Engine Mechanical - 3.5L (L66): Removal & Installation Saturn VUE I

Removal Procedure

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).
2. Loosen the drive belt tensioner by rotating the tensioner pulley clockwise while sliding the drive belt off the tensioner.
3. Remove the drive belt.
4. Clean and inspect the serpentine drive belt surfaces.

Installation Procedure

1. Route the belt around all pulleys, except the tensioner.
2. Rotate the tensioner pulley clockwise and install the drive belt.
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .
2. Remove the drive belt tensioner bolts.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolts. Tighten: Tighten the drive belt tensioner bolts to 22 N.m (16 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .

1. Install the engine support fixture long bar (6) to the vehicle.
2. Install the engine support fixture long bar legs (1).
3. Install the crossbar (4) to the engine support fixture long bar.
4. Install the lift hook (2) to the rear of the engine support fixture crossbar, and install the lift hook wing nut (3).
5. Install the lift hook (5) to the front of the engine support fixture crossbar, and install the lift hook wing nut (3).
6. Install the engine support fixture long bar to crossbar holding pin.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).
2. Support the engine. Refer to «Engine Support Fixture»(ref-188818-S20851670772005090200000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
4. Remove the engine mount to bracket bolts.
5. Remove the engine mount to frame rail nuts.
6. Remove the engine mount from the vehicle.

1. Position the engine mount onto the frame rail studs.
2. Install the engine mount to frame rail stud nuts. Tighten: Tighten the nuts to 110 N.m (81 lb ft).
3. Install the engine mount to engine mount bracket bolts. Take care when aligning the engine mount to engine mount bracket bolt holes, while hand tightening all the bolts.
4. Tighten the engine mount to engine mount bracket bolts. Tighten: Tighten the bolts to 110 N.m (81 lb ft).
5. Lower the vehicle.
6. Remove the engine support. Refer to «Engine Support Fixture»(ref-188818-S20851670772005090200000) .
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).

1. Remove the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-188818-S21684585052005090200000) .
2. Remove the engine mount bracket to engine bolts.
3. Remove the engine mount bracket from the engine.

1. Position the engine mount bracket to the engine.
2. Apply sealant Saturn P/N 21485277 (GM P/N 12345382) or equivalent, to the engine mount bracket lower bolt only and install the engine mount bracket to engine bolts. Tighten: Tighten the bolts to 44 N.m (33 lb ft).
3. Install the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-188818-S21684585052005090200000) .

Scheme 105

Remove the oil level indicator.

Install the oil level indicator.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
2. Remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-188818-S06831653442005090200000) .
3. Remove the oil flow control module.
4. Clean and inspect the oil flow control module sealing area.

1. Install a NEW oil flow control module screen.
2. Install the oil flow control module and bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install a new oil filter. Refer to «Engine Oil and Oil Filter Replacement»(ref-188818-S06831653442005090200000) .

1. Remove the outlet resonator/duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-188786-S38084220082005090200000) in Engine Controls - 3.5L (L66).
3. Disconnect the PCV hoses from the intake manifold.
4. Disconnect the brake booster hose from the intake manifold.
5. Remove the intake manifold top cover nuts and bolts.
6. Remove and discard the intake manifold top cover gasket.
7. Remove the IAT2 sensor.
8. Disconnect the PCV hose.
9. Remove the air outlet duct bracket.
10. Remove the intake manifold nuts and bolts.
11. Remove the intake manifold.
12. Remove and discard the intake manifold gasket.

1. Install the intake manifold with gasket.
2. Install the intake manifold nuts and bolts in sequence.
3. Tighten the intake manifold nuts and bolts. Tighten: Tighten the intake manifold nuts and bolts to first pass to 11 N.m (97 lb in). Tighten the intake manifold nuts and bolts final pass to 22 N.m (16 lb ft).
4. Install the outlet duct bracket and nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
5. Install the IAT2 sensor. Tighten: Tighten the IAT2 sensor to 18 N.m (13 lb ft).
6. Install the intake manifold top cover gasket.
7. Install the intake manifold top cover, nuts, and bolts.
8. Tighten the nuts, and bolts in sequence. Tighten: Tighten the nuts and bolts to first pass to 6 N.m (53 lb in). Tighten the nuts and bolts final pass to 12 N.m (106 lb in).
9. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-188786-S38084220082005090200000) in Engine Controls - 3.5L (L66).
10. Connect the PCV hoses to the intake manifold.
11. Connect the brake booster hose from the intake manifold.
12. Install the outlet resonator/duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-188818-S06890148622005090200000) .
2. Remove the intake manifold spacer top gasket. Discard the gasket.
3. Remove the intake manifold spacer and spacer bottom gasket. Discard the gasket.

1. Install a NEW intake manifold spacer bottom gasket.
2. Install the intake manifold spacer.
3. Install a NEW intake manifold spacer top gasket.
4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-188818-S06890148622005090200000) .

1. Remove the left fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) in Engine Controls - 3.5L (L66).
2. Remove the lower intake manifold nuts (530) and bolts (532).
3. Remove the lower intake manifold and gasket. Discard the gasket.

1. Install a NEW lower intake manifold gasket.
2. Install the lower intake manifold.
3. Install the nuts (530) and bolts (532). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).
4. Install the left fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) .

1. Remove the right fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) in Engine Controls - 3.5L (L66).
2. Remove the lower intake manifold nuts (530) and bolts (532).
3. Remove the lower intake manifold and gasket. Discard the gasket.

1. Install a NEW lower intake manifold gasket.
2. Install the lower intake manifold.
3. Install the nuts (530) and bolts (532). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).
4. Install the right fuel rail. Refer to «Fuel Rail Assembly Replacement»(ref-188786-S31979179522005090200000) .

1. Remove the oil level indicator.
2. Remove the oil fill cap.
3. Remove the PCV valve and bolt. Refer to «Positive Crankcase Ventilation Valve Replacement»(ref-188786-S26707080572005090200000) in Engine Controls - 3.5L (L66).
4. Disconnect the ignition wring harness from the ignition coils and retaining bracket.
5. Remove the wiring harness bracket bolt from the cylinder head.
6. Remove the bolts (708), and ignition coils (707).
7. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
8. Remove the seals (540), if required.

1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).
2. Tighten the bolts in sequence. Tighten: Tighten the bolts a first pass to 6 N.m (53 lb in). Tighten the bolts a final pass to 12 N.m (106 lb in).
3. Install the ignition coils (707) and bolts (708). Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the wiring harness bracket bolt to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Connect the ignition wiring harness to the retaining bracket and ignition coils.
6. Install the oil level indicator (429) and NEW O-rings (441).
7. Install the NEW O-rings (549 and 550), positive crankcase ventilation (PCV) valve (551) and bolt (552). Tighten: Tighten the bolt to 12 N.m (106 lb in).
8. Install the NEW O-ring (546) and cap (545).

1. Disconnect the vacuum brake booster hose.
2. Disconnect the MAP sensor connector.
3. Disconnect the IAT sensor connector.
4. Disconnect the ECT sensor connector.
5. Disconnect the EVAP purge hose from the purge valve.
6. Remove the intake manifold. Refer to «Intake Manifold Removal»(ref-188818-S07170049612005090200000) .
7. Disconnect the fuel injector connectors.
8. Remove the wiring harness bracket bolt from the valve rocker arm cover.
9. Remove the ignition coils. Refer to «Ignition Coil(s) Replacement - Bank 1»(ref-188786-S39476477052005090200000) .
10. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
11. Remove the seals (540), if required.

1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).
2. Tighten the bolts in sequence. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install the ignition coils (707) and bolts (708). Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the wiring harness bracket bolt to the valve rocker arm cover. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Connect the fuel injector connectors.
6. Install the intake manifold. Refer to «Intake Manifold Removal»(ref-188818-S07170049612005090200000) .
7. Connect the EVAP purge hose.
8. Connect the IAT sensor connector.
9. Connect the MAP sensor connector.
10. Connect the vacuum brake booster hose.
11. Connect the ECT sensor connector.

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) and «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
2. Loosen the adjusting nuts (217) and bolts (216).
3. Loosen the left side rocker shaft retaining bolts in sequence. Loosen the valve rocker shaft mounting bolts 2 turns at a time in sequence, to prevent damaging the valves or rocker arms.
4. Loosen the right side rocker shaft retaining bolts in sequence. Loosen the valve rocker shaft mounting bolts 2 turns at a time in sequence, to prevent damaging the valves or rocker arms.
5. Remove the bolts (1) and valve rocker arm and shaft assemblies.
6. Remove the lash adjusters (2).
7. Remove the intake valve rocker arms as an assembly (4) from the shaft (1). Refer to «Separating Parts»(ref-188818-S06867110702005090200000) .
8. Remove the exhaust valve rocker arms (6) and springs (5) from the shaft (7).
9. Remove the nuts (3) and bolts (2).
10. Note the installed location of the exhaust valve rocker arms (2).

