge tank outlet hose clamp (1) at the oil cooler.
11. Remove the surge tank outlet hose from the oil cooler.
12. Remove the oil cooler bolts.
13. Remove the oil cooler.

1. Position the oil cooler to the engine block.
2. Install the oil cooler bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install the surge tank outlet hose to the oil cooler.
4. Position the surge tank outlet hose clamp (1) at the oil cooler.
5. Install the radiator outlet hose to the oil cooler.
6. Install the radiator outlet hose to the thermostat housing.
7. Position the radiator outlet hose clamp (2) at the thermostat housing.
8. Position the radiator outlet hose clamp (1) at the oil cooler.
9. Install the radiator outlet hose clip (3) to the bracket.
10. Install the air inlet screen support and nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
11. Install the intake CMP sensor.
12. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
13. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) .

1. Remove the flywheel. Refer to «Engine Replacement (w/Manual Transmission)»(ref-269812-S32664313692007110200000) or «Engine Replacement (w/Automatic Transmission)»(ref-269812-S37176020462007110200000) .
2. Pry out the crankshaft rear oil seal using a flat-bladed tool.

1. Using the J 42067 , install a NEW crankshaft real oil seal. See «Special Tools»(ref-269812-S12310610572007110200000) .
2. Install the flywheel. Refer to «Engine Replacement (w/Manual Transmission)»(ref-269812-S32664313692007110200000) or «Engine Replacement (w/Automatic Transmission)»(ref-269812-S37176020462007110200000) .

Engine Flywheel Replacement

Tools Required

1. J 43653 Flywheel Holding Tool
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Remove the automatic transmission, if equipped. Refer to «Transmission Replacement»(ref-269780-S31710603532007110200000) .
2. Remove the starter, if equipped with a manual transmission. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
3. Remove the clutch, if equipped. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
4. Install the J 43653 (1) to the engine block in order to hold the flywheel.
5. Remove the flywheel bolts, if equipped with a automatic transmission.
6. Remove the flywheel.
7. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.
8. Remove the flywheel bolts, if equipped with a manual transmission.
9. Remove the flywheel.
10. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Install the flywheel, if equipped with a manual transmission.
2. Install the flywheel bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
3. Install the flywheel if equipped with an automatic transmission.
4. Install the flywheel bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
5. Remove the J 43653 (1) from the engine block.
6. Install the clutch, if equipped. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
7. Install the starter, if equipped with a manual transmission. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
8. Install the automatic transmission, if equipped. Refer to «Transmission Replacement»(ref-269780-S31710603532007110200000) .

Engine Replacement (w/Manual Transmission)

