2004 ENGINE Engine Mechanical - 4.2L

2004 Isuzu Ascender LS
2004 ENGINE Engine Mechanical - 4.2L - Ascender
2004 ENGINE
Engine Mechanical - 4.2L - Ascender
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specifications
Application Metric English
A/C Line Bracket Nut at Oil Level Indicator Tube 7 N.m 61 lb in
A/C Line Bracket Bolt at Engine Lift Bracket 10 N.m 89 lb in
A/C Compressor Bolts 50 N.m 37 lb ft
Accelerator Control Cable Bracket Bolt 10 N.m 89 lb in
A.I.R. Cover Stud 25 N.m 18 lb ft
Camshaft Cap Bolt 12 N.m 106 lb in
Camshaft Cover Bolt 10 N.m 89 lb in
Camshaft Position Actuator Valve Bolt 10 N.m 89 lb in
Connecting Rod Cap Bolt
 First Pass 25 N.m 18 lb ft
 Final Pass 110 degrees
Coolant Temperature Sensor 20 N.m 15 lb ft
Cooling Fan Hub Nut 56 N.m 41 lb ft
Crankshaft Balancer Bolt
 First Pass 150 N.m 110.6 lb ft
Crankshaft Main Bearing Cap Bolt
Crankshaft Position Sensor Bolt 10 N.m 89 lb in
Crankshaft Rear Housing Bolt 10 N.m 89 lb in
Cylinder Head Access Hole Plug - Plastic 5 N.m 44 lb in
Cylinder Head Bolt - 14
Cylinder Head End Bolts - 2 Short
 First Pass 7 N.m 62 lb in
Microsoft
Thursday, July 30, 2009 12:17:36
12:17:13 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Cylinder Head End Bolts - 1 Long

 First Pass 7 N.m 62 lb in
Cylinder Head Oil Gallery Plug 38 N.m 28 lb ft
Drive Belt Idler Pulley Bolt 50 N.m 37 lb ft
Drive Belt Tensioner Bolt 50 N.m 37 lb ft
Engine Block Oil Gallery Plug - Front and Rear 80 N.m 60 lb ft
Engine Block Oil Gallery Plug - Side 35 N.m 26 lb ft
Engine Flywheel Bolt
Engine Front Cover Bolt 10 N.m 89 lb in
Engine Front Cover Spacer Bolt 10 N.m 89 lb in
Engine Front Lift Bracket Bolt 50 N.m 37 lb ft
Engine Harness Bracket Bolt 50 N.m 37 lb ft
Engine Mount Bracket Bolt - Engine 50 N.m 37 lb ft
Engine Mount Bracket Bolt - Frame 110 N.m 81 lb ft
Engine Mount Nuts - Upper and Lower 70 N.m 52 lb ft
Engine Protection Shield Bolts 25 N.m 18 lb ft
EVAP Purge Solenoid Valve Bolt 10 N.m 89 lb in
Exhaust Camshaft Actuator Bolt
Exhaust Camshaft Position Sensor Bolt 10 N.m 89 lb in
Exhaust Manifold Bolt
 Second Pass 25 N.m 18 lb ft
 Final Pass 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Nut 10 N.m 89 lb in
Exhaust Manifold Heat Shield Stud 10 N.m 89 lb in
Exhaust Pipe Bolt 50 N.m 37 lb ft
Front Differential Bolt 85 N.m 63 lb ft
Fuel Injector Rail Bolt 10 N.m 89 lb in
Generator Battery Lead Nut 9 N.m 80 lb in
Heater Inlet Fitting 45 N.m 33 lb ft
Heater Outlet Fitting 45 N.m 33 lb ft
Ignition Coil Bolt 10 N.m 89 lb in
Intake Camshaft Sprocket Bolt
Microsoft
Thursday, July 30, 2009 12:17:13 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.

Intake Manifold Bolt 16 N.m 12 lb ft
Knock Sensor 25 N.m 18 lb ft
Oil Filter
Oil Filter Adapter 30 N.m 22 lb ft
Oil Filter Bypass Hole Plug 14 N.m 124 lb in
Oil Filter Fitting 30 N.m 22 lb ft
Oil Level Indicator Tube Stud 10 N.m 89 lb in
Oil Level Sensor Bolt 10 N.m 89 lb in
Oil Pan Bolt - Ends 10 N.m 89 lb in
Oil Pan Bolt - Sides 25 N.m 18 lb ft
Oil Pan Drain Plug 26 N.m 19 lb ft
Oil Pan Nut 25 N.m 18 lb ft
Oil Pan Stud 11 N.m 97 lb in
Oil Pressure Sensor 20 N.m 15 lb ft
Oil Pump Cover Bolt 10 N.m 89 lb in
Oil Pump Pickup Tube 10 N.m 89 lb in
Oil Pump Pressure Relief Valve 14 N.m 124 lb in
Power Steering Pump Bolt 25 N.m 18 lb ft
Power Steering Pump Bracket Bolt 50 N.m 37 lb ft
Spark Plug 18 N.m 13 lb ft
Starter Motor Bolt 50 N.m 37 lb ft
Starter Motor Nut 50 N.m 37 lb ft
Starter Motor Stud 16 N.m 12 lb ft
Thermostat Housing bolt 10 N.m 89 lb in
Throttle Control Module Bolt 10 N.m 89 lb in
Timing Chain Tensioner Bolt 25 N.m 18 lb ft
Timing Chain Tensioner Guide Bolt 14 N.m 124 lb in
Timing Chain Tensioner Shoe Bolt 25 N.m 18 lb ft
Timing Chain Top Guide Bolt 10 N.m 89 lb in
Torque Converter Bolts 60 N.m 44 lb ft
Transmission Bell Housing Bolts 50 N.m 37 lb ft
Transmission Fluid Tube to Air Adapter Nut 10 N.m 89 lb in
Water Outlet Bolt 10 N.m 89 lb in
Water Pump Bolt 10 N.m 89 lb in
Water Pump Pulley Bolt 25 N.m 18 lb ft
Microsoft
ENGINE MECHANICAL SPECIFICATIONS
Engine Mechanical Specifications

Specification
Application Metric English
General
 Engine Type In-Line-6
 Displacement 4.2L 256 cu in
 RPO LL8
 VIN "S"
 Bore 93 mm 3.66 in
 Stroke 102 mm 4.02 in
 Compression Ratio 10:1
 Engine Compression Test 1482 KPa 215 psi
 Firing Order 1-5-3-6-2-4
 Spark Plug Gap 1.07 mm 0.042 in
Block
 Crankshaft Main Bearing Bore Diameter 78.070-78.088 mm 3.0760-3.0766 in
 Cylinder Bore Diameter 92.990-93.006 mm 3.6638-3.6644 in
 Cylinder Bore Out-of-Round 0.013 mm 0.0005 in
 Cylinder Head Deck Surface Flatness 0.08 mm 0.003 in
Cylinder Liner Recession 0.015 mm 0.0006 in
Camshaft
 Camshaft End Play - Exhaust 0.045-0.215 mm 0.0017-0.0084 in
 Camshaft End Play - Intake 0.051-0.201 mm 0.0020-0.0079 in
 Camshaft Journal Diameter - All Intake and 26.936-26.960 mm 1.0612-1.0622 in
Exhaust #2-#7
 Camshaft Journal Diameter - Exhaust #1 29.936-29.960 mm 1.1794-1.1804 in
 Camshaft Journal to Bore Clearance 0.040-0.085 mm 0.0015-0.0033 in
Connecting Rod
 Connecting Rod Bearing Clearance 0.021-0.065 mm 0.0008-0.0025 in
 Connecting Rod Bore Diameter - Bearing 60.322-60.338 mm 2.3749-2.3755 in
End
 Connecting Rod Bore Out-of-Round - 0.005 mm 0.0002 in
Bearing End
Connecting Rod Side Clearance 0.05-0.35 mm 0.0019-0.0137 in
Microsoft
Crankshaft
 Crankshaft End Play 0.112-0.388 mm 0.0044-0.0153 in
 Crankshaft Main Bearing Clearance 0.012-0.064 mm 0.0004-0.0025 in
 Crankshaft Main Journal Diameter 69.968-69.984 mm 2.7567-2.7574 in
 Crankshaft Main Journal Out-of-Round 0.005 mm 0.0002 in
 Crankshaft Main Journal Taper 0.005 mm 0.0002 in
Cylinder Head
 Surface Flatness - Block Deck 0.08 mm 0.003 in
 Surface Flatness - Exhaust Manifold Deck 0.08 mm 0.003 in
 Surface Flatness - Intake Manifold Deck 0.08 mm 0.003 in
Exhaust Manifold
 Surface Flatness 0.08 mm 0.003 in
Lubrication System
 Oil Capacity - with Filter 6.6 L 7.0 qts
 Oil Capacity - without Filter 6.1 L 6.5 qts
 Oil Pressure - Minimum 85 KPa 12 psi @ 1200 RPM
Oil Pump
 Gear Diameter - Drive 73.415-73.370 mm 2.893-2.891 in
 Gear Diameter - Driven 87-86.975 mm 3.428-3.426 in
 Gear Pocket - Depth 15.609-15.584 mm 0.615-0.614 in
 Gear Pocket - Diameter 87.065-87.040 mm 3.430-3.429 in
 Gear Thickness - Drive 15.546-15.521 mm 0.613-0.611 in
 Gear Thickness - Driven 15.360-15.511 mm 0.605-0.611 in
 Lobe Inner Diameter - Maximum 11.9 mm 0.469 in
 Relief Valve-to-Bore Clearance 2.57-1.63 mm 0.101-0.064 in
Piston Rings
 Piston Ring End Gap - First Compression 0.15-0.3 mm 0.0059-0.0118 in
Ring
 Piston Ring End Gap - Second Compression 0.36-0.51 mm 0.0142-0.0201 in
Ring
 Piston Ring End Gap - Oil Control Ring 0.250-0.760 mm 0.0098-0.0299 in
 Piston Ring to Groove Clearance - First 0.043-0.093 mm 0.0017-0.0037 in
Compression Ring
 Piston Ring to Groove Clearance - Second 0.043-0.093 mm 0.0017-0.0037 in
Compression Ring
Microsoft
 Piston Ring to Groove Clearance - Oil 0.059-0.215 mm 0.0023-0.0085 in

Control Ring
Pistons and Pins
 Piston - Piston Diameter 92.971-93.005 mm 3.6603-3.6616 in
 Piston - Piston Pin Bore Diameter 23.002-23.008 mm 0.9056-0.9058 in
 Piston - Piston to Bore Clearance -0.015-0.035 mm -0.0006-0.0014 in
 Pin - Piston Pin Clearance to Connecting Rod 0.001-0.018 mm 0.0004-0.0007 in
Bore
 Pin - Piston Pin Clearance to Piston Pin Bore 0.003-0.012 mm 0.00012-0.0005 in
 Pin - Piston Pin Diameter 22.996-22.999 mm 0.9054-0.9055 in
Valve System
 Valves - Valve Face Runout 0.038 mm 0.0015 in
 Valves - Valve Seat Runout 0.05 mm 0.002 in
 Valves - Valve Stem-to-Guide Clearance - 0.0375-0.0775 mm 0.0015-0.0030 in
Exhaust
 Valves - Valve Stem-to-Guide Clearance - 0.030-0.065 mm 0.0011-0.0025 in
Intake
 Valve Springs - Valve Spring Load - Closed 211.4-233.4 N @ 35 mm 47.5-52.5 lb @ 1.701 in
 Valve Springs - Valve Spring Load - Open 579-631 N @ 24.5 mm 130-142 lb @ 1.260 in
SEALERS, ADHESIVES, AND LUBRICANTS
Sealers, Adhesives, and Lubricants

Application Type of Material
Camshaft Position Actuator Bolt Sealant
Camshaft Position Sensor Bolt Sealant
Coolant Sensor Threads Sealant
Crankshaft Position Sensor Bolt Sealant
Cylinder Head Core Hole Plugs Sealant
Cylinder Head Expansion Plugs - Aluminum Sealant
Engine Block Front Oil Gallery Plug Sealant
Engine Block Plug Sealant
Engine Front Cover Surface Sealant
Engine Oil 5W-30 Oil
EVAP Purge Solenoid Valve Bolt Sealant
Exhaust Manifold Bolt Threads Threadlock
Exhaust Manifold Heat Shield Nuts Anti-Sieze
Lubricant Lubricant
Microsoft
Oil Level Indicator Tube Stud Sealant

Oil Pan Surface Sealant
Oil Pressure Sensor Threads Sealant
Oil Pump Pipe Bolt Sealant
Parts Cleaner Cleaner
PVC Hose Lubricant
Rear Oil Seal Housing Surface (3-Bond) Sealant
Throttle Control Module Bolt Sealant
Timing Chain Guide Bolt Threadlock
THREAD REPAIR SPECIFICATIONS
Engine Block - Top View
Fig. 1: Engine Block Thread Repair - Top View

Courtesy of GENERAL MOTORS CORP.
Engine Block - Top View

Service
Hole Thread Counterbore Stop Drill Depth Tap Depth
Location Size Drill Tool Collar Tap Driver Insert (Max) (Min)
- mm (in) mm (in)
1 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
2 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
Microsoft
3 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009

4 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
5 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
6 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
7 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
8 M6x1 201 202 n/a 203 204 205 30 1.182 26 1.024
9 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
10 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
11 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
12 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
13 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
14 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
15 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
16 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
17 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009
Engine Block - Bottom View
Fig. 2: Engine Block Thread Repair - Bottom View

Engine Block - Bottom View

Service
Microsoft

- mm (in) mm (in)
1 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
2 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
3 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
4 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
5 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
6 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
7 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
8 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
9 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
10 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
11 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
12 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
13 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
14 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
15 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
16 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
17 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
18 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
19 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
20 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
21 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
22 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
23 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
24 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
25 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
26 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
27 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
28 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
29 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
30 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
31 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
32 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
33 20 x 16 n/a n/a n/a n/a n/a n/a 33 1.300 23 0.906
34 8 x 1.25 n/a n/a n/a n/a n/a n/a 30 1.182 25 0.985
35 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
36 10 x 1.5 417 n/a n/a 418 419 420 53 2.088 45 1.773
Engine Block - Left Side View
Microsoft
Fig. 3: Engine Block Thread Repair - Left Side View

Engine Block - Left Side View

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
2 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
3 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
M 12 x
4 856 857 n/a 858 859 416 33 1.3 17 0.669
1.75
M 24 x
5 n/a n/a n/a n/a n/a n/a 30 1.182 20 0.788
1.5
M 10 x
6 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 28 x
7 n/a n/a n/a n/a n/a n/a 25 0.985 17 0.669
1.25
M 10 x
8 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
9 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
Microsoft
M8x
10 206 207 n/a 208 209 210 25 0.985 20 0.788
1.25
11 M6x1 201 202 n/a 203 204 205 25 0.985 20 0.788
M8x
12 206 207 n/a 208 209 210 25 0.985 20 0.788
1.25
M8x
13 206 207 n/a 208 209 210 25 0.985 20 0.788
1.25
14 M6x1 201 202 n/a 203 204 205 19 0.748 15 0.591
M8x
15 206 207 n/a 208 209 210 25 0.985 20 0.788
1.25
M 10 x
16 211 212 n/a 213 214 420 25 0.985 20 0.788
1.5
M8x
17 206 207 n/a 208 209 210 19 0.748 15 0.591
1.25
M 10 x
18 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M8x
19 206 207 n/a 208 209 210 33 1.3 27 1.063
1.25
20 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
M 10 x
21 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
22 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
23 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
24 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
Engine Block - Right Side View
Microsoft
Fig. 4: Engine Block Thread Repair - Right Side View

