Engine Mechanical - 3.5L (L66): Other Saturn VUE I

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

The engine identification (ID) number (1) is located on the left-side rear of the engine block.

1. Digits 1-5 identify the engine type.
2. Digits 6-12 identify the engine serial number.

Scheme 147

1. Tensioner pulley (232)
2. Crankshaft sprocket (237)
3. Idler pulley (239)
4. Camshaft sprocket - left (241)
5. Camshaft sprocket - right (248)
6. Water pump (300)

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Tools Required

SA9127E Gage Bar Set

1. Warm up the engine to a normal operating temperature of 98°C (208° F).
2. Turn the ignition switch OFF.
3. Remove the ignition coils. Refer to «Valve Rocker Arm Cover Removal - Left»(ref-188818-S28565888732005090200000) and «Valve Rocker Arm Cover Removal - Right»(ref-188818-S17036198812005090200000) .
4. Remove the spark plugs.
5. Attach the adapter (1), hose (2) and compression gage (3) to a spark plug hole.
6. Connect a tachometer.
7. Connect the scan tool.
8. Turn the ignition switch to the ON position.
9. Using the scan tool, command the injectors all off.
10. Depress the accelerator pedal to open the throttle fully.
11. Crank the engine with the starter motor and measure the compression.
12. Perform the measurement on each cylinder and compare the readings. Specification: Compression pressure: minimum 990 kPa (145 psi) at 200 RPM Maximum compression variation: 200 kPa (28 psi)
13. If the compression is not within specifications, inspect for the following conditions and measure the compression again. Improperly adjusted valves Improperly positioned timing belt and sprockets Damaged or worn valves or seats Damaged cylinder head gasket Damaged or worn piston rings Damaged or worn piston and cylinder bore
14. Using the scan tool, perform the PCM Reset Procedure to return the fuel injectors to normal operation.

SA9105E Engine Support Fixture (3-Bar)

EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See Special Tools and Equipment .

EN 46330 Timing Belt Tensioner Retaining Pin. See Special Tools and Equipment .

EN 46337 Timing Belt Alignment Kit. See Special Tools and Equipment .

EN 46337 Timing Belt Alignment Kit. See Special Tools and Equipment .

EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See Special Tools and Equipment .

1. Rotate the balancer and align the white mark on the balancer (1) with the locating tab (2) on the front cover.
2. Inspect for cylinder number 1 piston at TDC. The pointer on the upper cover (2) will be aligned with the number 1 cylinder TDC mark (1) on the camshaft sprocket.
3. Use the EN 46337 and a breaker bar in order to retain the balancer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
4. Remove the bolt (227), balancer (228) and guide (236).

EN 46331 Timing Belt Tensioner Pulley Retaining Bolt. See Special Tools and Equipment .

1. Use the EN 46331 to retain the tensioner pulley. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten until snug.
2. Loosen the idler pulley bolt (238) about 5 or 6 turns.
3. Remove the belt (235).
4. Remove the EN 46331 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See Special Tools and Equipment .

1. Use the EN 46337 in order to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. Remove the bolt (240), sprocket (241), bolts (242), cover (244) and seal (243).
3. Remove the bolt (723) and camshaft position (CMP) sensor (700).
4. Remove the bolts (212), cap (211), O-ring (210) and camshaft (209).
5. Remove the seal (223).

EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See Special Tools and Equipment .

1. Use the EN 46337 in order to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. Remove the bolt (249), sprocket (248), bolts (247), cover (246) and seal (245).
3. Remove the bolts (212), cap (211), O-ring (210) and camshaft (209).
4. Remove the seal (223).

SA9178NE-A Dial Bore Gauge

1. Using the SA9178NE-A , measure the cylinder bore wear and taper. Measure the bore both parallel and perpendicular to the crankshaft. Measure the bore at the top, center and bottom of each cylinder. If the bore size or taper exceeds the service limit of 89.065 mm (3.5065 in), the block must be bored and fitted with oversized pistons. Scored or scratched cylinder bores must be honed. Specification: Cylinder bore diameter - new: 89.0-89.015 mm (3.5039-3.5045 in) Cylinder bore diameter - service limit: 89.065 mm (3.5065 in) Cylinder bore diameter - with 0.25 mm oversize pistons: 89.25-89.265 mm (3.5138-3.5144 in) Maximum reboring limit: 0.25 mm (0.01 in) Cylinder bore taper limit: 0.05 mm (0.002 in) measured at the top and bottom of the cylinder bore
2. Using a straight edge and feeler gage, measure the top of the cylinder block for warpage. Specification: Cylinder block deck surface flatness - new: 0.07 mm (0.003 in) maximum Cylinder block deck surface flatness - service limit: 0.1 mm (0.004 in)
3. Inspect for the following conditions: Gasket sealing surfaces for excessive scratches or gouging Threaded bolt holes for damaged threads Restrictions within the coolant or oil passages

