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

Removal Procedure

1. Grasp the intake manifold cover by the front right corner and pull up in order to disengage the cover from the stud.
2. Grasp the intake manifold cover by the front left corner and pull up in order to disengage the cover from the stud.
3. Grasp the intake manifold cover by the rear and pull up in order to disengage the cover from the stud.
4. Remove the intake manifold cover.

Installation Procedure

1. Place the intake manifold cover onto the engine over the studs.
2. Push down on the intake manifold cover directly over the rear stud in order to engage the cover to the stud.
3. Push down on the intake manifold cover directly over the front right stud in order to engage the cover to the stud.
4. Push down on the intake manifold cover directly over the front left stud in order to engage the cover to the stud.

Scheme 58

Drive Belt Replacement

Scheme 59

Drive Belt Tensioner Replacement

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

1. Remove the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-269813-S17030623372007110200000) .
2. Remove the right engine mount bracket bolts and bracket.

1. Position the right engine mount bracket to the engine block.
2. Install the right engine mount bracket bolts until snug. NOTE: Refer to «Fastener Notice»(ref-269768-S31088373702007110200000) .
3. Tighten the right engine mount bracket bolts. Tighten: Tighten the bolts in the sequence shown to 55 N.m (41 lb ft).
4. Install the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-269813-S17030623372007110200000) .

1. Remove the left engine mount. Refer to «Engine Mount Replacement - Left Side»(ref-269813-S42415595082007110200000) .
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .
3. Remove the starter solenoid positive battery cable nut (4) from the starter.
4. Remove the positive battery cable terminal (5) from the starter.
5. Reposition the positive battery cable boot (4).
6. Remove the generator positive battery cable nut (2) from the generator.
7. Remove the positive battery cable terminal (5) from the generator.
8. Remove the engine harness clip (4) from the intake manifold.
9. Remove the left side engine mount bracket bolts and bracket.

1. Position the left engine mount bracket to the engine block.
2. Install the left engine mount bracket bolts until snug. NOTE: Refer to «Fastener Notice»(ref-269768-S31088373702007110200000) .
3. Tighten the left engine mount bracket bolts. Tighten: Tighten the bolts in the sequence shown to 55 N.m (41 lb ft).
4. Install the positive battery cable terminal (5) to the generator.
5. Install the generator positive battery cable nut (2) to the generator. Tighten: Tighten the nut to 20 N.m (15 lb ft).
6. Position the positive battery cable boot (4).
7. Install the engine harness clip (4) to the intake manifold.
8. Install the positive battery cable terminal (5) to the starter.
9. Install the starter solenoid positive battery cable nut (4) to the starter. Tighten: Tighten the nut to 10 N.m (89 lb in).
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .
11. Install the left engine mount. Refer to «Engine Mount Replacement - Left Side»(ref-269813-S42415595082007110200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .
2. Remove the left engine mount upper nut.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
4. Remove the left engine mount lower nut.
5. Remove the right engine mount lower nut.
6. Position an adjustable jack below the oil pan. Place a block of wood between the oil pan and the jack.
7. Raise the engine using the adjustable jack until the engine mount can be removed.
8. 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 50 N.m (37 lb ft).
5. Install the left engine mount lower nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
6. Lower the vehicle.
7. Install the left engine mount upper nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
8. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .

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. Loosen the transmission mount nuts.
6. Remove the left engine mount lower nut.
7. Remove the right brake hose bracket bolt.
8. Remove the right brake line clip at the crossmember.
9. Position an adjustable jack below the oil pan. Place a block of wood between the oil pan and the jack.
10. Raise the engine using the adjustable jack until the engine mount can be removed.
11. 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. NOTE: Refer to «Fastener Notice»(ref-269768-S31088373702007110200000) .
5. Install the right brake hose bracket bolt. Tighten: Tighten the nut 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. Tighten the transmission mount nuts. Tighten: Tighten the nuts to 55 N.m (41 lb ft).
8. Remove the right engine mount lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
9. Lower the vehicle.
10. Install the right engine mount upper nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
11. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-269791-S37299777822007110200000) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .
2. Remove the oil level indicator.
3. Remove the engine harness clip (1) from the oil level indicator tube.
4. Remove the fuel line clip from the oil level indicator tube.
5. Remove the knock sensor clip from the oil level indicator tube.
6. Remove the oil level indicator tube bolt.
7. Remove the oil level indicator tube.

1. Lubricate the oil level indicator tube O-ring seal with lubricant, GM P/N 12345501 (Canadian P/N 992704), or equivalent.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the knock sensor clip to the oil level indicator tube.
5. Install the fuel line clip to the oil level indicator tube.
6. Install the engine harness clip (1) to the oil level indicator tube.
7. Install the oil level indicator.
8. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .

Scheme 60

Crankcase Ventilation Hoses/Pipes Replacement

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269813-S28128464812007110200000) .
2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-269804-S09474602372007110200000) .
3. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-269804-S27119679922007110200000) .
4. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
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 oil level indicator tube bolt.
8. Disconnect the engine harness electrical connector (1) from the fuel injector electrical connector.
9. Disconnect the electronic throttle actuator electrical connector (3).
10. Disconnect the windshield wiper motor electrical connector.
11. Remove the engine harness clip from the wiper motor.
12. Remove the engine harness clip from the surge tank air bleed hose.
13. Reposition the radiator surge tank air bleed hose clamp at the engine (1).
14. Remove the air bleed hose (2) from the engine and reposition.
15. Disconnect the air conditioning (A/C) refrigerant pressure sensor electrical connector.
16. Remove the engine harness clip (4) from the intake manifold.
17. Disconnect the engine harness electrical connector (3) from the knock sensor harness.
18. Remove the knock sensor connector clip from the oil level indicator tube.
19. Reposition the engine harness.
20. Remove the intake manifold bolts and nuts.
21. Remove the intake manifold.
22. Remove the intake manifold gasket, if necessary.

1. Install the intake manifold gasket, if necessary.
2. Install the intake manifold. NOTE: Refer to «Fastener Notice»(ref-269768-S31088373702007110200000) .
3. Install the intake manifold bolts and nuts. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
4. Position the engine harness.
5. Install the knock sensor connector clip to the oil level indicator tube.
6. Connect the engine harness electrical connector (3) to the knock sensor harness.
7. Install the engine harness clip (4) to the intake manifold.
8. Connect the A/C refrigerant pressure sensor electrical connector.
9. Position and install the air bleed hose (2) to the engine.
10. Position the radiator surge tank air bleed hose clamp at the engine (1).
11. Install the engine harness clip to the surge tank air bleed hose.
12. Connect the windshield wiper motor electrical connector.
13. Install the engine harness clip to the wiper motor.
14. Connect the electronic throttle actuator electrical connector (3).
15. Connect the engine harness electrical connector (1) to the fuel injector electrical connector.
16. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
17. Install the brake booster hose to the intake manifold.
18. Position the brake booster vacuum hose clamp at the intake manifold.
19. Install the EVAP canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
20. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-269804-S27119679922007110200000) .
21. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-269804-S09474602372007110200000) .
22. 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. See «Special Tools»(ref-269813-S05044843192007110200000) .
2. J 45059 Angle Meter

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. See «Special Tools»(ref-269813-S05044843192007110200000) .
5. Remove the crankshaft balancer bolt and washer. 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 and washer. 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 .
4. Remove the J 43653 (1) from the engine block. See «Special Tools»(ref-269813-S05044843192007110200000) .
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-269813-S20842056102007110200000) .
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-269813-S20842056102007110200000) .

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.

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

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 45027 Tensioner Tool
2. J 45059 Angle Meter

1. Remove the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
2. Remove the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-269804-S31797581732007110200000) .
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-269813-S41173384042007110200000) .
5. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(ref-269813-S18648746202007110200000) .
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 to 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 3 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. Install the timing chain crankshaft sprocket to the crankshaft with the timing mark in the 5 o'clock position.
11. Assemble the intake camshaft actuator to the timing chain with the timing mark lined up with the blue colored link (1). Install and hand tighten a NEW intake camshaft actuator bolt.
12. 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).
13. Route the timing chain around the crankshaft sprocket and line up the first pink link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
14. Install the adjustable timing chain guide through the opening in the cylinder head. Install the adjustable timing chain bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
15. Install the exhaust camshaft actuator (1) and a NEW bolt (2) loosely onto the exhaust camshaft.
16. Align the timing mark on the actuator with the last pink colored link. Tighten the bolt finger tight.
17. If the camshaft is 180 degrees out of time, use the following procedure to re-align the camshaft. Using a 24-mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft actuator seats in the notch in the front of the intake camshaft. Turn the crankshaft 45 degrees in either direction. Turn the intake cam to the appropriate location. Turn the crankshaft back to TDC.
18. When the actuator seats on the cam, tighten the actuator bolt hand tight.
19. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
20. Install the fixed timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
21. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
22. Install a 24 mm wrench onto the hex on the intake camshaft. Using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus 30 degrees using the J 45059 .
23. Install a 24 mm wrench onto the hex on the exhaust camshaft. Using a torque wrench, tighten the camshaft actuator bolt. Tighten: Tighten the bolt to 85 N.m (63 lb ft), plus 30 degrees J 45059 .
24. Remove the old oil from the timing chain tensioner.
25. Inspect the timing chain tensioner. If the timing tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
26. 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) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
27. 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.
28. 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.
29. 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.
30. 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 27.1 thorough 27.4.
31. Ensure that all dirt and debris are removed from the timing chain tensioner threaded hole in the cylinder head.
32. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
33. 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.
34. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads and install the timing chain guide bolt access hole plug. Tighten: Tighten the plug to 90 N.m (59 lb ft).
35. Install the engine front cover. Refer to «Engine Front Cover Replacement»(ref-269813-S18648746202007110200000) .
36. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269813-S41173384042007110200000) .
37. Install the #1 cylinder spark plug. Refer to «Spark Plug Replacement»(ref-269804-S31797581732007110200000) .
38. 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-269813-S20419987212007110200000) .
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. 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.
6. Center the foot of the J 43650 on the balance shaft bushing.
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. 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. When the tension releases, remove the J 43650 and the balance shaft bushing.