Engine Block - Right Side View

Service
- mm (in) mm (in)
1 16 x 1.5 n/a n/a n/a n/a n/a n/a 32 1.260 23 0.906
2 16 x 1.5 n/a n/a n/a n/a n/a n/a 32 1.260 23 0.906
3 16 x 1.5 n/a n/a n/a n/a n/a n/a 32 1.260 23 0.906
4 10 x 1.5 n/a n/a n/a n/a n/a n/a 33 1.300 27 1.063
5 16 x 1.5 211 212 n/a 213 214 420 32 1.260 23 0.906
6 10 x 1.5 n/a n/a n/a n/a n/a n/a 33 1.300 27 1.063
7 10 x 1.5 211 212 n/a 213 214 420 33 1.300 27 1.063
8 10 x 1.5 211 212 n/a 213 214 420 33 1.300 27 1.063
9 10 x 1.5 211 212 n/a 213 214 420 33 1.300 27 1.063
10 10 x 1.5 211 212 n/a 213 214 420 33 1.300 27 1.063
11 16 x 2 211 212 n/a 213 214 420 24 0.945 16 0.630
12 10 x 1.5 n/a n/a n/a n/a n/a n/a 29 1.142 26 1.024
13 8 x 1.25 211 212 n/a 213 214 420 23 0.906 18 0.709
14 10 x 1.5 n/a n/a n/a n/a n/a n/a 29 1.142 26 1.024
15 8 x 1.25 211 212 n/a 213 214 420 23 0.906 18 0.709
Microsoft
16 16 x 1.5 206 207 n/a 208 209 210 32 1.260 23 0.906

17 20 x 1.5 n/a n/a n/a n/a n/a n/a 29 1.142 26 1.024
Engine Block - Front View
Fig. 5: Engine Block Thread Repair - Front View

Engine Block - Front View

Service
- mm (in) mm (in)
1 6 x 1 405 n/a 407 203 204 205 30 1.182 26 1.024
2 6 x 1 201 202 n/a 203 204 205 18 0.709 14 0.551
3 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
4 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
5 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
6 6 x 1 405 n/a 407 203 204 205 30 1.182 26 1.024
7 6 x 1 405 n/a 407 203 204 205 30 1.182 26 1.024
8 6 x 1 405 n/a 407 203 204 205 30 1.182 26 1.024
9 6 x 1 405 n/a 407 203 204 205 30 1.182 26 1.024
Microsoft
10 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024

11 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024
12 6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
13 6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
14 6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
15 6x1 201 202 n/a 203 204 205 30 1.182 26 1.024
16 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024
17 16 x 1.5 405 n/a 407 203 204 205 24 0.945 16 0.630
18 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024
19 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
20 8 x 1.25 206 207 n/a 208 209 210 30 1.182 25 0.985
21 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024
Engine Block - Rear View
Fig. 6: Engine Block Thread Repair - Rear View

Engine Block - Rear View

Service
Microsoft
- mm (in) mm (in)
1 10 x 1.5 211 212 n/a 213 214 216 39 1.536 33 1.300
2 10 x 1.5 211 212 n/a 213 214 420 39 1.536 33 1.300
3 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
4 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
5 10 x 1.5 211 212 n/a 213 214 420 39 1.536 33 1.300
6 16 x 1.5 n/a n/a n/a n/a n/a n/a 24 0.945 16 0.630
7 10 x 1.5 211 212 n/a 213 214 420 39 1.536 33 1.300
8 10 x 1.5 211 212 n/a 213 214 215 57 2.245 54 2.127
9 10 x 1.5 211 212 n/a 213 214 420 39 1.536 33 1.300
10 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
11 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
12 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
13 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
14 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
15 6x1 201 202 n/a 203 204 205 20 0.788 16 0.630
16 10 x 1.5 211 212 n/a 213 214 215 39 1.536 33 1.300
17 10 x 1.5 211 212 n/a 213 214 215 57 2.245 54 2.127
18 10 x 1.5 211 212 n/a 213 214 420 39 1.536 33 1.300
Cylinder Head - Top View
Fig. 7: Cylinder Head Thread Repair - Top View

Microsoft
Cylinder Head - Top View

Service
- mm (in) mm (in)
1 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
2 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
3 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
4 M 6 x 1 405 n/a 407 203 204 205 THRU THRU
5 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
6 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
7 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
8 M 6 x 1 405 n/a 407 203 204 205 THRU THRU
9 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
10 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
11 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
12 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
13 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
14 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
15 M 6 x 1 405 n/a 407 203 204 205 THRU THRU
16 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
17 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
18 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
19 M 6 x 1 405 n/a 407 203 204 205 THRU THRU
20 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
21 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
22 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
23 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
24 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
25 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
26 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
27 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
28 M 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
29 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
30 M 6 x 1 201 202 n/a 203 204 205 23 0.906 19 0.748
31 M 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
32 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
33 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
34 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
35 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
36 M 6 x 1 405 n/a 406 203 204 205 28 1.103 24 0.945
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37 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945

38 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
39 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
40 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
41 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
42 M6x1 201 202 n/a 203 204 205 23 0.906 19 0.748
43 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
44 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
45 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
46 M6x1 201 202 n/a 203 204 205 23 0.906 19 0.748
47 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
48 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
49 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
50 M6x1 201 202 n/a 203 204 205 23 0.906 19 0.748
51 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
52 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
53 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
54 M6x1 201 202 n/a 203 204 205 23 0.906 19 0.748
55 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
56 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
57 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
58 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
59 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945
60 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
61 M6x1 201 202 n/a 203 204 205 23 0.906 19 0.748
62 M6x1 201 202 n/a 203 204 205 22 0.866 18 0.709
Cylinder Head - End View (Front)
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Fig. 8: Cylinder Head Thread Repair - End View (Front)

Cylinder Head - End View (Front)

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 215 28 1.103 22 0.866
1.5
M 10 x
2 211 212 n/a 213 214 215 28 1.103 22 0.866
1.5
M 24 x
3 n/a n/a n/a n/a n/a n/a THRU THRU
1.5
4 M 6 x 1 201 202 n/a 203 204 205 28 1.103 23 0.906
M 24 x
5 n/a n/a n/a n/a n/a n/a THRU THRU
1.5
M8x
6 206 207 n/a 208 209 210 28 1.103 23 0.906
1.25
Cylinder Head - End View (Rear)
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Fig. 9: Cylinder Head Thread Repair - End View (Rear)

Cylinder Head - End View (Rear)

Service
- mm (in) mm (in)
M 14 x
1 409 410 n/a 411 412 413 36 1.418 28 1.103
1.5
M 14 x
2 409 410 n/a 411 412 413 36 1.418 28 1.103
1.5
M 10 x
3 211 212 n/a 213 214 215 28 1.103 22 0.866
1.5
M 10 x
4 211 212 n/a 213 214 215 28 1.103 22 0.866
1.5
Cylinder Head - Intake Manifold Deck View
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Fig. 10: Cylinder Head Thread Repair - Intake Manifold Deck View
Cylinder Head - Intake Manifold Deck View

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
M 10 x
2 211 212 n/a 213 214 215 28 1.103 22 0.866
1.5
M 10 x
3 211 212 n/a 213 214 420 33 1.3 27 1.063
1.5
4 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
5 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
6 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
7 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
8 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
9 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
10 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
11 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
12 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
13 M 6 x 1 201 202 n/a 203 204 205 23 0.906 18 0.709
Cylinder Head - Exhaust Manifold Deck View
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Fig. 11: Cylinder Head Thread Repair - Exhaust Manifold Deck View
Cylinder Head - Exhaust Manifold Deck View

Service
- mm (in) mm (in)
1 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
2 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
3 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
4 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
5 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
6 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
7 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
8 6 x 1 405 n/a 406 203 204 205 28 1.103 23 0.906
9 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
10 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
11 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
12 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
13 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
14 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
15 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
16 8 x 1.25 206 207 n/a 208 208 210 28 1.103 23 0.906
17 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
18 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
19 8 x 1.25 206 207 n/a 208 209 210 28 1.103 23 0.906
Oil Pan - Top View
Microsoft
Fig. 12: Oil Pan Thread Repair - Top View

Oil Pan - Top View

Service
- mm (in) mm (in)
M8x
1 206 207 n/a 208 209 415 THRU THRU
1.25
M8x
2 206 207 n/a 208 209 415 THRU THRU
1.25
M 12 x
3 856 857 n/a 858 859 416 THRU THRU
1.75
Oil Pan - Left Side View
Microsoft
Fig. 13: Oil Pan Thread Repair - Left Side View

Oil Pan - Left Side View

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 420 40 1.576 25 0.985
1.5
M 10 x
2 211 212 n/a 213 214 420 40 1.576 25 0.985
1.5
M 10 x
3 856 857 n/a 858 859 855 42 1.654 25 0.985
1.5
M 10 x
4 856 857 n/a 858 859 855 42 1.654 25 0.985
1.5
M 10 x
5 856 857 n/a 858 859 855 42 1.654 25 0.985
1.5
M 10 x
6 856 857 n/a 858 859 855 42 1.654 25 0.985
1.5
Oil Pan - Right Side View
Microsoft
Fig. 14: Oil Pan Thread Repair - Right Side View

Oil Pan - Right Side View

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 420 42 1.654 25 0.985
1.5
M 10 x
2 211 212 n/a 213 214 420 42 1.654 25 0.985
1.5
M 10 x
3 211 212 n/a 213 214 420 42 1.654 25 0.985
1.5
M 10 x
4 211 212 n/a 213 214 420 42 1.654 25 0.985
1.5
Oil Pan - Rear View
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Fig. 15: Oil Pan Thread Repair - Rear View

Oil Pan - Rear View

Service
- mm (in) mm (in)
M 10 x
1 211 212 n/a 213 214 215 THRU THRU
1.5
M 10 x
2 211 212 n/a 213 214 215 THRU THRU
1.5
M 10 x
3 211 212 n/a 213 214 215 THRU THRU
1.5
M 10 x
4 211 212 n/a 213 214 215 THRU THRU
1.5
Engine Front Cover
Microsoft
Fig. 16: Engine Front Cover Thread Repair

Engine Front Cover

Service
1 M 6 x 1 n/a n/a n/a n/a n/a n/a 30 1.182 26 1.024
2 M 6 x 1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
3 M 6 x 1 201 202 n/a 203 204 205 THRU THRU
4 M 6 x 1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
5 M 6 x 1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
6 M 6 x 1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
7 M 6 x 1 201 202 n/a 203 204 205 17 0.669 14 0.551
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8 M6x1 201 202 n/a 203 204 205 17 0.669 14 0.551

9 M6x1 201 202 n/a 203 204 205 17 0.669 14 0.551
10 M6x1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
11 M6x1 201 202 n/a 203 204 414 THRU THRU
12 M6x1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
13 M6x1 201 202 n/a 203 204 205 16.5 0.65 13 0.512
14 M6x1 n/a n/a n/a n/a n/a n/a 30 1.182 26 1.024
Crankshaft Rear Oil Seal Housing
Microsoft
Fig. 17: Crankshaft Rear Oil Seal Housing Thread Repair

Crankshaft Rear Oil Seal Housing

Service
Microsoft
- mm (in) mm (in)
1 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
2 M 6 x 1 201 202 n/a 203 204 205 22 0.866 18 0.709
COMPONENT LOCATOR
DISASSEMBLED VIEWS
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Fig. 18: Engine Block, Crankshaft & Pistons Disassembled View

Callouts For Fig. 18

Callout Component Name
100 Engine Block
101 Transmission Locator Pin
102 Cylinder Head Locator Pin
102 Cylinder Head Locator Pin
103 Main Bearing Cap Locator Pin
104 Engine Front Cover Locator Pin
105 Cylinder Sleeve
106 Connecting Rod Bolt
107 Connecting Rod Cap
108 Connecting Rod Lower Bearing
109 Connecting Rod Upper Bearing
110 Connecting Rod
111 Connecting Rod Bushing
112 Piston Pin Retainer
112 Piston Pin Retainer
113 Piston Pin
114 Piston
115 Oil Control Ring Set
116 Lower Compression Ring
117 Upper Compression Ring
118 Crankshaft
119 Upper Main Bearings
120 Main Thrust Bearing
121 Lower Main Bearing
122 Main Bearing Cap
123 Main Bearing Cap Stiffener
124 Main Bearing Cap Bolt
125 Flywheel - Automatic Transmission
126 Flywheel Bolt
127 Crankshaft Sprocket
128 Crankshaft Balancer
129 Crankshaft Balancer Bolt
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Fig. 19: Cylinder Head, Valves, Lifters, Timing Component & Camshaft Disassembled View

200 Cylinder Head
201 Cylinder Head Gasket
202 Engine Lift Bracket
203 Engine Lift Bracket Bolts
204 Intake Valve
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205 Exhaust Valve

206 Access Hole Plugs
207 Cylinder Head Bolt
208 Valve Lash Adjusters
209 Valve Seals
210 Valve Springs
211 Valve Spring Retainers
212 Valve Keys
213 Valve Rocker Arms
214 Cylinder Head Bolt
215 Spark Plug
216 A.I.R. Pipe Plug
217 Water Jacket Plug
218 Oil Gallery Plug
219 Oil Gallery Plug
220 Timing Chain Top Guide
221 Timing Chain Top Guide Bolt
222 Intake Camshaft
223 Exhaust Camshaft
224 Camshaft Cap Bolts
225 Camshaft Cap
225 Camshaft Cap
226 Exhaust Camshaft Actuator
227 Exhaust Camshaft Actuator Bolt
228 Intake Camshaft Sprocket
229 Intake Camshaft Sprocket Bolt
230 Timing Chain
231 Timing Chain Tensioner Shoe
232 Timing Chain Tensioner Shoe Bolt
233 Timing Chain Guide
234 Timing Chain Guide Bolt
235 Timing Chain Tensioner
236 Timing Chain Tensioner Bolt
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Fig. 20: Cooling, Water Pump Disassembled View


300 Water Pump
301 Water Pump Pulley
302 Water Pump Pulley Bolt
303 Water Pump Gasket
304 Water Pump Bolt
305 Thermostat Housing
306 Thermostat Housing Seal
307 Thermostat Housing Bolt
308 Water Outlet
309 Water Outlet Bolt
310 Water Outlet Seal
311 Heater Inlet Hose Fitting
312 Heater Outlet Hose Fitting
313 Coolant Temperature Sensor
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Fig. 21: Oil Pan, Pump, Filter, Tube Disassembled View


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400 Oil Pan

401 Oil Pan Bolt
401 Oil Pan Bolt
402 Oil Pan Nut
403 Oil Pan Stud
404 Oil Drain Plug
405 Oil Drain Plug Gasket
406 Oil Pump Pickup Tube
407 Oil Pump Pickup Tube Bolt
407 Oil Pump Pickup Tube Bolt
408 Oil Filter
409 Oil Filter Adapter
410 Oil Filter Bypass Valve
411 Oil Pump
412 Oil Pump Seal
413 Oil Pump Bolt
414 Oil Pressure Relief Valve
415 Oil Pressure Relief Valve Spring
416 Oil Pressure Relief Valve Plug
417 Oil Pump Inner Gear
418 Oil Pump Outer Gear
419 Oil Pump Pickup Tube O-ring/Gasket - Model Dependent
420 Oil Pressure Switch
421 Camshaft Position Actuator Solenoid Valve
422 Camshaft Position Actuator Solenoid Valve Bolt
423 Oil Level Indicator Tube
424 Oil Level Indicator
425 Oil Level Indicator Tube Stud
426 Oil Level Indicator Tube Nut
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Fig. 22: Intake Manifold, Rails, Covers Disassembled View


