Engine Mechanical - 2.2L (L61): Removal & Installation Saturn VUE I

Installation Procedure

1. Install the tensioner assembly and bolt (if removed). Tighten: Tighten the drive belt tensioner bolt 45 N.m (33 lb ft).
2. Route the belt around the alternator and the A/C compressor.
3. Install the J 44811 onto the tensioner and unload spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. Release the tensioner and remove the tool.
5. Install the right engine inner splash shield.
6. Install the right wheel and hand tighten the wheel nuts.
7. Lower the vehicle. Tighten: Tighten the wheel nuts 125 N.m (92 lb ft).
8. Connect the negative battery cable Tighten: Tighten the battery terminal bolt 17 N.m (23 lb ft).

Removal Procedure

1. Disconnect the negative battery cable.
2. Raise the vehicle on the hoist. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
3. Remove the right wheel and the splash shield.
4. Install the J 44811 onto the tensioner. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
5. Remove the accessory drive belt.
6. Remove the tensioner assembly.
7. Remove the tensioner bolt.

1. Install the tensioner assembly and bolt, if removed. Tighten: Tighten the drive belt tensioner bolt 45 N.m (33 lb ft).
2. Route the belt around the alternator and the A/C compressor.
3. Install the J 44811 onto the tensioner and unload spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. Release the tensioner and remove the tool.
5. Install the right engine inner splash shield.
6. Install the right wheel and hand tighten the wheel nuts.
7. Lower the vehicle. Tighten: Tighten the wheel nuts 125 N.m (92 lb ft).
8. Connect the negative battery cable Tighten: Tighten the battery terminal bolt 17 N.m (23 lb ft).

1. Apply RTV sealant (or equivalent) to the EOP switch threads.
2. Install the EOP switch. Tighten: Tighten the engine oil pressure switch to 22 N.m (16 lb ft).
3. Connect the EOP switch harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
4. Check the oil level and fill if low.
5. Start the engine and check for leaks.

1. Place the mount bracket to the engine.
2. Install the mount bracket to engine bolts. Tighten: Tighten the bolts to 110 N.m (81 lb ft).
3. Install the RH mount. Refer to «Engine Mount Replacement»(ref-188814-S40505371042005090200000) .
4. Balance the powertrain mounts. Refer to «Powertrain Mount Balance Procedure - Total Mount»(ref-188814-S16773052562005090200000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188785-S38439795262005090200000) in Engine Controls.
2. Place a floor jack with a wood block under the engine oil pan in order to support the powertrain.
3. Remove the mount to mount bracket bolts.
4. Remove the mount to frame rail nuts.
5. Remove the RH mount.

1. Install the RH mount to the frame rail studs.
2. Install the RH mount to frame rail nuts. Tighten: Tighten the nuts to 110 N.m (81 lb ft).
3. Hand start the RH mount to bracket bolts.
4. Balance the powertrain mounts. Refer to «Powertrain Mount Balance Procedure - Total Mount»(ref-188814-S16773052562005090200000) .
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188785-S38439795262005090200000) in Engine Controls.

1. Install the oil level indicator tube into the block.
2. Install the oil level indicator tube bolt to the intake manifold. Tighten: Tighten the oil indicator tube assembly bolt - L61 to 10 N.m (89 lb in).

Scheme 3

1. Disconnect the intake air temperature (IAT) sensor connector.
2. Loosen the clamp at the air cleaner assembly.
3. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air vent hose at the outlet duct assembly.
6. Remove the outlet resonator/duct assembly.
7. Cover the throttle body opening with a shop towel and use the shop air to remove any dirt at the base of the throttle body to intake and intake manifold to cylinder head.
8. Disconnect the harness connector at the throttle body.
9. Remove the throttle body bolts.
10. Remove the throttle body.
11. Remove the throttle body gasket.
12. Block the intake manifold opening with a clean shop towel to prevent dirt from entering.
13. Remove the engine control module (ECM) bolts and set the ECM aside.
14. Disconnect the electrical connectors (injector harness) attach to the side of the manifold and position the harness away from the manifold and set aside.
15. Disconnect the manifold absolute pressure (MAP) sensor.
16. Disconnect the purge hose.
17. Disconnect the electrical attachment bolt at bottom of the manifold.
18. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
19. Disconnect the electrical harness clips at the bottom of the manifold.
20. Lower the vehicle.
21. Remove the oil level tube bolt and rotate tube away from the manifold.
22. Remove the intake manifold bolts and nuts.
23. Pull the manifold away from the cylinder head.
24. Disconnect the brake booster hose at the manifold by releasing the white tab.
25. Remove the intake manifold assembly.
26. Remove the intake manifold gasket and discard.
27. Block the intake manifold to cylinder head openings with a clean shop towel to prevent dirt from entering.

Scheme 4

1. Remove the shop towel from the throttle body opening.
2. Install the intake manifold gasket to manifold.
3. Connect the brake booster hose to intake manifold.
4. Install the intake manifold to cylinder head.
5. Install the intake manifold bolts and nuts. Tighten Tighten the intake manifold-to-cylinder head bolts L61 to 10 N.m (89 lb in). Tighten the intake manifold-to-cylinder head nuts L61 to 10 N.m (89 lb in).
6. Install the oil level indicator tube assembly and bolt. Tighten: Tighten the oil level indicator tube-to-intake manifold bolt L61 to 10 N.m (89 lb in).
7. Install the ECM assembly and bolts.
8. Attach the electrical harness to the bottom of the intake manifold.
9. Connect the electrical connector at the ECM, injector harness and MAP sensor.
10. Connect the purge hose.
11. Remove the shop towel from the throttle body opening.
12. Install the new throttle body gasket.
13. Install the throttle body assembly and bolts. Tighten: Tighten the throttle body-to-intake manifold bolts L61 to 10 N.m (89 lb in).
14. Connect the throttle body electrical connector.
15. Position the outlet resonator/duct assembly into position.
16. Connect the PCV fresh air vent hose assembly.
17. Tighten the clamp at the throttle body assembly.
18. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
19. Tighten the clamp at the air cleaner assembly.
20. Connect the intake air temperature (IAT) sensor connector.

Crankshaft Balancer Replacement

Tools Required

1. J 38122-A Crankshaft Pulley Holder
2. J 44811 Accessory Belt Tensioner Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Scheme 5

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Raise the vehicle on a hoist.
3. Remove the right wheel and splash shield.
4. Install the J 44811 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
5. Remove the accessory drive belt.
6. Install the J 38122-A .
7. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.

Scheme 6

1. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
2. Install the balancer pulley onto the crankshaft indexing keyway. Use care to properly align the flats on the balancer pulley with the flats on the oil pump drive in the front cover assembly.
3. Install the crankshaft damper pulley.
4. Install a new crankshaft balancer pulley bolt with washer assembly.
5. Install the J 38122-A . Tighten: Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) +75 degrees.
6. Route the belt around the alternator and A/C compressor.
7. Install the J 44811 onto the tensioner and unload the spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
8. Release the tensioner and remove the tool.
9. Install the right engine inner splash shield.
10. Install the right wheel and hand tighten the nuts.
11. Lower the vehicle. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).

Oil Pump Replacement

Tools Required

1. J 38122-A Crankshaft Pulley Holder
2. J 44811 Accessory Belt Tensioner Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. SA9105E Engine Three-Bar Fixture. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Install the SA9105E setup for SUV application. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Refer to «Engine Support Fixture»(ref-188814-S13211755102005090200000) .
9. Remove the right hand mount. Refer to «Engine Mount Replacement»(ref-188814-S40505371042005090200000) .
10. Remove the right hand engine mount bracket.
11. Jack the vehicle or raise on a hoist «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
12. Remove the right wheel and splash shield.
13. Install the J 44811 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
14. Remove the accessory drive belt.
15. Remove the tensioner bolt.
16. Remove the tensioner assembly.
17. Install the J 38122-A .
18. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley.
19. Remove the front cover.
20. Remove the lower water pump assembly bolt.
21. Remove the front cover/oil pump assembly and gasket.