Cylinder Boring and Honing

1. Measure the cylinder bores. Refer to «Engine Block Cleaning and Inspection»(ref-188818-S13550553192005090200000) .
2. Hone the cylinder bores with honing oil and a 400 grit stone in a 60 degree crosshatch pattern.
3. Clean the cylinder block of all metal particles. Wash the cylinder bores with hot soapy water. Dry and oil immediately to prevent rusting.
4. If scoring or scratches are still present in the cylinder bore after honing to the service limit, the cylinder must be bored, honed and fitted with oversize pistons. Some light vertical scoring or scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

SA9179NE Dial Indicator

1. Clean the crankshaft oil passages. Remove all debris or restrictions.
2. Inspect the crankshaft for the following conditions: Journals for wear (1) Journals should be smooth with no signs of scoring, wear or damage. Grooves or scoring (2) Scratches or wear (3) Pitting or imbedded material (4)
3. Inspect the key (1), keyway (2) and threaded holes (3) for damage.
4. Install the front and rear upper main bearings to the engine block.
5. Position the crankshaft in the engine block.
6. Use the SA9179NE to measure the main journal runout. Rotate the crankshaft two complete revolutions. The difference between the journal measurements must not exceed the service limit. Specification: Crankshaft total runout - new: 0.02 mm (0.0008 in) Crankshaft total runout - service limit: 0.03 mm (0.0012 in)
7. Measure the main and connecting rod journals for an out-of-round condition. Measure each journal in 2 places 90 degrees opposite each other. The difference between the measurements on each journal must not exceed the service limit. Specification: Journal out-of-round - new: 0.005 mm (0.0002 in) Journal out-of-round - service limit: 0.01 mm (0.0004 in)
8. Measure the main and connecting rod journals for excessive taper. Measure each journal at the edges (1). Specification: Journal taper - new: 0.005 mm (0.0002 in) Journal taper - service limit: 0.01 mm (0.0004 in)

Crankshaft End Play Measurement

1. Push the crankshaft firmly away from the SA9179NE and position the tip of the dial indicator against the end of the crankshaft.
2. Zero the dial indicator and push the crankshaft firmly toward the SA9179NE . If the end play measurement exceeds the service limit, inspect the thrust washers and the thrust surface of the crankshaft. Specification: Crankshaft end play - new: 0.1-0.35 mm (0.004-0.014 in) Crankshaft end play - service limit: 0.45 mm (0.018 in)
3. Replace parts as required. The thrust surface of the crankshaft is a fixed dimension and should not be changed by grinding or shimming.

Connecting Rod Bearing Clearance Measurement

1. Remove the connecting rod bolts (115), cap (116) and lower bearing half (117).
2. Clean the crankshaft rod journal and bearing half with a clean shop towel.
3. Place 1 strip of plastic gaging material across the rod journal.
4. Install the lower bearing half, cap and bolts. Refer to «Piston, Connecting Rod, and Bearing Installation»(ref-188818-S30988595932005090200000) .
5. Remove the bolts, bearing cap and bearing half. Refer to «Piston, Connecting Rod, and Bearing Removal»(ref-188818-S38033290692005090200000) .
6. Measure the widest part of the plastic gaging material (1).
7. If the measurement is too wide or too narrow, remove the upper bearing half and install a new complete bearing of the same color and measure again. Do not file, shim or scrape the bearings or caps to adjust clearance.
8. If the plastic gaging measurement is still incorrect, try the next larger or smaller bearing. If the correct clearances cannot be obtained, replace the crankshaft assembly. Specification: Connecting rod bearing-to-journal clearance - new: 0.02-0.044 mm (0.0008-0.0017 in) Connecting rod bearing-to-journal clearance - service limit: 0.05 mm (0.002 in)