1. Install the balance shaft bushing using the J 43650 .
2. Seat the balance shaft busing into the bore using the J 43650 and a wrench.
3. When the J 43650 is fully seated in the engine block, remove it with a wrench.
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-269813-S20419987212007110200000) .

1. Remove the timing chain, sprocket and tensioner. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269813-S20419987212007110200000) .
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. 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.
6. Center the foot of the J 43650 on the balance shaft bushing.
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. 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. When the tension releases, remove the J 43650 and the balance shaft bushing (right side shown, left side similar).

1. Install the balance shaft bushing using the J 43650 (right side shown, left side similar).
2. Seat the balance shaft busing into the bore using the J 43650 and a wrench.
3. When the J 43650 is fully seated in the engine block, remove it with a wrench.
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-269813-S20419987212007110200000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269813-S28128464812007110200000) .
2. Remove the intake manifold cover studs.
3. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .
4. Reposition the positive crankcase ventilation (PCV) hose clamp.
5. Remove the PCV hose from the cover.
6. Disconnect the intake (1) and exhaust (2) camshaft position actuator solenoid valve electrical connectors.
7. Remove the engine harness clip (1) from the cam cover.
8. Remove the engine harness bracket (1) from the intake manifold cover stud.
9. Disconnect the evaporative emission (EVAP) canister purge solenoid valve electrical connector (1).
10. Remove the engine harness clip (2) from the EVAP purge solenoid bracket.
11. Remove the engine harness clips (3, 4) from the cam cover.
12. Remove the ignition coils. Refer to «Ignition Coil Replacement»(ref-269804-S25792277752007110200000) .
13. Remove the camshaft cover bolts.
14. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Install the ignition coils. Refer to «Ignition Coil Replacement»(ref-269804-S25792277752007110200000) .
3. Install the engine harness clips (3, 4) to the cam cover.
4. Install the engine harness clip (2) to the EVAP purge solenoid bracket.
5. Connect the EVAP canister purge solenoid valve electrical connector (1).
6. Install the engine harness bracket (1) to the intake manifold cover stud.
7. Install the engine harness clip (1) to the cam cover.
8. Connect the intake (1) and exhaust (2) camshaft position actuator solenoid valve electrical connectors.
9. Install the PCV hose from the cover.
10. Position the PCV hose clamp.
11. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-269804-S09420887832007110200000) .
12. Install the intake manifold cover studs. Tighten: Tighten the studs to 9 N.m (80 lb in).
13. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-269813-S28128464812007110200000) .

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-269813-S41173384042007110200000) .
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-269813-S41173384042007110200000) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .

1. Remove the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-269813-S23517150172007110200000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the intake camshaft (1).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers with GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the intake camshaft (1). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(ref-269813-S23517150172007110200000) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-269813-S09216530992007110200000) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the exhaust camshaft (3).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element adjusters.

1. Install the hydraulic element adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM PN 12345501 (Canadian PN 992704) or equivalent.
3. Lubricate the valve tips with GM PN 12345501 (Canadian PN 992704) or equivalent.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster, apply lubricate GM PN 12345501 (Canadian PN 992704) or equivalent.
5. Install the exhaust camshaft (3). Lubricate with GM PN 12345501 (Canadian PN 992704) or equivalent.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the bolts to 10 N.m (89 lb in).
8. Install the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(ref-269813-S09216530992007110200000) .

Camshaft Position Intake Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool. See «Special Tools»(ref-269813-S05044843192007110200000) .
2. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269813-S41173384042007110200000) .
2. Remove the upper timing chain guide bolts and guide.
3. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
4. Loosen, but DO NOT remove the intake camshaft actuator bolt.
5. Install one of the tools (1) from the J 44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-269813-S05044843192007110200000) . Firmly tighten the nuts.
6. Install one of the tools (1) from the J 44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. See «Special Tools»(ref-269813-S05044843192007110200000) . 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 .
8. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269813-S41173384042007110200000) .