1. Install the front cover assembly.
2. Install the front cover assembly bolts and lower water pump bolt. Tighten: Tighten the cover-to-block bolts - L61 to 25 N.m (18 lb ft). Tighten the water pump bolts - L61 to 25 N.m (18 lb ft).
3. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
4. Install the balancer pulley onto the crankshaft indexing keyway. Use care to properly align the flats on the balancer pulley with the flats on the oil pump drive in the front cover assembly.
5. Install the crankshaft damper pulley.
6. Install a new crankshaft balancer pulley bolt with washer assembly.
7. Install the J 38122-A . Tighten: Tighten the crankshaft pulley bolt - L61 to 100 N.m (74 lb ft) +75 degrees.
8. Install the drive belt tensioner assembly. Tighten: Tighten the drive belt tensioner bolt - L61 to 45 N.m (33 lb ft).
9. Route the belt around the alternator and A/C compressor. Install the J 44811 onto the tensioner and unload spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
10. Release the tensioner and remove the tool.
11. Install the right engine inner splash shield.
12. Install the right wheel and hand tighten the wheel nuts.
13. Lower the vehicle.
14. Tighten the wheel nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
15. Install the right hand engine bracket and bolts to the engine. Refer to «Engine Mount Replacement»(ref-188814-S40505371042005090200000) . Tighten: Tighten the engine mount bracket-to-engine bolts - L61 to 110 N.m (81 lb ft).
16. Install the shims on the right hand side rail studs.
17. Install the right hand engine shims onto the studs.
18. Install the right hand engine mount over the body side rail studs.
19. Install the right hand engine mount nuts. Tighten: Tighten the engine mount bracket-to-body nuts to 110 N.m (81 lb ft).
20. Install the right hand engine mount bolts to the engine mount bracket. Tighten: Tighten the engine mount-to-engine mount bracket bolts to 50 N.m (37 lb ft).
21. Remove the SA9105E . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
22. Position the outlet resonator/duct assembly into position.
23. Connect the PCV fresh air vent hose assembly.
24. Tighten the clamp at the throttle body assembly.
25. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
26. Tighten the clamp at the air cleaner assembly.
27. Connect the intake air temperature (IAT) sensor connector.
28. Connect the negative battery cable. Tighten: Tighten the negative battery terminal bolt to 17 N.m (13 lb ft) + 75 degrees.

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

1. J 38122-A Crankshaft Pulley Holder. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 43405 Engine Support Fixture Adaptor. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. J 44811 Accessory Belt Tensioner Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. SA9105E 3-Bar Engine Support Fixture. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
5. SA9127E Gage Bar Set. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
6. J 39914 Serpentine Belt Tension Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
7. J 45027 Tensioner Tool. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to the support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Remove the air cleaner assembly hold-down bolt.
9. Remove the air cleaner assembly.
10. Remove the ignition module bolts.
11. Remove the ignition module assembly.
12. Disconnect the de-gas hose at the clamp at the cylinder head and unclip from the fuel rail. Position away from the cam cover assembly.
13. Disconnect the ground strap at the rear of the cam cover assembly.
14. Relieve the fuel system pressure.
15. Disconnect the after the pressure has been relieved.
16. Disconnect the fuel rail bracket and bolt at the rear of the cam cover.
17. While supporting the fuel rail assembly with an open end wrench, loosen the transfer line fitting at the fuel rail.
18. Position the fuel line away from the cam cover assembly.
19. Remove the cam cover assembly bolts.
20. Remove the cam cover assembly.
21. Locate the No. 1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove the spark plugs. This will ease the rotation effort.
22. Remove the upper timing chain guide.
23. Remove the timing chain tensioner.
24. Remove the fixed timing chain guide access plug.
25. Using a magnetic socket, remove the upper fixed guide bolt.
26. Install the set up for SUV application.
27. Remove the right-hand engine mount-to-bracket bolts.
28. Remove the right-hand mount assembly nuts.
29. Remove the right-hand engine mount assembly.
30. Remove the right-hand mount bracket.
31. Remove the right-hand engine mount bracket.
32. Raise the vehicle on a hoist.
33. Remove the right wheel and splash shield.
34. Install the block of wood (1x2x4) between the oil pan and the cradle.
35. Install the J 44811 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
36. Remove the accessory drive belt.
37. Remove the tensioner bolt. To remove the bolt, an access hole has been provided through the inner and outer engine rail.
38. Remove the tensioner assembly.
39. Install the J 38122-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
40. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.
41. Remove the front cover assembly bolts.
42. Remove the lower water pump assembly bolt.
43. Remove the front cover assembly and gasket.
44. Remove the adjustable guide bolt.
45. Remove the lower fixed guide bolt.
46. Remove the fixed guide.
47. Use a 24 mm wrench to hold the camshaft assembly while removing the exhaust sprocket bolt. Discard the bolt.
48. Remove the exhaust sprocket.
49. Remove the adjustable guide through the top of the cylinder head.
50. Use a 24 mm wrench to hold the camshaft assembly while removing the intake sprocket bolt. Discard the bolt.
51. Remove the intake sprocket.
52. Remove the timing chain assembly through the top of the cylinder head.
53. Remove the timing chain drive sprocket from the crankshaft.
54. Remove the timing chain oiler nozzle and bolt.
55. Clean the oil nozzle orifice on the block to remove any debris.
56. Inspect the timing chain guide for wear.
57. Inspect the timing chain and the sprockets for signs of excessive wear, chipping, or seizure to links on the chain.

1. Install the timing chain oiler nozzle and the bolt, then tighten. Tighten: Tighten the timing chain oil nozzle bolt to 10 N.m (89 lb in).
2. Install the timing chain drive sprocket to the crankshaft.
3. Using the dampener, rotate the crank so that the mark on the timing chain drive sprocket is at 5 o'clock position.
4. Set the crankshaft to 60 degrees before the top dead center.
5. Position the exhaust camshaft with the offset slot to 2 o'clock position.
6. Position intake camshaft with offset slot to 11 o'clock position.
7. Assemble the chain to the intake camshaft sprocket aligning the upper link to the INT diamond timing mark on the camshaft sprocket.
8. Lower the assembly through chain housing opening on top of the cylinder head. Use care to make sure that the chain goes around both sides of the cylinder block bosses.
9. Route the chain around the crankshaft sprocket and align the silver link to the timing mark.
10. Install the intake camshaft sprocket with the chain in proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on the flats on the camshaft until the camshaft aligns with the sprocket.
11. Install the new intake camshaft sprocket bolt and finger tighten.
12. Install the adjustable timing chain guide through the opening at the top of the cylinder head and install the chain guide bolt. Tighten: Tighten the timing chain guide (adjustable) bolt to 10 N.m (89 lb in).
13. Install the exhaust camshaft sprocket loosely on the exhaust camshaft with the timing mark on the sprocket aligned with the silver link.
14. Install new camshaft sprocket bolt loosely.
15. Align the camshaft sprocket with the chain in proper position to the camshaft. Rotate the exhaust clockwise using a 24 mm wrench on the flats on the camshaft until the camshaft aligns with the sprocket.
16. Verify that all the colored links are aligned with the appropriate intake (1), crankshaft sprocket (2), and (3) exhaust marks.
17. Verify the crankshaft sprocket timing mark is at 5 o'clock.
18. If marks are not correct, you must repeat the timing procedure.
19. Install the fixed timing chain guide and bolts. Tighten: Tighten the timing chain fixed bolts to 10 N.m (89 lb in).
20. Apply the thread sealant Permatex® Thread Pipe Sealant or equivalent compound to the thread. Install fixed guide bolt access hole plug. Tighten: Tighten the timing chain bolt access hole plug to 40 N.m (30 lb ft).
21. Tighten intake and exhaust camshaft sprocket bolts while holding camshaft with 24 mm wrench. Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) + 30 degrees
22. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
23. Measure the timing chain tensioner assembly from end-to-end.
24. 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 J45027-2 (2) into a vise. Install the notch end of the piston assembly into the J45027-2 (2).
25. Using J45027-1 (1), turn the ratchet cylinder into the piston.
26. Inspect the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt of debris out with a lint free cloth.
27. 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.
28. At this point, the tensioner should measure approximately 72 mm (2.83 in) (1) from end-to-end. If the tensioner does not read 72 mm (2.83 in) (1) from end to end repeat step 24
29. Ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
30. Install the new timing chain tensioner assembly bolt and tighten. Tighten: Tighten the timing chain tensioner assembly bolt to 75 N.m (55 lb ft).
31. 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.
32. Install the upper timing chain guide and bolts. Tighten: Tighten the timing chain guide (upper) bolts to 10 N.m (89 lb in).
33. Raise the vehicle if necessary.
34. Install the new front cover gasket.
35. Install the front cover assembly.
36. Install the front cover assembly bolts. Tighten: Tighten the front cover-to-block bolts to 25 N.m (18 lb ft).
37. Install the front cover water pump bolt. Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
38. Lubricate the front seal and the sealing surface of the pulley with the clean motor oil.
39. Install the balancer pulley onto the crankshaft indexing keyway. Use care to properly align the flats on the balancer pulley with the flats on the oil pump drive in the front cover assembly.
40. Install the crankshaft damper pulley.
41. Install the new crankshaft balancer pulley bolt with the washer assembly.
42. Install the J 38122-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Tighten: Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) + 75 degrees
43. Install the accessory drive belt tensioner. Tighten: Tighten the drive belt tensioner bolts to 45 N.m (33 lb ft).
44. Route belt around the alternator and the A/C compressor.
45. Install the J 39914 onto the tensioner and unload spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
46. Release the tensioner and remove the tool.
47. Install the right hand engine bracket and bolts. Tighten: Tighten the engine mount bracket-to-engine bolts to 110 N.m (81 lb ft).
48. Install the right hand engine mount shims.
49. Install the right hand engine mount onto the body side rail studs.
50. Install the right hand engine mount-to-body nuts. Tighten: Tighten the engine mount-to-body nuts to 110 N.m (81 lb ft).
51. Install the right-hand engine mount-to-engine mount bracket bolts. Tighten: Tighten the engine mount-to-engine mount bracket bolts to 50 N.m (37 lb ft).
52. Remove the SA9105E . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
53. Install the right engine inner splash shield.
54. Install the right wheel and hand-tighten the wheel nuts.
55. Tighten the wheel nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
56. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
57. Assemble the camshaft cover and gasket using care to make sure that gasket is located in retaining groove on camshaft cover.
58. Install the cover on cylinder head and hand-tighten the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
59. Reposition fuel line assembly.
60. Install the transfer line fitting at fuel to fuel rail. Tighten: Tighten the transfer line fitting-to-fuel rail to 10 N.m (89 lb in).
61. Connect the fuel rail bracket and bolt to the cylinder head. Tighten: Tighten the fuel line bracket bolt to 10 N.m (89 lb in).
62. Connect the ground strap to the camshaft cover assembly. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
63. Connect the degas hose and attach to the fuel rail.
64. Connect the coolant pipe bracket bolts to the cylinder head. Tighten: Tighten the coolant pipe bracket bolt to 10 N.m (89 lb in).
65. Install the spark plugs (if removed). Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
66. Install the ignition module assembly to the cam cover and hand-tighten the retaining bolts. Tighten: Tighten the ignition module-to-camshaft cover bolts to 8 N.m (71 lb in).
67. Install the air cleaner assembly and bolt. Tighten: Tighten the air cleaner-to-support bracket bolt to 10 N.m (89 lb in).
68. Install the outlet resonator/duct assembly into position.
69. Connect the PCV fresh air vent hose assembly.
70. Tighten the clamp at the throttle body assembly.
71. Position the outlet resonator/duct assembly up with support bracket and install push-pin.
72. Tighten the clamp at the air cleaner assembly.
73. Connect the intake air temperature (IAT) sensor connector.
74. Connect the negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).