Crankshaft Main Bearing Clearance Measurement

1. Remove the bolts (108 and 109) caps (103) and lower bearings (106). Refer to «Crankshaft and Bearings Removal»(ref-188818-S14574670692005090200000) .
2. Clean each main journal and bearing half with a clean shop towel.
3. Place 1 strip of plastic gaging material across each main journal.
4. Install the bearings, caps and bolts. Refer to «Crankshaft and Bearings Installation»(ref-188818-S07470310202005090200000) .
5. Remove the bolts, bearing caps and bearings. Refer to «Crankshaft and Bearings Removal»(ref-188818-S14574670692005090200000) .
6. Measure the widest part of the plastic gaging material (1).
7. If the measurement is too wide or too narrow, remove the crankshaft and the bearing upper half. Install a new bearing assembly of the same color and measure again. Do not file, shim or scrape the bearings or caps to adjust the clearance.
8. If the plastic gaging measurement is still incorrect, try the next larger or smaller bearing. If the correct clearances cannot be obtained, replace the crankshaft assembly. Specification: Main bearing-to-journal clearance - new: 0.02-0.044 mm (0.0008-0.0017 in) Main bearing-to-journal clearance - service limit: 0.05 mm (0.002 in)

Main Bearing Selection

1. Locate the main journal bore diameter markings on the engine block rear flange. The first letter or bar (1) identifies crankshaft main journal number 1.
2. Locate the main journal outside diameter (O.D.) markings on the front of the crankshaft. The first number (1) identifies crankshaft main journal number 1.
3. Select the main journal bearings. Refer to «Crankshaft Bearings Selection Specifications»(ref-188818-S01583992042005090200000) .

Connecting Rod Bearing Selection

1. Locate the journal bore diameter marking (1) on the side of the connecting rod.
2. Locate the connecting journal diameter marking on the front of the crankshaft. The first letter (2) identifies connecting rod journal number 1.
3. Select the connecting rod journal bearings. Refer to «Connecting Rod Bearings Selection Specifications»(ref-188818-S19033741522005090200000) .

J 25070 Heat Gun or equivalent

1. Remove the piston rings (122) from the piston.
2. Apply clean engine oil to the piston pin retaining clips (121).
3. Rotate the clips and position the clip end gap to the cutout area of the piston pin bore (1).
4. Remove the clips (121). Start in the cutout area of the piston pin bore.
5. Use the J 25070 or equivalent to heat the piston and connecting rod assembly to approximately 70°C (158°F).
6. Remove the pin (119) from the piston (120) and connecting rod (118).

Piston Selection

1. Measure the piston diameter.
2. Measure the cylinder bore diameter. Refer to «Engine Block Cleaning and Inspection»(ref-188818-S13550553192005090200000) .
3. Calculate the clearance between the piston and the cylinder bore. Specification: Piston-to-bore clearance - new: 0.015-0.04 mm (0.0006-0.0016 in) Piston-to-bore clearance - service limit: 0.08 mm (0.003 in)
4. A 0.25 mm (0.010 in) oversize piston can be identified by the numbers 25 on the top of the piston.

Piston Ring Selection

1. Insert the piston ring (122) into the cylinder 15-20 mm (0.6-0.8 in) (a) from the bottom of the bore.
2. Measure the piston ring end gap (b) with a feeler gage. If the gap is too small, check to see if you have the proper rings for the application. If the gap is too large, check the cylinder bore diameter against the wear limits. Refer to «Engine Block Cleaning and Inspection»(ref-188818-S13550553192005090200000) . If the bore diameter exceeds the service limit, the cylinder block must be bored and fitted with oversize pistons and piston rings. Specification: Piston ring end gap - top ring - production: 0.2-0.35 mm (0.008-0.014 in) Piston ring end gap - second ring - production: 0.4-0.55 mm (0.016-0.022 in) Piston ring end gap - oil ring - production: 0.2-0.7 mm (0.008-0.028 in) Piston ring end gap - top ring - service limit: 0.6 mm (0.024 in) Piston ring end gap - second ring - service limit: 0.7 mm (0.028 in) Piston ring end gap - oil ring - service limit: 0.8 mm (0.031 in)