1. Install the bolts (2) and nuts (3). Do not tighten the nuts at this time.
2. Install the intake valve rocker arm assemblies (4) onto the shaft (1).
3. Install the bolts to the shaft (1).
4. Install the exhaust valve rocker arms (6) and springs (5) onto the shaft (7).
5. Note the installed position of the exhaust valve rocker arms (2).
6. Install the bolts to the shaft (3).
7. Install the lash adjusters (2).
8. Install the rocker arm and shaft assemblies and bolts (1).
9. Tighten the left side rocker shaft retaining bolts in sequence. Tighten the bolts 2 turns at a time in sequence, to ensure that the rocker arms do not bind on the valves. Tighten: Tighten the bolts in sequence a first pass to 12 N.m (106 lb in). Tighten the bolts in sequence a final pass to 24 N.m (17 lb ft).
10. Tighten the right side rocker shaft retaining bolts in sequence. Tighten the bolts 2 turns at a time in sequence, to ensure that the rocker arms do not bind on the valves.
11. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) and «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43059 Valve Retainer Remover/Installer
2. SA9102E-A Valve Stem Seal Installer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. SA9127E Spark Plug Port Adapter
4. EN 46335 Valve Spring Compressor. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
5. EN 46336 Valve Guide Seal Installer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Remove the valve rocker arms. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
2. Remove the spark plug. Refer to «Spark Plug Replacement»(ref-188786-S37855960042005090200000) in Engine Controls - 3.5L (L66).
3. Install the SA9127E and apply air pressure to the cylinder in order to keep the valve from dropping into the cylinder.
4. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer to loosen the valve keepers.
5. Compress the valve spring with the EN 46335 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
6. Use the magnetic end of the J 43059 in order to remove the valve keepers (1).
7. Remove the EN 46335 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
8. Remove the valve spring retainer (2).
9. Remove the valve spring.
10. Remove the valve seal using the SA9102E-A . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Lubricate the valve stem, valve seal and guide with engine oil.
2. Use the EN 46336 to install the valve stem oil seals onto the guides. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Intake valve seals have a white spring (1). Exhaust valve seals have a black spring (2).
3. Position the valve spring on the spring seat.
4. Place the valve spring retainer (2) onto the valve spring.
5. Compress the valve spring using the EN 46335 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
6. With the spring compressed, install the valve keepers into the J 43059 .
7. Place the keepers (1) into position by pushing the tool downward.
8. Release the tension on the spring compressor and remove the EN 46335 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
9. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-blow hammer. The valve keepers and the spring should remain in place.
10. Relieve the air pressure from the cylinder and remove the SA9127E .
11. Install the spark plug. Refer to «Spark Plug Replacement»(ref-188786-S37855960042005090200000) in Engine Controls - 3.5L (L66).
12. Install the valve rocker arms. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .

1. Remove the intake manifold. Refer to «Intake Manifold Removal»(ref-188818-S07170049612005090200000) .
2. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) or «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
3. Adjust the values. Refer to «Valve Lash Adjustment»(ref-188818-S01598069582005090200000) .

1. Install the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) or «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
2. Install the intake manifold. Refer to «Intake Manifold Removal»(ref-188818-S07170049612005090200000) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .
2. Remove the right front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
3. Turn the crankshaft so its white mark (1) lines up with the pointer (2).
4. 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 pulley.
5. Use the EN 46337 and a breaker bar in order to retain the balancer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
6. Remove the bolt (227), balancer (228) and guide (236).

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).
6. Install the right front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
7. Install the drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .

1. Drain the oil. Refer to «Engine Oil and Oil Filter Replacement»(ref-188818-S06831653442005090200000) .
2. Remove the crossunder exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (L66)»(ref-188835-S36346828162005090200000) or «Exhaust Manifold Pipe Replacement (L61)»(ref-188835-S00143955642005090200000) in Engine Exhaust.
3. Remove the oil pan.
4. Clean sealer material from the block and oil pan assembly.
5. Remove the engine rear cover.
6. Remove the crossunder exhaust pipe brace.
7. Remove the oil pan bolts, and oil pan.
8. Clean sealer material from the block and oil pan assembly.

1. Clean the oil pan and engine block sealing surfaces.
2. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent evenly to the oil pan mating surface of the engine block.
3. Install the oil pan to the engine.
4. Install the oil pan bolts. Tighten Tighten the bolts, a first pass to 6 N.m (53 lb in). Tighten the bolts, a second pass to 12 N.m (106 lb in).
5. Install the rear engine cover.
6. Install the crossunder exhaust pipe brace.
7. Install the crossunder exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (L66)»(ref-188835-S36346828162005090200000) or «Exhaust Manifold Pipe Replacement (L61)»(ref-188835-S00143955642005090200000) in Engine Exhaust.
8. Refill the engine with oil and adjust the oil level.
9. Start the vehicle and inspect for oil leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
2. Disconnect the oil pressure sensor connector.
3. Remove the oil pressure sensor (1).

1. Apply sealant GM P/N 12346240 (Canadian P/N 10953493).
2. Install the oil pressure sensor (1). Tighten: Tighten the sensor to 18 N.m (13 lb ft).
3. Connect the oil pressure sensor connector.
4. Lower the vehicle.

Oil Pump Replacement

Tools Required

1. J 35268-A Camshaft/Front Main Seal Installer
2. J 42065 Crank Hub Holding Tool
3. J 42098 Crank Hub TORX Socket

1. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
2. Remove the timing belt idler pulley. Refer to «Timing Belt Idler Pulley Replacement»(ref-188818-S32802631692005090200000) .
3. Remove the oil flow control module. Refer to «Oil Flow Control Module Replacement»(ref-188818-S40522858332005090200000) .
4. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-188818-S30228833642005090200000) .
5. Remove the oil pump pickup tube.
6. Remove the oil pump bolts (423).
7. Remove the oil pump (424).
8. Clean the oil pump sealing surfaces if pump is to be reinstalled.

1. Install NEW O-rings (427) onto the oil transfer pipe (428).
2. Install the pipe (428) into the block.
3. Apply sealant GM P/N 12346240 or equivalent, evenly to the block mating surface of the oil pump housing and to the inner threads of the bolt holes.
4. Install the pins (426).
5. Install a NEW O-ring (426).
6. Install the oil pump assembly and bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
7. Install a NEW O-ring.
8. Install the oil pump pickup tube.
9. Install the oil pump pickup tube bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
10. Install the oil pan. Refer to «Oil Pan Replacement»(ref-188818-S30228833642005090200000) .
11. Install the oil flow control module. Refer to «Oil Flow Control Module Replacement»(ref-188818-S40522858332005090200000) .
12. Install the timing belt idler pulley. Refer to «Timing Belt Idler Pulley Replacement»(ref-188818-S32802631692005090200000) .
13. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
2. Drain the engine oil.
3. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-188818-S30228833642005090200000) .
4. Remove the oil pipe bolts.
5. Remove the oil pipe screen assembly.
6. Remove the oil pipe O-ring. Discard.
7. Clean the gasket surfaces.

1. Install a NEW oil pump pipe O-ring.
2. Install the oil pipe screen assembly.
3. Install the oil pump pipe bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the oil pan. Refer to «Oil Pan Replacement»(ref-188818-S30228833642005090200000) .
5. Lower the vehicle.
6. Refill the engine with 4.73 L (5 qt) of oil.
7. Start the vehicle and inspect for leaks and correct oil pressure.

Crankshaft Front Oil Seal Replacement

Tools Required

1. EN 46342 Driver Handle
2. EN 46347 Crankshaft Front Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
2. Remove the crankshaft gear. Refer to «Crankshaft Gear Replacement»(ref-188818-S27257840052005090200000) .
3. Carefully drill a small, shallow pilot hole into the steel ring of the seal.
4. Screw in a self tapping screw.
5. Use pliers to pull out the front main oil seal.
6. Clean all sealing surfaces.

1. Coat the lip of the front main oil seal with a small amount of clean engine oil to aid in the installation.
2. Use the EN 46347 and. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . EN 46342 to install the oil seal. Gently tap and install the new oil seal until the tool bottoms on the oil pump housing.
3. Ensure that the front main oil seal is fully and evenly seated.
4. Install the crankshaft gear. Refer to «Crankshaft Gear Replacement»(ref-188818-S27257840052005090200000) .
5. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
2. Remove the rear cover bolts.
3. Remove the rear cover.