Intake Camshaft and Lifter Replacement

Tools Required

1. J 43655 Camshaft Support Holding. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. SA9127E-7 Gage Bar Set. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Disconnect the electrical connector at the ignition module.
9. Remove the ignition module assembly with bolts.
10. Disconnect the coolant de-gas hose clip on the fuel rail.
11. Disconnect the ground strap at the rear of the cam cover assembly.
12. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) in Engine Controls - 2.2L (L61).
13. Disconnect the gage bar set SA9127E-7 after the pressure has been relieved. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
14. Disconnect the fuel ail bracket and bolt at the rear of the cam.
15. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at fuel.
16. Position the fuel line away from the cam cover assembly.
17. Remove then cam cover assembly bolts.
18. Remove the cam cover assembly.
19. Remove the purge solenoid from the power steering plate.
20. Remove the power steering block off plate if the intake camshaft is being removed.
21. Locate the number 1 piston to approximately 60 degrees before top dead center, diamond shaped hole on the intake camshaft sprocket at the 12 o'clock position. Remove the spark plugs. This will ease rotation effort.
22. Remove the upper timing chain guide.
23. Remove the front camshaft caps.
24. Install the J 43655 through the sprocket holes from the timing side of the sprocket towards the rear of the engine. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
25. With guide pin installed in the sprocket, align the guide pins into the slots on the support plate.
26. Tighten the support bracket to cylinder head. Tighten: Tighten the support plate to cylinder head to 10 N.m (89 lb in).
27. Install the wing nuts and tighten.
28. Hold each camshaft in place using a 24 mm open end wrench and carefully remove the camshaft sprocket timing retaining bolts and washers. Discard the torque-to-yield bolts.
29. Slide the camshaft sprockets away from the camshafts.
30. To release the spring tension on the camshaft, after the camshaft is disengaged from the sprocket, rotate the camshaft using a 24 mm wrench to a neutral position.
31. Uniformly loosen and remove the remaining camshaft bearing cap bolts.
32. Carefully pull the camshafts straight up to avoid damaging the cylinder head thrust surfaces.

Scheme 7

1. Allow the engine to idle.
2. Ensure install rocker arms are in their proper location, followers.
3. Lubricate the camshaft bearing journals with clean engine oil and install both camshafts.
4. When installing the camshafts, align to position camshaft slot in line with the notch on the sprockets.
5. Install all bearing caps except the front caps and rear intake camshaft cap, if serviced. Tighten down the bearing caps uniformly. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
6. Verify camshaft timing.
7. Slide the camshaft sprockets and timing chain on the guide pins toward the camshafts. Rotate the camshafts with a 24 mm open end wrench to properly align the camshaft and sprockets.
8. Install new camshaft sprocket bolt and tighten. This will pull the camshaft sprockets into the cams. Hold the camshaft with the 24 mm open end wrench during tightening. Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) +30 degrees.
9. Remove the J 43655 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
10. Install the front camshaft caps. Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
11. Install the upper timing chain guide and bolts. Tighten: Tighten the timing chain guide upper bolts to 10 N.m (89 lb in).
12. Install the rear intake camshaft bearing cap.
13. Install the rear intake camshaft bearing cap. Tighten: Tighten the intake camshaft rear cap to 25 N.m (18 lb ft).
14. Install the power steering block-off plate. Tighten: Tighten the power steering block-off plate to 25 N.m (18 lb ft).
15. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
16. Assemble the camshaft cover and gasket. Use care to make sure the gasket is located in the retaining groove on the camshaft cover.
17. Install the cover on the cylinder head and hand-tighten the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
18. Reposition the fuel line assembly.
19. Install the transfer line fitting at the fuel-to-fuel rail. Tighten: Tighten the transfer line fitting-to-fuel rail to 10 N.m (89 lb in).
20. Connect the fuel rail bracket and bolt to the cylinder head. Tighten: Tighten the fuel line transfer bolt to 10 N.m (89 lb in).
21. Connect the ground strap to the camshaft cover assembly. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
22. Connect the degas hose and clamp to the cylinder head.
23. Connect the degas hose bracket and bolt to the cylinder head. Tighten: Tighten the coolant pipe bracket bolt to 10 N.m (89 lb in).
24. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
25. Install the ignition module assembly to cam cover and hand tighten the retaining bolts. Tighten: Tighten the ignition module-to-camshaft cover bolts to 8 N.m (71 lb in).
26. Position the outlet resonator/duct assembly into position.
27. Connect the PVC fresh air vent hose assembly.
28. Tighten the clamp at the throttle body assembly.
29. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
30. Tighten the clamp at the air cleaner assembly.
31. Connect the intake air temperature (IAT) sensor connector.
32. Connect the negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).

Exhaust Camshaft and Lifter Replacement

Tools Required

1. J 43655 Camshaft Support Holding. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. SA9127E Gage Bar Set. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Disconnect the electrical connector at the ignition module.
9. Remove the ignition module assembly with bolts.
10. Disconnect the coolant de-gas hose clip on the fuel rail.
11. Disconnect the ground strap at the rear of the cam cover assembly.
12. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) in Engine Controls - 2.2L (L61).
13. Disconnect the gage bar set SA9127E after the pressure has been relieved.
14. Disconnect the fuel rail bracket and bolt at the rear of the cam.
15. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at fuel.
16. Position the fuel line away from the cam cover assembly.
17. Remove then cam cover assembly bolts.
18. Remove the cam cover assembly.
19. Remove the purge solenoid from the power steering plate.
20. Remove the power steering block off plate if the intake camshaft is being removed.
21. Locate the number 1 piston to approximately 60 degrees before top dead center, diamond shaped hole on the intake camshaft sprocket at the 12 o'clock position. Remove the spark plugs. This will ease rotation effort.
22. Remove the upper timing chain guide.
23. Remove the front camshaft caps.
24. Install the J 43655 through the sprocket holes from the timing side of the sprocket towards the rear of the engine. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
25. With guide pin installed in the sprocket, align the guide pins into the slots on the support plate.
26. Tighten the support bracket to cylinder head. Tighten: Tighten the support plate to cylinder head to 10 N.m (89 lb in).
27. Install the wing nuts and tighten.
28. Hold each camshaft in place using a 24 mm open end wrench and carefully remove the camshaft sprocket timing retaining bolts and washers. Discard the torque-to-yield (TTY) bolts.
29. Slide the camshaft sprockets away from the camshafts.
30. To release the spring tension on the camshaft, after the camshaft is disengaged from the sprocket, rotate the camshaft using a 24 mm wrench to a neutral position.
31. Uniformly loosen and remove the remaining camshaft bearing cap bolts.
32. Carefully pull the camshafts straight up to avoid damaging the cylinder head thrust surfaces.