Camshaft Position Exhaust Actuator Replacement

Tools Required

1. J 44217 Timing Chain Tensioner Tool. See «Special Tools»(ref-269813-S05044843192007110200000) .
2. J 45027 Tensioner Tool
3. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269813-S41173384042007110200000) .
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. See «Special Tools»(ref-269813-S05044843192007110200000) . 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. See «Special Tools»(ref-269813-S05044843192007110200000) . 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 .
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 in) from end to end (a). If the tensioner does not measure 72 mm (2.83 in) from end to end (a) repeat steps 8.1-8.4.
16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner. Tighten: Tighten the tensioner to 75 N.m (66 lb ft).
18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.
19. Install the upper timing chain guide and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
20. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(ref-269813-S41173384042007110200000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor
2. J 36017 Valve Guide Seal Remover
3. J 43653 Flywheel Holding Tool. See «Special Tools»(ref-269813-S05044843192007110200000) .
4. J 43655 Sprocket Holding Tool. See «Special Tools»(ref-269813-S05044843192007110200000) .

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 . See «Special Tools»(ref-269813-S05044843192007110200000) .
4. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-269813-S35539942512007110200000) or «Exhaust Camshaft and Lifter Replacement»(ref-269813-S26080326722007110200000) .
5. Remove the camshaft roller followers.
6. Install the front section of the J 43649 to the second camshaft cover bolt hole.
7. Install the remaining parts of the J 43649 to the cylinder head.
8. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-269804-S31797581732007110200000) .
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 .
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.

1. Using the J 36017 install the NEW valve seal. 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 .
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.
9. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-269804-S31797581732007110200000) .
10. Install the camshaft roller followers.
11. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-269813-S35539942512007110200000) or «Exhaust Camshaft and Lifter Replacement»(ref-269813-S26080326722007110200000) .
12. If used, remove the J 43653 . See «Special Tools»(ref-269813-S05044843192007110200000) .
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 intake manifold. Refer to «Intake Manifold Replacement»(ref-269813-S02569112372007110200000) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LE5)»(ref-269792-S23748177242007110200000) or «Exhaust Manifold Replacement (LNF)»(ref-269792-S34959777142007110200000) .
4. Remove the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269813-S20419987212007110200000) .
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-269827-S35142802562007110200000) .
6. Remove the negative battery cable ground terminal bolt.
7. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.
8. Disconnect the intake camshaft position (CMP) sensor electrical connector.
9. Remove the evaporative emission (EVAP) canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
10. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
11. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
12. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
13. Reposition the radiator inlet hose clamp at the engine.
14. Remove the radiator inlet hose from the cylinder head.
15. Remove the intake manifold cover bracket bolts and bracket.
16. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
17. Remove the cylinder head.
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 .
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. Install the intake manifold cover bracket and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
11. Position the engine wiring harness ground terminal (2) and install the bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
12. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
13. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
14. Connect the intake CMP sensor electrical connector.
15. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
16. Install the negative battery cable ground terminal bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
17. Install the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(ref-269813-S20419987212007110200000) .
18. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LE5)»(ref-269792-S23748177242007110200000) or «Exhaust Manifold Replacement (LNF)»(ref-269792-S34959777142007110200000) .
19. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-269813-S02569112372007110200000) .
20. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-269827-S28005560912007110200000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-269827-S35142802562007110200000) .
21. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(ref-269813-S26852545992007110200000) .
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.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(ref-269813-S26852545992007110200000) .

Engine Flywheel Replacement

Tools Required

1. J 38122-A Harmonic Balancer Holder. See «Special Tools»(ref-269813-S05044843192007110200000) .
2. J 45059 Angle Meter

1. Remove the automatic transmission, if equipped. Refer to «Transmission Replacement»(ref-269780-S31710603532007110200000) .
2. Remove the clutch, if equipped. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
3. Using the J 38122-A , hold the crankshaft balancer. See «Special Tools»(ref-269813-S05044843192007110200000) .
4. Remove the flywheel bolts, if equipped with a automatic transmission.
5. Remove the flywheel.
6. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.
7. Remove the flywheel bolts, if equipped with a manual transmission.
8. Remove the flywheel.
9. 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 .
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 .
5. Remove the J 38122-A . See «Special Tools»(ref-269813-S05044843192007110200000) .
6. Install the clutch, if equipped. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
7. 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