J 25070 Heat Gun or equivalent

1. Install 1 retaining clip (121).
2. Apply clean engine oil to the piston pin bore, piston pin, and connecting rod pin bore.
3. Use the J 25070 or equivalent in order to heat the piston to approximately 70°C (158°F).
4. Assemble the piston and connecting rod with the alignment marks (1) on the same side.
5. Install the piston pin (119) and clip (121).
6. Install the piston rings (122).
7. The top compression ring (1) has a 1D identification mark. The second compression ring (2) has a 2C identification mark. The manufacturing identification marks must face the top of the piston.
8. Using a feeler gage, measure the ring-to-groove clearance. Specification: Top compression ring clearance - new: 0.055-0.08 mm (0.0022-0.0031 in) Top compression ring clearance - service limit: 0.15 mm (0.006 in) Second compression ring clearance - new: 0.03-0.055 mm (0.0012-0.0022 in) Second compression ring clearance - service limit: 0.13 mm (0.005 in)
9. Rotate the piston rings in order to position the end gaps. Do not position any ring gap at the piston thrust surface. Do not position any ring gap in line with the piston pin and pin bore. Top compression ring (1) Oil spacer ring (1) Oil rings (2, 4) Second compression ring (3) Piston pin (5)

Measuring Camshaft End Play

1. Remove the rocker arms (215 and 218) and springs (219) from the shafts (220 and 221).
2. Lubricate the bolt (214) threads and flanges with clean engine oil.
3. Install the rocker arm shafts (220, 221) and bolts (214) to the cylinder heads.
4. Tighten the left cylinder head rocker shaft bolts in sequence. Tighten: Tighten the bolts a first pass to 12 N.m (106 lb in). Tighten the bolts a final pass to 24 N.m (17 lb ft).
5. Tighten the right cylinder head rocker shaft bolts in sequence. Tighten: Tighten the bolts a first pass to 12 N.m (106 lb in). Tighten the bolts a final pass to 24 N.m (17 lb ft).
6. Install the camshafts (209), caps (211), and bolts (212). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
7. Seat the camshaft by pushing it toward the rear of the cylinder head.
8. Use the SA9179NE in order to measure the end play. Zero the dial indicator against the end of the camshaft. Push the camshaft forward and rearward and measure the end play. Specification: Camshaft end play - new: 0.05-0.2 mm (0.002-0.008 in) Camshaft end play - service limit: 0.2 mm (0.008 in)

EN 46330 Timing Belt Tensioner Retaining Pin. See Special Tools and Equipment .

1. Inspect the tensioner pulley (232) for a grooved or worn belt contact surface or worn bearing.
2. Inspect the idler pulley (239) for a grooved or worn belt contact surface or worn bearing.
3. Inspect the camshaft and crankshaft sprockets for wear or other damage.
4. Inspect the belt for cracking, missing or damaged teeth.
5. Inspect for oil or coolant soaking. Replace the belt if it is oil or coolant soaked. Remove any residual oil or coolant on the belt.
6. Remove the EN 46330 from the tensioner (252). See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . The tensioner rod should move outward from the housing and extend to full stroke.
7. Measure the dimension of the rod at full stroke (a). If the rod extended measures less than or exceeds the specification, replace the tensioner assembly. Specification: Tensioner rod fully extended: 48.8-58.7 mm (1.92-2.31 in)
8. Push on the rod with normal hand pressure. The rod should exert excessive resistance and should not retract easily into the housing. If the rod can be retracted into the housing using normal hand pressure, measure the tensioner spring for proper load. Specification: Tensioner spring load: 151 N (34 lb) at 58.7 mm (2.31 in) Tensioner spring load: 185 N (41.5 lb) at 54.4 mm (2.14 in) Tensioner spring load: 228 N (51 lb) at 48.8 mm (1.92 in)

Valve Guide Reaming/Valve and Seat Grinding

Tools Required

1. EN 46341 Valve Guide Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. EN 46345 Valve Guide Reamer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. SA9179NE Dial Indicator