Tools Required

1. J 42451-1 Engine Support Adapter
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
2. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
3. Recover the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-269812-S19225222632007110200000) .
5. Remove the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
6. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(ref-269808-S31845114672007110200000) or «Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100)»(ref-269808-S24484123692007110200000) or «Fuel Pressure Relief (High Pressure Side)»(ref-269808-S37419534322007110200000) .
7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
8. Disconnect the fuel feed pipe (1) from the fuel line. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
9. Remove the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) and «Charge Air Cooler Outlet Pipe Replacement»(ref-269808-S27974399432007110200000) .
10. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
11. Remove the transmission. Refer to «Transmission Replacement»(ref-269781-S26654548322007110200000) .
12. After the transmission is removed, reinstall the bolt from the differential case bracket assembly to body, in order to remove the support from under the rear drive module.
13. Remove the turbocharger heat shield bolts (1) and shield.
14. Remove the charge air cooler pipe to turbocharger bolts (1).
15. Remove the charge air cooler pipe and gasket (2) from the turbocharger.
16. Cap or plug the turbocharger opening.
17. Reposition the radiator inlet hose clamp at the engine.
18. Remove the radiator inlet hose from the engine.
19. Reposition the radiator inlet hose out of the way.
20. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
21. Reposition the radiator outlet hose clamp (1) at the oil cooler.
22. Remove the radiator outlet hose from the thermostat housing and oil cooler.
23. Remove the radiator outlet hose clip (3) from the bracket.
24. Reposition the radiator outlet hose out of the way.
25. Reposition the surge tank outlet hose clamp (2) at the thermostat housing.
26. Reposition the surge tank outlet hose clamp (1) at the oil cooler.
27. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
28. Reposition the surge tank outlet hose clamp (2) at the surge tank.
29. Remove the surge tank outlet hose from the surge tank.
30. Remove the surge tank clip (1) from the oil level indicator tube bracket.
31. Remove the surge tank outlet hose from the vehicle.
32. Reposition the surge tank air bleed hose clamp (1) at the engine.
33. Remove the surge tank air bleed hose clip (3) from the surge tank bracket.
34. Remove the surge tank air bleed hose from the engine.
35. Reposition the air bleed hose out of the way.
36. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
37. Remove the heater inlet (1) and outlet (2) hoses from the thermostat housing.
38. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
39. Drain the engine oil.
40. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
41. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
42. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum pump.
43. Remove the positive battery cable lead nut (2) at the starter.
44. Remove the positive battery cable lead (3) from the starter.
45. Remove the engine wiring harness clip (4) from the oil level indicator tube bracket.
46. Remove the engine wiring harness terminal (3) from the starter.
47. Remove the engine wiring harness terminal nut (2) from the starter.
48. Remove the engine wiring harness terminal (1) from the starter.
49. Remove the engine wiring harness clip (4) from the oil level indicator tube.
50. Lower the vehicle.
51. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
52. Cut the engine harness tie straps (1).
53. Remove the negative battery cable ground bolt (6) from the front engine lift bracket.
54. Remove the negative battery cable ground terminal (5) from the engine lift bracket.
55. Reposition the negative/positive battery cable out of the way.
56. Disconnect the engine wiring harness electrical connector (1) from the transmission oil cooler pump.
57. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
58. Remove the engine wiring harness clip (1) from the oil level indicator tube bracket.
59. Disconnect the engine wiring harness electrical connector (1) from the generator.
60. Reposition the positive battery cable terminal boot (4).
61. Remove the generator terminal nut (1).
62. Remove the positive battery cable terminal (3) from the generator.
63. Disconnect the engine wiring harness electrical connector (4) from the A/C compressor.
64. Disconnect the engine wiring harness electrical connector (1) from the fuel injector jumper electrical connector.
65. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
66. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
67. Remove the engine wiring harness clip (3) from the intake manifold brace.
68. Disconnect the engine wiring harness electrical connector from the EVAP canister purge solenoid valve.
69. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
70. Disconnect the engine wiring harness electrical connector (1) from the A/C refrigerant pressure sensor.
71. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum sensor.
72. Disconnect the engine wiring harness electrical connector (1) from the windshield wiper motor.
73. Remove the engine harness clip (2) from the wiper motor hole.
74. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
75. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
76. Remove the engine wiring harness clip (3) from the high pressure fuel pump bracket.
77. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator.
78. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP actuator.
79. Remove the engine harness clip (1) from the camshaft cover.
80. Disconnect the engine wiring harness electrical connectors from the ignition coils.
81. Disconnect the engine wiring harness electrical connector (1) from the heated oxygen sensor (HO2S) (3).
82. Disconnect the engine wiring harness electrical connector (4) from the exhaust CMP sensor.
83. Remove the engine harness ground terminal bolt (2) and reposition the engine harness ground terminal (1).
84. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
85. Disconnect the engine harness clips (2) from the camshaft cover.
86. Disconnect the engine harness clip (1) from the camshaft cover.
87. Remove the engine wiring harness clip (3) from the turbocharger coolant feed pipe stud (2).
88. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe tab.
89. Disconnect the engine wiring harness electrical connector from the boost sensor.
90. Remove the engine wiring harness ground bolt (2) from the cylinder head.
91. Remove the engine wiring harness ground terminal (1) from the cylinder head.
92. Remove the engine harness clips (3, 4) from the front studs.
93. Gather all branches of the engine harness and lay off to the side.
94. Reposition the vacuum hose clamp (5) at the turbocharger.
95. Remove the vacuum hose from the turbocharger.
96. Remove the vacuum hose from the turbocharger coolant feed pipe clips (4).
97. Reposition the vacuum hose out of the way.
98. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
99. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
100. Remove the turbocharger coolant feed pipe bracket bolt from the cylinder head.
101. Remove the turbocharger coolant feed pipe bracket from the vehicle.
102. Remove the A/C compressor line bolt and reposition the line off to the side.
103. Raise and support the vehicle.
104. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
105. Lower the vehicle.
106. Remove the left engine mount upper nut.
107. Remove the right engine mount upper nut.
108. Install the J 42451-1 to the engine, if necessary.
109. Install a suitable engine lifting devise to the engine.
110. Remove the engine from the vehicle.
111. Remove the clutch pressure plate and disc. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
112. Remove the flywheel bolts and flywheel.
113. Install the engine to an engine stand.
114. Remove the A/C compressor bolts and compressor.
115. Remove the catalytic converter to bracket bolts.
116. Remove the catalytic converter nuts (2).
117. Remove the catalytic converter (3) and gasket (1) from the turbocharger and bracket (4).