500 Intake Manifold
501 Intake Manifold Seal
502 Intake Manifold Bolt
503 Positive Crankcase Vent Hose
504 Throttle Control Module
505 Throttle Control Module Bolt
506 Throttle Control Module Seal
507 Fuel Injector Rail
508 Fuel Injector Rail Bolt
509 Crankshaft Rear Oil Seal Housing
510 Crankshaft Rear Oil Seal Housing Bolt
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511 Crankshaft Rear Oil Seal

512 Engine Front Cover
513 Engine Front Cover Bolt
514 Engine Front Center Cover Bolt
515 Engine Front Oil Seal
516 Engine Front Cover Bolt
517 Engine Front Cover Bolt Spacer
518 Camshaft Cover
519 Camshaft Cover Bolt
520 Camshaft Cover Seal
521 Oil Fill Cap
Fig. 23: Exhaust Manifold & Sensors Disassembled View


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600 Exhaust Manifold
601 Exhaust Manifold Gasket
602 Exhaust Manifold Bolt
603 Exhaust Manifold Heat Shield
604 Exhaust Manifold Heat Shield Stud
605 Exhaust Manifold Heat Shield Nut
700 Ignition Control Module
701 Ignition Control Module Spring
702 Ignition Control Module Boot
703 Exhaust Camshaft Position Sensor
704 Exhaust Camshaft Position Sensor Bolt
705 EVAP Emission Canister Purge Solenoid
706 EVAP Emission Canister Purge Solenoid Bolt
707 Knock Sensor
708 Knock Sensor
709 Crankshaft Position Sensor
710 Crankshaft position Sensor Bolt
ENGINE IDENTIFICATION
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Fig. 24: View Of Engine Identification Tag


1 Engine ID Location
2 Engine ID Location
The first digit identifies the engine build location - All first digits will be a V, this
3
engine is only being built at Flint Engine South
4 The second digit identifies the build year
5 The third and fourth digits identify the build month
6 The fifth and sixth digits identify the build date
7 The seventh through tenth digits identify the engine build sequence
SCHEMATIC AND ROUTING DIAGRAMS

TIMING CHAIN ALIGNMENT DIAGRAM
Microsoft
Microsoft
Fig. 25: Timing Chain Alignment Diagram


1 Timing Marks
1 Timing Marks
1 Timing Marks
DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views, or Engine Component Description, and
Lubrication Description. Reviewing the description and operation information will help you determine the
correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation
information will also help you determine if the condition described by the customer is normal operation. Refer
to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and
where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform A Diagnostic System Check in Engine Controls before using the symptom tables (if applicable).
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
Disassembled Views, and Engine Component Description, and Lubrication Description.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for
repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The
diagnostic flow is the place to start when repairs are necessary.
Visual/Physical Inspection
 Inspect for aftermarket devices which could affect the operation of the engine.
 Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
 Check for the correct oil level, proper oil viscosity, and correct filter application.
 Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
 Compare the engine sounds (if applicable) to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
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Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
 Base Engine Misfire without Internal Engine Noises

 Base Engine Misfire with Abnormal Internal Lower Engine Noises
 Base Engine Misfire with Abnormal Valve Train Noise
 Base Engine Misfire with Coolant Consumption
 Base Engine Misfire with Excessive Oil Consumption
 Engine Compression Test
 Engine Noise on Start-Up, but Only Lasting a Few Seconds
 Upper Engine Noise, Regardless of Engine Speed
 Lower Engine Noise, Regardless of Engine Speed
 Engine Noise Under Load
 Engine Will Not Crank - Crankshaft Will Not Rotate
 Oil Consumption Diagnosis
 Oil Pressure Diagnosis and Testing
 Oil Leak Diagnosis
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES
Base Engine Misfire without Internal Engine Noises

Cause Correction
Abnormalities (severe cracking, bumps, or missing Replace the drive belt.
areas) in the accessory drive belt
(Abnormalities in the accessory drive system and/or
components may cause engine RPM variations and
lead to a misfire DTC. A misfire code may be
present without an actual misfire condition).
Worn, damaged, or mis-aligned accessory drive Inspect the components, and repair or replace as
components or excessive pulley runout and may required.
lead to a misfire DTC.
(A misfire code may be present without an actual
misfire condition.)
Loose or improperly installed engine flywheel or Repair or replace the flywheel and/or balancer as
crankshaft balancer required.
misfire condition.)
Restricted exhaust system Repair or replace as required.
(A severe restriction in the exhaust flow can cause
Microsoft
significant loss of engine performance and may set a

DTC. Possible causes of restrictions include
collapsed or dented pipes or plugged mufflers
and/or catalytic converters).
Improperly installed or damaged vacuum hoses Repair or replace as required.
Improper sealing between the intake manifold and Replace the intake manifold, gaskets, cylinder head,
cylinder head or throttle body. and/or throttle body as required.
Improperly installed or damaged MAP sensor Repair or replace the MAP sensor as required.
(The sealing grommet of the MAP sensor should not
be torn or damaged.)
Damage to the MAP sensor housing and/or O-ring Replace the intake manifold.
seal
Worn or loose valve rocker arms Replace the valve rocker arms as required.
(The rocker arm bearing end caps and/or needle
bearings should be intact and in the proper position)
Worn valve lash adjusters Replace the valve lash adjusters.
Stuck valves Repair or replace as required.
(Carbon buildup on the valve stem can cause the
valve not to close properly.)
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as required.
Worn camshaft lobes Replace the camshaft and valve lash adjusters.
Excessive oil pressure  Perform an oil pressure test. Refer to Oil
Pressure Diagnosis and Testing.
 Repair or replace the oil pump as required.
Faulty cylinder head gasket and/or cracking or other  Inspect for spark plugs saturated by coolant.
damage to the cylinder head and engine block
 Inspect the cylinder head, engine block,
cooling system passages.
(Coolant consumption may or may not cause the and/or head gasket.
engine to overheat.)  Repair or replace as required.
Worn Piston Rings  Inspect the spark plugs for oil deposits.
(Oil consumption may or may not cause the engine
 Inspect the cylinders for a loss of
to misfire.)
compression. Refer to Engine Compression
Test.
 Perform cylinder leak down and compression
testing to identify the cause.
 Repair or replace as required.
A damaged crankshaft reluctor wheel Replace the sensor and/or crankshaft as required.
(A damaged crankshaft reluctor wheel can result in
different symptoms depending on the severity and
location of the damage.)
 Systems with electronic communications

(DIS or coil per cylinder) and severe reluctor
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ring damage may exhibit periodic loss of

crankshaft position, stop delivering a signal,
and then re-sync the crankshaft position.)
 Systems with electronic communication (DIS
or coil per cylinder) and slight reluctor ring
damage may exhibit no loss of crankshaft
position and no misfire may occur. However,
a P0300 DTC may be set.
 Systems with mechanical communications
(high voltage switch) and severe reluctor ring
damage may cause additional pulses and
effect fuel and spark delivery to the point of
generating a P0300 DTC or P0336.
BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
Base Engine Misfire with Abnormal Internal Lower Engine Noises

Cause Correction
Abnormalities (severe cracking, bumps or missing Replace the drive belt.
areas) in the accessory drive belt
(Abnormalities in the accessory drive system and/or
components may cause engine RPM variations,
noises similar to a faulty lower engine and also lead
to a misfire condition. A misfire code may be
present without an actual misfire condition.)
Worn, damaged, or mis-aligned accessory drive Inspect the components, repair or replace as
components or excessive pulley runout required.
misfire condition.)
Loose or improperly installed engine flywheel or Repair or replace the flywheel and/or balancer as
crankshaft balancer required.
misfire condition.)
 Inspect the cylinders for a loss of
to misfire.)
Test.
testing to determine the cause.
Worn Crankshaft Thrust Bearings Replace the crankshaft and bearings as required.
(Severely worn thrust surfaces on the crankshaft
and/or thrust bearing may permit fore and aft
movement of the crankshaft and create a DTC
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without an actual misfire condition.)
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Base Engine Misfire with Abnormal Valve Train Noise

Cause Correction
Worn or loose valve rocker arms Replace the valve rocker arms as required.
(The rocker arm bearing end caps and/or needle
bearings should be intact within the rocker arm
assembly.)
Stuck valves Repair or replace as required.
(Carbon buildup on the valve stem can cause the
valve not to close properly.)
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as required.
Worn camshaft lobes Replace the camshaft, valve lash adjusters, and
rocker arms.
Sticking valve lash adjusters Replace as required.
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Base Engine Misfire with Coolant Consumption

Cause Correction
Faulty cylinder head gasket and/or cracking or other  Inspect for spark plugs saturated by coolant.
damage to the cylinder head and engine block
cooling system passages.  Perform a cylinder leak down test.
(Coolant consumption may or may not cause the  Inspect the cylinder head and engine block for
engine to overheat.) damage to the coolant passages and/or a
faulty head gasket.
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
Base Engine Misfire with Excessive Oil Consumption

Cause Correction
Worn valves, valve guides and/or valve stem oil  Inspect the spark plugs for oil deposits.
seals
to misfire.)  Inspect the cylinders for a loss of
Test.
testing to determine the cause.
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ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity 1. Drain the oil.
2. Install the correct viscosity oil.
Worn crankshaft thrust bearing  Inspect the thrust bearing and crankshaft.
Damaged or faulty oil filter by-pass valve  Inspect the oil filter by-pass valve for proper
operation.
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Upper Engine Noise, Regardless of Engine Speed

Cause Correction
Low oil pressure  Perform an oil pressure test. Refer to Oil
Worn or damaged valve rocker arm  Inspect the rocker arm for wear or missing
needle bearings
 Replace the valve rocker arms as required.
Improper lubrication to the valve rocker arms Inspect the following components, and repair or
replace as required:
The valve rocker arm

 The valve lash adjusters
 The oil filter bypass valve
 The oil transfer tube
 The oil pump and pump screen
 The engine block oil galleries
Broken valve spring Replace the valve spring.

Worn or dirty valve lash adjusters Replace the valve lash adjusters.
Stretched or broken timing chain and/or damaged Replace the timing chain and sprockets.
sprocket teeth
Worn engine camshaft lobes  Inspect the engine camshaft lobes.
 Replace the camshaft, valve lash adjusters,
and rocker arms as required.
Worn valve guides or valve stems Inspect the following components, and repair as
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required:
The valves

 The valve guides
Stuck Valves Inspect the following components, and repair as

(Carbon on the valve stem or valve seat may cause required:
the valve to stay open)
 The valves
 The valve guides
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Lower Engine Noise, Regardless of Engine Speed

Cause Correction
 Repair or replace damaged components as
required.
Worn accessory drive components  Inspect the accessory drive system.
(Abnormalities such as severe cracking, bumps or
missing areas in the accessory drive belt and/or  Repair or replace as required.
misalignment of system components.)
Loose or damaged crankshaft balancer  Inspect the crankshaft balancer.
Detonation or spark knock Verify the correct operation of the ignition controls
system. Refer to Engine Controls.
Loose torque converter bolts  Inspect the torque converter bolts and
flywheel.
Loose or damaged flywheel Repair or replace the flywheel.

Oil pump screen loose, damaged or restricted  Inspect the oil pump screen.
Oil transfer tube loose, damaged or restricted  Inspect the transfer tube.
Excessive piston-to-cylinder bore clearance  Inspect the piston and cylinder bore.
 Repair as required.
Excessive piston pin-to-bore clearance  Inspect the piston, piston pin, and the
connecting rod.
Excessive connecting rod bearing clearance Inspect the following components, and repair as
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required:
 The connecting rod bearings

 The connecting rods
 The crankshaft
 The crankshaft journals
Excessive crankshaft bearing clearance Inspect the following components, and repair as
required:
 The crankshaft bearings

Incorrect piston, piston pin and connecting rod  Verify the pistons, piston pins and connecting
installation rods are installed correctly.
(Pistons must be installed with the mark or dimple
on the top of the piston facing the front of the  Repair as required.
engine. Piston pins must be centered in the
connecting rod pin bore.)
ENGINE NOISE UNDER LOAD
Engine Noise Under Load

Cause Correction
Detonation or spark knock Verify the correct operation of the ignition controls.
Refer to Engine Controls.
Loose torque converter bolts  Inspect the torque converter bolts and
flywheel.
Cracked flywheel (automatic transmission)  Inspect the flywheel bolts and flywheel.
Excessive connecting rod bearing clearance Inspect the following components, and repair as
required:
 The connecting rod bearings

 The connecting rods
 The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair as
required:
 The crankshaft bearings

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 The cylinder block crankshaft bearing bore
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
Engine Will Not Crank - Crankshaft Will Not Rotate

Cause Correction
Seized accessory drive system component 1. Remove the accessory drive belt.
2. Confirm that the engine will rotate. Rotate the
crankshaft by hand at the crankshaft balancer
or flywheel location.
3. Repair or replace the components as required.
Seized automatic transmission torque converter 1. Remove the torque converter-to-flywheel
bolts.
2. Confirm that the engine will rotate. Rotate the
crankshaft by hand at the crankshaft balancer
or flywheel location.
Broken timing chain  Inspect the timing chain and gears.
 Repair or replace the components as required.

Seized timing chain or timing gears  Inspect the timing chain and gears for foreign
material or a seized chain.
Seized or broken camshaft  Inspect the camshaft.
Bent valve in the cylinder head  Inspect the valves and the cylinder head.
Seized oil pump  Inspect the oil pump assembly.
Hydraulically locked cylinder 1. Remove spark plugs and check for fluid in the
cylinder. When rotating the engine with the
 Coolant/antifreeze in the cylinder spark plugs removed, the piston (on
 Oil in the cylinder compression stroke) will push fluid from the
 Fuel in the cylinder combustion chamber.
2. Inspect for failed/broken head gasket.
3. Inspect for a cracked engine block or cylinder
head.
4. Inspect for a sticking fuel injector.
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Material in the cylinder  Inspect the cylinder for damaged components

and/or foreign materials.
 Broken valve
 Broken piston ring(s)
 Piston material
 Foreign material
Seized crankshaft or connecting rod bearings  Inspect crankshaft and connecting rod
bearings.
Bent or broken connecting rod  Inspect the connecting rods.
Broken crankshaft  Inspect the crankshaft.
COOLANT IN COMBUSTION CHAMBER
Coolant in Combustion Chamber

Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an "overtemperature" condition which may cause engine component damage.
 A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer
to Engine Will Not Crank - Crankshaft Will Not Rotate.
 Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder
bore.
 Inspect by performing a Cylinder Leakage Test. During this test, excessive air bubbles within the
coolant may indicate a faulty gasket or damaged component.
 Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block, with low compression, may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement.
Warped cylinder head Replace the cylinder head and gasket. Refer to
Cylinder Head Replacement.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder sleeve or engine block Replace the components as required.
Cylinder head or engine block porosity Replace the components as required.
COOLANT IN ENGINE OIL
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Coolant in Engine Oil

Cause Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant
entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may
lead to an "overtemperature" condition which may cause engine component damage. Contaminated
engine oil and oil filter should be changed.
 Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not
properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower
Engine Noise, Regardless of Engine Speed.
 Inspect by performing a Cylinder Leakage Test. During this test, excessive air bubbles within the
cooling system may indicate a faulty gasket or damaged component.
 Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block with low compression may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Faulty external engine oil cooler Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement.
Warped cylinder head Replace the cylinder head gasket. Refer to Cylinder
Head Replacement.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder sleeve or engine block Replace the components as required.
Cylinder head, block, or manifold porosity Replace the components as required.
Faulty sealing on engine front cover Reseal or replace front cover.
ENGINE COMPRESSION TEST
Tools Required
J 38722 Compression Tester. See Special Tools and Equipment.
A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the
head gasket.
IMPORTANT: The battery must be at or near full charge. Do not block the throttle open.
1. Remove the air duct from the throttle control module.