Measuring Valve Stem-to-Guide Clearance - Dial Indicator Method

1. Slide the valve out of the guide, approximately 10 mm (0.4 in), in order to measure the guide-to-stem clearance with the SA9179NE . Rock the stem in the direction of the normal thrust. If the measurement exceeds the service limit, install a new valve and measure again. If the measurement is within the service limit, assemble using existing valve. If the measurement with a new valve exceeds the service limit, replace the valve guide.
2. Compare the measurements to the specifications. Specification: Intake valve stem-to-guide clearance - new: 0.02-0.045 mm (0.0008-0.0018 in) Intake valve stem-to-guide clearance - service limit: 0.08 mm (0.003 in) Exhaust valve stem-to-guide clearance - new: 0.055-0.08 mm (0.0022-0.0031 in) Exhaust valve stem-to-guide clearance - service limit: 0.11 mm (0.004 in)

Measuring Valve Stem-to-Guide Clearance - Micrometer Method

1. Measure the outside diameter (O.D.) of the valve stem (c). Take measurements in 3 places along the stem.
2. Measure the inside diameter (I.D.) of the valve guide (a). Take measurements in 3 places along the guide bore.
3. Calculate the stem-to-guide clearance (b). Specification: Intake valve stem-to-guide clearance - new: 0.02-0.045 mm (0.0008-0.0018 in) Intake valve stem-to-guide clearance - service limit: 0.08 mm (0.003 in) Exhaust valve stem-to-guide clearance - new: 0.055-0.08 mm (0.0022-0.0031 in) Exhaust valve stem-to-guide clearance - service limit: 0.11 mm (0.004 in)

Valve Seat Reconditioning

1. Renew the valve seats using a seat cutting tool. Carefully cut a 45 degree seat, removing only enough material to ensure a smooth and concentric seat. Bevel the upper edge of the seat with a 30 degree cutter. Bevel the lower edge of the intake valve seat with a 67 degree cutter. Bevel the lower edge of the exhaust valve seat with a 60 degree cutter. Make 1 additional light pass with a 45 degree cutter in order to remove any possible burrs created during the cutting process. Specification: Valve seat width - new: 1.25-1.55 mm (0.049-0.061 in) Valve seat width - service limit: 2.0 mm (0.079 in)
2. After resurfacing the valve and/or seat, inspect for even valve seating. Apply Gear Pattern Checking Grease GM P/N 1052351 (Canadian P/N 10953497) or equivalent to the valve face (1). Insert the valve in its original location in the cylinder head. Lift and snap the valve closed against the seat several times.
3. The actual valve seating surface (2) should be centered on the seat. If the seat surface is too high or closer to the valve stem, a second cut with the 67 degree intake or 60 degree exhaust cutter must be made. An additional pass with the 45 degree cutter must also be made prior to completion. If the seat surface is too low or closer to the large end of the valve, a second cut with the 30 degree cutter must be made. An additional pass with the 45 degree cutter must also be made prior to completion.
4. Insert the intake and exhaust valves into the cylinder head. Measure the valve stem installed height (a). If the valve stem installed height is over the service limit, replace the valve and measure again. If the installed height remains over the service limit, replace the cylinder head. Specification: Intake valve stem installed height - new: 46.75-47.55 mm (1.841-1.872 in) Intake valve stem installed height - service limit: 47.8 mm (1.882 in) Exhaust valve stem installed height - new: 46.68-47.48 mm (1.838-1.869 in) Exhaust valve stem installed height - service limit: 47.73 mm (1.879 in)

Engine Prelubing

Tools Required

1. J 45299 Engine Preluber
2. EN 46333 Oil Pressure Testing Adapter. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Remove the engine oil filter (410) and fill with clean engine oil.
2. Install the oil filter. Tighten: Tighten the oil filter to 12 N.m (106 lb in).
3. Remove the oil pressure switch (1).
4. Install the EN 46333 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
5. Install the flexible hose to the EN 46333 and open the valve. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
6. Pump the handle on the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
7. Close the valve and remove the flexible hose and adapter from the engine.
8. Install the oil pressure sensor to the engine. Tighten: Tighten the switch to 18 N.m (13 lb ft).
9. Top-off the engine oil to the proper level.

EN 46330 Timing Belt Tensioner Retaining Pin. See Special Tools and Equipment .