1. Allow the engine to idle.
2. Ensure install rocker arms are in their proper location, followers.
3. Lubricate the camshaft bearing journals with clean engine oil and install both camshafts.
4. When installing the camshafts, align to position camshaft slot in line with the notch on the sprockets.
5. Install all bearing caps except the front caps and rear intake camshaft cap, if serviced. Tighten down the bearing caps uniformly. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
6. Verify camshaft timing.
7. Slide the camshaft sprockets and timing chain on the guide pins toward the camshafts. Rotate the camshafts with a 24 mm open end wrench to properly align the camshaft and sprockets.
8. Install new camshaft sprocket bolt and tighten. This will pull the camshaft sprockets into the cams. Hold the camshaft with the 24 mm open end wrench during tightening. Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) +30 degrees.
9. Remove the J 43655 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
10. Install the front camshaft caps. Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
11. Install the upper timing chain guide and bolts. Tighten: Tighten the timing chain guide upper bolts to 10 N.m (89 lb in).
12. Install the rear intake camshaft bearing cap.
13. Install the rear intake camshaft bearing cap. Tighten: Tighten the intake camshaft rear cap to 25 N.m (18 lb ft).
14. Install the power steering block-off plate. Tighten: Tighten the power steering block-off plate to 25 N.m (18 lb ft).
15. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
16. Assemble the camshaft cover and gasket. Use care to make sure the gasket is located in the retaining groove on the camshaft cover.
17. Install the cover on the cylinder head and hand-tighten the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
18. Re-position the fuel line assembly.
19. Install the transfer line fitting at the fuel-to-fuel rail. Tighten: Tighten the transfer line fitting-to-fuel rail to 10 N.m (89 lb in).
20. Connect the fuel rail bracket and bolt to the cylinder head. Tighten: Tighten the fuel line transfer bolt to 10 N.m (89 lb in).
21. connect the ground strap to the camshaft cover assembly. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
22. Connect the degas hose and clamp to the cylinder head.
23. Connect the degas hose bracket and bolt to the cylinder head. Tighten: Tighten the coolant pipe bracket bolt to 10 N.m (89 lb in).
24. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
25. Install the ignition module assembly to cam cover and hand tighten the retaining bolts. Tighten: Tighten the ignition module-to-camshaft cover bolts to 8 N.m (71 lb in).
26. Position the outlet resonator/duct assembly into position.
27. Connect the PVC fresh air vent hose assembly.
28. Tighten the clamp at the throttle body assembly.
29. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
30. Tighten the clamp at the air cleaner assembly.
31. Connect the intake air temperature (IAT) sensor connector.
32. Connect the negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).

Cylinder Head Replacement

Tools Required

1. J 38122-A Crankshaft Pulley Holder. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 43405 Engine Support Fixture Adapter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. J 44811 Accessory Belt Tensioner Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. J 45122 Engine Support Adapter
5. SA9105E Engine Three Bar Fixture. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
6. SA9127E Gage Bar Set. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
7. J 45027 Tensioner Tool. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove outlet resonator/duct assembly.
8. Remove the air cleaner assembly hold-down bolt.
9. Remove the air cleaner assembly.
10. Remove the ignition module bolts.
11. Remove the ignition module assembly.
12. Disconnect ECM electrical connector and ground at ECM.
13. Remove oil level indicator bolt to manifold.
14. Disconnect the electrical connector at the throttle body.
15. Disconnect the electrical connector at the fuel injector harness and the attachment at bottom of the intake manifold.
16. Disconnect the electrical connector at purge solenoid and MAP sensor.
17. Disconnect the vacuum hose at the brake booster.
18. Disconnect the coolant pipe bracket bolts to front of cylinder head.
19. Disconnect the degas hose at clamp at the cylinder head and unclip from the fuel rail. Position away from the cam cover assembly.
20. Disconnect ground strap at rear of the cam cover assembly.
21. Relieve fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) in Engine Controls - 2.2L (L61).
22. Disconnect the SA9127E after pressure has been relieved. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
23. Disconnect the fuel rail bracket and bolt at the rear cam cover.
24. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at the fuel rail.
25. Position the fuel line away from the cam cover assembly.
26. Remove the cam cover assembly bolts.
27. Remove the cam cover assembly.
28. Locate the No.1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.
29. Remove upper timing chain guide.
30. Remove the timing chain tensioner.
31. Remove the fixed timing chain guide access plug.
32. Using a magnetic socket, remove the upper fixed guide bolt.
33. Install SA9105E set up for SUV application. Also, use J 45122 with long hooks from J 43405 . Refer to «Engine Support Fixture»(ref-188814-S13211755102005090200000) .
34. Remove the right-hand engine mount-to-bracket bolts.
35. Remove the right-hand mount assembly nuts.
36. Remove the right-hand engine mount assembly.
37. Remove the right-hand mount bracket.
38. Remove the right-hand engine mount bracket.
39. Raise the vehicle on hoist.
40. Remove the right wheel and splash shield.
41. Remove J 44811 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
42. Remove the accessory drive belt.
43. Remove the tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.
44. Remove the tensioner assembly.
45. Install J 38122-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
46. Remove the crankshaft balancer pulley bolt and pulley. Discard the pulley bolt.
47. Remove the front cover assembly bolts.
48. Remove the lower water pump assembly bolt.
49. Remove the front cover assembly and gasket.
50. Drain the coolant system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
51. Remove the exhaust manifold pipe to the manifold nuts.
52. Disconnect the electrical connectors at the front and rear oxygen sensors.
53. Remove down pipe to intermediate pipe nuts.
54. Remove down pipe assembly.
55. Lower the vehicle.
56. Remove the upper radiator hose from cylinder head.
57. Use a 24 mm wrench to hold the camshaft assembly while removing the exhaust sprocket bolt. Discard the bolt.
58. Remove the exhaust sprocket.
59. Remove the adjustable guide through the top of the cylinder head.
60. Remove the fixed timing chain guide.
61. Use a 24 mm wrench to hold the camshaft assembly while removing the intake sprocket bolt. Discard the bolt.
62. Remove the intake sprocket.
63. Remove the timing chain assembly through top of cylinder head.
64. Remove the timing chain drive sprocket from the crankshaft.
65. Remove the timing chain oiling nozzle and remove any debris from hole in block.
66. Inspect timing chain guide for wear.
67. Inspect the timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on the chain.
68. Install floor jack with block of wood and support the engine at the center of the oil pan.
69. Remove engine three bar engine support fixture to allow cylinder head to be removed.
70. Remove cylinder head bolts using loosening sequence.
71. With assistance, remove the cylinder head from block with the exhaust and intake manifold attached.