2. Remove the ignition control modules.
3. Disable the fuel system.
4. Remove the spark plugs.
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Fig. 26: Measuring Engine Compression

5. Measure the engine compression, using the following procedure:

1. Firmly install J 38722 to the spark plug hole. See Special Tools and Equipment.
2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder.
3. Check and record the readings on J 38722 at each stroke. See Special Tools and Equipment.
4. Disconnect J 38722 . See Special Tools and Equipment.
5. Repeat the compression test for each cylinder.
6. Record the compression readings from all of the cylinders. A normal reading should be approximately
1482 kPa (215 psi).
The lowest reading should not be less than 70 percent of the highest reading.
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7. The following are examples of the possible measurements:

 When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
 When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, or if the compression improves considerably with the
addition of three squirts of oil, the piston rings may be the cause.
 When the compression is low on the first stroke and does not build up in the following strokes, or
the addition of oil does not affect the compression, the valves may be the cause.
 When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the
head gasket may be the cause.
8. Install the air duct to the throttle body.
9. Install the spark plugs.
10. Enable the fuel system.
11. Install the ignition control modules.
CYLINDER LEAKAGE TEST
Tools Required
J 35667-A Cylinder Head Leakdown Tester. See Special Tools and Equipment.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
IMPORTANT: A leakage test may be performed to measure cylinder/combustion chamber

leakage. High cylinder leakage may indicate one or more of the following:
 Worn or burnt valves

 Broken valve springs
 Stuck valve lash adjuster
 Damaged piston
 Worn piston rings
 Worn or scored cylinder bore
 Damaged cylinder head gasket
 Cracked or damaged cylinder head
 Cracked or damaged engine block
1. Disconnect the battery ground negative cable.

2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Control.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the
compression stroke.
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4. Install J 35667-A . See Special Tools and Equipment.
Fig. 27: Checking For Cylinder Leakage

IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to prevent the
engine from rotating.
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5. Apply shop air pressure to J 35667-A and adjust according to the manufacturers instructions. See Special
Tools and Equipment.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and
may require component service. In excessive leakage situations, inspect for the following conditions:
 Air leakage sounds at the throttle control module or air inlet hose may indicate a worn or burnt
intake valve or a broken valve spring.
 Air leakage sounds at the exhaust system tailpipe may indicate a worn or burnt exhaust valve or a
broken valve spring.
 Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube may indicate worn
piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a
damaged cylinder head.
 Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder
head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.
OIL CONSUMPTION DIAGNOSIS
Oil Consumption Diagnosis

Checks Causes
Excessive oil consumption (not due to leaks) is the use of 0.95 L (1.0 qts) or more of engine oil within
2,414 kilometers (1,500 miles).
Preliminary The causes of excessive oil consumption may include the following
conditions:
 External oil leaks
Refer to Oil Leak Diagnosis.
 Incorrect oil level or improper reading of the oil level indicator
With the vehicle on a level surface, run the engine for a few
minutes, allow adequate drain down time (2-3 minutes) and check
for the correct engine oil level.
 Improper oil viscosity
Refer to the vehicle owners manual and use the recommended

SAE grade and viscosity for the prevailing temperatures.
 Continuous high speed driving and/or severe usage

 Crankcase ventilation system restrictions or malfunctioning
components
 Worn valve guides and/or valve stems
 Worn or improperly installed valve stem oil seals
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 Piston rings broken, worn, not seated properly
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
 Piston and rings improperly installed or miss-fitted to the cylinder

bore
OIL PRESSURE DIAGNOSIS AND TESTING
Tools Required
 J 21867 Pressure Gage and Hose Assembly. See Special Tools and Equipment.
 J 42907 Oil Pressure Tester. See Special Tools and Equipment.
1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time (2-
3 minutes) and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full
on the oil level indicator.
3. Run the engine briefly (10-15 seconds) and verify low or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following:
 Oil diluted by water or glycol (anti freeze)
 Foamy oil
6. Remove the oil filter and install the J 42907 . See Special Tools and Equipment.
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Fig. 28: Measuring Oil Pressure Using J 42907

7. Install J 21867 or equivalent to the J 42907 . See Special Tools and Equipment.
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to Engine Mechanical Specifications.
10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following:
 Oil pump worn or dirty
Refer to Oil Pump Cleaning and Inspection.
 Oil pump screen loose, plugged, or damaged

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 Oil pump screen O-ring seal missing or damaged

 Malfunctioning oil pump pressure regulator valve
 Excessive bearing clearance
 Cracked, porous, or restricted oil galleries
 Oil gallery plugs missing or incorrectly installed
Refer to Engine Block Plug Installation.
 Broken valve lash adjusters
Repair as necessary
11. If the reading on J 21867 or equivalent is within specifications, inspect for the following. See Special
 Plugged or incorrect oil filter and/or malfunctioning oil bypass valve
 Malfunctioning vehicle oil pressure gage or sensor
Repair as necessary
OIL LEAK DIAGNOSIS
Oil Leak Diagnosis

Step Action Yes No
IMPORTANT:
You can repair most fluid leaks by first visually locating the leak, repairing or replacing the
component, or by resealing the gasket surface. Once the leak is identified, determine the cause of
the leak. Repair the cause of the leak as well as the leak itself.
1. Operate the vehicle until it reaches normal

operating temperature.
2. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
1
3. Wait 15 minutes.
4. Check for drippings.
Are drippings present? Go to Step 2 System OK

Can you identify the type of fluid and the approximate
2
location of the leak? Go to Step 10 Go to Step 3
1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
3 2. Check for leaks at the following locations:
 Sealing surfaces
 Fittings
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 Cracked or damaged components

1. Completely clean the entire engine and
surrounding components.
2. Operate the vehicle for several kilometers (miles)
at normal operating temperature and at varying
speeds.
3. Park the vehicle on a level surface, over a large
4 sheet of paper or other clean surface.
4. Wait 15 minutes.
5. Identify the type of fluid, and the approximate
location of the leak.

2. Check for leaks at the following locations:
5  Fittings

1. Completely clean the entire engine and
surrounding components.
2. Apply an aerosol-type powder (baby powder,
foot powder, etc.) to the suspected area.
3. Operate the vehicle for several kilometers (miles)
at normal operating temperature and at varying
6 speeds.
4. Identify the type of fluid, and the approximate
location of the leak, from the discolorations in
the powder surface.

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 Fittings
7  Cracked or damaged components

Use J 28428-E to identify the type of fluid, and the
approximate location of the leak. Refer to the
manufacturer's instructions when using the tool. Can
8
you identify the type of fluid and the approximate
location of the leak? See Special Tools and
Equipment. Go to Step 10 Go to Step 9
9  Fittings

location of the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage.
Special attention should be shown to the
following areas:
 Higher than recommended fluid levels
 Higher than recommended fluid pressures
 Plugged or malfunctioning fluid filters or

pressure bypass valves
 Plugged or malfunctioning engine
ventilation system
 Improperly tightened or damaged fasteners
10
 Cracked or porous components
 Improper sealants or gaskets where

required
 Improper sealant or gasket installation
 Damaged or worn gaskets or seals
 Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications

to the engine? Go to Step 11 System OK
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Repair or replace all damaged or modified components.

11
Does the engine still leak oil? Go to Step 1 System OK
CRANKCASE VENTILATION SYSTEM INSPECTION/DESCRIPTION
A crankcase ventilation system is used in order to provide a more complete scavenging of crankcase vapors.
The air cleaner supplies fresh air through a filter to the crankcase. The crankcase mixes the fresh air with blow-
by gases. This mixture then passes through a pipe located in the intake manifold.
The crankcase ventilation system has no serviceable components so no maintance of the system is required.
DRIVE BELT CHIRPING DIAGNOSIS
Diagnostic Aids
The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to
spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water
on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution.
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the chirping noise.
Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belt removed.
4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the
drive belt grooves from the accumulation of rubber dust.
6: Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves
across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley.
10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
12: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
14: Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
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temporary repair.
Drive Belt Chirping Diagnosis

Step Action Yes No
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
DEFINITION: The following items are indications of chirping:
 A high pitched noise that is heard once per revolution of the drive belt or a pulley.
 It usually occurs on cold damp mornings and will subside once vehicle reached normal operating
temp.
Did you review the Drive Belt Symptom operation and Go to Symptoms -
1 perform the necessary inspections? Engine
Go to Step 2 Mechanical
Verify that there is a chirping noise. Go to Diagnostic
2
Does the engine make the chirping noise? Go to Step 3 Aids
1. Remove the drive belt. Refer to Drive Belt
Replacement. Go to Engine
3 2. Operate the engine for no longer than 30 to 40 Noise on Start-
seconds. Up, but Only
Lasting a Few
Does the chirping noise still exist? Seconds Go to Step 4
Inspect for severe pilling exceeding 1/3 of the belt
4 groove depth.
Does the belt grooves have pilling? Go to Step 5 Go to Step 6
Clean the drive belt pulleys with a suitable wire brush.
5
Did you complete the repair? Go to Step 15 Go to Step 6
Inspect for misalignment of the pulleys.
6
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace or repair any misaligned pulleys.
7
Inspect for bent or cracked brackets.
8
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent or cracked brackets.
9
Inspect for improper, loose or missing fasteners.
10
Did you find the condition? Go to Step 11 Go to Step 12
Tighten any loose fasteners.
Replace any improper or missing fasteners. Refer to
11
Fastener Tightening Specifications.
Inspect for a bent pulley.
12
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Replace the bent pulley.

13
Replace the drive belt. Refer to Drive Belt Replacement Go to Diagnostic
14
Did you complete the repair? Go to Step 15 Aids
Operate the system in order to verify the repair.
15
Did you correct the condition? System OK Go to Step 3
DRIVE BELT SQUEAL DIAGNOSIS
Diagnostic Aids
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the squeal noise.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are
operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose
or wrong fluid, or a generator failing are suggested items to inspect.
Test Description
2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table
3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing
the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set
when the engine is operating with the drive belt removed.
4: This test is to verify that an accessory drive component does not have a seized bearing. With the belt
remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory
drive components with the engine operating by varying the load on the components to verify that the
components operate properly.
5: This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
6: This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner
from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction.
proper installation procedure for that pulley.
8: This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle
compare the pulley sizes.
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Drive Belt Squeal Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt (this is unusual for a drive belt with
multiple ribs)
 The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning
compressor engagement snapping the throttle, or slipping on a seized pulley or a faulty accessory
drive component.
1
perform the necessary inspections? Go to Step 2 Engine Mechanical
Verify that there is a squeal noise. Go to Diagnostic
2
Does the engine make the squeal noise? Go to Step 3 Aids
1. Remove the drive belt(s). Refer to Drive Belt
Replacement Go to Engine
Lasting a Few
Does the noise still exist? Seconds Go to Step 4
Inspect for an accessory drive component seized
4 bearing or a faulty accessory drive component.
Did you find and correct the condition? Go to Step 9 Go to Step 5
Test the drive belt tensioner for proper operation. Refer
5 to Drive Belt Tensioner Diagnosis
Inspect for the correct drive belt length. Refer to Drive
6 Belt Replacement
Inspect for misalignment of a pulley.
7 -
Inspect for the correct pulley size. Go to Drive Belt
8 Did you find and correct the condition? Idler Pulley
Go to Step 9 Replacement
9 System OK
Did you correct the condition? Go to Step 3
DRIVE BELT WHINE DIAGNOSIS
Diagnostic Aids
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The drive belt(s) will not cause the whine noise.
If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure
they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged,
the power steering system restricted or the wrong fluid, or the generator failing.
Test Description
3: This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive
components. When removing the drive belt the water pump may not be operating and the engine may
overheat. Also DTCs may set when the engine is operating with the drive belt removed.
4: The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings.
The drive belt(s) may have to be installed and the accessory drive components operated separately by
varying their loads. Refer to the suspected accessory drive component for the proper inspection and
replacement procedure.
Drive Belt Whine Diagnosis

Step Action Yes No
NOTE:
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component
failed bearing.
Verify that there is a whine noise. Go to Diagnostic
2
Does the engine make the whine noise? Go to Step 3 Aids
Replacement. Go to Engine
Lasting a Few
Does the whine noise still exist? Seconds Go to Step 4
Inspect for a failed accessory drive component bearing. Go to Diagnostic
4
Did you find and repair the condition? Go to Step 5 Aids
5 -
Did you correct the condition? System OK
DRIVE BELT RUMBLING DIAGNOSIS
Diagnostic Aids
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Vibration from the engine operating may cause a body component or another part of the vehicle to make
rumbling noise.
The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be
the only repair for the symptom.
If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s)
is installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom.
3: This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be
confused with an internal engine noise due to the similarity in the description. Remove only one drive belt
at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive
belt removed.
4: Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of
the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and
may be seen at the edge of the belt our felt as a lump in the belt.
5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
Drive Belt Rumbling Diagnosis

Step Action Yes No
NOTE:
DEFINITION:
 A low pitch tapping, knocking, or thumping noise heard at or just above idle.
 Heard once per revolution of the drive belt or a pulley.
 Rumbling may be caused from:
 Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive
belt pulley groove
 The separation of the drive belt
 A damaged drive belt
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Verify that there is a rumbling noise. Go to Diagnostic

2
Does the engine make the rumbling noise? Go to Step 3 Aids
Replacement Go to Engine
Lasting a Few
Does the rumbling noise still exist? Seconds Go to Step 4
Inspect the drive belt(s) for damage, separation, or
4 sections of missing ribs.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive
5 belt pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable wire
brush.
6 2. Reinstall the drive belt. Refer to Drive Belt
Replacement

Install a new drive belt. Refer to Drive Belt
7 Replacement
Did you complete the replacement? Go to Step 8 -
Operate the system in order to verify the repair. Go to Diagnostic
8
Did you correct the condition? System OK Aids
DRIVE BELT VIBRATION DIAGNOSIS
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C
system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the
generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive
components.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom such as the exhaust system, or the drivetrain.
3: This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration.
When removing the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4: The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to
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inspect the condition of the belt.

installed.
8: This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan
for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect
for a bent fan shaft or bent mounting flange.
9: This step should only be performed if the water pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play.
Compare the water pump with a known good water pump.
10: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
Drive Belt Vibration Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The following items are indications of drive belt vibration:
 The vibration is engine-speed related.

 The vibration may be sensitive to accessory load.
Verify that the vibration is engine related. Go to Diagnostic
2
Does the engine make the vibration? Go to Step 3 Aids
1. Remove the drive belt. Refer to Drive Belt Go to Diagnostic
Replacement Starting Point -
Vibration
2. Operate the engine for no longer than 30 to 40 Diagnosis and
3 seconds. Correction in
Vibration
Does the engine still make the vibration? Diagnosis and
Correction Go to Step 4
Inspect the drive belt for wear, damage, debris build-up
4 and missing drive belt ribs.
5 Replacement
Did you complete the replacement? Go to Step 11 Go to Step 6
6
1. Tighten any loose fasteners.
2. Replace improper or missing fasteners. Refer to
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Fastener Tightening Specifications.

7
Inspect for damaged fan blades or bent fan clutch shaft,
if the fan is belt driven. Refer to Cooling Fan and
8
Shroud Replacement
Inspect for a bent water pump shaft, if the water pump is
belt driven. Refer to Water Pump Replacement (LL8)
9
and Water Pump Replacement (LM4) .
Inspect for bent or cracked brackets. Go to Diagnostic
10
Did you find and correct the condition? Go to Step 11 Aids
11 System OK
Did you correct the condition? Go to Step 3
DRIVE BELT FALLS OFF DIAGNOSIS
Diagnostic Aids
If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive
belt.
Test Description
2: This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt
when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off.
Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
proper installation procedure of that pulley.
5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
6: Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
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installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
Drive Belt Falls Off Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
Inspect for a damaged drive belt.
2
3 Replacement.
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5
Inspect for a bent or dented pulley.
5
Inspect for a bent or a cracked bracket.
6
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
1. Tighten any loose fasteners.
2. Replace improper or missing fasteners. Refer to
8 Fastener Tightening Specifications.