1. Install the catalytic converter (3) and gasket (1) to the turbocharger and bracket (4).
2. Install the catalytic converter nuts (2). Tighten: Tighten the nuts to 59 N.m (43 lb ft).
3. Install the catalytic converter to bracket bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
4. Install the A/C compressor and bolts. Tighten: Tighten the bolts in the sequence shown to 22 N.m (16 lb ft).
5. Install a suitable engine lifting devise to the engine.
6. Remove the engine from the stand.
7. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
8. Install the flywheel and bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
9. Install the clutch pressure plate and disc. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
10. Install the engine to the vehicle.
11. Install the right engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
12. Install the left engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
13. Remove the J 42451-1 from the engine, if necessary.
14. Raise and support the vehicle.
15. Position the power steering pump bracket to the engine and install the bracket bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
16. Lower the vehicle.
17. Position the A/C compressor line and install the bolt. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
18. Position the turbocharger coolant feed pipe to the vehicle.
19. Install the turbocharger coolant feed pipe bracket bolt (3) to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
20. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head. Tighten: Tighten the fitting to 35 N.m (26 lb ft).
21. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
22. Position the vacuum hose to the turbocharger.
23. Install the vacuum hose to the turbocharger.
24. Position the vacuum hose clamp (5) at the turbocharger.
25. Install the vacuum hose to the turbocharger coolant feed pipe clips (4).
26. Position the branches of the engine harness to the engine.
27. Install the engine harness clips (3, 4) to the front studs.
28. Install the engine wiring harness ground terminal (1) to the cylinder head.
29. Install the engine wiring harness ground bolt (2) to the cylinder head. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
30. Connect the engine wiring harness electrical connector to the boost sensor.
31. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe tab.
32. Install the engine wiring harness clip (3) to the turbocharger coolant feed pipe stud (2).
33. Connect the engine harness clips (2) to the camshaft cover.
34. Connect the engine harness clip (1) to the camshaft cover.
35. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
36. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
37. Position the engine harness ground terminal (1) and install the engine harness ground terminal bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
38. Connect the engine wiring harness electrical connector (1) to the HO2S (3).
39. Connect the engine wiring harness electrical connectors to the ignition coils.
40. Install the engine harness clip (1) to the camshaft cover.
41. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator.
42. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator.
43. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
44. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
45. Install the engine wiring harness clip (3) to the high pressure fuel pump bracket.
46. Connect the engine wiring harness electrical connector (1) to the windshield wiper motor.
47. Install the engine harness clip (2) to the wiper motor hole.
48. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum sensor.
49. Connect the engine wiring harness electrical connector (1) to the A/C refrigerant pressure sensor.
50. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid valve.
51. Connect the engine wiring harness electrical connector to the MAP sensor.
52. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
53. Connect the engine wiring harness electrical connector (2) to the knock sensor.
54. Install the engine wiring harness clip (3) to the intake manifold brace.
55. Connect the engine wiring harness electrical connector (1) to the fuel injector jumper electrical connector.
56. Install the positive battery cable terminal (3) to the generator.
57. Install the generator terminal nut (1). Tighten: Tighten the nut to 20 N.m (15 lb ft).
58. Position the positive battery cable terminal boot (4).
59. Connect the engine wiring harness electrical connector (4) to the A/C compressor.
60. Connect the engine wiring harness electrical connector (1) to the generator.
61. Connect the engine wiring harness electrical connector (2) to the knock sensor.
62. Install the engine wiring harness clip (1) to the oil level indicator tube bracket.
63. Connect the engine wiring harness electrical connector (1) to the transmission oil cooler pump.
64. Position the negative/positive battery cable to the engine.
65. Install the negative battery cable ground terminal (5) to the engine lift bracket.
66. Install the negative battery cable ground bolt (6) to the front engine lift bracket. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
67. Install NEW tie straps (1) to the engine wiring harness.
68. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
69. Raise the vehicle.
70. Install the engine wiring harness terminal (3) to the starter.
71. Install the engine wiring harness terminal (1) to the starter.
72. Install the engine wiring harness terminal nut (2) to the starter. Tighten: Tighten the nut to 3 N.m (27 lb in).
73. Install the engine wiring harness clip (4) to the oil level indicator tube.
74. Install the positive battery cable lead (3) to the starter.
75. Install the positive battery cable lead nut (2) at the starter. Tighten: Tighten the nut to 10 N.m (89 lb in).
76. Install the engine wiring harness clip (4) to the oil level indicator tube bracket.
77. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum pump.
78. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
79. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
80. Lower the vehicle.
81. Install the heater inlet (1) and outlet (2) hoses to the thermostat housing.
82. Position the heater inlet and outlet hose clamps at the thermostat housing.
83. Position the air bleed hose to the engine.
84. Install the surge tank air bleed hose to the engine.
85. Install the surge tank air bleed hose clip (3) to the surge tank bracket.
86. Position the surge tank air bleed hose clamp (1) at the engine.
87. Install the surge tank clip (1) to the oil level indicator tube bracket.
88. Position the surge tank outlet hose clamp (2) at the surge tank.
89. Install the surge tank outlet hose to the thermostat housing and oil cooler.
90. Position the surge tank outlet hose clamp (1) at the oil cooler.
91. Position the surge tank outlet hose clamp (2) at the thermostat housing.
92. Position the outlet hose to the engine.
93. Install the radiator outlet hose clip (3) to the bracket.
94. Install the radiator outlet hose to the thermostat housing and oil cooler.
95. Position the radiator outlet hose clamp (1) at the oil cooler.
96. Position the radiator outlet hose clamp (2) at the thermostat housing.
97. Position the inlet hose to the engine.
98. Install the radiator inlet hose to the engine.
99. Position the radiator inlet hose clamp at the engine.
100. Remove the cap or plug from the turbocharger opening.
101. Install the charge air cooler pipe to the turbocharger.
102. Install the charge air cooler pipe to turbocharger bolts (1). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
103. Install the turbocharger heat shield and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
104. Install the transmission. Refer to «Transmission Replacement»(ref-269781-S26654548322007110200000) .
105. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
106. Install the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) and «Charge Air Cooler Outlet Pipe Replacement»(ref-269808-S27974399432007110200000) .
107. Connect the fuel feed pipe (1) to the fuel line. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
108. Connect the EVAP canister purge solenoid tube to the valve (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
109. Install the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
110. Install the drive belt. Refer to «Drive Belt Replacement»(ref-269812-S19225222632007110200000) .
111. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
112. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
113. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
114. Fill the engine with oil.

Engine Replacement (w/Automatic Transmission)