1. Transfer all components. (intake manifold, plugs, ect.)
2. Set crankshaft to 60 degrees before top dead center.
3. Install the cylinder head gasket placing OPEN facing up.
4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
5. Lightly apply clean engine oil to threads and to the bottom side of flange of head bolts. Allow oil to drain before installing.
6. Install and torque cylinder head bolts in sequence. Tighten: Tighten the cylinder head bolts to 30 N.m (22 lb ft) + 155 degrees.
7. Coat the front cylinder head crankcase bolts with Permatex® Threadlocker® Blue P/N 21485278, or equivalent. Tighten: Tighten the cylinder head front chaincase bolts to 35 N.m (24 lb ft).
8. Install the SA9105E that was removed earlier. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
9. Position the exhaust camshaft with offset slot to the 10 o'clock position.
10. Position the intake camshaft with offset slot to the 2 o'clock position.
11. Install timing chain drive sprocket to the crankshaft.
12. Using dampener, rotate the crank so that the mark on the timing chain drive sprocket is at the 5 o'clock position.
13. Install timing chain oiling nozzle and bolt. Tighten: Tighten the timing chain oil nozzle bolt to 10 N.m (89 lb ft).
14. Assemble the chain to the intake camshaft sprocket aligning the copper link to INT diamond timing mark on camshaft sprocket.
15. Lower assembly through chain housing opening on top of the cylinder head. Use care to make sure that the chain goes around both sides of the cylinder block bosses.
16. Route chain around crankshaft sprocket and align silver link to timing mark.
17. Install the intake camshaft sprocket with the chain in the proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
18. Install new intake camshaft sprocket bolt and finger tighten.
19. Install adjustable timing chain guide through the opening at the top of the cylinder head and install chain guide bolt. Tighten: Tighten the timing chain guide adjustable bolt to 10 N.m (89 lb in).
20. Install exhaust camshaft sprocket loosely on exhaust camshaft with timing mark on sprocket aligned with silver link.
21. Install new camshaft sprocket bolt loosely.
22. Align the exhaust camshaft sprocket with the chain in proper position to the camshaft. Rotate exhaust clockwise using a 24 mm wrench on flats on camshaft until the camshaft aligns with sprocket.
23. Verify that all colored links are aligned with the appropriate intake (1), crankshaft sprocket (2), and exhaust marks.
24. Verify crankshaft sprocket timing mark is at the 5 o'clock position.
25. If marks are not correct you must repeat the timing procedure.
26. Install the fixed timing chain guide and bolts. Tighten: Tighten the timing chain fixed bolts to 10 N.m (89 lb in).
27. Apply thread sealant Permatex® Thread Pipe Sealant (or equivalent) compound to the thread. Install the fixed guide bolt access hole plug. Tighten: Tighten the timing chain guide bolt access hole plug to 40 N.m (30 lb ft).
28. Tighten the intake and exhaust camshaft sprocket bolts while holding the camshaft with 24 mm wrench. Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) +30 degrees.
29. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring or washer is damaged replace the timing chain tensioner.
30. Measure the timing chain tensioner assembly from end to end.
31. 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 J 45027 (2) into a vise. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Install notch end of piston assembly into J 45027 (2). See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Using J 45027 (1), turn the ratchet cylinder into the piston. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
32. 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 lint free cloth.
33. 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.
34. At this point the tensioner should measure approximately 72 mm (2.83 in) (1) from end to end. If the tensioner does not read 72 mm (2.83 in) (1) from end to end repeat step 30.
35. Ensure all dirt and debris is removed from the timing chain tensioner threaded hold in the cylinder head.
36. Install new timing chain tensioner assembly and tighten. Tighten: Tighten the timing chain tensioner assembly bolt to 75 N.m (55 lb ft).
37. 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.
38. Install upper timing chain guide and bolts. Tighten: Tighten the timing chain guide upper bolts to 10 N.m (89 lb ft).
39. Raise the vehicle if necessary.
40. Install new front cover gasket.
41. Install the front cover assembly.
42. Install the front cover assembly bolts. Tighten: Tighten the front cover-to-block bolts to 25 N.m (18 lb ft).
43. Install the front cover water pump bolts. Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
44. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
45. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
46. Install the crankshaft damper pulley.
47. Install new crankshaft balancer pulley bolt with washer assembly.
48. Install crankshaft pulley holder J 38122-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Tighten: Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) +75.
49. Install accessory drive belt tensioner. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
50. Route belt around the alternator and the A/C compressor.
51. Install J 39914 onto tensioner and upload spring tension from tensioner while positioning belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
52. Release tensioner and remove the tool
53. Position manifold down pipe with gasket onto flange studs.
54. Install exhaust manifold pipe to exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts to 30 N.m (22 lb ft).
55. Attach electrical harness at bottom intake manifold.
56. Position oil level indicator into oil pan assembly.
57. Install oil level indicator tube bolt. Tighten:: Tighten the oil level indicator-to-manifold bolt to 10 N.m (89 lb in).
58. Remove the oil drain plug and drain oil. Tighten: Tighten the oil drain plug to 25 N.m (18 lb ft).
59. Lower the vehicle.
60. Remove the oil filter and install a new oil filter.
61. Fill the engine with oil. Tighten: Tighten the oil filter cap to 25 N.m (18 lb ft)
62. Install right-hand engine bracket and bolts. Tighten: Tighten the engine mount bracket-to-engine bolts to 90 N.m (66 lb ft).
63. Install shims on right hand engine mount studs.
64. Install right-hand engine mount onto body side rail studs.
65. Install right-hand engine mount to body nuts. Tighten: Tighten the engine mount-to-body nuts to 110 N.m (81 lb ft).
66. Install right-hand engine mount to engine mount bracket bolts. Tighten: Tighten engine mount-to-engine mount bracket bolts to 55 N.m (41 lb ft).
67. Install the right engine inner splash shield.
68. Install the right wheel and hand-tighten wheel nuts.
69. Tighten wheel nuts. Tighten: Tighten wheel nuts to 125 N.m (92 lb ft).
70. Remove three bar engine support fixture.
71. Visually inspect the camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
72. Assemble the camshaft cover and gasket using care to make sure that the gasket is located in the retaining groove on the camshaft cover.
73. Install cover on the cylinder head and tighten the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
74. Position engine harness and install fasteners at cam cover.
75. Connect the throttle body connector.
76. Attach ECM ground and ECM connector.
77. Connect the fuel injector harness.
78. Connect the upper radiator hose.
79. Connect the brake booster hose at booster
80. Connect EVAP purge hose and connector.
81. Connect the oxygen sensors at the exhaust manifold.
82. Reposition the fuel line assembly.
83. Install transfer line at fuel-to-fuel rail. Tighten: Tighten the transfer line fitting-to-fuel rail to 10 N.m (89 lb in).
84. Connect the fuel rail bracket and bolt to the cylinder head. Tighten: Tighten the fuel line bracket bolt to 10 N.m (89 lb in).
85. Connect the ground strap to the camshaft cover assembly. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
86. Connect the degas hose and attach to the fuel fail.
87. Connect the coolant pipe bracket bolts to the cylinder head. Tighten: Tighten the coolant pipe bracket bolt to 10 N.m (89 lb in).
88. Install spark plugs, if removed. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
89. Install the ignition module assembly to cam cover and hand tighten retaining bolts. Tighten: Tighten the Ignition module-to-camshaft cover bolts to 8 N.m (71 lb in).
90. Install air cleaner assembly and bolt. Tighten: Tighten air cleaner-to-support bracket bolt to 10 N.m (89 lb in).
91. Install outlet resonator/duct assembly into position.
92. Connect PCV fresh air vent hose assembly.
93. Tighten clamp at throttle body assembly.
94. Position outlet resonator/duct assembly up with support bracket and install push-pin.
95. Tighten the clamp at the air cleaner assembly.
96. Connect intake air temperature (IAT) sensor connector.
97. Install coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
98. Connect negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
99. Start the vehicle and inspect for leaks.

1. Remove the oil level indicator tube bolt to manifold.
2. Remove the oil level indicator assembly.
3. Remove the oil level tube.
4. The O-ring seal should be replaced if damaged.
5. Install the SA9105E set up for SUV application. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Refer to «Engine Support Fixture»(ref-188814-S13211755102005090200000) .
6. Remove the right hand engine mount bolts to bracket and body.
7. Remove the right hand engine mount.
8. Raise the engine approximately 3 inches using the support tool.
9. Raise the vehicle.
10. Remove only the lower A/C compressor bolt to oil pan.
11. Remove the oil pan drain plug and drain the engine oil.
12. Remove the engine oil pan bolts.
13. Remove the oil pan using pry points to separate the pan from the engine block.
14. Clean all oil pan, block mating surfaces, and oil pan bolts.

Scheme 8

1. Clean oil from the mating surface before the oil pan is installed to assure a proper seal. Oil may drain from the oil pump assembly.
2. Apply a 2 mm bead of Permatex® The Right Stuff to the oil pan.
3. Ensure the engine block to oil pan mating surfaces are clean and dry.
4. Place the oil pan into position and hand tighten the pan bolts.
5. Tighten the oil pan using the appropriate sequence. Tighten: Tighten the oil pan bolts - L61 to 15 N.m (11 lb ft).
6. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug - L61 to 25 N.m (18 lb ft).
7. Install the lower A/C bolt. Tighten: Tighten the A/C compressor bolt - L61 to 20 N.m (15 lb ft).
8. Lower the vehicle.
9. Install the right hand engine mount.
10. Install the oil level indicator tube into the block.
11. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt - L61 to 10 N.m (89 lb in).
12. Remove the oil fill cap.
13. Fill the engine with 4.73 L (5 qt) of new 5W-30 engine oil.
14. Install the oil fill cap.
15. Start the engine and inspect for leaks.
16. Check the engine oil level after the engine is OFF for 5 minutes. This will allow the engine oil to drain down into the oil pan from the cylinder head.
17. Verify the oil level and inspect for leaks.