Test the drive belt tensioner for operating correctly.
9 Refer to Drive Belt Tensioner Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt
10 Tensioner Replacement.
Inspect for failed drive belt idler and drive belt tensioner
11 pulley bearings. Go to Diagnostic
12
Did you correct the condition? System OK Go to Step 2
DRIVE BELT EXCESSIVE WEAR DIAGNOSIS
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Diagnostic Aids
Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt(s) to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s)
fall off.
Test Description
2: The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear
on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one groove on a pulley.
3: The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The
drive belt ribs should match all of the grooves on all of the pulleys.
4: This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt(s) should not come in contact with an engine or a body component when
snapping the throttle.
Drive Belt Excessive Wear Diagnosis

Step Action Yes No
NOTE:
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
Inspect the drive belt(s) for the proper installation. Refer
2 to Drive Belt Replacement.
Did you find this condition? Go to Step 5 Go to Step 3
Inspect for the proper drive belt.
3
Did you find this condition? Go to Step 5 Go to Step 4
Inspect for the drive belt rubbing against a bracket, hose,
4 or wiring harness. Go to Diagnostic
Replace the drive belt. Refer to Drive Belt
5 Replacement.
Did you complete the replacement? Go to Step 6 -
6 Operate the system in order to verify the repair.
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Did you correct the condition? System OK -
DRIVE BELT TENSIONER DIAGNOSIS
Inspection Procedure
NOTE: Allowing the drive belt tensioner to snap into the free position may result
in damage to the tensioner.
1. Remove the drive belts. Refer to Drive Belt Replacement.

2. Position a hex-head socket on the belt tensioner pulley bolt head.
3. Move the drive belt tensioner through it's full travel.
 The movement should feel smooth.
 There should be no binding.
 The tensioner should return freely.
4. If any binding is observed, replace the tensioner. Refer to Drive Belt Tensioner Replacement.
5. Install the drive belt. Refer to Drive Belt Replacement.
CAMSHAFT POSITION (CMP) ACTUATOR DIAGNOSIS
For overall description of the camshaft position sensor refer to Exhaust Camshaft Position Actuator
Description.
The camshaft position actuator will only phase 25-cam degrees retard (counterclockwise). Full advance
(clockwise) is 0 degrees. The arrow on the actuator shows advance direction.
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Fig. 29: Identifying Camshaft Position (CMP) Actuator

The camshaft position actuator should always be serviced/replaced in the full advanced position (full clockwise
or 0 degrees). New replacement (service) camshaft position actuators are shipped at full advance or 0 degrees.
To be sure the camshaft position actuator is performing properly, perform the following to help in the
diagnostics.
1. Use a 25 mm (1 in) wrench on the hex of the exhaust camshaft to rotate the exhaust camshaft and
camshaft position actuator back and forth (clockwise and counterclockwise) to purge the oil out of the
camshaft position actuator.
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Fig. 30: View Of Camshaft Position (CMP) Actuator Full Advanced Position
2. To perform an on-vehicle test, scribe or draw a line (1) on the camshaft position actuator, flush with the
head, in the full advanced position. See arrow on the camshaft position actuator. With the engine at TDC
on #1 cylinder, the wording should be level.
3. Use a 25 mm (1 in) wrench on the hex of the exhaust camshaft to rotate the camshaft and camshaft
position actuator counterclockwise to full retard.
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Fig. 31: View Of Camshaft Position (CMP) Actuator Full Retard Position
4. Scribe or draw a line (2) on the camshaft position actuator at that position.
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Fig. 32: Measuring Distance Between The Two Camshaft Position (CMP) Actuator Positions
5. Measure the distance between the two lines. The measurement (3) should be 14-15 mm (0.55-0.59 in). If
the measurement is far more or far less, the camshaft position actuator needs to be replaced.
REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
1. Install 3/8 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to
relieve the tension on the drive belt.
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Fig. 33: View Of Drive Belt

2. Remove the drive belt.

3. Release the tension on the tensioner arm.
Installation Procedure
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Fig. 34: View Of Drive Belt

1. Route the drive belt over all the pulleys except the drive belt tensioner pulley.
2. Install the 3/8 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise.
3. Install the drive belt over the drivebelt tensioner pulley.
4. Slowly release the tension to the drive belt tensioner arm.
5. Inspect for proper installation of the drive belt on the pulleys.
DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure
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1. Remove the drive belt. Refer to Drive Belt Replacement.

2. Remove the drive belt tensioner bolt.
Fig. 35: View Of Drive Belt Tensioner

3. Remove the drive belt tensioner.
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Fig. 36: View Of Drive Belt Tensioner

1. Install the drive belt tensioner.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the drive belt tensioner bolt.
Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
3. Install the drive belt Drive Belt Replacement.
DRIVE BELT IDLER PULLEY REPLACEMENT

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Removal Procedure

2. Remove the idler pulley bolt from the idler pulley bracket.
3. Remove idler pulley.
1. Install the idler pulley and secure the pulley with the bolt.
Tighten: Tighten the idler pulley bolt to 50 N.m (37 lb ft).
ENGINE MOUNT INSPECTION
Front Engine Mount
NOTE: Broken or deteriorated mounts can cause misalignment and destruction of

certain drive train components. When a single mount breaks, the
remaining mounts are subjected to abnormally high stresses.
1. Install a pole jack underneath the oil pan.
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Fig. 37: Block Of Wood Between Engine Oil Pan And Pole Jack
2. Insert a block of wood between the engine oil pan and the pole jack.
3. Raise the jack until the wooden block contacts the engine oil pan.
4. Raise the engine in order to place a slight tension on the rubber cushion. Observe both mounts while
raising the engine.
5. Replace the mounts if any of the following conditions exist:
 Hard rubber surface covered with heat check cracks
 The rubber cushion separated from the metal plate of the mount
 The rubber cushion is split through the center
 The mount is leaking
6. If there is movement between a metal plate of the mount and its attaching points, lower the engine and
tighten the bolts or nuts attaching the mount to the engine, the frame or the bracket.
ENGINE MOUNT AND BRACKET REPLACEMENT - LEFT

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Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
in Engine Electrical.
Fig. 38: Identifying Cooling Fan

2. Remove the cooling fan. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
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Fig. 39: View Of MAP Sensor & Retainer

3. Remove the manifold absolute pressure (MAP) sensor electrical connector and the retainer (1).
4. Remove the MAP sensor (2).
5. Remove the left shock module (if frame mount is being removed). Refer to Shock Module Replacement
in Front Suspension.
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Fig. 40: View Of Upper Engine Mount Nuts

6. Remove the right and the left upper engine mount nuts (1).
7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and
Underbody.
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IMPORTANT: When placing jack onto the oil pan, pay close attention to not damage the
oil level sender.
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
11. Raise the engine with the jack just enough to clear the engine mount stud.
Fig. 41: View Of Left Engine Mount

12. Remove the left engine mount from the bracket.

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Fig. 42: View Of Left Engine Mount Bracket Bolts

13. Remove the left engine mount bracket bolts (1).

14. Remove the left engine mount bracket.
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Fig. 43: View Of Left Frame Engine Mount Bracket Bolts

15. Remove the left frame engine mount bracket bolts.

16. Remove the left frame engine mount bracket, if required.
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1. Install the left frame engine mount bracket, if removed.
2. Install the left frame engine mount bracket bolts, if removed.
Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft).
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3. Install the left engine mount bracket and secure the bracket with the bolts (1).
Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
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4. Install the left engine mount onto the bracket.

5. Lower the engine onto the engine mounts.
6. Install the right and the left upper engine mount nuts (1).
Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the jack from under the vehicle.
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8. Install the engine protection shield and secure the shield with the bolts. Refer to Engine Protection
Shield Replacement in Frame and Underbody.
9. Install the right and the left lower engine mount nuts.
Tighten: Torque the lower engine mount nuts to 70 N.m (52 lb ft).
10. Lower the vehicle.

11. Install the left shock module. Refer to Shock Module Replacement in Front Suspension.

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12. Install the MAP sensor (2).

13. Install the MAP sensor retainer (1) and the electrical connector.

14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in
Engine Electrical.
ENGINE MOUNT AND BRACKET REPLACEMENT - RIGHT
Removal Procedure
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1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure

2. Remove the cooling fan. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
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3. Remove the manifold absolute pressure (MAP) sensor electrical connector and retainer (1).
4. Remove the MAP sensor (2).
5. Remove the right shock module, if frame engine mount is being removed. Refer to Shock Module
Replacement in Front Suspension.
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6. Remove the right and the left upper engine mount nuts (1).
8. Remove the right and the left lower engine mount nuts.
9. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and
Underbody.
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IMPORTANT: When placing jack onto the oil pan, pay close attention to not damaging
the oil level sender.
10. Lower the vehicle and place a floor jack under the oil pan with a block of wood.
11. Raise the engine with the jack just enough to clear the engine mount studs.
12. Remove the right engine mount from the bracket. Note the location of the heat shield for installation.

13. Graphic shows left, right is similar.
Remove the right engine mount bracket bolts.
14. Remove the right engine mount bracket.

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Remove the right frame engine mount bracket bolts, if required.
16. Remove the right frame engine mount bracket, if required.
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Install the right frame engine mount bracket, if removed.
2. Install the right frame engine mount bracket bolts, if removed.
Tighten: Tighten the mount bracket bolts to 110 N.m (81 lb ft).
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Install the right engine mount bracket and secure with the bolts (1).
Tighten: Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).
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4. Install the right engine mount.
IMPORTANT: Ensure that the heat shield is located properly over the anti-rotation
feature - right side only.
5. Lower the engine onto the engine mounts.

6. Install the right and the left upper engine mount nuts (1).
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Tighten: Tighten the upper engine mount nuts to 70 N.m (52 lb ft).
7. Raise the vehicle and remove the floor jack from under the vehicle.
8. Install the engine protection shield and secure with the bolts. Refer to Engine Protection Shield
Replacement in Frame and Underbody.
9. Install the right and the left lower engine mount nuts.
Tighten: Tighten the lower engine mount nuts to 70 N.m (52 lb ft).

11. Install the right shock module. Refer to Shock Module Replacement in Front Suspension.
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12. Install the MAP sensor (2).

13. Install the MAP sensor retainer (1) and the electrical connector.
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14. Connect the cooling fan hub nut to the water pump shaft.
15. Install the cooling fan. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in
Engine Electrical.
CRANKCASE VENTILATION HOSES/PIPES REPLACEMENT
Removal Procedure
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Fig. 59: View Of Crankcase Ventilation Hose Location

1. Disconnect the crankcase dirty air hose from the intake manifold.
2. Disconnect the crankcase dirty air hose from the positive crankcase ventilation (PCV) orifice tube.
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Fig. 60: Top Of Engine View

3. Loosen the throttle body clamps (2).

4. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator.
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Fig. 61: View Of Engine Bolts & Air Cleaner Outlet Resonator
5. Remove the 2 resonator to engine bolts (4) from the air cleaner outlet resonator (5).
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Fig. 62: View Of Crankcase Clean Air Hose & Air Cleaner Outlet Resonator
6. Lift up the front of the air cleaner outlet resonator (2).

7. Disconnect the crankcase clean air hose from the valve cover port.
8. Disconnect the crankcase clean air hose from the air cleaner outlet resonator (2).
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Fig. 63: View Of Crankcase Clean Air Hose & Air Cleaner Outlet Resonator
1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2).
2. Connect the crankcase clean air hose to the valve cover port.
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Fig. 64: View Of Engine Bolts & Air Cleaner Outlet Resonator
3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5).
Tighten: Tighten the bolts to 6 N.m (53 lb in).
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Fig. 65: Top Of Engine View

4. Tighten the throttle body clamps (2).
Tighten: Tighten the clamps to 4 N.m (35 lb in).
5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator.
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6. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N
5728223) or equivalent.
7. Connect the crankcase dirty air hose to the intake manifold.
8. Connect the crankcase dirty air hose to the PCV orifice tube.
INTAKE MANIFOLD REPLACEMENT
Removal Procedure
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure .

2. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
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Fig. 67: View Of PCM Assembly

3. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
4. Remove the PCM mounting studs (5) and position the PCM out of the way.
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Fig. 68: View Of Engine Coolant Temperature Electrical Connector

5. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
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Fig. 69: Fuel Feed And Fuel Return Pipes (Left Side Of Engine)
NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection

Cleaning Notice in Cautions and Notices.
6. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to Quick Connect Fitting
(s) Service (Metal Collar) .
7. Disconnect the integral clip (3) from the wire harness bracket.
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Fig. 70: View Of Engine Wire Harness Bracket & Bolts

8. Remove the engine wire harness bracket bolt.

9. Position the engine electrical wire harness bracket with wires attached out of the way.
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Fig. 71: View Of MAP Sensor Electrical Connector

10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
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11. Disconnect the crankcase ventilation hose from the intake manifold.
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Fig. 73: View Of Vacuum Brake Booster Hose

12. Disconnect the vacuum brake booster hose at the intake manifold.
13. Remove the generator. Refer to Generator Replacement (4.2L Engine) or Generator Replacement
(5.3L Engine) in Engine Electrical.
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Fig. 74: View Of Intake Manifold & Bolts

IMPORTANT: The intake manifold bolts are captured within the intake manifold. Do not
attempt to remove the bolts from the intake manifold.
14. Loosen the intake manifold bolts.

15. Remove the intake manifold.
1. Install a new intake manifold gasket to the intake manifold.
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2. Install the intake manifold onto the engine and secure the manifold with the bolts.
Tighten: Tighten the intake manifold bolts to 10 N.m (89 lb in).
3. Install the generator. Refer to Generator Replacement (4.2L Engine) or Generator Replacement (5.3L
Engine) in Engine Electrical.
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Fig. 76: View Of Vacuum Brake Booster Hose

4. Install the vacuum brake booster hose to the intake manifold.
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5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N
5728223) or equivalent.
6. Install the crankcase ventilation hose.
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Fig. 78: View Of MAP Sensor Electrical Connector

7. Connect the MAP sensor electrical connector.

8. Properly position the engine electrical harness bracket to the intake manifold.
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Fig. 79: View Of Engine Wire Harness Bracket & Bolts

9. Install the engine electrical harness bracket bolt.
Tighten: Tighten the bolt to 10 N.m (89 lb in).
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Fig. 80: Fuel Feed And Fuel Return Pipes (Left Side Of Engine)
10. Connect the integral clip (3) to the wire harness bracket.
11. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to Quick Connect Fitting(s)
Service (Metal Collar) .
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Fig. 81: View Of Engine Coolant Temperature Electrical Connector

12. Connect the ECT sensor electrical connector (1).
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Fig. 82: View Of PCM Assembly

13. Install the PCM mounting studs (5) to the intake manifold.
Tighten: Tighten the studs to 6 N.m (53 lb in).
14. Install the PCM (1) onto the studs (5).