1. Using a hydraulic press, slowly compress the tensioner.
2. Insert the EN 46330 through the housing and rod. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. Install the bushing (234), tensioner bracket (233) and bolt (250). Tighten: Tighten the bolt to 25 N.m (19 lb ft).
4. Install the pulley (232) and nut (231). Tighten: Tighten the nut to 80 N.m (59 lb ft).
5. Install the tensioner (252) and bolts (251). Tighten: Tighten the bolts to 12 N.m (106 lb in).

EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See Special Tools and Equipment .

1. Clean all oil from the balancer (228), guide (236), bolt (227) and crankshaft.
2. Lubricate the threads of the bolt (227) with clean engine oil.
3. Install the guide (236), balancer (228) and bolt (227). Install the guide with the concave surface facing the balancer.
4. Use the EN 46337 and a breaker bar in order to retain the crankshaft balancer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
5. Tighten the balancer bolt. Tighten: Tighten the bolt to 245 N.m (181 lb ft).

Intake Manifold

The cast aluminum intake manifold incorporates passages for air intake to each cylinder and a passage for the exhaust gas recirculation (EGR) system. The drive-by-wire throttle body and the intake air temperature (IAT) sensor are mounted to the intake manifold. The positive crankcase ventilation (PCV) hose and evaporative emission (EVAP) valve are connected to vacuum fittings on the manifold.

Camshaft Drive System

The crankshaft drive sprocket rotates the timing belt and in-turn rotates the camshaft sprockets. Belt tension is provided by the hydraulic auto-tensioner assembly. The hydraulic auto-tensioner automatically compensates for tension variations caused by changes in belt temperature. A timing belt idler pulley and a timing belt tensioner pulley are also incorporated into the design. 2 steel camshafts, 1 per bank, are used to operate both intake and exhaust rocker arms. The timing belt also drives the water pump assembly.

Valve Train

1 intake and 1 exhaust rocker arm shaft are used for each cylinder bank. Rocker shafts are retained to the cylinder heads by bolts. 5 roller type rocker arms are used for each cylinder, 3 intake and 2 exhaust. The rocker arms pivot on the rocker shafts. Each rocker arm has a nut and bolt type mechanical adjuster. Periodic valve adjustment is required. Refer to Intake Rocker Arm Control System Operation .

Cylinder Head

The cast aluminum cylinder heads have 2 intake and 2 exhaust valves per cylinder. The cylinder head has line-bored camshaft journals. This design eliminates the use of bearing caps and retaining bolts and improves the ease of assembly. The single overhead camshaft is installed into the cylinder head from the rear or back-side of the head. The camshaft cap retains the camshaft and controls camshaft end-play. The valve rocker arm shafts are directly fastened onto the cylinder head with 1 dowel pin at each end of the shaft for positioning. The valve guides and valve seats are pressed into the head. The valve guides are replaceable, but must be reamed for proper guide-to-valve stem clearance after installation. The catalytic converters mount directly to the side of each cylinder head.

Crankshaft

The crankshaft is of a cast iron design. The crankshaft is supported by 4 main bearings. The bearings are retained by bearing caps which are machined with the engine block for proper alignment and clearance. Journal number 3 is the thrust journal. Flat areas on the front of the crankshaft drive the oil pump assembly. A keyway and key on the front of the crankshaft align and position the timing belt drive sprocket and crankshaft balancer.

Engine Block

The cast aluminum V-shaped engine block is a deep-skirt design with 4 main bearing caps. The iron cylinder liners are a cast in place design. Coolant jackets encircle the cylinders. The 4 cast-iron bearing caps are cross-bolted to the engine block and each are retained by 2 vertically and 2 horizontally located bolts. Right side cylinders are numbered front-to-rear as 1-2-3. Left side cylinders are numbered front-to-rear 4-5-6. The firing order is 1-4-2-5-3-6.

Oil Pan

The cast aluminum oil pan retains the engine oil sump. The oil pan is positioned to the engine block by dowel pins and sealed to the engine block with an RTV type sealant.

Ignition

The V6 engine uses a coil-on-plug direct-ignition design. The camshaft position (CMP) sensor is mounted to the left-upper rear timing belt cover. The left camshaft sprocket has 3 spokes, or protrusions, incorporated into the rear of the sprocket that are used to create the camshaft sensor input signal. The dual-sensor crankshaft position (CKP) sensor assembly is located at the front of the engine at the oil pump housing. The timing belt drive sprocket has 22 spokes, or protrusions, incorporated into the rear edge of the sprocket that are used to create the crankshaft sensor input signal.