Tools Required

1. J 42451-1 Engine Support Adapter
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
2. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
3. Recover the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-269812-S19225222632007110200000) .
5. Remove the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
6. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(ref-269808-S31845114672007110200000) or «Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100)»(ref-269808-S24484123692007110200000) or «Fuel Pressure Relief (High Pressure Side)»(ref-269808-S37419534322007110200000) .
7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
8. Disconnect the fuel feed pipe (1) from the fuel line. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
9. Remove the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) and «Charge Air Cooler Outlet Pipe Replacement»(ref-269808-S27974399432007110200000) .
10. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
11. Remove the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
12. Remove the turbocharger heat shield bolts (1) and shield.
13. Remove the charge air cooler pipe to turbocharger bolts (1).
14. Remove the charge air cooler pipe and gasket (2) from the turbocharger.
15. Cap or plug the turbocharger opening.
16. Reposition the radiator inlet hose clamp at the engine.
17. Remove the radiator inlet hose from the engine.
18. Reposition the radiator inlet hose out of the way.
19. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
20. Reposition the radiator outlet hose clamp (1) at the oil cooler.
21. Remove the radiator outlet hose from the thermostat housing and oil cooler.
22. Remove the radiator outlet hose clip (3) from the bracket.
23. Reposition the radiator outlet hose out of the way.
24. Reposition the surge tank outlet hose clamp (2) at the thermostat housing.
25. Reposition the surge tank outlet hose clamp (1) at the oil cooler.
26. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
27. Reposition the surge tank outlet hose clamp (2) at the surge tank.
28. Remove the surge tank outlet hose from the surge tank.
29. Remove the surge tank clip (1) from the oil level indicator tube bracket.
30. Remove the surge tank outlet hose from the vehicle.
31. Reposition the surge tank air bleed hose clamp (1) at the engine.
32. Remove the surge tank air bleed hose clip (3) from the surge tank bracket.
33. Remove the surge tank air bleed hose from the engine.
34. Reposition the air bleed hose out of the way.
35. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
36. Remove the heater inlet (1) and outlet (2) hoses from the thermostat housing.
37. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
38. Drain the engine oil.
39. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
40. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
41. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum pump.
42. Lower the vehicle.
43. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
44. Cut the engine harness tie straps (1).
45. Remove the negative battery cable ground bolt (6) from the front engine lift bracket.
46. Remove the negative battery cable ground terminal (5) from the engine lift bracket.
47. Reposition the negative/positive battery cable out of the way.
48. Disconnect the engine wiring harness electrical connector (1) from the transmission oil cooler pump.
49. Disconnect the engine wiring harness electrical connector (1) from the generator.
50. Reposition the positive battery cable terminal boot (4).
51. Remove the generator terminal nut (1).
52. Remove the positive battery cable terminal (3) from the generator.
53. Disconnect the engine wiring harness electrical connector (4) from the A/C compressor.
54. Disconnect the engine wiring harness electrical connector (1) from the fuel injector jumper electrical connector.
55. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
56. Disconnect the engine wiring harness electrical connector (1) from the A/C refrigerant pressure sensor.
57. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum sensor.
58. Disconnect the engine wiring harness electrical connector (1) from the windshield wiper motor.
59. Remove the engine harness clip (2) from the wiper motor hole.
60. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
61. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
62. Remove the engine wiring harness clip (3) from the high pressure fuel pump bracket.
63. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator.
64. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP actuator.
65. Remove the engine harness clip (1) from the camshaft cover.
66. Disconnect the engine wiring harness electrical connectors from the ignition coils.
67. Disconnect the engine wiring harness electrical connector (1) from the heated oxygen sensor (HO2S) (3).
68. Disconnect the engine wiring harness electrical connector (4) from the exhaust CMP sensor.
69. Remove the engine harness ground terminal bolt (2) and reposition the engine harness ground terminal (1).
70. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
71. Disconnect the engine harness clips (2) from the camshaft cover.
72. Disconnect the engine harness clip (1) from the camshaft cover.
73. Remove the engine wiring harness clip (3) from the turbocharger coolant feed pipe stud (2).
74. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe tab.
75. Disconnect the engine wiring harness electrical connector from the boost sensor.
76. Remove the engine wiring harness ground bolt (2) from the cylinder head.
77. Remove the engine wiring harness ground terminal (1) from the cylinder head.
78. Remove the engine harness clips (3, 4) from the front studs.
79. Gather all branches of the engine harness and lay off to the side.
80. Reposition the charge air bypass valve vacuum hose clamp (5) at the turbocharger.
81. Remove the vacuum hose from the turbocharger coolant feed pipe clips (4).
82. Remove the charge air bypass valve solenoid.
83. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
84. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
85. Remove the turbocharger coolant feed pipe bracket bolt from the cylinder head.
86. Remove the turbocharger coolant feed pipe bracket from the vehicle.
87. Remove the A/C compressor line bolt and reposition the line off to the side.
88. Raise and support the vehicle.
89. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
90. Remove the torque converter to flywheel bolts.
91. Remove the 4 lower bellhousing bolts (2).
92. Lower the vehicle.
93. Remove the remaining upper 5 bellhousing bolts (1).
94. Remove the left engine mount upper nut.
95. Remove the right engine mount upper nut.
96. Install the J 42451-1 to the engine, if necessary.
97. Install a suitable engine lifting devise to the engine.
98. Separate the engine from the transmission.
99. Remove the engine from the vehicle.
100. Remove the flywheel bolts and flywheel.
101. Install the engine to an engine stand.
102. Remove the A/C compressor bolts and compressor.
103. Remove the catalytic converter to bracket bolts.
104. Remove the catalytic converter nuts (2).
105. Remove the catalytic converter (3) and gasket (1) from the turbocharger and bracket (4).