15. Install the PCM retaining bolts (3).
Tighten: Tighten the bolts to 8 N.m (71 lb in).
16. Install the PCM retaining nuts (6).
Tighten: Tighten the nuts to 8 N.m (71 lb in).
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17. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in
Engine Electrical.
19. Inspect for leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.
CAMSHAFT COVER REPLACEMENT
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement.
Fig. 83: View Of Oil Level Indicator Tube Bracket Nut

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2. Remove the A/C line at the oil level indicator tube bracket nut.
Fig. 84: View Of Engine Lift Hook & A/C Bracket Bolt
3. Remove the A/C bracket bolt from the engine lift hook.
4. Position the A/C line out of the way.
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Fig. 85: View Of Engine Lift Bracket

5. Remove the engine lift bracket.

6. Disconnect the ignition control module electrical connectors.
7. Loosen the ignition control module bolts.
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Fig. 86: View Of Ignition Control Module

8. Remove the ignition control module.
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Fig. 87: View Of Engine Electrical Harness Housing

9. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage
the clips that hold the housing in place.
10. Disconnect the fuel injection harness electrical connector.
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Fig. 88: View Of Camshaft Cover Bolts

11. Loosen and remove the camshaft cover bolts.
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Fig. 89: View Of Camshaft Cover & Bolts

12. Remove the camshaft cover.

13. Clean and inspect the camshaft cover. Refer to Camshaft Cover Cleaning and Inspection.
1. Install a new camshaft cover seal.

2. Install new rubber ignition control module seals.
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3. Install the camshaft cover and secure with the cam cover bolts.
Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
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Fig. 91: View Of Ignition Control Module

4. Install the ignition control modules and secure the modules with bolts.
Tighten: Tighten the ignition coil bolts to 10 N.m (89 lb in).
5. Connect the ignition control module electrical connectors.

6. Install the fuel injector electrical connectors.
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7. Install the engine electrical harness housing (1).
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8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut.
Tighten: Tighten the A/C line bracket nut to 7 N.m (62 lb in).
9. Install the engine lift bracket and secure the lift hook with the bolts.
Tighten: Tighten the lift bracket bolts to 50 N.m (37 lb ft).
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Fig. 94: View Of Engine Lift Hook & A/C Bracket Bolt
10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt.
Tighten: Tighten the A/C bracket bolt to 10 N.m (89 lb in).
11. Install the intake manifold. Refer to Intake Manifold Replacement.
VALVE ROCKER ARM AND VALVE LASH ADJUSTER REPLACEMENT
Tools Required
 J 36660-A Torque Angle Meter

 J 44222 Camshaft Sprocket Holding Tool. See Special Tools and Equipment.
Removal Procedure
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1. Remove the camshaft cover. Refer to Camshaft Cover Replacement.

2. Remove the exhaust and the intake sprocket bolts.
Fig. 95: View Of J 44222 Installed Onto Cylinder Head

3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in
order to maintain chain tension and keep from disturbing the timing chain components. See Special Tools
and Equipment.
4. Carefully move the sprockets with the timing chain off of the camshafts.
IMPORTANT: Place the camshaft caps in a rack to ensure the caps are installed in the
same location from which they were removed.
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5. Remove the camshaft cap bolts.
Fig. 96: Installing Camshaft Retainer Caps

6. Remove the camshaft caps.
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Fig. 97: Removing/Installing Camshafts

7. Remove the camshafts.
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Fig. 98: View Of Valve Rocker Arms

IMPORTANT: Once removed, place the valve rocker arms and valve lash adjusters in an
organized order so the components can be installed into the original
locations.
8. Remove the valve rocker arms.
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Fig. 99: View Of Valve Lash Adjusters

9. Remove the valve lash adjusters.
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1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
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3. Lubricate the valve rocker arm roller.

4. Install the valve rocker arms in their original locations.
5. Coat the camshaft journals with engine oil.
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6. Install the camshafts to their original position
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7. Install the camshaft caps onto their original journal.
Tighten: Tighten the camshaft cap bolts to 12 N.m (106 lb in).
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8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 . See Special
9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt.
Tighten:
 Tighten the intake camshaft sprocket bolt the first pass 20 N.m (15 lb ft).
 Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100
degrees.
 Tighten the exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft).
 Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135
degrees.
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10. Install the camshaft cover. Refer to Camshaft Cover Replacement.
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Tools Required
 J 38820 Valve Stem Seal Remover and Installer. See Special Tools and Equipment.
 J 44228 Valve Spring Compressor. See Special Tools and Equipment.
Removal Procedure
IMPORTANT: Organize the valve train components when disassembling so they can be
reassembled in the same location and matched up with the same components,
as previously installed.
1. Remove the cam cover. Refer to Camshaft Cover Replacement.

2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls-4.2 L.
3. Remove the exhaust and the intake sprocket bolts.
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4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components.
See Special Tools and Equipment.
5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension.
6. Carefully move the sprockets with the timing chain, off of the camshafts.
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10. Using a suitable adapter, apply air pressure to the cylinder.
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Fig. 108: View Of J 44228 Base Plate

11. Install the J 44228 and compress the valve springs. See Special Tools and Equipment.
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Fig. 109: View Of Valve Keys

12. Remove the valve keys.

13. Remove the J 44228 . See Special Tools and Equipment.
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Fig. 110: View Of Valve Springs & Retainer

14. Remove the valve spring retainer and the valve spring.
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Fig. 111: View Of J 38820 & Valve Seals

15. Use the J 38820 and remove the seals. See Special Tools and Equipment.
16. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
IMPORTANT: Lubricate the valve stems with clean engine oil before installing.
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1. Use the J 38820 to install the valve seals. There is only one size seal. See Special Tools and Equipment.
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2. Install the valve spring and the valve spring retainer.
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Fig. 114: View Of J 44228 Base Plate

3. Use the J 44228 and compress the valve springs. See Special Tools and Equipment.
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4. Install the valve keys.

6. Remove the air pressure to the cylinder.
7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil.
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8. Install the camshafts to their original position.
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9. Install the camshaft caps onto their original journal.
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10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222 . See Special
11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt.
Tighten:
 Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft).
 Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100
degrees.
degrees.
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12. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls-4.2 L.
OIL LEVEL INDICATOR AND TUBE REPLACEMENT
Removal Procedure

1. Remove the A/C line bracket nut.

2. Remove the A/C line bracket from the oil level indicator tube stud.
3. Disconnect the O2 sensor electrical connector from the oil level indicator bracket.
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Fig. 120: View Of Oil Level Indicator Tube Stud

4. Remove the oil level indicator tube stud.

5. Pull the indicator out of the tube.
6. Pull the tube out of the block.
1. Install the oil level indicator tube into the engine block.
2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads.
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3. Install the oil level indicator tube stud.
Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in).

4. Install the A/C line bracket to oil level indicator tube and secure with the nut.
Tighten: Tighten the A/C line bracket nut to 7 N.m (6 lb in).
5. Connect the O2 sensor electrical connector.

6. Install the oil level indicator into the tube.
CYLINDER HEAD REPLACEMENT

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Tools Required
J 36660-A Torque Angle Meter
Removal Procedure

2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (4.2L Engine) .
3. Remove the front cover. Refer to Engine Front Cover Replacement.
Fig. 122: View Of Cylinder Head Access Hole Plugs
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4. Remove the cylinder head access hole plugs.
Fig. 123: View Of Timing Chain Tensioner Shoe & Bolt

5. Remove the timing chain tensioner shoe bolt.

6. Remove the timing chain tensioner shoe.
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Fig. 124: View Of Timing Chain Guide & Bolts

7. Remove the timing chain tensioner guide bolts.

8. Remove the timing chain tensioner guide.
9. Remove the timing chain and the sprockets. Refer to Timing Chain, Sprockets, and/or Tensioner
Replacement.
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Fig. 125: View Of Cylinder Head Bolts

10. Loosen and remove the cylinder head bolts.
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Fig. 126: View Of Cylinder Head

11. Remove the cylinder head.
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Fig. 127: View Of Cylinder Head Gasket

12. Remove the cylinder head gasket.

13. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent
damage to the deck face.
14. If replacing cylinder head refer to Cylinder Head Disassemble.
15. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
IMPORTANT: Ensure number 1 piston is at top dead center. The crank pin will be at 12
o'clock when the number 1 piston is at top dead center.
1. If installing new cylinder head, refer to Cylinder Head Assemble.

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2. Install the dowel pins, cylinder head locator, if necessary.

3. Install a new cylinder head gasket.
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4. Install the cylinder head.
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5. Install new cylinder head bolts.
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Fig. 131: Tightening Sequence For Cylinder Head Bolts

6. Tighten the new cylinder head bolts in the following sequence:
Tighten:
1. Tighten the cylinder head bolts (1-14) in sequence to 30 N.m (22 lb ft).
2. Use J 36660-A to tighten the cylinder head bolts in sequence an additional 155 degrees.
3. Tighten the (2 Short) end bolts to 7 N.m (62 lb in).
Use J 36660-A to tighten the short cylinder head end bolts an additional 60 degrees.
4. Tighten the (1 Long) end bolt to 7 N.m (62 lb in).

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Use J 36660-A to tighten the long cylinder head end bolt an additional 120 degrees.

7. Install the cylinder head access hole plugs.
Tighten: Tighten the plugs to 5 N.m (44 lb in).
8. Install the timing chain and sprockets. Refer to Timing Chain, Sprockets, and/or Tensioner
Replacement.
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9. Install the front cover. Refer to Engine Front Cover Replacement.

11. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (4.2L Engine) .
CRANKSHAFT BALANCER REPLACEMENT
Tools Required

 J 41478 Crankshaft Front Oil Seal Installer. See Special Tools and Equipment.
 J 41816-2 Crankshaft End Protector. See Special Tools and Equipment.
 J 44226 Crankshaft Balancer Remover/Holder. See Special Tools and Equipment.
Removal Procedure
1. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
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Fig. 133: View Of Crankshaft Balancer Bolt

3. Carefully loosen and remove the balancer bolt.
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Fig. 134: Removing The Crankshaft Balancer Using J 41816-2

4. Install J 41816-2 into the end of the crankshaft. See Special Tools and Equipment.
IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
5. Use a 3 jaw puller to remove the crankshaft balancer.

6. Remove the 3 jaw puller and the J 41816-2 . See Special Tools and Equipment.
7. Remove the crankshaft balancer shim from the crankshaft snout.
8. Clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer Cleaning and Inspection.
IMPORTANT: The crankshaft balancer does not have a key-way; so the crankshaft could
turn when tightening, causing an improper torque. Make sure to follow the
installation procedure to prevent damage.
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2. Remove the torque converter access plug in the dry part of the oil pan.
3. Use the torque converter holding tool from the J 44226 kit and secure the torque converter while
tightening the crankshaft balancer. See Special Tools and Equipment.
4. Install a new crankshaft balancer shim GM P/N 12573950 over the crankshaft snout, against the
crankshaft gear.
Fig. 135: Installing Crankshaft Balancer Using The J 41478

5. Using the J 41478 install and seat the crankshaft balancer. See Special Tools and Equipment.
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7. While still holding the flywheel, install the balancer washer and the bolt.
Tighten: Tighten the crankshaft balancer bolt to 150 N.m (110 lb ft). Use the J 36660-A in order to
tighten the balancer bolt an additional 180 degrees.
8. Remove the torque converter holding tool.

9. Install the torque converter access plug into the oil pan.
12. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
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CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Tools Required
J 44218 Seal Installer. See Special Tools and Equipment.
Removal Procedure
IMPORTANT: Do not damage the engine front cover or the crankshaft.
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
Fig. 137: View Of Crankshaft Front Oil Seal

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2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal.

1. Apply the engine oil to the outside diameter of the crankshaft front oil seal.
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Fig. 139: Installing Crankshaft Front Oil Seal Using J 44218

2. Use the J 44218 to install the front oil seal. See Special Tools and Equipment.
4. Install the crank balancer shaft. Refer to Crankshaft Balancer Replacement.
ENGINE FRONT COVER REPLACEMENT
Tools Required
J 44219 Cover Alignment Pins. See Special Tools and Equipment.
Removal Procedure
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1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Engine
Cooling.
2. Remove the cooling fan and the shroud. Refer to Cooling Fan and Shroud Replacement in Engine
Cooling.
4. Remove the water pump. Refer to Water Pump Replacement (LL8) or Water Pump Replacement
(LM4) in Engine Cooling.
5. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
6. Remove the power steering pump. Refer to Power Steering Pump Replacement (5.3L) or Power
Steering Pump Replacement (4.2L) in Power Steering.
8. Remove the oil pan. Refer to Oil Pan Replacement.
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Fig. 140: View Of Engine Front Cover Bolts

10. Remove the 7 mm center bolt (1).

11. Loosen and remove the remaining engine front cover bolts.
12. Place two of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to
release the front cover from the engine.
13. Remove the two bolts from the front cover.
14. Remove the oil pump. Refer to Oil Pump Replacement.
15. Clean and Inspect the front cover. Refer to Engine Front Cover Cleaning and Inspection.
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1. Install the J 44219 , onto the engine. See Special Tools and Equipment.
Fig. 141: Aligning Engine Front Cover Using J 44219

IMPORTANT: The engine front cover must be installed within 10 minutes from when the
sealer was applied.
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Fig. 142: Applying Sealant To Engine Front Cover

2. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 to the trace grooves on back side of the engine
front cover (1).
3. Also apply sealant on the inside three bolt hole bosses on the cover.
4. Align the oil pump to the crankshaft sprocket splines.
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5. Install the front cover.
6. Install the front cover bolts, tightening the center bolt last (1).
Tighten: Tighten the front cover bolts to 10 N.m (89 lb in).

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9. Install the oil pan. Refer to Oil Pan Replacement.

11. Install the power steering pump. Refer to Power Steering Pump Replacement (5.3L) or Power Steering
Pump Replacement (4.2L) in Power Steering System.
12. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
13. Install the water pump. Refer to Water Pump Replacement (LL8) or Water Pump Replacement
(LM4) in Engine Cooling.
15. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
16. Fill the engine with coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in
Engine Cooling.
CAMSHAFT POSITION ACTUATOR REPLACEMENT - EXHAUST
Tools Required

 J 44217 Timing Chain Retention Tool
Removal Procedure

2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with
the cylinder head to cam cover mating surface.
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Fig. 144: View Of Top Chain Guide

3. Remove the top chain guide bolts.

4. Remove the top chain guide.
5. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on
the timing chain link across from it.
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Fig. 145: Installing 44217 & EN-44217-45 To Timing Chains

6. Install the J-44217 (1).

1. Install the hook portion of the timing chain retention tools into one of the timing chain links near
the timing chain shoe on both sides of the engine.
2. Tighten the wing nuts.
3. Ensure the hooks are still in one of the links and the gage blocks of the tool are firmly in place on
the edge of the head.
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Fig. 146: View Of Exhaust Camshaft Position Actuator

7. Remove the exhaust camshaft position actuator bolt.

8. Remove the exhaust camshaft position actuator.
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Fig. 147: Aligning Exhaust Camshaft Position Actuator

1. Install the exhaust camshaft actuator into the timing chain.

2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator
sprocket (1).
IMPORTANT: Ensure the alignment pin is engaged between the camshaft and the
exhaust camshaft position actuator.
3. Install the exhaust camshaft actuator onto the exhaust camshaft.
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NOTE: The camshaft actuator must be fully advanced during installation. Engine
damage may occur if the camshaft actuator is not fully advanced.
IMPORTANT: Ensure the camshaft actuator is rotated clockwise relative to the camshaft
prior to tightening the bolt. Do not force the camshaft actuator to rotate
clockwise. If it does not move easily, it is already fully advanced. New
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camshaft actuators are already packaged in the fully advanced

(clockwise) position.
4. Install the exhaust camshaft actuator bolt.
Tighten:
 Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135
degrees.
5. Remove the J-44217 .

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6. Install the top chain guide.