Crankshaft Rear Oil Seal Replacement

Tools Required

1. J 42067 Rear Crankshaft Seal Installer. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 43653 Flywheel Holding Tool. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Remove the transaxle assembly. Refer to «Transmission Replacement»(ref-188804-S03198339012005090200000) in Automatic Transmission - VT25E, or «Transmission Replacement»(ref-188822-S18222099482005090200000) in Manual Transmission - Getrag 5 Speed.
2. If servicing the rear main seal on a manual transaxle vehicle, refer to «Clutch Assembly Replacement»(ref-188788-S15312790642005090200000) in Clutch.
3. Install the J 43653 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. Remove the flexplate/flywheel bolts and discard.
5. Remove the flexplate/flywheel assembly.
6. Clean the thread adhesive from the flywheel bolts. Use a nylon bristle to clean the bolt holes from the crankshaft.
7. Remove the J 43653 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
8. Remove the rear main seal by using a seal removal tool, or by inserting a self tapping screw and slide hammer into the seal.

Scheme 9

1. Make sure the rear main seal bore is free from debris. If a sealer is present, it must be removed to assure proper installation of the rear main seal.
2. Lubricate the outer diameter of the rear main seal with clean engine oil.
3. Using the J 42067 , press the new seal into the housing until fully seated. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . The installer will control the depth of the seal installation.
4. Install the flywheel/flexplate.
5. Install new flywheel bolts.
6. Install the J 43653 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
7. Tighten the flywheel bolts. Tighten: Tighten the flywheel bolts L61 to 53 N.m (39 lb ft) +25 degrees.
8. Remove the J 43653 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
9. If the vehicle is equipped with a manual transaxle. Install the clutch assembly. Refer to «Clutch Assembly Replacement»(ref-188788-S15312790642005090200000) in Clutch.
10. Install the transaxle assembly. Refer to «Transmission Replacement»(ref-188804-S03198339012005090200000) in Automatic Transmission - VT25E, or «Transmission Replacement»(ref-188822-S18222099482005090200000) in Manual Transmission - Getrag 5 Speed.

Engine Replacement

Tools Required

1. J 36346 Fascia Retainer Remover. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 39914 Serpentine Belt Tension Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. J 43828 Ball Joint Separator
4. J 44811 Accessory Belt Tensioner Unloader. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
5. J 45341 Rear Wheel Drive Shaft Removal Tool
6. SA91100C Tie Rod Separator
7. SA9127E Gage Bar Set. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
8. SA9805E Fuel Line Separator. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Scheme 10

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Disconnect the air intake temperature (IAT) sensor connector.
3. Loosen the clamp air cleaner assembly.
4. Remove the pushpin attachment from the outlet resonator/duct assembly to the support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the positive crankcase ventilation (PCV) fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Cover the throttle body opening with a shop towel. Use shop air to remove any dirt around the throttle body and intake manifold to cylinder head.
9. Remove the underhood fuse block (UHFB) fuse cover by separating the clips on each side.
10. Remove the UHFB fuse cover.
11. Remove the inner UHFB fuse cover.
12. Loosen the three connectors through bolts (1) at the top of the UHFB.
13. Remove the battery and the electronic power steering feed wire connection nut and remove the wire from the UHFB stud.
14. Release the tabs on each side of the UHFB with a screwdriver.
15. Raise the UHFB from the connectors. Disconnect the electrical connectors on each side of UHFB.
16. Remove the UHFB from the vehicle.
17. Remove the battery cable and the harness attachment clips the on side of battery tray/UHFB bracket assembly.
18. Remove the main connectors from the UHFB housing.
19. Lay the battery positive cable wire over the engine. The battery cables will be removed with powertrain assembly.
20. Remove the electrical harness clips to battery tray.
21. Remove the UHFB and the battery tray bolts.
22. Remove the UHFB and the battery tray.
23. Disconnect the electrical connectors at the transaxle control module (TCM), if equipped.
24. Remove the engine-to-body ground bolt.
25. Disconnect the connector for the rear O2 sensor.
26. Remove the vacuum hose with the check valve from the booster and lay across the engine.
27. Disconnect the 8-way electrical connector.
28. Remove the main engine harness gray connector and lay over the engine assembly. This will allow the engine harness to be removed the with powertrain.
29. If equipped with the automatic range transaxle, disconnect the shifter cable plastic retainer by using a screwdriver. Slightly pry between the shifter cable plastic retainer and the transaxle range switch.
30. Disconnect the shift lever cables from the shift control housing by prying with even pressure using a J 36346 or equivalent manual transmission only. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
31. Disconnect the shift lever cables from the shift lever cable bracket manual transmission only.
32. Disconnect the pressure line from the clutch actuator cylinder by removing the C-clip then pulling the line away from the clutch actuator cylinder manual transmission only.
33. Disconnect the back-up lamp switch (1) and the front wheel speed sensor (WSS) (2) manual transmission only.
34. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
35. Disconnect the upper radiator hose at the engine cylinder head.
36. Disconnect the lower radiator hose at the coolant pipe.
37. Disconnect the degas hose at surge tank.
38. Disconnect the surge hose at the bottom of the surge tank.
39. Disconnect the heater hoses from the heater core at the front of the dash.
40. Relieve the fuel system pressure using the «Fuel Pressure Relief Procedure»(ref-188785-S01720955142005090200000) in Engine Controls - 2.2L (L61).
41. Disconnect the SA9127E after the pressure has been relieved. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
42. Remove the safety clip and disconnect the fuel line transfer line at the quick connect from the fuel line using the SA9805E . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
43. Disconnect the purge hoses at the rear of the purge solenoid.
44. Remove the headlamp assemblies.
45. Using long tie straps, secure the radiator/condenser fan assembly to the radiator support assembly.
46. Raise the vehicle.
47. Remove the front left-hand (LH) wheel.
48. Remove the front LH wheel inner splash shield. IMPORTANT: A piece of hardwood should be used between the transaxle case and cradle assembly. This wood will support the transaxle when the LH mount bolts are removed.
49. Install a piece of hardwood 1 x 2 x 4 between the transaxle case and the engine cradle assembly.
50. Remove the front right-hand (RH) wheel.
51. Remove the wheel inner splash shield.
52. Install a piece of hardwood 1 x 2 x 4 between the engine oil pan and engine cradle assembly near the crankshaft.
53. Install the accessory J 44811 tool onto the tensioner. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
54. Remove the accessory drive belt.
55. Disconnect the electrical connector at the A/C compressor.
56. Disconnect the electrical connector at the A/C pressure transducer on-line.
57. Remove the A/C compressor bolts.
58. Support the compressor and the line assembly to the body with support straps.
59. Remove the pushpins that retain the air deflector assembly to the cradle.
60. Drain the transaxle fluid.
61. If equipped with automatic, disconnect the transaxle lines from the transaxle.
62. Disconnect the rear O2 sensor.
63. Remove the exhaust pipe-to-manifold flange bolts.
64. Remove the exhaust pipe to intermediate pipe nuts.
65. Remove the converter pipe assembly and the support intermediate pipe assembly.
66. Remove the propshaft bolts to the power take-off unit (PTU) - AWD Only.
67. Remove the propshaft bolts at the rear axle assembly - AWD Only.
68. Remove the propshaft support bracket-to-body bolts - AWD Only.
69. Remove the propshaft assembly - AWD Only.
70. If equipped with automatic, remove the shifter cable from the bracket assembly.
71. Remove the steering gear to the intermediate shaft bolt.
72. Remove the tie rod to knuckle nuts.
73. Separate the tie rod assemblies from the knuckle assemblies using the SA91100C .
74. Remove the lower control arm cotter pins and the nuts to knuckle assembly.
75. Separate the J 43828 .
76. Remove the lower stabilizer link nuts to the stabilizer bar.
77. Remove the LH axle shaft assembly from the transaxle.
78. Disconnect the RH shaft assembly from the intermediate drive shaft using the J 45341 tool with the appropriate slide tool.
79. Lower the vehicle.
80. Remove the RH engine mount to the engine bracket bolts. The engine should rest on the wood blocks.
81. Remove the LH transaxle mount to the transaxle bolts, the transaxle should rest on the wood blocks.
82. Raise the vehicle on the hoist.
83. Position the engine support table under the powertrain assembly.
84. With the table positioned, fully raise the table to contact with powertrain assembly.
85. Remove the cradle to body bolts.
86. Lower the engine table and raise the body on the hoist until the engine/transaxle and the cradle assembly is free from the vehicle.