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-269813-S08456875012007110200000) .
5. Remove the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
6. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027-100)»(ref-269804-S07383113652007110200000) or «Fuel Pressure Relief (Without CH 48027-100)»(ref-269804-S01657826532007110200000) .
7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
8. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269804-S15489853832007110200000) .
9. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
10. Remove the transmission. Refer to «Transmission Replacement»(ref-269781-S26654548322007110200000) .
11. 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.
12. Reposition the radiator inlet hose clamp at the engine.
13. Remove the radiator inlet hose.
14. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 23.
15. Reposition the radiator outlet hose clamps at the thermostat housing and oil cooler.
16. Remove the radiator outlet hose from the thermostat housing and oil cooler.
17. Reposition the outlet hose out of the way.
18. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
19. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
20. Reposition the surge tank outlet hose clamp at the surge tank.
21. Remove the surge tank clip from the oil level indicator tube bracket.
22. Remove the surge tank outlet hose. Proceed to step 26.
23. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
24. Remove the radiator outlet hose from the thermostat housing.
25. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
26. Reposition the surge tank air bleed hose clamp at the engine.
27. Remove the surge tank air bleed hose (1) from the engine.
28. Reposition the air bleed hose (2) out of the way.
29. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
30. Remove the heater inlet (2) and outlet (1) hoses from the thermostat housing.
31. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
32. Drain the engine oil.
33. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
34. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
35. Lower the vehicle.
36. Remove the positive battery cable clip (7) from the bracket.
37. Cut the engine harness tie straps.
38. Remove the negative battery cable ground bolt.
39. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.
40. Disconnect the engine wiring harness electrical connector (1) from the generator.
41. Reposition the positive battery cable terminal boot (4).
42. Remove the generator terminal nut (2).
43. Remove the positive battery cable terminal from the generator (5).
44. Disconnect the engine wiring harness electrical connector (6) from the A/C compressor.
45. Reposition the negative/positive battery cable.
46. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.
47. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
48. Remove the engine harness clip from the wiper motor hole.
49. Remove the engine harness clip from the surge tank air bleed hose.
50. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) actuator.
51. Disconnect the engine wiring harness electrical connector (2) from the exhaust CMP actuator.
52. Remove the engine harness clip (1) from the camshaft cover.
53. Disconnect the engine wiring harness electrical connectors from the ignition coils.
54. Remove the connector position assurance (CPA) retainers from the heated oxygen sensor (HO2S) electrical connectors.
55. Disconnect the engine wiring harness electrical connector (1) from the front HO2S.
56. Disconnect the engine wiring harness electrical connector (2) from the rear HO2S.
57. Disconnect the engine harness clips (1) from the junction block bracket.
58. Disconnect the HO2S electrical connector clip (4) from the strut.
59. Disconnect the engine wiring harness electrical connector from the intake CMP sensor.
60. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
61. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
62. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
63. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
64. Disconnect the engine harness clip (2) from the EVAP canister purge solenoid valve bracket.
65. Disconnect the engine harness clips (3, 4) from the camshaft cover.
66. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
67. Remove the engine harness bracket (1) from the intake manifold cover stud.
68. Disconnect the engine harness clip (2) from the bracket.
69. Remove the intake manifold cover bracket bolts and bracket.
70. Gather all branches of the engine harness and lay off to the side.
71. Remove the A/C compressor line bolt and reposition the line off to the side.
72. Raise and support the vehicle.
73. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
74. Lower the vehicle.
75. Remove the left engine mount upper nut.
76. Remove the right engine mount upper nut.
77. Install the J 42451-1 to the engine.
78. Install a suitable engine lifting devise to the engine.
79. Remove the engine from the vehicle.
80. Remove the clutch pressure plate and disc. Refer to «Clutch Drive Plate and Clutch Driven Plate»(ref-269814-S28412505712007110200000) .
81. Remove the flywheel bolts and flywheel.
82. Install the engine to an engine stand.
83. Remove the A/C compressor bolt and compressor.
84. Remove the catalytic converter to bracket bolt.
85. Remove the catalytic converter nuts (1).
86. Remove the catalytic converter gasket (2) and converter from the engine.