7. Add threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the top chain guide bolt threads.
8. Install the top chain guide bolts.
Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
TIMING CHAIN, SPROCKETS, AND/OR TENSIONER REPLACEMENT
Tools Required

 J 44221 Camshaft Holding Tool. See Special Tools and Equipment.
Removal Procedure

2. Remove the engine front cover. Refer to Engine Front Cover Replacement.
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Fig. 150: Releasing Tension On Timing Chain

3. Release the tension on the timing chain by moving the tensioner shoe in.
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Fig. 151: View Of Tee At Timing Chain Tensioner

4. Place the tee into the tensioner to hold the shoe in place.
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Fig. 154: View Of Timing Chain & Sprockets

9. Remove the intake camshaft sprocket bolt.

10. Remove the intake camshaft sprocket.
11. Remove the timing chain.
12. Remove the crankshaft sprocket.
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Fig. 158: View Of Timing Chain Tensioner & Bolts

18. Remove the timing chain tensioner bolts.

19. Remove the timing chain tensioner.
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IMPORTANT: Every seventh link of the timing chain is darkened to aid in aligning the
timing marks.
1. Install the timing chain tensioner and secure the tensioner with the bolts.
Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
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2. Install the timing chain tensioner guide and secure the guide with the bolts.
Tighten: Tighten the timing chain tensioner guide to 10 N.m (89 lb in).
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3. Install the timing chain tensioner shoe and secure the shoe with the bolt.
Tighten: Tighten the timing chain tensioner shoe bolt to 26 N.m (19 lb ft).
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4. Install the cylinder head access hole plugs.
Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).
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Fig. 163: Installing J 44221 Onto Camshafts

5. Install the J 44221 with the camshaft flats up and the number 1 piston at top dead center. The crank pin
will be at 12 o'clock when the number 1 piston is at top dead center. See Special Tools and Equipment.
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Fig. 164: Installing Timing Chain & Sprockets

6. Install the crankshaft sprocket (1).

7. Install the intake camshaft sprocket into the timing chain.
8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1).
9. Feed the timing chain down through the opening in the head.
10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing
mark on to the crankshaft sprocket.
IMPORTANT: It may be necessary to remove J 44221 to rotate and hold the camshaft
(hex) to align the pin to the camshaft sprocket. See Special Tools and
Equipment.
11. Install the intake camshaft sprocket onto the intake camshaft.
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12. Install the intake camshaft sprocket washer and bolt.
Fig. 165: Installing Exhaust Camshaft Actuator Into The Timing Chain
14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1).
IMPORTANT: It may be necessary to remove the J 44221 to rotate and hold the
camshaft hex to align the pin to the camshaft sprocket. See Special Tools
and Equipment.
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IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to
tightening the bolt.
16. Install the exhaust camshaft actuator bolt.
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Tighten:
 Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135
degrees.
17. Install the intake camshaft sprocket bolt.
Tighten:
 Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 ft lb).
 Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
Fig. 167: View Of Tee At Timing Chain Tensioner

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18. Remove the tee in the timing chain tensioner to regain tension on the timing chain.
Fig. 168: View Of Timing Chain Aligning Marks

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20. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown.


22. Add threadlock GM P/N 12345496 on the top chain guide bolt threads.
Tighten: Tighten the top chain guide bolts to 10 N.m (89 lb in).
24. Install the engine front cover. Refer to Engine Front Cover Replacement.
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CAMSHAFT REPLACEMENT
Tools Required

 J 36660-A Torque/Angle Meter
Removal Procedure

2. Remove the intake and the exhaust camshaft sprocket bolts.

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3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in
order to maintain chain tension and keep from disturbing the timing chain components. See Special Tools
and Equipment.
4. Carefully move the sprockets with the timing chain, off of the camshafts.

6. Remove the camshaft caps and store.
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1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
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2. Install the intake and exhaust camshafts to their original positions.

3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See Special
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IMPORTANT: Install the camshaft caps onto their original locations. The camshaft caps
are pin stamped for direction and numerical order.
4. Install the camshaft caps and bolts.
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6. Carefully move the sprockets back onto the camshafts and remove the J 44222 . See Special Tools and
Equipment.
7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt.
Tighten:
 Tighten the intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft).
 Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100
degrees.
degrees.
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OIL FILTER ADAPTER AND BYPASS VALVE ASSEMBLY REPLACEMENT
Removal Procedure
1. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
Fig. 176: View Of Oil Filter Adapter

2. Remove the oil filter adapter.

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Fig. 177: View Of Oil Filter Bypass Valve

3. Remove the oil filter bypass valve.
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1. Install the oil filter bypass valve.
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2. Install the oil filter adapter.
Tighten: Tighten the oil filter adapter to 30 N.m (22 lb ft).
3. Install the oil filter. Refer to Engine Oil and Oil Filter Replacement.
OIL PAN REPLACEMENT

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Removal Procedure
Fig. 180: View Of A/C Compressor & Mounting Bolts

2. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3).
3. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
4. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
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Fig. 181: Securing Front Differential To Frame

5. Remove the front differential and secure to the frame. Refer to Differential Carrier Assembly
Replacement (4.8L, 5.3L, 6.0L V-8) in Front Drive Axle.
6. Remove the front drive axle intermediate shaft bearing assembly. Refer to Intermediate Shaft Bearing
Assembly Replacement - Front Drive Axle (S4WD) or Intermediate Shaft Bearing Assembly
Replacement - Front Drive Axle (A4WD) in Front Drive Axle.
7. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
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Fig. 182: View Of Transmission Cooler Lines & Clips

8. Unclip the transmission cooler lines from the engine block.

9. Remove 4 transmission bell housing bolts that are attached to the oil pan.
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Fig. 183: View Of Engine & Oil Pan Bolts

10. Remove the remaining oil pan bolts.

11. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the
engine (1).
12. Clean and inspect the oil pan. Refer to Oil Pan Cleaning and Inspection.
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Fig. 184: Applying Sealant To Oil Pan

IMPORTANT: The oil pan must be installed within 10 minutes from when sealer was
applied.
1. Apply a 3 mm (0.12 in) bead of sealer GM P/N 12378521 to the block, rather than the oil pan.
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IMPORTANT: When you install the oil pan, it could be shifted front or back a little which
could cause a transmission alignment problem. The back of the oil pan
needs to be flush with the block.
2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly.
3. Install the oil pan bolts.
Fig. 185: Inspecting Oil Pan Alignment

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4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission
mounting surface.
Tighten:
 Tighten the oil pan side bolts to 25 N.m (18 lb ft).
 Tighten the oil pan end bolts to 10 N.m (89 lb in).
5. Install the 4 transmission bell housing bolts that attach to the oil pan.
Tighten: Tighten bolts to 47 N.m (35 lb ft).

6. Clip transmission cooler lines to the engine block.

7. Install the front drive axle intermediate shaft bearing assembly. Refer to Intermediate Shaft Bearing
Assembly Replacement - Front Drive Axle (S4WD) or Intermediate Shaft Bearing Assembly
Replacement - Front Drive Axle (A4WD) in Front Drive Axle.
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8. Install the oil drain plug and filter. Refer to Engine Oil and Oil Filter Replacement.
Fig. 187: Securing Front Differential To Frame

9. Install the front differential to the engine. Refer to Differential Carrier Assembly Replacement (4.8L,
5.3L, 6.0L V-8) in Front Drive Axle.
10. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
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Fig. 188: View Of A/C Compressor & Mounting Bolts

11. Install the A/C compressor 2 bottom bolts (4).
Tighten: Tighten all 4 bolts (2, 3, 4) to 50 N.m (37 lb ft).
12. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
Engine Electrical.
IMPORTANT: Inspect the engine for oil leaks in order to ensure all sealing surfaces are
sealed.
14. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
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ENGINE OIL PRESSURE SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure
2. Remove the engine shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
Fig. 189: View Of Oil Pressure Switch & Connector

3. Remove the electrical connector from the oil pressure switch.

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4. Remove the oil pressure switch.
Fig. 190: View Of Oil Pressure Switch & Connector

1. Install the oil pressure switch.

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Tighten: Tighten the oil pressure switch to 20 N.m (15 lb ft).
2. Install the electrical connector to the oil pressure switch.

3. Install the engine shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
OIL PUMP REPLACEMENT
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover Replacement.
Fig. 191: Exploded View Of Oil Pump

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2. Remove the oil pump cover bolts.

3. Remove the oil pump cover.
4. Mark the inner and the outer gears in relation to the oil pump housing.
5. Remove the inner and the outer oil pump gears.
6. Remove the oil pump pressure relief valve plug.
7. Remove the oil pump pressure relief valve and the spring.

1. Install the oil pump pressure relief valve and the spring.
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2. Install the oil pump pressure relief valve plug.
Tighten: Tighten the oil pump pressure relief valve to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.

4. Install the oil pump cover.
5. Install the oil pump cover bolts.
Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
6. Install the front cover. Refer to Engine Front Cover Replacement.
CRANKSHAFT REAR OIL SEAL AND HOUSING REPLACEMENT
Tools Required

 J 44219 Cover Alignment Pins. See Special Tools and Equipment.
 J 44227 Rear Seal Installer. See Special Tools and Equipment.
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement (LM4) or Transmission Replacement

(LL8) in Automatic Transmission - 4L60-E/4L65-E.
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Fig. 193: View Of Flywheel & Bolts

2. Remove the flywheel bolts and remove the flywheel.
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Fig. 194: View Of Crankshaft Rear Oil Seal Housing & Bolts
3. Remove the crankshaft rear oil seal housing bolts.

4. Install 2 bolts into the jackscrew holes (1) to release the cover from the block.
5. Remove the crankshaft and rear oil seal housing.
6. Remove the oil seal from the crankshaft snout.
1. Use the J 44227 to install the crankshaft rear oil seal. See Special Tools and Equipment.
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Fig. 195: Applying Sealant To Rear Oil Seal Housing

3. Apply a 3 mm (0.12 in) bead of GM P/N 12378521 to the rear oil seal housing (1).
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Fig. 196: View Of J 44219 Guide Pins Installed Into Rear Of Engine Block
4. Install the J 44219 guide pins (1) into the block. See Special Tools and Equipment.
IMPORTANT:  When installing a new seal, use the plastic installation sleeve
supplied with the new seal.
 The seal installation sleeve should come off after the seal is
installed. Discard the sleeve.
5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft. See Special
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6. Install the crankshaft rear oil seal housing bolts, except the 2 in place of the guide pins.
7. Remove the J 44219 guide pins. See Special Tools and Equipment.
8. Install the remaining 2 crankshaft rear oil seal housing bolts.
Tighten: Tighten all the oil seal housing bolts to 10 N.m (89 lb in).
Fig. 197: View Of Oil Pan Sealing Area On Crankshaft Rear Oil Seal Housing
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9. Wipe off any excess material from the bottom of the oil pan sealing area (1).
Fig. 198: Tightening Sequence For Flywheel Bolts

10. Install the flywheel and secure with the bolts.
Tighten: Tighten the flywheel bolts in sequence to 25 N.m (18 lb ft).
11. Use the J 36660-A to tighten the bolts an additional 50 degrees.

12. Install the transmission. Refer to Transmission Replacement (LM4) or Transmission Replacement
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CRANKSHAFT REAR OIL SEAL REPLACEMENT
Tools Required
J 44227 Rear Seal Installer. See Special Tools and Equipment.
Removal Procedure

2. Remove the flywheel. Refer to Engine Flywheel Replacement.
IMPORTANT: Do not damage the crankshaft or seal bore.
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Fig. 199: View Of Crankshaft Rear Oil Seal Housing & Seal
3. Pry the crankshaft rear oil seal out of the rear oil seal housing using a suitable tool.
IMPORTANT: Use the plastic installation sleeve supplied with the new seal when
installing a new seal.
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Fig. 200: Installing Crankshaft Rear Oil Seal Using J 44227

1. Use J 44227 to install the crankshaft rear oil seal. See Special Tools and Equipment.
3. Remove the seal installation sleeve after the seal is installed. Discard the sleeve.
4. Install the flywheel. Refer to Engine Flywheel Replacement.
ENGINE FLYWHEEL REPLACEMENT
Tools Required
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J 36660-A Torque Angle Meter
Removal Procedure


IMPORTANT: Note the position and the direction of the engine flywheel before removal.
2. Remove the flywheel bolts.

3. Remove the flywheel.
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4. Clean and Inspect the flywheel. Refer to Engine Flywheel Cleaning and Inspection.
1. Add threadlock GM P/N 12345493 (Canadian P/N 10953488) to the new flywheel bolts.
Fig. 202: Tightening Sequence For Flywheel Bolts

2. Install the flywheel and secure the flywheel with the new bolts.
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Tighten:
1. Tighten the bolts in sequence to 25 N.m (18 lb ft).
2. Use the J 36660-A in order to tighten the bolts an additional 50 degrees.

ENGINE REPLACEMENT
Tools Required
J 44220 Engine Lift Bracket. See Special Tools and Equipment.
Removal Procedure
1. Remove the hood. Refer to Hood Replacement in Body Front End.

3. Drain engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Engine
Cooling.
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air
Conditioning.
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Fig. 203: View Of Oil Pan Drain Plug

IMPORTANT: Keep drain plug removed during engine removal and installation.
5. Remove the oil pan drain plug and drain the oil.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the
procedure.
7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -
4.2L.
8. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L
9. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure (MAP)
Sensor Replacement in Engine Controls - 4.2L
10. Remove the washer solvent container. Refer to Washer Solvent Container Replacement in
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Wipers/Washer Systems.
11. Remove the grill. Refer to Grille Replacement in Exterior Trim.
12. Remove the headlamp housing. Refer to Headlamp Housing Panel Replacement in Body Front End.
13. Remove the radiator support brace. Refer to Brace Replacement - Radiator Support Diagonal in Body
Front End.
14. Remove the hood latch. Refer to Hood Latch Support Replacement in Body Front End.
15. Disconnect A/C lines at the condenser.
16. Disconnect the transmission cooler lines at the engine, not the radiator.
17. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud
rearward for clearance. Refer to Cooling Fan and Shroud Replacement in Engine Cooling.
18. Remove the radiator with condenser and transmission cooler lines. Refer to Radiator Replacement
(SWB - Short Wheel Base) or Radiator Replacement (LWB - Long Wheel Base) in Engine Cooling.
20. Remove the power steering pump bolts and lay the pump aside.
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Fig. 204: View Of Heater Hoses & Secondary AIR Reaction Solenoid Valve
21. Ensure the heater hoses at the heater core are disconnected.
22. Remove the secondary air injection (AIR) reaction solenoid valve. Refer to Secondary Air Injection
(AIR) Solenoid Valve Replacement in Engine Controls - 4.2L.
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Fig. 205: View Of Lift Hook

23. Install the lift hook J 44220 to the AIR port on the engine head. See Special Tools and Equipment.
24. Disconnect the oxygen sensor electrical connector.
25. Disconnect the A/C line at the accumulator.
26. Disconnect the front axle actuator electrical connector.
27. Disconnect the camshaft phaser actuator valve electrical connector.
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28. Unclip the transmission cooler lines from right side of the engine block.
29. Disconnect the ignition coil harness connectors.
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30. Carefully disconnect harness retainer at clips (1) and remove.