Scheme 11

1. With the powertrain supported on the jacking table, raise the powertrain into position.
2. Raise the powertrain assembly into position. Align the lower radiator alignment pins with the cradle assembly. Be sure all the hoses and the electrical harnesses are correctly routed and free from the loading path of the powertrain assembly.
3. Raise the transaxle into the vehicle to align the input shaft to the center of clutch. Guide the transaxle into position, rotate back and forth to align the input shaft splines to the clutch disc manual transmission only.
4. Position the cradle guide pins into the location and install the new cradle-to-body bolts. Tighten: Tighten the frame-to-body bolts to 155 N.m (114 lb ft).
5. Lower the vehicle.
6. Install the RH engine mount-to-engine bracket bolts. Tighten: Tighten the engine mount-to-engine bracket bolts to 50 N.m (37 lb ft).
7. Install the RH engine mount assembly and the nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
8. Install the LH transaxle mount-to-transaxle bolts. Tighten: Tighten the LH transaxle mount-to-engine bracket bolts to 50 N.m (37 lb ft).
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
10. Remove the wood blocks between the cradle and the powertrain.
11. Swing the axle shafts into position and fully seat the axles into the transaxle.
12. Position the strut assemblies onto the lower control arms.
13. Install the lower control arm nut. Tighten: Tighten the lower control arm-to-knuckle nut to 10 N.m (89 lb in) +150 degrees.
14. Verify the axles are fully seated.
15. Position the stabilizer link into position and install the nut.
16. Install the stabilizer nut. Tighten: Tighten the stabilizer link to strut to 65 N.m (48 lb ft).
17. Install tie rod end into strut knuckle assembly. Tighten: Tighten the tie rod knuckle assembly to 50 N.m (37 lb ft).
18. Install the steering shaft to the intermediate shaft.
19. Install the steering shaft-to-intermediate shaft bolt. Tighten: Tighten the steering shaft-to-rack bolt to 34 N.m (25 lb ft).
20. Install the propshaft into position. Hand-tighten the center bearing nuts - AWD Only.
21. Install the propshaft into position - AWD Only.
22. Install the propshaft-to-PTU bolts - AWD Only. Tighten: Tighten the propshaft-to-PTU bolts to 25 N.m (19 lb ft).
23. Install the propshaft into the rear axle assembly - AWD Only.
24. Install the propshaft to rear module bolts - AWD Only. Tighten: Tighten the propshaft-to-rear module bolts to 50 N.m (37 lb ft).
25. Tighten the propshaft support bearing bolts - AWD Only. Tighten: Tighten the propshaft support bearing bolts to 25 N.m (19 lb ft).
26. Install the propshaft support strap - AWD Only. Tighten: Tighten the propshaft guard strap to 25 N.m (19 lb ft).
27. Connect the transaxle lines-to-transaxle. Tighten Tighten the transaxle cooler lines-to-transaxle stud 20 N.m (15 lb ft) - Automatic Only. Tighten the transaxle cooler lines-to-transaxle nut 10 N.m (89 lb in) - Automatic Only.
28. Install the gasket and down pipe-to-intermediate pipe assembly.
29. Hand tighten the nuts.
30. Install the gasket and down pipe-to-exhaust manifold. Tighten: Tighten the down pipe-to-intermediate pipe nuts to 50 N.m (37 lb ft).
31. Route the O2 harness into position at heat shield.
32. Install the A/C compressor to the engine block. Tighten: Tighten the A/C compressor-to-block bolt to 25 N.m (18 lb ft).
33. Connect the A/C compressor harness-to-compressor.
34. Connect the A/C pressure transducer-to-sensor.
35. Install the route belt around alternator and the A/C compressor.
36. Install the J 39914 onto the tensioner and unload the spring tension from the tensioner while positioning the belt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
37. Release the tensioner and remove the tool.
38. Attach the front air deflector to the cradle assembly.
39. Route and install the shifter cable onto the bracket.
40. Install the right engine inner splash shield.
41. Install the right wheel and hand tighten the wheel nuts.
42. Install the LH inner splash shield.
43. Install the left wheel and hand tighten the wheel nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
44. Lower the vehicle.
45. Connect the shifter cable to the transaxle range switch. Adjustment is required. Refer to «Shift Cable Adjustment»(ref-188804-S01590709472005090200000) in Automatic Transmission - VT25-E.
46. Connect the clutch hydraulic line to the actuator cylinder by inserting and pushing in the C-clip until it stops manual transmission only.
47. Connect the shift cables into the shift cable bracket manual transmission only.
48. Connect the shift cable ends to the transaxle manual transmission only.
49. Connect the heater hoses to the heater core at the front of the dash.
50. Connect the purge hose at the purge solenoid.
51. Connect the fuel transfer line to the quick connect to the fuel line.
52. Connect the surge hose at the bottom of the surge tank.
53. Connect the degas hose at the surge tank.
54. Connect the lower radiator hose at the coolant pipe.
55. Connect the upper radiator hose at the engine cylinder head.
56. Cut the radiator support straps and remove.
57. Install the headlamp assemblies and the torque bolts.
58. Route the engine ground under the A/C line.
59. Install the engine ground-to-body bolt. Tighten: Tighten the engine ground-to-body bolt to 20 N.m (15 lb ft).
60. Install the UHFB and the battery tray.
61. Install the UHFB and the battery tray bolts. Tighten: Tighten the battery tray bolts to 16 N.m (11 lb ft).
62. Route the engine harness into position and install the main engine and the body harness connectors into the UHFB housing.
63. Snap the connectors into position in the UHFB.
64. Connect both electrical connectors (2) underneath the UHFB.
65. Install the UHFB while aligning the UHFB with the connectors.
66. Snap the UHFB into position.
67. Tighten the UHFB connector bolts (1). Tighten: Tighten the UHFB connector bolts to 4 N.m (35 lb in).
68. Install the battery and electronic power steering (EPS) feed wire to the UHFB stud and tighten the nut. Tighten: Tighten the battery positive-to-UHFB stud to 10 N.m (89 lb in).
69. Install the UHFB fuse cover into position.
70. Connect the electrical connectors to the TCM, if equipped.
71. Install the battery cable and the harness attachment clips on the side of the battery tray/UHFB bracket assembly.
72. Install the battery and the cover.
73. Install the brake vacuum hose into the booster.
74. Connect the rear O2 sensor connector.
75. Secure the rear O2 sensor to the body clips, near air cleaner assembly.
76. Remove the shop towel from the throttle body opening.
77. Position the outlet resonator/duct assembly into position.
78. Connect the PCV fresh air vent hose assembly.
79. Tighten the clamp at the throttle body assembly.
80. Position the outlet resonator/duct assembly up with the support bracket and install the pushpin.
81. Tighten the clamp at air the cleaner assembly.
82. Connect the intake air temperature (IAT) sensor connector.
83. Connect the negative battery cable. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
84. Fill the coolant system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
85. Start the engine and fill the transaxle fluid. Refer to «Transmission Fluid Replacement»(ref-188804-S13658497612005090200000) .
86. Check for leaks.
87. If excessive engine idle vibration is noticed, mount adjustment procedure can be performed. Refer to «Powertrain Mount Balance Procedure - Total Mount»(ref-188814-S16773052562005090200000) .
88. Verify the wheel alignment is within specifications.

Engine Oil and Oil Filter Replacement

1. Using a 14-flat 68 mm (2.68 in) oil filter wrench or a 32 mm (1.26 in) socket, fully unscrew the oil filter cap from the housing. Allow the oil to drain back from the filter housing assembly.
2. Remove the oil filter cap assembly with the filter.
3. Grasp the oil filter cap with the filter element attached and gently tap the filter off onto an approved recycling container.
4. Inspect the O-seal on the cap assembly. Replace if worn, cut or damaged.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
6. Remove the engine oil drain plug and drain the oil into an approved container.
7. Inspect the engine oil drain plug. Replace the drain plug if the sealing surface is worn or damaged.
8. Remove the engine oil drain plug and drain the oil into an approved container.
9. Install the engine oil drain plug. Tighten: Tighten the oil pan drain plug - L61 to 25 N.m (18 lb ft).
10. Lower the vehicle.
11. Snap a new oil filter element into the oil filter cap.
12. Install the oil filter cap with the element into the casting in the block and tighten. Tighten: Tighten the oil filter cap to 25 N.m (18 lb ft).
13. Remove the engine oil fill cap.
14. Fill the engine with .73 L (5 qt) of new 5W-30 engine oil.
15. Install the engine oil filler cap.
16. Start the engine and inspect for leaks.
17. Check the engine oil level after the engine is OFF for 5 minutes. This will allow the engine oil to drain down into the oil pan from the cylinder head.
18. Reset the CHANGE OIL SOON telltale lamp. Refer to «Engine Oil and Oil Filter Replacement»(ref-188814-S21939914862005090200000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-188814-S01716317782005090200000) or «Exhaust Camshaft and Lifter Replacement»(ref-188814-S05282039002005090200000) .
2. Remove the camshaft roller followers.
3. Install the J 43649 to the cylinder head. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-188785-S26995136992005090200000) in Engine Controls - 2.2L (L61).
5. Install an air hose adaptor into the spark plug hole.
6. Pressurize the cylinder to 690 kPa (100 psi).
7. Compress the valve spring.
8. Remove the valve spring keepers.
9. Remove the valve spring.
10. Using the J 36017 remove the valve seal. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Using the J 36017 install the valve seal. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. Install the valve spring.
3. Compress the valve spring.
4. Install the valve spring keepers.
5. Remove the air hose adaptor into the spark plug hole.
6. Remove the J 43649 from the cylinder head. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
7. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-188785-S26995136992005090200000) in Engine Controls - 2.2L (L61).
8. Install the camshaft roller followers.
9. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(ref-188814-S01716317782005090200000) or «Exhaust Camshaft and Lifter Replacement»(ref-188814-S05282039002005090200000) .