1. Install the rear cover.
2. Install the rear cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Lower the vehicle.

1. Remove the engine drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .
2. Remove the right splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
3. Remove the engine balancer using the EN 46337 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
4. Remove the timing belt cover bolts (8).
5. Remove the timing belt cover (7).

1. Install the timing belt cover (7).
2. Install the timing belt cover bolts (8). Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install the engine balancer using the EN 46337 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
4. Install the splash shield. Refer to «Splash Shield Replacement - Engine»(ref-188792-S35668225222005090200000) in Body Front End.
5. Install the engine drive belt. Refer to «Drive Belt Replacement»(ref-188818-S03085051622005090200000) .

1. Remove the timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) .
2. Remove the timing belt (235). Refer to «Timing Belt Removal»(ref-188818-S01594980722005090200000) .

1. Install the timing belt (235). Refer to «Timing Belt Installation»(ref-188818-S32889893842005090200000) .
2. Install the timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) .
3. Perform the idle learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) in Engine Controls - 3.5L (L66).

1. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
2. Remove the bolts (7).
3. Remove the tensioner (6).
4. Remove the bolt (1), tensioner pulley assembly (2) and bushing (3).
5. Remove the nut (5) and pulley (4).

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 tensioner (252) and bolts (251). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the bushing (3), tensioner bracket (2) and bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the pulley (4) and nut (5). Tighten: Tighten the nut to 80 N.m (59 lb ft).
6. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Remove the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
2. Remove the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
3. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
4. Remove the upper radiator hose.
5. Remove the exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-188786-S08144135862005090200000) in Engine Controls - 3.5L (L66).
6. Remove the left rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) .
7. Remove the left camshaft drive sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) .
8. Alternately loosen the rocker shaft retaining bolts a few turns at a time using the loosening sequence.
9. Remove the rocker arm and shaft assembly.
10. Remove the rear camshaft cap, bolts, and O-ring.
11. Remove the camshaft from the cylinder head.
12. Remove the camshaft seal.
13. Clean all of the bearing surfaces.
14. Clean all of the sealing surfaces.
15. Clean and inspect the camshafts. Refer to «Camshafts Cleaning and Inspection»(ref-188818-S40446113852005090200000) .

1. Lubricate the camshaft journals and bores with clean engine oil.
2. Install the camshaft, NEW O-ring, cap, and bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install a new camshaft seal. Refer to «Camshaft Oil Seal Replacement»(ref-188818-S04815620952005090200000) .
4. Install the rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
5. Install the left camshaft drive sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) .
6. Install the left rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) .
7. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-188786-S08144135862005090200000) in Engine Controls - 3.5L (L66).
8. Install the upper radiator hose.
9. Fill the radiator with engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
10. Install the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
11. Install the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.

1. Remove the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
2. Remove the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
3. Remove the underhood fuse/relay box.
4. Disconnect the fuel feed line from the fuel rail. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-188785-S22434906122005090200000) in Engine Controls - 3.5L (L66).
5. Disconnect the engine harness connectors to gain access.
6. Remove the powertrain control module (PCM). Refer to «Powertrain Control Module (PCM) Replacement»(ref-188786-S14245230712005090200000) in Engine Controls - 3.5L (L66).
7. Remove the right rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
8. Remove the right camshaft drive sprocket. Refer to «Camshaft Drive Sprocket Replacement - Right»(ref-188818-S14189107942005090200000) .
9. Alternately loosen the rocker shaft retaining bolts a few turns at a time using the loosening sequence.
10. Remove the rocker arm and shaft assembly.
11. Remove the rear camshaft cap, bolts, and O-ring.
12. Remove the camshaft from the cylinder head.
13. Remove the camshaft seal.
14. Clean all of the bearing surfaces.
15. Clean all of the sealing surfaces.
16. Clean and inspect the camshafts. Refer to «Camshafts Cleaning and Inspection»(ref-188818-S40446113852005090200000) .

1. Lubricate the camshaft journals and bores with clean engine oil.
2. Install the camshaft, NEW O-ring, cap, and bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install a new camshaft seal. Refer to «Camshaft Oil Seal Replacement»(ref-188818-S04815620952005090200000) .
4. Install the rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
5. Install the right camshaft drive sprocket. Refer to «Camshaft Drive Sprocket Replacement - Right»(ref-188818-S14189107942005090200000) .
6. Install the right rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
7. Install the PCM. Refer to «Powertrain Control Module (PCM) Replacement»(ref-188786-S14245230712005090200000) in Engine Controls - 3.5L (L66).
8. Connect the engine harness connectors.
9. Connect the fuel feed line to the fuel rail. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-188785-S22434906122005090200000) in Engine Controls - 3.5L (L66).
10. Install the underhood fuse/relay box.
11. Install the battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
12. Install the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.

1. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
2. Remove the bolt (238).
3. Remove the pulley (239).

1. Install the pulley (239).
2. Install the bolt (238).
3. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Remove the appropriate camshaft sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) and «Camshaft Drive Sprocket Replacement - Right»(ref-188818-S14189107942005090200000) .
2. Remove the camshaft cover and bolts.
3. Remove the camshaft oil seal using a flat-bladed tool.

1. Use the EN 46334 to install the seal (223) into the cylinder head. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Rotate the bolt clockwise until the tool bottoms in the cylinder head bore.
2. Install the cover, NEW seal, and bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Install the camshaft sprocket. Refer to «Camshaft Drive Sprocket Replacement - Left»(ref-188818-S41543237672005090200000) and «Camshaft Drive Sprocket Replacement - Right»(ref-188818-S14189107942005090200000) .

1. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
2. Use the EN 46337 to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. Remove the camshaft bolt and sprocket.

1. Use the EN 46337 to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten: Tighten the camshaft sprocket bolt to 90 N.m (67 lb ft).
2. Install and adjust the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Remove the powertrain control module (PCM). Refer to «Powertrain Control Module (PCM) Replacement»(ref-188786-S14245230712005090200000) in Engine Controls.
2. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
3. Use the EN 46337 to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
4. Remove the camshaft bolt and sprocket.

1. Use the EN 46337 to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten: Tighten the camshaft sprocket bolt to 90 N.m (67 lb ft).
2. Install and adjust the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .

1. Remove the crankshaft position sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(ref-188786-S20736927252005090200000) in Engine Controls - 3.5L (L66).
2. Remove the guide (703).
3. Remove the sprocket and key (237 and 236).

1. Install the key and sprocket (236 and 237).
2. Install the guide (703).
3. Install the crankshaft position sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(ref-188786-S20736927252005090200000) in Engine Controls - 3.5L (L66).

1. Remove the left rocker cover (2). Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) .
2. Remove the left rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
3. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
4. Remove the coolant bridge. Refer to «Coolant Crossover Pipe Replacement»(ref-188798-S03632475632005090200000) in Engine Cooling.
5. Disconnect the left bank oxygen sensors.
6. Remove the left cylinder head. Refer to «Cylinder Head Removal - Left»(ref-188818-S29976782062005090200000) .

1. Install the left cylinder head. Refer to «Cylinder Head Installation - Left»(ref-188818-S26021212472005090200000) .
2. Connect the left bank oxygen sensors.
3. Install the coolant bridge. Refer to «Coolant Crossover Pipe Replacement»(ref-188798-S03632475632005090200000) in Engine Cooling.
4. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
5. Install the left rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
6. Adjust the valve lash. Refer to «Valve Rocker Arm and Valve Lash Adjuster Replacement»(ref-188818-S00483476612005090200000) .
7. Install the left rocker cover (2). Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) .

1. Remove the right rocker cover (2). Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .
2. Remove the right rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
3. Remove the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
4. Remove the coolant bridge. Refer to «Coolant Crossover Pipe Replacement»(ref-188798-S03632475632005090200000) in Engine Cooling.
5. Disconnect the right bank oxygen sensors.
6. Remove the right cylinder head. Refer to «Cylinder Head Removal - Right»(ref-188818-S18051622812005090200000) .

1. Install the right cylinder head. Refer to «Cylinder Head Installation - Right»(ref-188818-S26186103262005090200000) .
2. Connect the right bank oxygen sensors.
3. Install the coolant bridge. Refer to «Coolant Crossover Pipe Replacement»(ref-188798-S03632475632005090200000) in Engine Cooling.
4. Install the timing belt. Refer to «Timing Belt Replacement»(ref-188818-S29943911472005090200000) .
5. Install the right rocker arm and shaft assembly. Refer to «Valve Rocker Arm and Shaft Replacement»(ref-188818-S30275656642005090200000) .
6. Adjust the valve lash. Refer to «Valve Rocker Arm and Valve Lash Adjuster Replacement»(ref-188818-S00483476612005090200000) .
7. Install the right rocker cover (2). Refer to «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) .