1. Install the catalytic converter gasket (2) and converter to the engine.
2. Install the catalytic converter nuts (1). Tighten: Tighten the nuts to 25 N.m (18 lb ft).
3. Install the catalytic converter to bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 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 .
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 50 N.m (37 lb ft).
12. Install the left engine mount upper nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
13. Remove the J 42451-1 from the engine.
14. Raise and support the vehicle.
15. Position the power steering pump and 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 bolt to 22 N.m (16 lb ft).
18. Install the intake manifold cover bracket and bolts. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
19. Position the branches of the engine harness to the engine.
20. Connect the engine harness clip (2) to the bracket.
21. Install the engine harness bracket (1) to the intake manifold cover stud.
22. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
23. Connect the engine harness clips (3, 4) to the camshaft cover.
24. Connect the engine harness clip (2) to the EVAP canister purge solenoid valve bracket.
25. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
26. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
27. Position the engine wiring harness ground terminal (2) and install the bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
28. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
29. Connect the engine wiring harness electrical connector to the intake CMP sensor.
30. Connect the HO2S electrical connector clip (4) to the strut.
31. Connect the engine harness clips (1) to the junction block bracket.
32. Connect the engine wiring harness electrical connector (2) to the rear HO2S.
33. Connect the engine wiring harness electrical connector (1) to the front HO2S.
34. Install the CPA retainers to the HO2S electrical connectors.
35. Connect the engine wiring harness electrical connectors to the ignition coils.
36. Install the engine harness clip (1) to the camshaft cover.
37. Connect the engine wiring harness electrical connector (2) to the exhaust CMP actuator.
38. Connect the engine wiring harness electrical connector (1) to the intake CMP actuator.
39. Install the engine harness clip to the surge tank air bleed hose.
40. Connect the engine wiring harness electrical connector to the windshield wiper motor.
41. Install the engine harness clip to the wiper motor hole.
42. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor.
43. Position the negative/positive battery cable.
44. Connect the engine wiring harness electrical connector (6) to the A/C compressor.
45. Install the positive battery cable terminal to the generator (5).
46. Install the generator terminal nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft).
47. Position the positive battery cable terminal boot (4).
48. Connect the engine wiring harness electrical connector (1) to the generator.
49. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
50. Install the negative battery cable ground terminal bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
51. Install NEW tie straps to the engine harness.
52. Install the positive battery cable clip (7) to the bracket.
53. Raise and support the vehicle.
54. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
55. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
56. Lower the vehicle.
57. Install the heater inlet (2) and outlet (1) hoses to the thermostat housing.
58. Position the heater inlet and outlet hose clamps at the thermostat housing.
59. Position the air bleed hose (2).
60. Install the surge tank air bleed hose (1) to the engine.
61. Position the surge tank air bleed hose clamp at the engine.
62. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 66.
63. Install the radiator outlet hose to the thermostat housing.
64. Reposition the radiator outlet hose clamp at the thermostat housing.
65. Install the radiator outlet hose clip (1) to the outlet hose bracket. Proceed to step 71.
66. If the vehicle is equipped with a engine oil cooler, install the surge tank outlet hose.
67. Install the surge tank clip to the oil level indicator tube bracket.
68. Position the surge tank outlet hose clamp at the surge tank.
69. Install the surge tank outlet hose to the thermostat housing and oil cooler.
70. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.
71. Position the outlet hose.
72. Install the radiator outlet hose to the thermostat housing and oil cooler.
73. Position the radiator outlet hose clamps at the thermostat housing and oil cooler.
74. Install the radiator inlet hose.
75. Position the radiator inlet hose clamp at the engine.
76. Install the transmission. Refer to «Transmission Replacement»(ref-269781-S26654548322007110200000) .
77. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
78. Connect the fuel feed pipe (2) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269804-S15489853832007110200000) .
79. Connect the EVAP canister purge solenoid tube to the valve (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
80. Install the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
81. Install the drive belt. Refer to «Drive Belt Replacement»(ref-269813-S08456875012007110200000) .
82. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
83. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
84. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
85. Fill the engine oil.

Engine Replacement (w/Automatic Transmission)

Tools Required

1. J 42451-1 Engine Support Adapter
2. J 45059 Angle Meter

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-269813-S08456875012007110200000) .
5. Remove the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
6. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (With CH 48027-100)»(ref-269804-S07383113652007110200000) or «Fuel Pressure Relief (Without CH 48027-100)»(ref-269804-S01657826532007110200000) .
7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
8. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269804-S15489853832007110200000) .
9. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
10. Remove the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
11. Reposition the radiator inlet hose clamp at the engine.
12. Remove the radiator inlet hose.
13. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 23.
14. Reposition the radiator outlet hose clamps at the thermostat housing and oil cooler.
15. Remove the radiator outlet hose from the thermostat housing and oil cooler.
16. Reposition the outlet hose out of the way.
17. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
18. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
19. Reposition the surge tank outlet hose clamp at the surge tank.
20. Remove the surge tank clip from the oil level indicator tube bracket.
21. Remove the surge tank outlet hose. Proceed to step 26.
22. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
23. Remove the radiator outlet hose from the thermostat housing.
24. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
25. Reposition the surge tank air bleed hose clamp at the engine.
26. Remove the surge tank air bleed hose (1) from the engine.
27. Reposition the air bleed hose (2) out of the way.
28. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
29. Remove the heater inlet (2) and outlet (1) hoses from the thermostat housing.
30. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-269787-S34083630862007110200000) .
31. Drain the engine oil.
32. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
33. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
34. Lower the vehicle.
35. Remove the positive battery cable clip (7) from the bracket.
36. Cut the engine harness tie straps.
37. Remove the negative battery cable ground bolt.
38. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.
39. Disconnect the engine wiring harness electrical connector (1) from the generator.
40. Reposition the positive battery cable terminal boot (4).
41. Remove the generator terminal nut (2).
42. Remove the positive battery cable terminal from the generator (5).
43. Disconnect the engine wiring harness electrical connector (6) from the A/C compressor.
44. Reposition the negative/positive battery cable.
45. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.
46. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
47. Remove the engine harness clip from the wiper motor hole.
48. Remove the engine harness clip from the surge tank air bleed hose.
49. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) actuator.
50. Disconnect the engine wiring harness electrical connector (2) from the exhaust CMP actuator.
51. Remove the engine harness clip (1) from the camshaft cover.
52. Disconnect the engine wiring harness electrical connectors from the ignition coils.
53. Remove the connector position assurance (CPA) retainers from the heated oxygen sensor (HO2S) electrical connectors.
54. Disconnect the engine wiring harness electrical connector (1) from the front HO2S.
55. Disconnect the engine wiring harness electrical connector (2) from the rear HO2S.
56. Disconnect the engine harness clips (1) from the junction block bracket.
57. Disconnect the HO2S electrical connector clip (4) from the strut.
58. Disconnect the engine wiring harness electrical connector from the intake CMP sensor.
59. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
60. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
61. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
62. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
63. Disconnect the engine harness clip (2) from the EVAP canister purge solenoid valve bracket.
64. Disconnect the engine harness clips (3, 4) from the camshaft cover.
65. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
66. Remove the engine harness bracket (1) from the intake manifold cover stud.
67. Disconnect the engine harness clip (2) from the bracket.
68. Remove the intake manifold cover bracket bolts and bracket.
69. Gather all branches of the engine harness and lay off to the side.
70. Remove the A/C compressor line bolt and reposition the line off to the side.
71. Raise and support the vehicle.
72. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
73. Remove the torque converter to flywheel bolts.
74. Remove the 4 lower bellhousing bolts (2).
75. Lower the vehicle.
76. Remove the remaining upper 5 bellhousing bolts (1).
77. Remove the left engine mount upper nut.
78. Remove the right engine mount upper nut.
79. Install the J 42451-1 to the engine.
80. Install a suitable engine lifting devise to the engine.
81. Separate the engine from the transmission.
82. Remove the engine from the vehicle.
83. Remove the flywheel bolts and flywheel.
84. Install the engine to an engine stand.
85. Remove the A/C compressor bolt and compressor.
86. Remove the catalytic converter to bracket bolt.
87. Remove the catalytic converter nuts (1).
88. Remove the catalytic converter gasket (2) and converter from the engine.