Scheme 148

The intake rocker arm control system is designed to change valve timing and lift, depending on engine speed, vehicle speed, engine load, and other sensor inputs, by controlling intake valve rocker arm actuation. The intake rocker arm control system achieves low-end torque and low fuel consumption when operating in the low engine speed range, while maintaining high power output when operating in the high engine speed range. The engine has a normal 4 valve per cylinder arrangement. At low engine speed, the primary (4) and secondary (2) intake valve rocker arms operate at normal lift. At high engine speed, the primary (4) and secondary (2) intake rocker arms are mechanically connected to the mid intake rocker arm (3) to allow high valve lift. Synchronizing pistons (1) connect and disconnect the 3 intake rocker arms. Hydraulic pressure against a timing piston moves the synchronizing piston outward. A stopper piston and return spring move the synchronizing piston back or inward when hydraulic pressure is reduced.

The system consists of the following components

1. A spool valve assembly with solenoid
2. An oil pressure switch
3. Valve lash adjusters-lost motion assemblies
4. An intake rocker arm assembly with moving-internal pistons

Scheme 149

The primary (4) and secondary (2) rocker arms are not connected to the mid rocker arm (3) and are driven separately by the camshaft lobes (5 and 7). Even though the mid rocker arm (3) is following the center camshaft lobe (6), it has no effect on the opening and closing of the valves in the low RPM range. The valve lash adjuster (207) absorbs the lost motion action of the mid rocker arm.

Scheme 150

The oil is pulled from the oil sump through the screen (405). Oil pressure generated in the oil pump (424) is supplied through the oil filter (410) to the engine block (100). The oil pressure is then directed to the cylinder heads (200) for rocker arm and camshaft lubrication. The oil restrictors (431) located within the upper engine block reduce the oil pressure to eliminate intake rocker arm piston actuation.

Scheme 151

The synchronizing pistons (1) move in the direction, as indicated, to mechanically connect the primary (4), secondary (2), and mid (3) rocker arms. The 3 rocker arms move as a single unit and are driven by the high range camshaft lobe (6). In this mode of operation, the valve timing and lift are set for high speed operation.

Scheme 152

The oil is pulled from the oil sump through the screen (405). Oil pressure is generated in the oil pump (424) and is supplied through the oil filter (410) to the oil flow control module. The solenoid valve (412) is energized, moving the spool valve (414). Increased oil pressure is then supplied to the synchronizing pistons, which move to connect the primary, secondary, and mid rocker arms.

Scheme 153

The lash adjuster, or lost motion assembly (207), includes a spring and retainer. The lash adjuster is in constant contact with the mid (3) rocker arm. At low speeds, the lash adjuster suppresses unnecessary movement of the mid rocker arm. The lash adjuster functions as an auxiliary spring at high speeds to ensure smooth valve operation.

Scheme 154

The PCM (5) constantly monitors the changes in engine status, such as engine speed (1), engine load (2), vehicle speed (3), and coolant temperature (4). The PCM directs the oil flow control module (412) to provide higher oil pressure to the intake valve rocker arms as required. The oil pressure switch (437) provides a signal to the PCM that oil pressure is present.

The following criteria is required for intake rocker arm activation

1. Engine speed of 4,400 RPM or greater
2. Engine coolant temperature (ECT) sensor reading of 10°C (50°F) or greater
3. Battery voltage of 10.5 volts or greater
4. Transmission shift lever in a position other than P or N
5. Engine has been running for longer than 5 seconds
6. Additional information can be found within engine controls information. Refer to «Rocker Arm Oil Control System Description»(ref-188786-S21803615322005090200000) in Engine Controls - 3.5L (L66).

Scheme 155

The spool valve assembly, or oil flow control module, is mounted to the front right of the engine block at the oil pump housing. The module consists of an oil filter (410), solenoid (416), spool valve (414) and spring (413). The module controls oil flow between the oil pump and the synchronizing pistons of the intake rocker arms. When the solenoid is activated, the oil pressure pushes the spool valve downward. The spool valve then opens the oil passage, and hydraulic pressure is applied to the synchronizing pistons, thus activating the intake rocker arm control system. The oil pressure sensor (437) is located on the housing by the solenoid valve and is in a normally closed position. The switch is used to detect oil pressure and to activate the intake rocker arm control system. The PCM provides 5 volts to the switch, the switch opens through the body, the solenoid is energized, and oil pressure applied.