1. Remove the transmission. Refer to «Transmission Replacement»(ref-188853-S03985504542005090200000) .
2. Remove the flywheel bolts (2), and note the position of the flywheel to the crankshaft.
3. Remove the flywheel washer (3) and flywheel (1).

1. Position the flywheel (1) and flywheel washer (3) on the crankshaft as previously noted.
2. Install the flywheel bolts (2).
3. Tighten the flywheel bolts in sequence. Tighten: Tighten the flywheel bolts in sequence to 74 N.m (54 lb ft).
4. Install the transmission. Refer to «Transmission Replacement»(ref-188853-S03985504542005090200000) .

Crankshaft Rear Oil Seal Replacement

Tools Required

1. EN 46342 Driver Handle
2. EN 46351 Crankshaft Rear Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-188818-S22035204762005090200000) .
2. Remove the seal (124) from the rear cover.

1. Lubricate the lip of the oil seal with a light coat of grease.
2. Use the EN 46342 (1) and the EN 46351 (2) in order to install the seal squarely into the housing. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. Drive the new crankshaft oil seal until the tool bottoms onto the housing. A properly installed seal will be flush with the face of the housing.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(ref-188818-S22035204762005090200000) .

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls.
4. Secure the cooling module to the upper body structure.
5. Remove the battery and battery tray. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
6. Disconnect the transmission shifter cable.
7. Disconnect the wiring harness from the underhood junction block. Refer to «Underhood Electrical Center or Junction Block Replacement»(ref-188770-S16702237242005090200000) in Wiring Systems.
8. Evacuate the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-188838-S17860289302005090200000) in Heating, Ventilation and Air Conditioning.
9. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
10. Remove the powertrain control module (PCM). Refer to «Powertrain Control Module (PCM) Replacement»(ref-188786-S14245230712005090200000) in Engine Controls - 3.5L (L66).
11. Remove the A/C low pressure tube at the front lift bracket.
12. Disconnect the generator positive cable. Refer to «Generator Replacement (L61)»(ref-188769-S17470453972005090200000) or «Generator Replacement (L66)»(ref-188769-S37528647252005090200000) in Engine Electrical.
13. Disconnect the A/C high pressure switch harness.
14. Remove the A/C tube from the A/C compressor. Refer to «Compressor Hose Assembly Replacement (L66)»(ref-188838-S04341824632005090200000) or «Compressor Hose Assembly Replacement (L61)»(ref-188838-S19160751212005090200000) in Heating, Ventilation, and Air Conditioning.
15. Disconnect the A/C line from the condenser to compressor.
16. Disconnect the coolant reservoir hose from the engine to reservoir.
17. Disconnect the radiator inlet and outlet hoses from the engine.
18. Remove the inlet and outlet heater hoses (1, 2).
19. Remove the starter positive cable.
20. Relieve the fuel pressure. Refer to «Fuel Pressure Relief Procedure»(ref-188786-S07925041012005090200000) in Engine Controls - 3.5L (L66).
21. Disconnect the fuel feed line.
22. Disconnect the fuel EVAP line.
23. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
24. Remove the lower transaxle-to-engine bolts.
25. Remove the PTU. Refer to «Transfer Case Replacement»(ref-188836-S16712804522005090200000) in Transfer Case - MJ8
26. Remove the torque convertor inspection cover.
27. Remove the torque convertor to flywheel bolts.
28. Remove the front wheels. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
29. Remove the left wheelhouse liner. Refer to «Wheelhouse Liner Replacement - Front»(ref-188792-S24195053872005090200000) .
30. Disconnect the transmission cooler lines from the transmission and bracket. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-188822-S01332751752005090200000) in Manual Transmission - Getrag 5 speed.
31. Remove the left and right tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-188802-S04735716192005090200000) in Power Steering System.
32. Remove the left and right stabilizer bar links. Refer to «Stabilizer Shaft Link Replacement»(ref-188816-S11416908932005090200000) in Front Suspension.
33. Disconnect the left and right lower ball joints. Refer to «Lower Ball Joint Replacement»(ref-188816-S32456978242005090200000) in Front Suspension.
34. Remove the left and right axle shaft nuts. Refer to «Wheel Drive Shaft Replacement - Front»(ref-188827-S42461363522005090200000) in Wheel Drive Shafts.
35. For AWD, remove the propeller shaft completely from the vehicle. Refer to «Propeller Shaft Replacement»(ref-188830-S08632284852005090200000) in Propeller Shaft.
36. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-188784-S31697123032005090200000) in Steering Wheel and Column.
37. Remove the front exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (L66)»(ref-188835-S36346828162005090200000) or «Exhaust Manifold Pipe Replacement (L61)»(ref-188835-S00143955642005090200000) in Engine Exhaust.
38. Remove the 3 front fender pushpins to allow the front fender to flex.
39. Use a paint pen or magic marker to mark the frame to the body position.
40. Support the engine in the cradle with wood blocks.
41. Disconnect the front engine mount from the body. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission - 5AT.
42. Position the engine support table under the powertrain assembly.
43. With the table positioned, fully raise the table to contact with the powertrain assembly.
44. Remove the cradle bolts.
45. Slowly lower the table to the floor.
46. Remove the starter.
47. Remove the following components: Remove the A/C compressor. Refer to «Compressor Replacement (L61)»(ref-188838-S09725816932005090200000) or «Compressor Replacement (L66)»(ref-188838-S22502293252005090200000) in Heating, Ventilation and Air Conditioning. Remove the generator. Refer to «Generator Replacement (L61)»(ref-188769-S17470453972005090200000) or «Generator Replacement (L66)»(ref-188769-S37528647252005090200000) in Engine Electrical. Remove the front covers. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) . Remove the rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) and «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) . Remove the catalytic converters. Refer to «Catalytic Converter Replacement - Left»(ref-188835-S27092411932005090200000) and «Catalytic Converter Replacement - Right»(ref-188835-S09771527382005090200000) in Engine Exhaust. Remove the timing belt. Refer to «Timing Belt Removal»(ref-188818-S01594980722005090200000) . Remove the cylinder heads. Refer to «Cylinder Head Removal - Left»(ref-188818-S29976782062005090200000) and «Cylinder Head Removal - Right»(ref-188818-S18051622812005090200000) .
48. Remove the front engine mount from the engine. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission - 5AT.
49. Remove the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-188818-S21684585052005090200000) .
50. Separate the engine from the transmission.