Draining Fluids and Oil Filter Removal

1. 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 pump.
6. Apply sealant P/N 21485278 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.

Oil Level Indicator and Tube Removal

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

Exhaust Manifold Removal

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

Scheme 12

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

Crankshaft Damper Removal

1. Install the J 38122-A .
2. Remove the damper retaining bolt and washer. Use the J 38122-A and a breaker bar in order to prevent the crankshaft from rotating when loosening the bolt. Discard the bolt.
3. Remove the damper assembly.

Camshaft Cover Removal

1. Remove the power steering blockout plate.
2. Remove the camshaft cover grounding strap.
3. Remove the front lift bracket.
4. Remove the rear lift bracket.
5. Remove the ignition module and coil assembly.
6. 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 sprocket. 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 oil nozzle and bolt.

Intake Camshaft, Follower, and Adjuster Removal

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

Exhaust Camshaft, Follower, and Adjuster Removal

1. Mark bearing caps to ensure they are installed in the same position.
2. Remove the exhaust camshaft bearing cap bolts.
3. Remove the camshaft bearing 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 element adjusters.

Balance Shaft Drive Chain and Tensioner Removal

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

Balance Shaft Removal

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . 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. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . 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.See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) If the J 43650 is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment.See «Special Tools and Equipment»(ref-188814-S38890900672005090200000)
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 water pipe support bracket and bolts.
3. Remove the thermostat and water feed pipe retaining bolts.
4. Remove the thermostat housing and water feed pipe from the water pump cover.
5. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
6. Remove the water pump assembly.

Cylinder Head Removal

1. Remove the EGR cover (2), the bolts (1), and the EGR cover gasket (3).
2. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.
5. Clean all of the gasket surfaces.
6. 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.
7. Clean the old sealer/lube and dirt from the bolt holes.
8. Clean the bolt holes with a nylon bristle brush.
9. 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.
10. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Oil Pan Removal

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

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J-43966-1 Connecting Rod Guides. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 41742 Connecting Rod Guides. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

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 and J 41742 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. Inspect the position sensor for damage. Replace if necessary.
2. Remove the bedplate perimeter bolts.
3. Remove and discard the crankshaft bearing bolts.
4. 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.

Scheme 13

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plug.
4. Remove the six oil passage plugs on the sides of the block.
5. Remove the two water passage plugs on the top of the block.
6. Remove the two front oil passage plugs.
7. Remove the knock sensor and bolt.
8. Remove the oil pressure switch.
9. Remove the crankshaft position sensor and bolt.

Crankshaft and Bearings Installation

Tools Required

1. J 8087 (SA9178NE-A) Cylinder Bore Checking Gage. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Scheme 14

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

1. Tighten the bearing cap to specification.
2. Measure the bearing bore for taper and out-of-round using the J 8087 (SA9178NE-A). See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
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 two 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 I.D. in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing I.D. measurement to determine clearance. Determine whether clearance is within specification. If out of spec 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 using J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Refer to specification table. 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.

Crankshaft Rear Oil Seal Installation

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 and J 43953 Piston Ring Compressor. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. J-43966-1 and J 41742 Connecting Rod Guides. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Install the connecting rod bearings. Use the proper size 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 / J 41742 into the connecting rod bolt holes. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . This protects the crankshaft journal during piston and connecting rod installation.
3. Install the piston and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Install J 8037 / J 43953 over the piston. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the J 8037 / J 43953 against the engine block until all the rings have entered the cylinder bore. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . 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 bolt nuts to 25 N.m (18 lb ft), then rotate 100 degrees using J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).

Cylinder Head Installation

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow the oil to drain before installing.
4. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Then turn all the bolts 155 degrees in sequence. Use the J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
5. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).
6. Install the EGR cover (607), the bolts (608), and the EGR cover gasket (606). Tighten: Tighten the EGR cover bolts to 25 N.m (18 lb ft).

Balance Shaft Installation

1. Install the balance shaft bushing using the J 43650 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. When the J 43650 is fully seated in the engine block remove it with a wrench. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
4. Place the number one piston at TDC.
5. Install the balance shaft drive chain sprocket on the crankshaft.
6. Lubricate the balance shaft lobes with engine oil.
7. Install the balance shafts into their bores.
8. 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 P/N 21485278 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. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the water pipe support bracket and bolts. Tighten: Tighten the water pipe support bracket bolts to 10 N.m (89 lb in).
11. Install the engine coolant temperature sensor by hand.
12. Tighten the engine coolant temperature sensor. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

Timing Chain, Sprockets, Tensioner Installation

Tools Required

1. J 45027 Tensioner Tool. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

Scheme 15

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 sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket 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 sprocket and a new bolt loosely onto the exhaust camshaft.
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
8. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket 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 sprocket 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. Tighten: Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
12. Install the upper timing chain guide. 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 sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
14. Using a 24 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the exhaust camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
15. Remove the old oil from the timing chain tensioner.
16. Inspect the timing chain tensioner for scoring or free movement.
17. Inspect the timing chain chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
18. 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.
19. 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.
20. 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.
21. 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.
22. 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 16.1 and 16.4.
23. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
24. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
25. 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.
26. Inspect to ensure that all dirt and debris is removed from the timing chain oiling nozzle hole in the engine block.
27. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
28. Apply sealant P/N 21485277 compound to the thread, and install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (59 lb ft).

Crankshaft Front Oil Seal Installation

1. Install the seal into the front cover by driving it in from the timing chain side using J 35268-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
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. Tighten: Tighten the front lift bracket bolt to 25 N.m (18 lb ft).
4. Install the rear lift bracket. Tighten: Tighten the rear lift bracket bolts to 25 N.m (18 lb ft).
5. Install the ground strap. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
7. Install the ignition coil and module assembly to the cam cover. Tighten: Tighten the ignition coil and module assembly bolts to 10 N.m (89 lb in).
8. Install the power steering blockout plate. Tighten: Tighten the power steering blockout plate bolts to 25 N.m (18 lb ft).

Scheme 16

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of RTV P/N 21019581, around the perimeter of the oil pan and the oil suction port opening. Do not over apply the RTV. More than a 2 mm bead is not required.
3. Install the oil pan.
4. Install the oil pan bolts hand tight. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

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 5 W 30 engine oil.
3. Use J 44887 to install the oil filter adapter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Intake Manifold Installation

Note. Refer to Fastener Notice in Cautions and Notices.

Scheme 17

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 6 N.m (60 lb in).
2. Install a new intake manifold gasket on the intake manifold, if necessary.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate NEW fuel injector tip insulators with engine oil.
6. Install the NEW fuel injector tip insulators.
7. Install the fuel rail assembly.
8. Install the fuel rail stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
9. Install a NEW throttle body stud, if necessary. Tighten: Tighten the bolts and nuts to 6 N.m (60 lb in).
10. Install the throttle body. Tighten: Tighten the bolt and nuts to 10 N.m (89 lb in).
11. Install the EVAP emission canister valve (2). Tighten: Tighten the EVAP emission canister valve to 22 N.m (16 lb ft).
12. Install the EVAP emission canister valve tube (1).

Crankshaft Damper Installation

1. J 38122-A Harmonic Balancer Holder. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Install the damper onto the crankshaft indexing keyway. Use care to properly align the keyway and flats on the damper with the oil pump drive.
2. Install the J 38122-A . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
3. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar in order to prevent the crankshaft from rotating when tightening the bolt. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

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 to 14 N.m (124 lb in).
6. Coat the threads of the oxygen sensor with antiseize compound P/N 12397953.
7. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 30 N.m (22 lb ft).
8. Install the block heater and bolt, if equipped. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Install the exhaust manifold heat shield.
10. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).

Oil Level Indicator and Tube Installation

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

Engine Flywheel Installation

Tools Required

1. J 38122-A Harmonic Balancer Holder. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft damper with the J 38122-A , tighten the bolts evenly. See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) . Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 . See «Special Tools and Equipment»(ref-188814-S38890900672005090200000) .