1. Install the catalytic converter (3) and gasket (1) to the turbocharger and bracket (4).
2. Install the catalytic converter nuts (2). Tighten: Tighten the nuts to 59 N.m (43 lb ft).
3. Install the catalytic converter to bracket bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
4. Install the A/C compressor and bolts. Tighten: Tighten the bolts in the sequence shown to 22 N.m (16 lb ft).
5. Install a suitable engine lifting devise to the engine.
6. Remove the engine from the stand.
7. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
8. Install the flywheel and bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
9. Install the engine to the vehicle.
10. Install the right engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
11. Install the left engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
12. Remove the J 42451-1 from the engine, if necessary.
13. Install the upper 5 bellhousing bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
14. Raise and support the vehicle.
15. Install the 4 lower bellhousing bolts (2). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
16. Install the torque converter to flywheel bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
17. Position the power steering pump bracket to the engine and install the bracket bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
18. Lower the vehicle.
19. Position the A/C compressor line and install the bolt. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
20. Position the turbocharger coolant feed pipe to the vehicle.
21. Install the turbocharger coolant feed pipe bracket bolt (3) to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
22. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head. Tighten: Tighten the fitting to 35 N.m (26 lb ft).
23. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
24. Install the charge air bypass valve vacuum solenoid.
25. Install the charge air bypass valve vacuum hose to the turbocharger coolant feed pipe clips (4).
26. Position the charge air bypass valve vacuum hose clamp (5) at the turbocharger.
27. Place the charge air bypass valve solenoid out of the way.
28. Position the branches of the engine harness to the engine.
29. Install the engine harness clips (3, 4) to the front studs.
30. Install the engine wiring harness ground terminal (1) to the cylinder head.
31. Install the engine wiring harness ground bolt (2) to the cylinder head. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
32. Connect the engine wiring harness electrical connector to the boost sensor.
33. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe tab.
34. Install the engine wiring harness clip (3) to the turbocharger coolant feed pipe stud (2).
35. Connect the engine harness clips (2) to the camshaft cover.
36. Connect the engine harness clip (1) to the camshaft cover.
37. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
38. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
39. Position the engine harness ground terminal (1) and install the engine harness ground terminal bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
40. Connect the engine wiring harness electrical connector (1) to the HO2S (3).
41. Connect the engine wiring harness electrical connectors to the ignition coils.
42. Install the engine harness clip (1) to the camshaft cover.
43. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator.
44. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator.
45. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
46. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
47. Install the engine wiring harness clip (3) to the high pressure fuel pump bracket.
48. Connect the engine wiring harness electrical connector (1) to the windshield wiper motor.
49. Install the engine harness clip (2) to the wiper motor hole.
50. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum sensor.
51. Connect the engine wiring harness electrical connector (1) to the A/C refrigerant pressure sensor.
52. Connect the engine wiring harness electrical connector (2) to the knock sensor.
53. Connect the engine wiring harness electrical connector (1) to the fuel injector jumper electrical connector.
54. Install the positive battery cable terminal (3) to the generator.
55. Install the generator terminal nut (1). Tighten: Tighten the nut to 20 N.m (15 lb ft).
56. Position the positive battery cable terminal boot (4).
57. Connect the engine wiring harness electrical connector (4) to the A/C compressor.
58. Connect the engine wiring harness electrical connector (1) to the generator.
59. Connect the engine wiring harness electrical connector (1) to the transmission oil cooler pump.
60. Position the negative/positive battery cable to the engine.
61. Install the negative battery cable ground terminal (5) to the engine lift bracket.
62. Install the negative battery cable ground bolt (6) to the front engine lift bracket. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
63. Install NEW tie straps (1) to the engine wiring harness.
64. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
65. Raise the vehicle.
66. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum pump.
67. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
68. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
69. Lower the vehicle.
70. Install the heater inlet (1) and outlet (2) hoses to the thermostat housing.
71. Position the heater inlet and outlet hose clamps at the thermostat housing.
72. Position the air bleed hose to the engine.
73. Install the surge tank air bleed hose to the engine.
74. Install the surge tank air bleed hose clip (3) to the surge tank bracket.
75. Position the surge tank air bleed hose clamp (1) at the engine.
76. Install the surge tank clip (1) to the oil level indicator tube bracket.
77. Position the surge tank outlet hose clamp (2) at the surge tank.
78. Install the surge tank outlet hose to the thermostat housing and oil cooler.
79. Position the surge tank outlet hose clamp (1) at the oil cooler.
80. Position the surge tank outlet hose clamp (2) at the thermostat housing.
81. Position the outlet hose to the engine.
82. Install the radiator outlet hose clip (3) to the bracket.
83. Install the radiator outlet hose to the thermostat housing and oil cooler.
84. Position the radiator outlet hose clamp (1) at the oil cooler.
85. Position the radiator outlet hose clamp (2) at the thermostat housing.
86. Position the inlet hose to the engine.
87. Install the radiator inlet hose to the engine.
88. Position the radiator inlet hose clamp at the engine.
89. Remove the cap or plug from the turbocharger opening.
90. Install the charge air cooler pipe to the turbocharger.
91. Install the charge air cooler pipe to turbocharger bolts (1). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
92. Install the turbocharger heat shield and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
93. Install the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
94. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
95. Install the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-269808-S27907518832007110200000) and «Charge Air Cooler Outlet Pipe Replacement»(ref-269808-S27974399432007110200000) .
96. Connect the fuel feed pipe (1) to the fuel line. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269808-S23169660002007110200000) .
97. Connect the EVAP canister purge solenoid tube to the valve (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269808-S02204408682007110200000) .
98. Install the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
99. Install the drive belt. Refer to «Drive Belt Replacement»(ref-269812-S19225222632007110200000) .
100. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
101. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
102. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
103. Fill the engine with oil.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Allow the oil to drain completely.
5. Install the oil pan drain plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
6. Use a 32 mm (1 1/4 in) socket on the hex on top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap.
7. Remove the oil filter cap and filter.
8. Remove the oil filter from the oil filter cap.
9. Inspect the oil filter cap O-ring seal for damage, replace as necessary.

1. Install a NEW oil filter to the oil filter cap.
2. Install the oil filter cap and filter.
3. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap. Tighten: Tighten the oil filter cap until fully seated. DO NOT exceed 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(ref-269835-S13618802802007110200000) .

Draining Fluids and Oil Filter Removal

1. Use J 44887 to remove the oil filter cap. See «Special Tools»(ref-269812-S12310610572007110200000) . Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

1. Remove the balancer retaining bolt and washer. Discard the bolt.
2. Remove the balancer using a universal removal tool.

Engine Flywheel Removal

1. Remove the flywheel attaching bolts.
2. Remove the flywheel, if the vehicle has a manual transmission.
3. Remove the flywheel attaching bolts.
4. Remove the flywheel, if the vehicle has an automatic transmission.

Scheme 4

After the flywheel housing has been removed, mount the engine block to a suitable engine stand.

Oil Level Indicator and Tube Removal

1. Disconnect the knock sensor from the oil level indicator tube.
2. Remove the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bracket to the intake manifold bolt.
4. Remove the oil level indicator and the oil level indicator tube from the oil pan.
5. Inspect the O-rings for damage. Replace if damaged.