1. Align the engine to the transmission.
2. Apply sealant Saturn P/N 21485277 (GM P/N 12345382) or equivalent, to the two upper transmission-to-engine bolts only, and install the transmission-to-engine mounting bolts. Tighten: Tighten the bolts to 64 N.m (47 lb ft).
3. Install the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-188818-S21684585052005090200000) .
4. Install the front engine mount to the engine. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission - 5AT.
5. Install the following components: Install the cylinder heads. Refer to «Cylinder Head Removal - Left»(ref-188818-S29976782062005090200000) and «Cylinder Head Removal - Right»(ref-188818-S18051622812005090200000) . Install the timing belt. Refer to «Timing Belt Removal»(ref-188818-S01594980722005090200000) . Install the catalytic converters. Refer to «Catalytic Converter Replacement - Left»(ref-188835-S27092411932005090200000) and «Catalytic Converter Replacement - Right»(ref-188835-S09771527382005090200000) in Engine Exhaust. Install the rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(ref-188818-S05829638572005090200000) and «Valve Rocker Arm Cover Replacement - Right»(ref-188818-S27302606522005090200000) . Install the front covers. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) . Install the generator. Refer to «Generator Replacement (L61)»(ref-188769-S17470453972005090200000) or «Generator Replacement (L66)»(ref-188769-S37528647252005090200000) in Engine Electrical. Install the A/C compressor. Refer to «Compressor Replacement (L61)»(ref-188838-S09725816932005090200000) or «Compressor Replacement (L66)»(ref-188838-S22502293252005090200000) in Heating, Ventilation and Air Conditioning.
6. Install the starter. Refer to «Starter Motor Replacement (L61)»(ref-188769-S23390421582005090200000) or «Starter Motor Replacement (L66)»(ref-188769-S39410823652005090200000) in Engine Electrical.
7. Install the powertrain assembly to the vehicle.
8. Install the cradle bolts. Refer to «Frame Replacement (L61)»(ref-188812-S24581244232005090200000) or «Frame Replacement (L66)»(ref-188812-S09436621842005090200000) in Frame and Underbody.
9. Remove the engine support table.
10. Install the front engine mount bolts to the body. Refer to «Automatic Transmission Mount Replacement - Rear»(ref-188853-S41521518782005090200000) in Automatic Transmission - 5AT.
11. Remove the wood blocks from the cradle.
12. Install the lower transaxle-to-engine bolts. Tighten: Tighten the bolts to 64 N.m (47 lb ft).
13. Install the PTU. Refer to «Transfer Case Replacement»(ref-188836-S16712804522005090200000) in Transfer Case - MJ8.
14. Install the torque convertor- to- flywheel bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).
15. Install the torque convertor inspection cover. Tighten: Tighten the bolts to 12 N.m (9 lb ft).
16. Install the 3 front fender pushpins
17. Install the front exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (L66)»(ref-188835-S36346828162005090200000) or «Exhaust Manifold Pipe Replacement (L61)»(ref-188835-S00143955642005090200000) in Engine Exhaust.
18. Connect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-188784-S31697123032005090200000) in Steering Wheel and Column.
19. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-188830-S08632284852005090200000) in Propeller Shaft.
20. Install the left and right axle shaft nuts. Refer to «Wheel Drive Shaft Replacement - Front»(ref-188827-S42461363522005090200000) in Wheel Drive Shafts.
21. Connect the left and right lower ball joints. Refer to «Lower Ball Joint Replacement»(ref-188816-S32456978242005090200000) in Front Suspension.
22. Install the left and right stabilizer bar links. Refer to «Stabilizer Shaft Link Replacement»(ref-188816-S11416908932005090200000) in Front Suspension.
23. Install the left and right tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-188802-S04735716192005090200000) in Power Steering System.
24. Connect the transmission cooler lines to the transmission and bracket. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-188822-S01332751752005090200000) in Manual Transmission - Getrag 5 Speed.
25. Install the left wheelhouse liner. Refer to «Wheelhouse Liner Replacement - Front»(ref-188792-S24195053872005090200000) in Body Front End.
26. Install the front tires. Refer to «Tire and Wheel Removal and Installation»(ref-188815-S07973846162005090200000) in Tires and Wheels.
27. Lower the vehicle.
28. Install the fuel EVAP line.
29. Connect the fuel feed line. Refer to «Fuel Hose/Pipes Replacement - Chassis»(ref-188785-S22434906122005090200000) in Engine Controls.
30. Install the starter positive cable. Tighten: Tighten the starter cable to 10 N.m (89 lb in).
31. Install the inlet and outlet heater hoses.
32. Connect the inlet and outlet radiator hoses to the engine.
33. Install the A/C tube to the A/C compressor. Refer to «Compressor Hose Assembly Replacement (L66)»(ref-188838-S04341824632005090200000) or «Compressor Hose Assembly Replacement (L61)»(ref-188838-S19160751212005090200000) in Heating, Ventilation and Air Conditioning.
34. Connect the coolant reservoir hose from the engine to reservoir.
35. Connect the A/C line from the condenser to compressor.
36. Connect the A/C high pressure switch harness.
37. Connect the generator positive cable and nut. Tighten: Tighten the nut to 12 N.m (106 lb in).
38. Install the A/C lower pressure tube at the front lift bracket. Refer to «Liquid Line Replacement (L61)»(ref-188838-S28338896012005090200000) or «Liquid Line Replacement (L66)»(ref-188838-S34611107932005090200000) in Heating, Ventilation and Air Conditioning.
39. Install the PCM. Refer to «Powertrain Control Module (PCM) Replacement»(ref-188786-S14245230712005090200000) in Engine Controls.
40. Connect the radiator inlet and outlet hoses to the engine.
41. Fill the vehicle with coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) in Engine Cooling.
42. Connect the wiring harness to the underhood junction block. Refer to «Underhood Electrical Center or Junction Block Replacement»(ref-188770-S16702237242005090200000) in Wiring Systems.
43. Connect the transmission shifter cable.
44. Remove the cooling module support.
45. Install the battery tray and battery. Refer to «Battery Tray Replacement (L61)»(ref-188769-S41969954022005090200000) or «Battery Tray Replacement (L66)»(ref-188769-S02099368162005090200000) in Engine Electrical.
46. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-188786-S18482282612005090200000) in Engine Controls - 3.5L (L66).
47. Install the air outlet duct assembly. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.5L (L66).
48. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
49. Perform the idle learn procedure. Refer to «Idle Learn Procedure»(ref-188786-S26252071172005090200000) in Engine Controls - 3.5L (L66).

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
2. Position the oil drain pan under the engine oil drain plug.
3. Remove the engine oil drain plug.
4. Clean and inspect the engine oil drain plug, repair or replace if necessary.
5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary.
6. Remove the oil filter.
7. Clean and inspect the oil filter sealing area, repair or replace if necessary.

1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter.
2. Install the new oil filter. Refer to «Maintenance Items»(ref-188821-S41609004022005090200000) in Maintenance and Lubrication. Tighten: Tighten the filter to 7/8 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug. Tighten: Tighten the plug to 39 N.m (29 lb ft).
4. Remove the oil drain pan.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «Capacities - Approximate Fluid»(ref-188821-S22063397902005090200000) or «Fluid and Lubricant Recommendations»(ref-188821-S00161270662005090200000) and «Explanation of Scheduled Services»(ref-188821-S14881865052005090200000) in Maintenance and Lubrication.

Draining Fluids and Oil Filter Removal

1. Remove the oil filter (410).
2. Remove the oil drain plug (403) and O-ring (401) and allow the oil to drain.
3. Remove the left side coolant drain plug (113) and washer (114) and allow the coolant to drain.
4. Remove the block coolant heater and washer, if applicable, and allow the coolant to drain.
5. Loosen the right side coolant drain plug (110) and allow the coolant to drain.

Engine Lift Bracket Removal

1. Remove the bolts (710).
2. Remove the bracket (709).

Scheme 106

Remove the bolts (127), washer (126) and flywheel (125).

Throttle Body Removal

1. Remove the bolt (711).
2. Remove the manifold absolute pressure (MAP) sensor (712).
3. Remove the O-ring (713) from the sensor, if required.
4. Remove the throttle body coolant hoses.
5. Remove the nuts (519) and bolts (555).
6. Remove the throttle body (518) and gasket (517).
7. Remove the studs (516), if required.

Intake Manifold Removal

1. Remove the bolts (727), EVAP valve with hoses (718) and clamps (719).
2. Remove the positive crankcase ventilation (PCV) hose (548) and clamps (549).
3. Remove the intake air temperature (IAT) sensor (715) and O-ring (714).
4. Remove the bolts (513) and nuts (514).
5. Remove the cover (512) and gasket (511).
6. Remove the studs (515), if required.
7. Remove the bolts (508) and nuts (507).
8. Remove the manifold (500), gaskets (520) and spacer (521).
9. Remove the nuts (503) and bolts (504), if required.
10. Remove the covers (502 and 505), gaskets (501 and 506) and studs (553), if required.
11. Remove the bolts (510) and exhaust gas recirculation (EGR) tube (509), if required.
12. Remove the cap (554).
13. Remove the bolts (729) and dampener (728), if required.

Fuel Rail and Injectors Removal

1. Remove the nuts (731) and bolts (524).
2. Remove the fuel rail with injectors (523), hoses, and fuel pipe from the manifolds, as an assembly.
3. Remove the clips (526), injectors (527) and O-rings (525 and 528) as required.

Timing Belt Cover Removal

1. Remove the bolts (261).
2. Remove the covers (257 and 259).
3. Remove the bolts (262).
4. Remove the cover (229).
5. Remove the seals (230, 256, 258 and 272), if required.

Engine Mount Bracket Removal - Front

1. Remove the bolts (721).
2. Remove the mount bracket (722).

Timing Belt Tensioner Removal

1. Remove the bolts (251).
2. Remove the tensioner (252).
3. Remove the bolt (250), tensioner pulley assembly (233) and bushing (234).
4. Remove the nut (231) and pulley (232), if required.

Timing Belt Idler Pulley Removal

1. Remove the bolt (238).
2. Remove the pulley (239).

Timing Belt Drive Sprocket Removal

1. Remove the nut (702), bolts (730), and guide (703).
2. Remove the crankshaft position (CKP) sensor (704) and harness (701).
3. Remove the guide (236). Note, the concave area of the guide faces the front of engine.
4. Remove the sprocket (237) and key (123).