Scheme 156

Oil is pulled from the oil pan sump by the crankshaft driven oil pump (424) assembly. The oil pump forces pressurized oil from the pump through the oil filter (410), to the engine block (100) main oil gallery. A regulator valve (419) located within the oil pump housing, controls pressure and vents excess oil back to the inlet side of the oil pump. The main oil gallery distributes pressurized oil to the main (2) and connecting rod (3) bearings. Oil then flows to the cylinder heads (200) and lubricates the camshafts (1) and rocker arms (215 and 218). The engine oil pressure switch (705) is a normally closed switch and is mounted onto the oil pump housing. The oil pressure switch is designed to warn the driver in the event engine oil pressure drops below the recommended value.

Oil Filter

The oil filter (410) is threaded onto the oil flow control module housing. Incorporated into the oil filter design are check and bypass valves. The check valve prevents oil from draining out of the engine oil galleries when the engine is not running. The bypass valve allows oil to bypass the filter element in the event of a restriction within the filter.

Cleanliness and Care

1. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
2. When any internal engine parts are serviced, care and cleanliness is important.
3. When components are removed for service, they should be marked, organized or retained in a specific order for reassembly. Refer to «Separating Parts»(ref-188818-S06867110702005090200000) .
4. At the time of installation, components should be installed in the same location and with the same mating surface as when removed.
5. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch. These surfaces should be covered or protected to avoid component damage.
6. A liberal coating of clean engine oil should be applied to friction areas during assembly.
7. Proper lubrication will protect and lubricate friction surfaces during initial operation.

J 28410 Gasket Remover. See Special Tools and Equipment .

Gasket Reuse and Applying Sealants

1. Do not reuse any gasket unless specified.
2. Gaskets that can be reused will be identified in the service procedure.
3. Do not apply sealant to any gasket or sealing surface unless called out in the service information.

Separating Components

1. Use a rubber mallet to separate components.
2. Bump the part sideways to loosen the components.
3. Bumping should be done at bends or reinforced areas to prevent distortion of parts.

Cleaning Gasket Surfaces

1. Remove all gasket and sealing material from the part using the J 28410 or equivalent. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. Care must be used to avoid gouging or scraping the sealing surfaces.
3. Do not use any other method or technique to remove sealant or gasket material from a part.
4. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage.

Pipe Joint Compound

1. Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2 non-rigid parts, such as the oil pan and the engine block, are assembled together.
2. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: Exhaust manifold Head gasket Other surfaces where gasket eliminator is specified
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(ref-188814-S00288320702005090200000) .
4. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes.
5. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
6. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. RTV sealant hardens when exposed to air. This type sealer is used where two non-rigid parts, such as the intake manifold and the engine block, are assembled together.
2. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: Exhaust manifold Head gasket Other surfaces where a gasket eliminator is specified
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(ref-188814-S00288320702005090200000) .
4. Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes.
5. Assemble components while RTV is still wet, within 3 minutes. Do not wait for RTV to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

1. Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where 2 rigid parts, such as castings, are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
2. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(ref-188814-S00288320702005090200000) .
3. Apply a continuous bead of gasket eliminator to one flange. Surfaces to be sealed must be clean and dry.
4. Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
5. Tighten bolts to specifications. Do not overtighten.
6. After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Separating Parts

Separate, mark or organize the following components

1. Piston and the piston pin
2. Piston to the specific cylinder bore
3. Piston rings to the piston
4. Connecting rod to the crankshaft journal
5. Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
6. Crankshaft main and connecting rod bearings
7. Camshaft and valve lash adjusters
8. Rocker arm position onto the rocker arm shafts
9. Valve to the valve guide
10. Engine block main bearing cap location and direction
11. Oil pump drive and driven gears

Tools and Equipment

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available

1. Approved eye protection and safety gloves
2. A clean, well lit, work area
3. A suitable parts cleaning tank
4. A compressed air supply
5. Trays or storage containers to keep parts and fasteners organized
6. An adequate set of hand tools
7. Approved engine repair stand
8. An approved engine lifting device that will adequately support the weight of the components