Starter Removal

1. Remove the starter bolts.
2. Remove the starter.

Engine Oil Cooler Removal

1. Remove the oil cooler bolt.
2. Remove the oil cooler.

Intake Manifold Removal

1. Disconnect the bypass valve solenoid hoses.
2. Remove the bypass valve solenoid bolt.
3. Remove the bypass valve solenoid with hoses.
4. Loosen and disconnect the fuel feed line tube nut.
5. Remove the fuel feed line bolts.
6. Remove the fuel feed line.
7. Inspect the fuel feed line nut for damaged threads.
8. Inspect the fuel feed line sealing bail for damage or debris.
9. Replace the fuel feed line if any damage is found.
10. Remove the high pressure fuel pump cover bolts.
11. Remove the high pressure fuel pump cover.
12. Remove the high pressure fuel pump noise insulator.
13. Remove the throttle body bolts.
14. Remove the throttle body.
15. Remove the vacuum pump bolts.
16. Remove the vacuum pump.
17. Remove the vacuum pump bracket bolt and nuts.
18. Remove the vacuum pump bracket.
19. Disconnect the rear knock sensor from the intake manifold brace.
20. Remove the intake manifold brace bolt.
21. Remove the intake manifold brace.
22. Remove the intake manifold bolts and nuts.
23. Remove the intake manifold.
24. Remove the intake manifold gasket.

Fuel Rail and Injectors Removal

Tools Required

1. J 2619-01 Slide Hammer
2. J-37281-A Injector Remover

1. Disconnect the electrical harness from the fuel rail harness connection.
2. Remove the fuel injector noise insulator.
3. Remove and discard the high pressure fuel line.
4. Disconnect all 4 fuel injector electrical connections.
5. Remove the fuel rail bolts.
6. Remove the fuel rail and injectors.
7. The injectors may stay in the cylinder head. Remove the fuel injector hold-down clamp before removing the injector.
8. Use J-37281-A and J 2619-01 to remove the injector.
9. Remove and discard the high pressure fuel pump bolts.
10. Remove the high pressure fuel pump.
11. Remove and discard the high pressure fuel pump gasket.
12. Remove and discard the high pressure fuel pump O-ring.
13. Remove the high pressure fuel pump roller lifter.

Turbocharger Removal

1. Remove the turbocharger heat shield bolts.
2. Remove the turbocharger heat shield.
3. Remove the catalytic converter nuts and bolts.
4. Remove the catalytic converter.
5. Remove the catalytic converter seal.
6. Remove the turbocharger oil feed pipe bolts.
7. Remove the turbocharger oil feed pipe gaskets.
8. Remove the turbocharger oil feed pipe.
9. Remove the turbocharger coolant return pipe bolts.
10. Remove the turbocharger coolant return pipe gaskets.
11. Remove the turbocharger coolant return pipe.
12. Remove the turbocharger outlet adapter bolts.
13. Remove the turbocharger outlet adapter.
14. Remove the turbocharger coolant feed pipe bolts.
15. Remove the turbocharger coolant feed pipe gaskets.
16. Remove the turbocharger coolant feed pipe.
17. Remove the catalytic converter bracket bolt and nut.
18. Remove the catalytic converter bracket.
19. Remove the turbocharger brace nut.
20. Remove the turbocharger brace.
21. Remove the turbocharger oil return pipe bolts.
22. Remove the turbocharger oil return pipe.
23. Remove and discard the turbocharger oil return pipe gasket.
24. Remove the PCV hose fitting bolt.
25. Remove the PCV hose fitting from the turbocharger with the hose still attached.
26. Remove the turbocharger nuts.
27. Remove the turbocharger.
28. Remove the turbocharger gasket.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield bolts.
2. Remove the exhaust manifold heat shield.
3. Remove the block heater bolt, if equipped.
4. Remove the block heater, if equipped.
5. Remove the exhaust manifold nuts.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.

Camshaft Cover Removal

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

Engine Front Cover and Oil Pump Removal

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

Timing Chain and Tensioner Removal

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

Intake Camshaft, Follower, and Adjuster Removal

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

Exhaust Camshaft, Follower, and Adjuster Removal

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

Balance Shaft Drive Chain and Tensioner Removal

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

Balance Shaft Removal

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools»(ref-269812-S12310610572007110200000) . Insert the tool with the foot parallel to the shaft.
4. When the J 43650 is inserted in the block turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(ref-269812-S12310610572007110200000) .
5. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) .
6. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(ref-269812-S12310610572007110200000) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.
7. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(ref-269812-S12310610572007110200000) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(ref-269812-S12310610572007110200000) .

Water Pump Removal

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

Cylinder Head Removal

1. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Clean all of the gasket surfaces.
5. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. IMPORTANT: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
6. Clean the old sealer/lube and dirt from the bolt holes.
7. Clean the bolt holes with a nylon bristle brush.
8. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
9. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools»(ref-269812-S12310610572007110200000) .

Oil Pan Removal

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

Piston, Connecting Rod, and Bearing Removal

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install J-43966-1 on the connecting rod bolts before removing the piston and connecting rod assembly. See «Special Tools»(ref-269812-S12310610572007110200000) .
7. Remove the piston and connecting rod assembly.

Lower Crankcase Removal

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

Crankshaft and Bearings Removal

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

Cylinder Sleeve Removal

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install the cylinder bore sleeve puller (1) through the cylinder bore.
3. Align the shoe (1) of the cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture (4) onto the threaded shaft of the cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
10. Remove the fixture, cylinder bore sleeve puller, and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(ref-269812-S28285328712007110200000) .

Installation Procedures

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. Insert the 4 attachment bolts into the legs of the fixture (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) into the groove of fixture (1).
8. Using a ratchet, rotate the threaded shaft of fixture (1) in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
10. Using a torque wrench, torque the threaded shaft to 102 N.m (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the fixture (1) from the cylinder block (100).