Water Pump Removal

1. Remove the bolts (301).
2. Remove the water pump (300).
3. Remove the O-ring (303).
4. Remove the pins (302).

Coolant Crossover Pipe Removal

1. Remove the throttle body coolant hoses, if required.
2. Remove the nuts (309) and bolts (310).
3. Remove the housing (308) and gaskets (306 and 307).
4. Remove the nuts (600), exhaust gas recirculation (EGR) valve (601), gasket (602) and studs (603), if required.
5. Remove the coolant temperature sensor (CTS) (717) and O-ring (716).
6. Remove the bolts (314), housing (313), O-ring (312) and thermostat (311).
7. Remove the coolant crossover pipe (305) and O-rings (304).

Valve Rocker Arm Cover Removal - Left

1. Remove the oil level indicator (429) and O-rings (441), if required.
2. Remove the oil fill cap (545) and O-ring (546), if required.
3. Remove the bolt (552), positive crankcase ventilation (PCV) valve (551) and O-rings (549, 550), if required.
4. Remove the bolts (708), ignition coils (707) and spark plugs (706).
5. Remove the bolts (543), with grommets (544), valve cover (542) and gasket (541).
6. Remove the seals (540), if required.

Valve Rocker Arm Cover Removal - Right

1. Remove the bolts (708), ignition coils (707) and spark plugs (706).
2. Remove the bolts (543), with grommets (544), valve cover (542) and gasket (541).
3. Remove the seals (540), if required.

Valve Rocker Arm and Shaft Removal

1. Loosen the adjusting nuts (217) and bolts (216).
2. Loosen the left side rocker shaft retaining bolts in sequence. Loosen the shaft mounting bolts 2 turns at a time in sequence, to prevent damaging the valves or rocker arms.
3. Loosen the right side rocker shaft retaining bolts in sequence. Loosen the shaft mounting bolts 2 turns at a time in sequence, to prevent damaging the valves or rocker arms.
4. Remove the bolts (214) and valve rocker arm and shaft assemblies.
5. Remove the lash adjusters (207).
6. Remove the intake valve rocker arms as an assembly (215) from the shaft (221). Refer to «Separating Parts»(ref-188818-S06867110702005090200000) .
7. Remove the exhaust valve rocker arms (218) and springs (219) from the shaft (220).
8. Remove the nuts (217) and bolts (216), if required.
9. Note the installed positions of the exhaust valve rocker arms (218).

Cylinder Head Removal - Left

1. Loosen the cylinder head bolts in sequence.
2. Remove the bolts (208).
3. Remove the cylinder head (200), gasket (225) and pins (226).

Cylinder Head Removal - Right

1. Loosen the cylinder head bolts in sequence.
2. Remove the bolts (208).
3. Remove the cylinder head (200), gasket (225) and pins (226).

Fuel Injection Manifold Removal - Left

1. Remove the nuts (530) and bolts (532).
2. Remove the manifold (531), gasket (533) and pins (547).
3. Remove the studs (535), if required.

Fuel Injection Manifold Removal - Right

1. Remove the nuts (530) and bolts (532).
2. Remove the manifold (531), gasket (533) and pins (547).
3. Remove the studs (535), if required.

Oil Pan Removal

1. Remove the bolts (409).
2. Remove the oil pan (400).
3. Remove the pins (402).
4. Clean the sealant from the oil pan and engine block sealing surfaces.

Oil Pump Pipe and Screen Assembly Removal

1. Remove the bolts (404, 407).
2. Remove the screen (405) and O-ring (406).

Crankshaft Oil Deflector Removal

1. Remove the bolts (407).
2. Remove the deflector (408).

Oil Flow Control Module Removal

1. Remove the bolts (436).
2. Remove the module (412) and O-ring (418).
3. Remove the bolts (417), solenoid (416) and O-ring (415), if required.
4. Remove the valve (414) and spring (413).
5. Remove the switch (437) and O-ring (440), if required.
6. Remove the fitting (411), if required.

Oil Pump Removal

1. Remove the oil pressure sensor (705).
2. Remove the bolts (423).
3. Remove the oil pump assembly (424) and O-ring (406).
4. Remove the pins (425).
5. Remove the oil transfer pipe (428) and O-rings (427).
6. Clean the sealant from the oil pump housing and engine block sealing surfaces.

Crankshaft Rear Oil Seal and Housing Removal

1. Remove the bolts (538).
2. Remove the housing (537).
3. Remove the O-ring (536).
4. Remove the pins (539).
5. Remove the seal (124) from the housing.
6. Clean the sealant from the housing and engine block sealing surfaces.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . SA9187NE Cylinder Ridge Reamer. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. J 41742 Connecting Rod Guide Pin

1. Rotate the engine to position the piston (120) at bottom dead center (BDC) in the cylinder.
2. If a ridge of metal or hard carbon can be felt around the top of any cylinder, use the J 24270 ,. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . SA9187NE , or equivalent in order to remove the cylinder ridge. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. Remove the bolts (115), cap (116), pins (128) and lower bearing half (117).
4. Use the J 41742 in order to remove the piston and connecting rod assembly from the block.
5. Remove the upper bearing half from the connecting rod.
6. Install the cap onto the connecting rod and mark or sort the bearings for assembly. Refer to «Separating Parts»(ref-188818-S06867110702005090200000) .

Crankshaft and Bearings Removal

1. Remove the bearing cap bolts (108, 109).
2. Remove the bearing caps (103) and lower bearings (106). Refer to «Separating Parts»(ref-188818-S06867110702005090200000) .
3. Remove the crankshaft (102), upper bearings (105) and thrust bearings (104).
4. Remove the pins (107).

Engine Block Plug Removal

1. Remove the block coolant heater and washer, if applicable.
2. Remove the left side coolant drain plug (113) and washer (114).
3. Remove the restrictor (431) and O-ring (430).
4. Remove the right side coolant drain plug (110), fitting (111) and washer (112).
5. Remove the restrictor (431) and O-ring (430).
6. Remove the knock sensor (720).

Valve Guide Replacement

1. Select the proper replacement guides and chill them in a freezer for approximately 1 hour.
2. Use a hot plate or an oven to evenly heat the cylinder head to 150°C (300°F). Monitor the temperature with a thermometer.
3. Working from the camshaft, or top, side, use the EN 46341 and an air hammer in order to drive the guide approximately 2 mm (0. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .1 in) towards the combustion chamber. This action will remove some of the carbon from the guide and ease in guide removal.
4. Turn the head over and use the EN 46341 and an air hammer to drive the guide out of the cylinder head. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . If the valve guide will not move, enlarge the guide bore with an 8 mm (5/16 in) drill bit.
5. Use the EN 46341 in order to install the NEW guides into the cylinder head. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Remove the valve guides, one at a time from the freezer, just prior to installation.
6. Measure the guide (264) for the properly installed height (a). Specification: Intake valve guide installed height: 21.20-22.2 mm (0.835-0.874 in) Exhaust valve guide installed height: 20.63-21.63 mm (0.812-0.852 in)
7. Coat the EN 46345 and the valve guide with cutting oil. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
8. Use the EN 46345 to ream the guide to the proper size. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Rotate the reamer clockwise the full length of the guide bore. Continue to rotate the reamer clockwise while removing from the guide bore.
9. Clean the guide in detergent and water to remove cutting residue.
10. Measure the valve stem-to-guide clearance. The valve should slide freely in the guide without exerting pressure.

Engine Block Plug Installation

1. Install the knock sensor (720). Tighten: Tighten the knock sensor to 31 N.m (23 lb ft).
2. Install the restrictor (431) and NEW O-ring (430).
3. Install the right side washer (112), fitting (111) and drain plug (110). Tighten: Tighten the fitting to 39.2 N.m (28.9 lb ft). Tighten the drain plug to 9.8 N.m (87 lb in).
4. Install the restrictor (431) and NEW O-ring (430).
5. Install the left side washer (114) and drain plug (113). Tighten: Tighten the drain plug to 78.5 N.m (57.9 lb ft).
6. Install the block coolant heater and washer, if applicable. Tighten: Tighten the heater to 60 N.m (44 lb ft).