1. Install the catalytic converter gasket (2) and converter to the engine.
2. Install the catalytic converter nuts (1). Tighten: Tighten the nuts to 25 N.m (18 lb ft).
3. Install the catalytic converter to bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 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 .
9. Install the engine to the vehicle.
10. Install the right engine mount upper nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
11. Install the left engine mount upper nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
12. Remove the J 42451-1 from the engine.
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 and 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 bolt to 22 N.m (16 lb ft).
20. Install the intake manifold cover bracket and bolts. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
21. Position the branches of the engine harness to the engine.
22. Connect the engine harness clip (2) to the bracket.
23. Install the engine harness bracket (1) to the intake manifold cover stud.
24. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-269804-S17243796372007110200000) .
25. Connect the engine harness clips (3, 4) to the camshaft cover.
26. Connect the engine harness clip (2) to the EVAP canister purge solenoid valve bracket.
27. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
28. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
29. Position the engine wiring harness ground terminal (2) and install the bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
30. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
31. Connect the engine wiring harness electrical connector to the intake CMP sensor.
32. Connect the HO2S electrical connector clip (4) to the strut.
33. Connect the engine harness clips (1) to the junction block bracket.
34. Connect the engine wiring harness electrical connector (2) to the rear HO2S.
35. Connect the engine wiring harness electrical connector (1) to the front HO2S.
36. Install the CPA retainers to the HO2S electrical connectors.
37. Connect the engine wiring harness electrical connectors to the ignition coils.
38. Install the engine harness clip (1) to the camshaft cover.
39. Connect the engine wiring harness electrical connector (2) to the exhaust CMP actuator.
40. Connect the engine wiring harness electrical connector (1) to the intake CMP actuator.
41. Install the engine harness clip to the surge tank air bleed hose.
42. Connect the engine wiring harness electrical connector to the windshield wiper motor.
43. Install the engine harness clip to the wiper motor hole.
44. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor.
45. Position the negative/positive battery cable.
46. Connect the engine wiring harness electrical connector (6) to the A/C compressor.
47. Install the positive battery cable terminal to the generator (5).
48. Install the generator terminal nut (2). Tighten: Tighten the nut to 20 N.m (15 lb ft).
49. Position the positive battery cable terminal boot (4).
50. Connect the engine wiring harness electrical connector (1) to the generator.
51. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
52. Install the negative battery cable ground terminal bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
53. Install NEW tie straps to the engine harness.
54. Install the positive battery cable clip (7) to the bracket.
55. Raise and support the vehicle.
56. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
57. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
58. Lower the vehicle.
59. Install the heater inlet (2) and outlet (1) hoses to the thermostat housing.
60. Position the heater inlet and outlet hose clamps at the thermostat housing.
61. Position the air bleed hose (2).
62. Install the surge tank air bleed hose (1) to the engine.
63. Position the surge tank air bleed hose clamp at the engine.
64. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 66.
65. Install the radiator outlet hose to the thermostat housing.
66. Reposition the radiator outlet hose clamp at the thermostat housing.
67. Install the radiator outlet hose clip (1) to the outlet hose bracket. Proceed to step 71.
68. If the vehicle is equipped with a engine oil cooler, install the surge tank outlet hose.
69. Install the surge tank clip to the oil level indicator tube bracket.
70. Position the surge tank outlet hose clamp at the surge tank.
71. Install the surge tank outlet hose to the thermostat housing and oil cooler.
72. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.
73. Position the outlet hose.
74. Install the radiator outlet hose to the thermostat housing and oil cooler.
75. Position the radiator outlet hose clamps at the thermostat housing and oil cooler.
76. Install the radiator inlet hose.
77. Position the radiator inlet hose clamp at the engine.
78. Install the starter. Refer to «Starter Motor Replacement»(ref-269786-S29634526052007110200000) .
79. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-269798-S27457483042007110200000) .
80. Connect the fuel feed pipe (2) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(ref-269804-S15489853832007110200000) .
81. Connect the EVAP canister purge solenoid tube to the valve (1). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-269804-S16956750632007110200000) .
82. Install the radiator. Refer to «Radiator Replacement»(ref-269827-S15768250342007110200000) .
83. Install the drive belt. Refer to «Drive Belt Replacement»(ref-269813-S08456875012007110200000) .
84. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-269779-S20502390932007110200000) .
85. Install the hood. Refer to «Hood Replacement»(ref-269773-S12949229602007110200000) .
86. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-269786-S13101067782007110200000) .
87. Fill the engine 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. 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 retainer for vehicles with automatic transmission.
4. Remove the flywheel, if the vehicle has an automatic transmission.
5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