Scheme 5

1. EN 45680-865 Debris Collector (3)
2. EN 45680-861 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction
5. EN 45680-881 Bore Chamfer Bit
6. EN 45680-899 Bore Trimmer Pilot, white in color

Scheme 6

1. Trim Tool Preloader (1)
2. EN 45680-412 Set Gage Ring (2)
3. EN 45680-413 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-414 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. Change the bore chamfer bit to EN 45680-881.
6. Change the bore trimmer pilot to EN 45680-885.
7. The groove side of the set gage ring (1) should be positioned upward on a flat surface.
8. Carefully position the trim tool assembly onto the set gage ring.
9. Loosen the shaft collar screw (2).
10. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
11. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
12. Place the trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
13. Install the 4 bolts (2) into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
14. Fasten drive adapter (1) into the drill chuck.
15. Connect a compressed air supply 517.10-861.84 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
16. Place the drive adapter and drill assembly (1) vertically onto the drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, apply firm downward force until the cutting action is complete.
17. Remove the drive adapter (1) and drill assembly from the trim tool assembly.
18. Turn off the compressed air valve (2).
19. Remove the trim tool assembly from the engine block.
20. Remove any material shavings that may be found on the metal shaving catch plug.
21. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug.
22. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
23. Using a light, illuminate the backside of the straight edge.
24. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
25. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
26. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.

Crankshaft and Bearings Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gage. See «Special Tools»(ref-269812-S12310610572007110200000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

Scheme 7

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

1. Tighten the bedplate to specification using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
2. Measure the bearing bore for taper and out-of-round using the J 8087 . See «Special Tools»(ref-269812-S12310610572007110200000) .
3. No taper or out-of-round should exist.

Bearing Selection

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

Lower Crankcase Installation

1. Install the upper crankshaft bearings and lubricate bearing surfaces with engine oil.
2. Install the crankshaft on the journals.
3. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) to the surfaces of the engine block to bedplate mating surfaces.
5. Install the lower crankcase. Tap gently into place with a suitable tool, if necessary. Ensure the lower crankcase is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten: Tighten the crankshaft bearing bolts in sequence to 20 N.m (15 lb ft). Using the J 45059 , tighten the crankshaft bearing bolts in sequence to 77 degrees. See «Special Tools»(ref-269812-S12310610572007110200000) .
7. Install the lower crankcase perimeter bolts. Tighten: Tighten the lower crankcase perimeter bolts in sequence to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Installation

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools»(ref-269812-S12310610572007110200000) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools»(ref-269812-S12310610572007110200000) . The seal should be flush to 0.5 mm (0.0197 in) deep.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 43953 Piston Ring Compressor
2. J-43966-1 Connecting Rod Guides. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Install the NEW connecting rod bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. See «Special Tools»(ref-269812-S12310610572007110200000) . This protects the crankshaft journal during piston and connecting rod installation.
3. Install the J 43953 , the piston, and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the J 43953 against the engine block until all the rings have entered the cylinder bore. Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use NEW bolts. Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.07-0.37 mm (0.0027-0.0145 in).

Cylinder Head Installation

1. Install the cylinder head gasket to the block.
2. Install the cylinder head. Ensure the number 1 cylinder is at top dead center (TDC). The key on the crankshaft should be on top in the 12 o'clock position.
3. Install the cylinder head bolts. Tighten: Tighten the bolts in sequence to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 30 N.m (22 lb ft).

Balance Shaft Installation

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(ref-269812-S12310610572007110200000) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See «Special Tools»(ref-269812-S12310610572007110200000) .
4. Place the number 1 piston at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts into their bores.
7. Install the balance shaft retaining bolts. Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).

Water Pump Installation

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

Timing Chain, Sprockets, Tensioner Installation

Tools Required

1. J 45027 Tensioner Tool. See «Special Tools»(ref-269812-S12310610572007110200000) .
2. J 45059 Angle Meter. See «Special Tools»(ref-269812-S12310610572007110200000) .

1. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
2. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
3. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
4. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
5. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
6. Hand tighten the new intake camshaft actuator bolt.
7. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
8. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
9. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
10. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
11. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
12. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
13. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
14. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
15. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
16. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
17. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
18. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
19. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
20. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
21. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
22. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
23. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft), plus 100 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .
24. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
25. Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
26. Install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

Crankshaft Front Oil Seal Installation

1. Install the seal into the front cover using the J 34115 . See «Special Tools»(ref-269812-S12310610572007110200000) .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

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

Camshaft Cover Installation

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

Oil Pan Installation

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

Crankshaft Balancer Installation

1. Install the balancer onto the crankshaft indexing keyway. Use care to properly align the keyway and flats on the balancer with the oil pump drive.
2. Install the crankshaft balancer using a universal balancer installer.
3. Install a NEW retaining bolt. Prevent the crankshaft from rotating when tightening the bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .

Oil Filter Adapter Installation

1. Install a new oil filter on the oil filter cap.
2. Lubricate the oil filter cap O-ring with 5W30 engine oil.
3. Use the J 44887 to install the oil filter adapter. See «Special Tools»(ref-269812-S12310610572007110200000) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Fuel Rail and Injectors Installation

1. Install the fuel rail with injectors into the cylinder head evenly.
2. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.
3. Start and hand tighten the remaining fuel rail bolts. Tighten: Tighten the fuel rail bolts in sequence to 22 N.m (16 lb ft). Tighten the fuel rail bolts in sequence a second time to 22 N.m (16 lb ft).
4. Install the fuel injector noise insulator.
5. Connect the electrical harness to the fuel rail harness connection.
6. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.
7. Lubricate the high pressure fuel pump roller lifter with 5W30 engine oil and install into the cylinder head bore.
8. Install a NEW high pressure fuel pump gasket.
9. Install a NEW high pressure fuel pump O-ring.
10. Install the high pressure fuel pump.
11. Start and hand-tighten the NEW high pressure fuel pump bolts evenly. Tighten: Tighten the high pressure fuel pump bolts evenly to 15 N.m (11 lb ft).
12. Install and hand-tighten both ends of the NEW high pressure fuel line. Tighten: Tighten the high pressure fuel line fitting nuts to 30 N.m (22 lb ft).