Crankshaft and Bearings Installation

1. Install the pins (107).
2. Lubricate the bearings (104 and 105) and crankshaft bearing surfaces with clean engine oil.
3. Install the upper bearings (105) to the block.
4. Install the crankshaft (102).
5. Install the thrust bearings (104) to number 3 journal.
6. Install the lower bearings (106) and bearing caps (103).
7. Install the bearing caps (103) with the alignment arrow facing the front of the engine.
8. Lubricate the bolt (108 and 109) threads and flanges with clean engine oil.
9. Install the bolts (108 and 109). Tighten: Tighten the bolts (109) in sequence to 74 N.m (54 lb ft). Tighten the bolts (108) in sequence to 49 N.m (36 lb ft).
10. Measure the crankshaft end-play. Refer to «Crankshaft and Bearings Cleaning and Inspection»(ref-188818-S16733130882005090200000) .

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Ring Compressor
2. J 41742 Connecting Rod Guide Pin
3. J 45059 Angle Meter or SA9140E Torque Angle Gage

1. Install the upper bearing half to the connecting rod.
2. Install the J 41742 to the connecting rod in order to guide the connecting rod onto the crankshaft journal.
3. Install the piston into the cylinder bore with the arrow or mark (1) on the top of the piston facing the front of the engine.
4. Hold the J 8037 firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
5. Install the lower bearing half (117), cap (116) and bolts (115). Tighten: Tighten the bolts a first pass to 20 N.m (14 lb ft). Tighten the bolts a final pass an additional 90 degrees using the J 45059 or SA9140E .
6. Measure the connecting rod end-play. Insert a feeler gage between the connecting rod and crankshaft. Specification: Connecting rod end play - new: 0.15-0.35 mm (0.006-0.014 in) Connecting rod end play - service limit: 0.45 mm (0.018 in)
7. If the connecting rod end-play is not within the service limit, install a new connecting rod and measure again. If it is still not within the service limit, replace the crankshaft.

Crankshaft Rear Oil Seal and Housing Installation

Tools Required

1. EN 46342 Driver Handle
2. EN 46351 Crankshaft Rear Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Lubricate the lip of the oil seal with a light coat of grease.
2. Use the EN 46342 (1) and the EN 46351 (2) in order to install the seal squarely into the housing. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. Drive the new crankshaft oil seal until the tool bottoms onto the housing. A properly installed seal will be flush with the face of the housing.
4. Clean and dry the engine block and housing mating surfaces.
5. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent evenly to the mating surface of the housing.
6. Install the pins (539).
7. Install the O-ring seal (536).
8. Install the housing (537) and bolts (538). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Crankshaft Front Oil Seal Installation

Tools Required

1. EN 46342 Driver Handle
2. EN 46347 Crankshaft Front Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

Scheme 107

Use the EN 46342 (1) and the EN 46347 (2) to install the oil seal. See Special Tools and Equipment . Gently tap and install the NEW oil seal until the tool bottoms on the oil pump housing.

Oil Pump Installation

1. Install NEW O-rings (427) onto the oil transfer pipe (428).
2. Install the pipe (428) into the block.
3. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent evenly to the block mating surface of the oil pump housing and to the inner threads of the bolt holes.
4. Install the pins (425).
5. Install a NEW O-ring (426).
6. Install the oil pump assembly (424) and bolts (423). Align the flat surfaces of the oil pump inner rotor with the flat surfaces of the crankshaft. Tighten: Tighten the bolts to 12 N.m (106 lb in).
7. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent to the threads of the switch (705).
8. Install the oil pressure switch (705). Tighten: Tighten the switch to 18 N.m (13 lb ft).

Timing Belt Drive Sprocket Installation

1. Install the key (123) and sprocket (237).
2. Install the guide (236).
3. Install the crankshaft position (CKP) sensor (704) and harness (701).
4. Install the guide (703), nuts (702), and bolts (730). Tighten: Tighten the nuts and bolts to 9.8 N.m (87 lb in).
5. Rotate the crankshaft to align the mark (2) on the sprocket (237) with the pointer (1) on the oil pump housing.

Oil Flow Control Module Installation

1. Install the spring (413) and valve (414). The valve must move freely in the bore.
2. Install the NEW O-ring (415), solenoid (416) and bolts (417). Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install a NEW O-ring (418).
4. Install the module (412) and bolts (436). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
5. Install 2 M20 x 1.5 mm nuts onto the fitting (411).
6. Install the fitting (411), if required. Tighten: Tighten the fitting to 49 N.m (36 lb ft).
7. Remove the 2 M20 x 1.5 mm nuts from the fitting.
8. Install a NEW O-ring (440) and switch (437). Tighten: Tighten the switch to 22 N.m (16 lb ft).

Crankshaft Oil Deflector Installation

1. Install the deflector (408).
2. Install the bolts (407). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Oil Pump Pipe and Screen Assembly Installation

1. Install a NEW O-ring (406).
2. Install the screen (405) and bolts (404, 407). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Oil Pan Installation

1. Clean and dry the oil pan mating surfaces.
2. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent evenly to the oil pan mating surface (1) of the engine block.
3. Install the pins (402).
4. Install the oil pan (400).
5. Install the bolts (409).
6. Tighten the bolts. Tighten: Tighten the bolts in sequence a first pass to 6 N.m (53 lb in). Tighten the bolts in sequence a final pass to 12 N.m (106 lb in).

Fuel Injection Manifold Installation - Left

1. Install the pins (547).
2. Install the gasket (533) and manifold (531).
3. Install the nuts (530) and bolts (532). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).
4. Install the stud (535). Tighten: Tighten the stud to 22 N.m (16 lb ft).

Fuel Injection Manifold Installation - Right

1. Install the pins (547).
2. Install the gasket (533) and manifold (531).
3. Install the nuts (530) and bolts (532). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).
4. Install the stud (535). Tighten: Tighten the stud to 22 N.m (16 lb ft).

Cylinder Head Installation - Left

1. Install the pins (226), NEW gasket (225) and cylinder head (200).
2. Apply clean engine oil to the threads and flanges of the cylinder head bolts (208).
3. Install the bolts (208).
4. Tighten the bolts in sequence. Tighten: Tighten the bolts a first pass in sequence to 39 N.m (29 lb ft). Tighten the bolts a second pass in sequence to 69 N.m (51 lb ft). Tighten the bolts a final pass in sequence to 98.1 N.m (72.3 lb ft).

Cylinder Head Installation - Right

1. Install the pins (226), NEW gasket (225) and cylinder head (200).
2. Apply clean engine oil to the threads and flanges of the cylinder head bolts (208).
3. Install the bolts (208).
4. Tighten the bolts in sequence. Tighten: Tighten the bolts a first pass in sequence to 39 N.m (29 lb ft). Tighten the bolts a second pass in sequence to 69 N.m (51 lb ft). Tighten the bolts a final pass in sequence to 98.1 N.m (72.3 lb ft).

Camshaft Installation - Left

Tools Required

1. EN 46334 Camshaft Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Lubricate the camshaft journals and bores with clean engine oil.
2. Install the camshaft (209), NEW O-ring (210), cap (211) and bolts (212). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Use the EN 46334 in order to install the seal (223) into the cylinder head. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Rotate the bolt clockwise until the tool bottoms in the cylinder head bore.
4. Install the camshaft position (CMP) sensor (700) and bolt (723). Tighten: Tighten the bolt to 4 N.m (35 lb in).
5. Install the cover (244), NEW seal (243) and bolts (242). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
6. Install the sprocket (241) and bolt (240).
7. Use the EN 46337 in order to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten: Tighten the bolt to 90 N.m (67 lb ft).
8. Rotate the camshaft to align the number 1 cylinder top dead center (TDC) mark on the sprocket (2) with the pointer on the rear cover (1).

Camshaft Installation - Right

Tools Required

1. EN 46334 Camshaft Oil Seal Driver. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Lubricate the camshaft journals and bores with clean engine oil.
2. Install the camshaft (209), NEW O-ring (210), cap (211) and bolts (212). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
3. Use the EN 46334 in order to install the seal (223) into the cylinder head. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Rotate the bolt clockwise until the tool bottoms in the cylinder head bore.
4. Install the cover (246), NEW seal (245) and bolts (247). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
5. Install the sprocket (248) and bolt (249).
6. Use the EN 46337 to retain the camshaft sprocket. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten: Tighten the bolt to 90 N.m (67 lb ft).
7. Rotate the camshaft to align the mark on the sprocket (2) with the pointer on the rear cover (1).