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

Exhaust Manifold Removal

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

Intake Manifold Removal

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

Camshaft Cover Removal

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

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner 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.

Timing Chain and Tensioner Removal

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

Intake Camshaft, 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. 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.
5. Center the foot of the J 43650 on the balance shaft bushing.
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. 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. When the tension releases, remove the J 43650 and the balance shaft bushing.

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 .

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

Crankshaft and Bearings Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gage
2. J 45059 Angle Meter

Scheme 61

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 .
2. Measure the bearing bore for taper and out-of-round using the J 8087 .
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 it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . Tighten: Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
7. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).

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. The J 42067 also establishes the depth of the seal in the crankshaft seal bore.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. EN-47836 Piston Ring Compressor
2. J 45059 Angle Meter
3. J-43966-1 Connecting Rod Guides

1. Install the connecting rod bearings. Use NEW bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.
3. Install EN-47836 , 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 EN-47836 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 .
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.
3. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Tighten the bolts an additional 155 degrees in sequence. Use the J 45059 .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).

Balance Shaft Installation

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

Water Pump Installation

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

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

Timing Chain, Sprockets, Tensioner Installation

1. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position.
2. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft actuator bolt.
3. 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).
4. 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.
5. Install the adjustable timing chain guide 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).
6. Install the exhaust camshaft actuator and a NEW bolt loosely onto the exhaust camshaft.
7. Align the timing mark on the actuator with the last matching colored link (3). Install the bolt finger tight.
8. If the camshaft is 180 degrees out of time, use the following procedure to re-align the cam. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft actuator seats in the notch in the front of the intake camshaft. Turn the crankshaft 45 degrees in either direction. Turn the intake cam to the appropriate location. Turn the crankshaft back to top dead center.
9. When the actuator seats on the cam, tighten the sprocket bolt hand tight.
10. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
11. Install the fixed timing chain guide and bolts. Tighten: Tighten the fixed timing chain guide bolts to 15 N.m (11 lb ft).
12. Install the upper timing chain guide and bolts. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
13. Using a 24 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 .
14. Using a 24 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 .
15. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
16. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the new timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
18. 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.
19. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
20. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) compound to the thread, and 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 35268-A . See «Special Tools»(ref-269813-S05044843192007110200000) .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

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

Camshaft Cover Installation

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

Oil Pan Installation

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

Crankshaft Balancer Installation

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 and washer. 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 .

Oil Filter Adapter Installation

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

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 6 N.m (53 lb in).
2. Install a new intake manifold gasket on the intake manifold.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate the fuel injector tip insulators with engine oil.
6. Install new fuel injector tip insulators.
7. Lubricate the fuel injector oil rings with engine oil.
8. Install the fuel rail assembly.
9. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install a new throttle body gasket.
11. Install the throttle body. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
12. Install the EVAP emission canister valve (2). Tighten: Tighten the EVAP canister valve bolt to 22 N.m (16 lb ft).
13. Install the EVAP emission canister valve tube (1).

Exhaust Manifold Installation

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

Oil Level Indicator and Tube Installation

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

Engine Flywheel Installation

1. Install the flywheel.
2. Install the NEW bolts.
3. Hold the crankshaft. Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 .