Intake Manifold Installation

1. Install a NEW intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold bolts and nuts. Tighten: Tighten the intake manifold bolts to 22 N.m (16 lb ft). Tighten the intake manifold nuts to 22 N.m (16 lb ft).
4. Install the intake manifold brace.
5. Install the intake manifold brace bolt. Tighten: Tighten the intake manifold brace bolt to 22 N.m (16 lb ft).
6. Connect the rear knock sensor to the intake manifold brace.
7. Install the vacuum pump bracket.
8. Install the vacuum pump bracket bolt and nut. Tighten: Tighten the vacuum pump bracket bolt and nut to 22 N.m (16 lb in).
9. Install the vacuum pump.
10. Install the vacuum pump bolts. Tighten: Tighten the vacuum pump bolts to 10 N.m (89 lb in).
11. Install the throttle body.
12. Install the throttle body bolts. Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).
13. Install the high pressure fuel pump noise insulator.
14. Install the high pressure fuel pump cover.
15. Install the high pressure fuel pump cover bolts. Tighten: Tighten the fuel pump cover bolts to 10 N.m (89 lb in).
16. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
17. Install the fuel feed line.
18. Install the fuel feed line bolts.
19. Connect the low pressure fuel line nut. Tighten: Tighten the low pressure fuel line nut to 30 N.m (22 lb ft). Tighten the fuel feed line bolts to 10 N.m (89 lb in).
20. Install the bypass valve solenoid with hoses.
21. Install the bypass valve solenoid bolts. Tighten: Tighten the bypass valve solenoid bolts to 10 N.m (89 lb in).
22. Connect the bypass valve solenoid hoses and clamps.

Exhaust Manifold Installation

1. Install new exhaust manifold studs. Tighten: Tighten the studs to 15 N.m (11 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten: Tighten the exhaust manifold nuts to 14 N.m (10 lb ft). Tighten the exhaust manifold nuts a second time to 14 N.m (10 lb ft).
6. Install the block heater, if equipped. Tighten: Tighten the block heater bolt to 10 N.m (89 lb in).
7. Install the exhaust manifold heat shield.
8. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 25 N.m (18 lb ft).

Turbocharger Installation

1. Install a new turbocharger oil return pipe gasket.
2. Install the turbocharger oil return pipe.
3. Install the turbocharger oil return pipe bolts. Tighten: Tighten the turbocharger oil return pipe bolts to 10 N.m (89 lb in).
4. Install a new turbocharger gasket.
5. Install the turbocharger.
6. Install the turbocharger nuts. Tighten: Tighten the turbocharger nuts to 30 N.m (22 lb ft). Tighten: Tighten the turbocharger nuts a second time to 35 N.m (26 lb ft).
7. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
8. Install the oil return pipe into the block.
9. Install the turbocharger brace.
10. Install the turbocharger brace nut. Tighten: Tighten the turbocharger brace upper nut to 50 N.m (37 lb ft).
11. Install the catalytic converter bracket.
12. Install the catalytic converter bracket bolt and nut. Tighten: Tighten the catalytic converter bracket bolt and nut to 50 N.m (37 lb ft).
13. Install the turbocharger coolant feed pipe.
14. Install the turbocharger coolant feed pipe gaskets.
15. Install the turbocharger coolant feed pipe bolts. Tighten: Tighten the turbocharger coolant feed pipe bolts to 20 N.m (15 lb ft). Tighten the turbocharger coolant feed pipe mounting bolt to 10 N.m (89 lb in).
16. Connect the positive crankcase ventilation (PCV) and hose assembly.
17. Install the turbocharger outlet adapter.
18. Install the turbocharger outlet adapter bolts. Tighten: Tighten the turbocharger outlet adapter bolts to 25 N.m (18 lb ft).
19. Install the turbocharger coolant return pipe.
20. Install the turbocharger coolant return pipe gaskets.
21. Install the turbocharger coolant return pipe bolts. Tighten: Tighten the turbocharger coolant return pipe bolts to 20 N.m (15 lb ft).
22. Install the turbocharger oil feed pipe.
23. Install the turbocharger oil feed pipe gaskets.
24. Install the turbocharger oil feed pipe bolts. Tighten: Tighten the turbocharger oil feed pipe bolts to 20 N.m (15 lb ft).
25. Install the catalytic converter seal.
26. Install the catalytic converter.
27. Install the catalytic converter bolts. Tighten: Tighten the catalytic converter bolts to 50 N.m (37 lb ft).
28. Install the catalytic converter nuts. Tighten: Tighten the catalytic converter nuts to 50 N.m 37 lb ft.
29. Install the turbocharger heat shield.
30. Install the turbocharger heat shield bolts. Tighten: Tighten the turbocharger heat shield bolts to 10 N.m (89 lb in).

Engine Oil Cooler Installation

1. Install the oil cooler.
2. Install the oil cooler bolts. Tighten: Tighten the oil cooler bolts to 22 N.m (16 lb ft).

Starter Installation

1. Install the starter.
2. Install the starter bolts. Tighten: Tighten the starter bolts to 53 N.m 39 lb ft.

Oil Level Indicator and Tube Installation

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

Engine Flywheel Installation

1. Install the flywheel.
2. Install the NEW bolts.
3. Hold the crankshaft. Tighten: Tighten the flywheel bolts to 53 N.m (39 lb ft), plus 25 degrees, using the J 45059 . See «Special Tools»(ref-269812-S12310610572007110200000) .