Valve Rocker Arm and Shaft Installation

1. Install the bolts (216) and nuts (217). Do not tighten the nuts at this time.
2. Install the intake valve rocker arm assemblies (215) onto the shaft (221).
3. Install the bolts (214) to the shaft (221).
4. Install the exhaust valve rocker arms (218) and springs (219) onto the shaft (220).
5. Note the installed position of the exhaust valve rocker arms (218).
6. Install the bolts to the shaft (220).
7. Install the lash adjusters (207).
8. Install the intake and exhaust rocker arm and shaft assemblies and bolts (214).
9. Tighten the left side rocker shaft retaining bolts in sequence. Tighten the bolts 2 turns at a time in sequence, to ensure that the rocker arms do not bind on the valves. Tighten: Tighten the bolts in sequence a first pass to 12 N.m (106 lb in). Tighten the bolts in sequence a final pass to 24 N.m (17 lb ft).
10. Tighten the right side rocker shaft retaining bolts in sequence. Tighten the bolts 2 turns at a time in sequence, to ensure that the rocker arms do not bind on the valves.

Water Pump Installation

1. Inspect and clean the O-ring groove and mating surfaces.
2. Install the pins (302).
3. Install the water pump (300) with NEW O-ring seal (303).
4. Install the bolts (301). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Timing Belt Idler Pulley Installation

1. Apply GM P/N 12346240 (Canadian P/N 10953493) to the threads of the idler pulley bolt.
2. Install the pulley (239) and bolt (238).

Timing Belt Installation

Tools Required

1. EN 46330 Timing Belt Tensioner Retaining Pin. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
2. EN 46331 Timing Belt Tensioner Pulley Retaining Bolt. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
3. EN 46337 Camshaft Sprocket/Crankshaft Balancer Holder. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .

1. Clean the belt sprockets and covers.
2. Rotate the crankshaft and align the top dead center (TDC) mark (2) on the sprocket (237) with the pointer on the oil pump housing (1).
3. Rotate the left camshaft sprocket to TDC by aligning the mark (2) on the sprocket with the pointer (1) on the cover.
4. Rotate the right camshaft sprocket to TDC by aligning the mark (2) on the sprocket with the pointer (1) on the cover.
5. Install the EN 46331 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Screw the EN 46331 all the way in by hand, until the tool contacts the timing belt tensioner. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) . Tighten until snug.
6. Install the belt (235) onto the sprockets. Install the timing belt in a clockwise sequence starting with the tensioner pulley. Refer to «Camshaft Timing Belt Alignment Diagram»(ref-188818-S11243791692005090200000) .
7. Tighten the idler pulley bolt (238). Tighten: Tighten the bolt to 44 N.m (33 lb ft).
8. Remove the EN 46330 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
9. Remove the EN 46331 . See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
10. Install the guide (236), balancer (228), and bolt (227). Tighten the bolt until snug.
11. Using the EN 46337 , rotate the crankshaft clockwise about 5 or 6 complete revolutions to position the timing belt on the sprockets. See «Special Tools and Equipment»(ref-188818-S16205029212005090200000) .
12. Align the mark (2) on the sprocket with the pointer (1) on the oil pump housing.
13. Inspect the left camshaft sprocket for proper alignment. The TDC mark (2) on the sprocket should align with the pointer (1) on the cover.
14. Inspect the right camshaft sprocket for proper alignment. The TDC mark (2) on the sprocket should align with the pointer (1) on the cover.
15. Remove the bolt (227), balancer (228) and guide (236).

Engine Mount Bracket Installation - Front

1. Install the mount bracket (722).
2. Apply sealant Saturn P/N 21485277, GM P/N 12345382, (Canadian P/N 10953489) or equivalent to the bolt (721) threads.
3. Install the bolts. Tighten: Tighten the bolts to 44 N.m (33 lb ft).

Timing Belt Cover Installation

1. Install the seals (230, 256, 258 and 272).
2. Install the cover (229).
3. Install the bolts (262). Tighten: Tighten the bolts to 12 N.m (106 lb in).
4. Install the covers (257 and 259).
5. Install the bolts (261). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Valve Rocker Arm Cover Installation - Left

1. Install NEW seals (540), NEW gasket (541), cover (542), and bolts (543).
2. Tighten the bolts in sequence. Tighten: Tighten the bolts a first pass to 6 N.m (53 lb in). Tighten the bolts a final pass to 12 N.m (106 lb in).
3. Apply anti-seize compound GM P/N 21485279 to the threads of the spark plugs.
4. Install the spark plugs (706). Tighten: Tighten the spark plugs to 18 N.m (13 lb ft).
5. Install the ignition coils (707) and bolts (708). Tighten: Tighten the bolts to 12 N.m (106 lb in).
6. Install the oil level indicator (429) and NEW O-rings (441).
7. Install the NEW O-rings (549 and 550), positive crankcase ventilation (PCV) valve (551) and bolt (552). Tighten: Tighten the bolt to 12 N.m (106 lb in).
8. Install the NEW O-ring (546) and cap (545).

Valve Rocker Arm Cover Installation - Right

1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).
2. Tighten the bolts in sequence. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Apply anti-seize compound GM P/N 21485279 to the threads of the spark plugs.
4. Install the spark plugs (706). Tighten: Tighten the spark plugs to 18 N.m (13 lb ft).
5. Install the ignition coils (707) and bolts (708). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Coolant Crossover Pipe Installation

1. Install the coolant crossover pipe (305) and NEW O-ring seals (304).
2. Install the thermostat (311), NEW O-ring (312), housing (313) and bolts (314). Align the notch in the housing with the alignment flange of the thermostat. Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install the coolant temperature sensor (CTS) (717) and NEW O-ring (716). Tighten: Tighten the sensor to 18 N.m (13 lb ft).
4. Install the studs (603). Tighten: Tighten the studs to 10 N.m (88 lb in).
5. Install the exhaust gas recirculation (EGR) valve (601), NEW gasket (602) and nuts (600). Tighten: Tighten the nuts to 22 N.m (16 lb ft).
6. Install NEW gaskets (306 and 307), housing (308), bolts (309) and nuts (310). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).

Fuel Rail and Injectors Installation

1. Install new O-rings (525 and 528) to the injectors (527).
2. Install the injectors (527) and clips (526) to the fuel rails.
3. Install the fuel rail and injectors (523), hoses, and fuel pipe to the manifolds as an assembly.
4. Install the bolts (524) and nuts (731). Tighten: Tighten the bolts to 9.8 N.m (87 lb in). Tighten the nuts to 12 N.m (106 lb in).

Intake Manifold Installation

1. Install the gaskets (520) and spacer (521).
2. Install the manifold (500), bolts (508) and nuts (507).
3. Tighten the nuts and bolts in sequence. Tighten: Tighten the nuts and bolts in sequence a first pass to 11 N.m (8 lb ft). Tighten the nuts and bolts in sequence a final pass to 22 N.m (16 lb ft).
4. Install the exhaust gas recirculation (EGR) tube (509) and bolts (510). Tighten: Tighten the bolts to 12 N.m (106 lb in).
5. Install the studs (553), gaskets (501 and 506) and covers (502 and 505).
6. Install the bolts (504) and nuts (503). Tighten: Tighten the bolts and nuts to 12 N.m (106 lb in).
7. Install the dampener (728) and bolts (729). Tighten: Tighten the bolts to 21 N.m (15.9 lb ft).
8. Install the cap (554).
9. Install the studs (515), gasket (511), cover (512), nuts (514) and bolts (513).
10. Tighten the nuts and bolts in sequence. Tighten: Tighten the nuts and bolts in sequence a first pass to 6 N.m (53 lb in). Tighten the nuts and bolts in sequence a second pass to 12 N.m (106 lb in).
11. Install the positive crankcase ventilation (PCV) hose (548) and clamps (549).
12. Install the EVAP valve (718), with hoses, clamps (719) and bolts (727). Tighten: Tighten the bolts to 9.8 N.m (87 lb in).
13. Install the intake air temperature (IAT) sensor (715) and NEW O-ring (714). Tighten: Tighten the sensor to 12 N.m (106 lb in).

Throttle Body Installation

1. Install the studs (516), if required. Tighten: Tighten the studs to 7.8 N.m (69 lb in).
2. Install the gasket (517) and throttle body (518).
3. Install the nuts (519) and bolts (555). Tighten: Tighten the nuts and bolts to 22 N.m (16 lb ft).
4. Install a NEW O-ring (713).
5. Install the MAP sensor (712) and bolt (711). Tighten: Tighten the bolt to 3.4 N.m (30 lb in).
6. Install the throttle body coolant hoses.

Engine Flywheel Installation

1. Install the flywheel (125), washer (126) and bolts (127).
2. Tighten the bolts in sequence. Tighten: Tighten the bolts in sequence to 74 N.m (54 lb ft).

Engine Lift Bracket Installation

1. Install the bracket (709).
2. Install the bolts (710). Tighten: Tighten the bolts to 12 N.m (106 lb in).