31. Remove power brake hose at booster.
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Fig. 208: View Of PCM

32. Remove the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls -
4.2L.
33. Disconnect the fuel lines at the fuel pressure regulator and cap lines. Refer to Fuel Pressure Regulator
Replacement in Engine Controls - 4.2L.
34. Remove all harnesses from the engine harness bracket.
35. Disconnect the front differential vent hose from the engine harness bracket.
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Fig. 209: View Of Engine Harness Bracket & Bolts

36. Remove the engine harness bracket bolt and remove bracket.
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Fig. 210: View Of Starter & Related Components

37. Disconnect starter electrical connections (1).

38. Disconnect the A/C pressure sensor and clutch electrical connector.
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Fig. 211: Rear Of Generator (Alternator) View

39. Disconnect generator electrical connector and battery lead (1).

40. Disconnect the knock sensor electrical connector.
41. Disconnect the crankshaft sensor electrical connector.
42. Disconnect the camshaft sensor electrical connector.
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Fig. 212: View Of Left Side Of Block

43. Remove 4 grounds on the left side of the block (1).

45. Remove the wheel drive shafts, left and right. Refer to Wheel Drive Shaft Replacement in Wheel Drive
Shafts.
46. Remove the propeller shaft from the front axle pinion yoke. Refer to Propeller Shaft Replacement -
Front in Propeller Shaft.
47. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Body Front
End.
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Fig. 213: View Of Exhaust Pipe At Exhaust Manifold

48. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
49. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (Short Wheelbase)
or Fuel Tank Shield Replacement (Long Wheelbase) in Frame and Underbody.
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Fig. 214: View Of Secondary AIR Pipes & Pump

50. Disconnect the secondary AIR pipes from the secondary AIR pump.
51. Remove the torque converter bolt access cover.
52. Remove the torque converter bolts.
53. Place a jack on the transmission oil pan for support.
54. Remove the transmission support. Refer to Transmission Support Replacement in Frame and
Underbody.
55. Lower the transmission enough to reach the top bell housing bolts.
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Fig. 215: View Of Bell Housing Bolts

56. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to
have access to 2 of the top bolts.
57. Raise the transmission.
58. Reinstall the transmission support using only 2 through bolts.
59. Remove the remaining bell housing bolts, for a total of 11 bolts.
60. Remove the left and right engine lower mount nuts.
61. Disconnect the oil pressure switch electrical connector.
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63. Remove the left upper engine mount nut (1).
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64. Remove the right upper engine mount nut (1).

65. Install the engine hoist.
66. Raise the engine out of the compartment slowly keeping the transmission supported.
67. Remove both engine mounts for clearance.
68. Remove the fasteners securing the AIR pipes to the back of the engine head.
69. Remove the AIR pipes from the vehicle.
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70. Continue raising the engine out of the vehicle.

71. Install the engine to the engine stand.
1. Remove the engine from the engine stand.

2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. Install the AIR pipes to the engine.
4. Install the fasteners securing the AIR pipes to the back of the engine head.
5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine
mount brackets before inserting into the chassis mount brackets.
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6. Lower the engine onto the mounts and install the upper engine mount nuts (1).
Tighten: Tighten the nuts to 70 N.m (51 lb ft).
7. Remove the engine hoist.

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8. Lay the radiator into the radiator support, but do not install the radiator completely.
Fig. 219: View Of Bell Housing Bolts

10. Install all of the lower bell housing bolts, excluding the top 4.
11. Remove the 2 through bolts securing the transmission support.
12. Lower the transmission.
13. Install the top 4 bell housing bolts.
Tighten: Tighten all 11 bell housing bolts to 50 N.m (37 lb ft).

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14. Raise the transmission.

15. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
16. Install the 3 torque converter bolts.
Tighten: Tighten the torque converter bolts to 60 N.m (44 lb ft).
17. Install the torque converter bolt cover.

18. Install the fuel tank shield, if removed. Refer to Fuel Tank Shield Replacement (Short Wheelbase) or
Fuel Tank Shield Replacement (Long Wheelbase) in Frame and Underbody.
Fig. 220: View Of Secondary AIR Pipes & Pump

19. Connect the secondary AIR pipes to the secondary AIR pump.
20. Install the engine protection shield. Refer to Engine Protection Shield Replacement .
21. Install the propeller shaft to the front axle pinion yoke. Refer to Propeller Shaft Replacement - Front in
Propeller Shaft.
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Fig. 221: View Of Exhaust Pipe At Exhaust Manifold

22. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.
Tighten: Tighten the exhaust pipe bolts to 50 N.m (37 lb ft).
23. Connect the oil pressure sensor electrical connector.
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24. Install the oil pan drain plug.
Tighten: Tighten the plug to 26 N.m (19 lb ft).
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Fig. 223: View Of Radiator Hose

25. Install the lower radiator hose (1).

26. Install the left and right wheel drive shafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive
Shafts.
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Fig. 224: View Of Left Side Of Block

28. Install the 4 grounds on the left side of the block (1).
29. Install the camshaft sensor electrical connectors.
30. Install the crankshaft sensor electrical connector.
31. Install the knock sensor electrical connector.
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Fig. 225: Rear Of Generator (Alternator) View

32. Install the generator electrical connector and battery lead (1).
Tighten: Tighten the generator battery lead nut to 9 N.m (80 lb in).
33. Install the A/C pressure sensor and clutch electrical connector.
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Fig. 226: View Of Starter & Related Components

34. Install starter electrical connectors and battery lead (1).
Tighten: Tighten the starter battery lead to 9 N.m (80 lb in).
35. Install the fuel lines at the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement in
Engine Controls - 4.2L.
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Fig. 227: View Of Engine Harness Bracket & Bolts

36. Install the engine harness bracket and bolt.
Tighten: Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
37. Install the front differential vent hose, to the engine harness bracket.
38. Install all the harnesses to the engine harness bracket.
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39. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 4.2L.
40. Install the power brake hose at booster

41. Install the harness retainer (1) to the original location.

42. Install the ignition coil harness electrical connectors.
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43. Clip the transmission cooler lines to the right side of the engine block.
44. Connect the camshaft phaser actuator valve electrical connector.
45. Connect the front axle actuator electrical connector.
46. Connect the A/C line at the accumulator.
47. Install the oxygen sensor electrical connector.
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Fig. 230: View Of Lift Hook

48. Remove the lift hook J 44220 . See Special Tools and Equipment.
49. Install the secondary AIR solenoid valve. Refer to Secondary Air Injection (AIR) Solenoid Valve
Replacement in Engine Controls - 4.2L.
50. Install the heater hoses to the heater core. Refer to Heater Hose Replacement - Inlet (SWB (Short
Wheel Base)) or Heater Hose Replacement - Inlet (LWB (Long Wheel Base)) and Heater Hose
Replacement - Outlet (SWB (Short Wheel Base)) or Heater Hose Replacement - Outlet (LWB (Long
Wheel Base)) in Heating, Ventilation, and Air Conditioning.
51. Install the power steering pump.
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Fig. 231: View Of Power Steering Pump Bolts

52. Install the power steering pump bolts.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).

54. Install cooling fan and shroud, tilting the radiator forward for clearance.
55. Finish installing the radiator. Refer to Radiator Replacement (SWB - Short Wheel Base) or Radiator
Replacement (LWB - Long Wheel Base) in Engine Cooling.
56. Install transmission cooler lines together.
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57. Install the MAP sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement in Engine
Controls - 4.2L.
58. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
59. Install the hood latch. Refer to Hood Latch Support Replacement in Body Front End.
60. Install the head lamp housing. Refer to Headlamp Housing Panel Replacement in Body Front End.
61. Install the grill. Refer to Grille Replacement in Exterior Trim.
62. Install the washer solvent container. Refer to Washer Solvent Container Replacement in
Wipers/Washer Systems.
63. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.2L.
Engine Electrical.
65. Install the hood. Refer to Hood Replacement in Body Front End.
66. Service the engine oil.
67. Fill the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Engine
Cooling.
68. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and
Air Conditioning.
69. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure
in Engine Controls - 4.2L.
IMPORTANT: After an overhaul, the engine should be tested. Use the following
procedure after the engine is installed in the vehicle.
Disable the ignition system.


 Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
 Enable the ignition system.
 Start the engine and listen for unusual noises.
 Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
 Run the engine speed at about 1000 RPM until the engine has reached normal operating
temperature.
 Listen for a sticking lifter and other unusual noises.
 Inspect for fuel, oil and/or coolant leaks while the engine is running.
 Perform a final inspection for the proper engine oil and coolant levels.
70. Install the hood. Refer to Hood Replacement in Body Front End.
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
1. Remove the oil fill cap.

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3. Remove the oil pan drain plug and drain the oil into a suitable container.
Fig. 232: View Of Oil Filter

4. Remove the oil filter using a suitable wrench.
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5. Inspect the old oil filter to ensure the filter seal is not left on the engine block.
1. Wipe the excess oil from the oil filter housing.

2. Lubricate the oil filter seal with clean engine oil.
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Fig. 233: View Of Oil Filter

3. Install the new oil filter.

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Tighten: Tighten the oil filter to 17 N.m (22 lb ft) plus 150 degrees.
4. Install the oil pan drain plug.
Tighten: Tighten the oil pan drain plug to 26 N.m (19 lb ft).

6. Fill the crankcase with the proper quantity of engine oil. Refer to Capacities - Approximate Fluid and
Fluid and Lubricant Recommendations in Maintenance and Lubrication.
7. Remove the oil level indicator.
8. Wipe the indicator with a clean cloth.
9. Install the oil level indicator.
10. Remove the oil level indicator and check the oil level.
11. Add oil if necessary.
12. Check for any oil leaks.
ENGINE FLYWHEEL REMOVAL
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1. Remove the flywheel bolts.

2. Remove the flywheel.
DRAINING FLUIDS AND OIL FILTER REMOVAL
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1. Remove the oil pan drain plug.

2. Drain the engine oil.
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Fig. 236: Locating Oil Filter

3. Remove the oil filter.
DRIVE BELT TENSIONER REMOVAL
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Fig. 237: View Of Drive Belt Tensioner & Bolt

1. Remove the drive belt tensioner bolt.

2. Remove the drive belt tensioner.
POWER STEERING PUMP BRACKET REMOVAL
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Fig. 238: View Of Power Steering Pump Bracket & Bolts

1. Remove the power steering pump bracket bolts.

2. Remove the power steering pump bracket.
DRIVE BELT IDLER PULLEY REMOVAL
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Fig. 239: View Of Drive Belt Idler Pulley & Bolts

1. Remove the drive belt idler pulley bolts.

2. Remove the drive belt idler pulley.
OIL LEVEL INDICATOR AND TUBE REMOVAL
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1. Remove the oil level indicator.

2. Remove the oil level indicator tube stud.
3. Remove the oil level indicator tube.
EXHAUST MANIFOLD REMOVAL
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Fig. 241: View Of Exhaust Manifold Heat Shield & Nuts

1. Remove the exhaust manifold heat shield nuts.

2. Remove the exhaust manifold heat shield.
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Fig. 242: View Of Exhaust Manifold Studs

3. Remove the exhaust manifold studs (if needed).
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Fig. 243: View Of Exhaust Manifold & Bolts

4. Remove the exhaust manifold bolts.

5. Remove the exhaust manifold.
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Fig. 244: View Of Exhaust Manifold Gasket

6. Remove the exhaust manifold gasket.
OIL FILTER ADAPTER REMOVAL
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1. Remove the oil filter adapter.
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2. Remove the oil filter bypass valve.
HEATER INLET HOSE FITTING REMOVAL
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Fig. 247: View Of Heater Inlet Hose Fitting

Remove the heater inlet hose fitting.
HEATER OUTLET HOSE FITTING REMOVAL
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Fig. 248: View Of Heater Outlet Hose Fitting

Remove the heater outlet hose fitting.
WATER OUTLET REMOVAL
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Fig. 249: View Of Water Outlet

1. Remove the water outlet bolts.

2. Remove the water outlet.
WATER PUMP REMOVAL
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Tool Required
J 41240 Fan Clutch Remover and Installer. See Special Tools and Equipment.
Fig. 250: View Of Water Pump Pulley, Bolts & J 41240

1. Install J 41240 to hold the pulley. See Special Tools and Equipment.
2. Remove the water pump pulley bolts.
3. Remove J 41240 . See Special Tools and Equipment.
4. Remove the water pump pulley
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Fig. 251: View Of Water Pump, Gasket & Bolts

5. Remove the water pump bolts.

6. Remove the water pump.
7. Remove the water pump gasket.
THERMOSTAT HOUSING REMOVAL
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Fig. 252: View Of Thermostat Housing & Bolts

1. Remove the thermostat housing bolts.

2. Remove the thermostat housing.
INTAKE MANIFOLD REMOVAL
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Fig. 253: View Of Throttle Control Module & Bolts

1. Remove the throttle control module bolts.

2. Remove the throttle control module.
3. Remove the throttle control module gasket.
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4. Remove the crankcase ventilation hose.
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5. Remove the intake manifold and bolts.
FUEL RAIL AND INJECTORS REMOVAL
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Fig. 256: View Of Fuel Injector Rail & Bolts

1. Remove the fuel injector rail bolts.

2. Remove the fuel injector rail.
CAMSHAFT POSITION ACTUATOR VALVE REMOVAL
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Fig. 257: View Of Camshaft Position Actuator Valve & Bolt

1. Remove the camshaft position actuator valve bolt.

2. Remove the camshaft position actuator valve.
CAMSHAFT COVER REMOVAL
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Fig. 258: View Of Ignition Control Modules & Bolts

1. Remove the ignition control modules and bolts.
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2. Remove the camshaft cover and bolts.
OIL PAN REMOVAL
NOTE: Remove the oil level sensor, located in the oil pan, before the oil pan is
removed. The sensor may be damaged if the oil pan is removed first.
1. Remove the oil level sensor.

2. Remove the oil pan bolts and nuts.
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Fig. 260: View Of Oil Pan & Bolts

3. Install two of the oil pan bolts into the threaded holes (jack bolts) to break the seal of oil pan (1).
4. Remove the oil pan.
OIL PUMP PIPE AND SCREEN ASSEMBLY REMOVAL
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Fig. 261: View Of Oil Pump Pipe, O-Ring & Bolts

1. Remove the oil pump pipe bolts.

2. Remove the oil pump pipe.
3. Discard the O-ring/gasket (419) - model dependent.
CRANKSHAFT BALANCER REMOVAL
Tools Required:
J 41816-2 Crankshaft End Protector. See Special Tools and Equipment.
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1. Remove the crankshaft balancer bolt.
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Fig. 263: Removing Crankshaft Balancer Using J 41816-2

2. Install J 41816-2 into the end of the crankshaft. See Special Tools and Equipment.
IMPORTANT: Do not pull on outer edge of the crankshaft balancer.
3. Use a three jaw puller to remove the crankshaft balancer.

4. Remove J 41816-2 . See Special Tools and Equipment.
ENGINE FRONT COVER REMOVAL
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1. Remove the 7 mm center bolt (1) first.

2. Remove the engine front cover bolts.
3. Remove the engine front cover.
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Fig. 265: View Of Crankshaft Snout, Balancer Friction Washer & Bolt
4. Remove the spacer bolt.

5. Remove the crankshaft balancer friction washer from the crankshaft snout.
OIL PUMP REMOVAL
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1. Remove the oil pump cover bolts.

2. Remove the oil pump cover.
3. Mark the inner and outer gears in relation to the oil pump housing.
4. Remove the inner and outer oil pump gears.
5. Remove the oil pump pressure relief valve plug.
6. Remove the oil pump pressure relief valve and spring.
CRANKSHAFT FRONT OIL SEAL REMOVAL
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IMPORTANT: Do not damage the engine front cover or the crankshaft.
Pry out the crankshaft front oil seal using a suitable tool.
TIMING CHAIN AND SPROCKETS REMOVAL
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5. Remove the intake camshaft sprocket bolt.

6. Remove the intake camshaft sprocket.
7. Remove the timing chain.
8. Remove the crankshaft sprocket.
CRANKSHAFT REAR OIL SEAL AND HOUSING REMOVAL
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Fig. 271: View Of Crankshaft Rear Oil Seal Housing, Bolts & Threaded Holes
1. Remove the crankshaft rear oil seal housing bolts.

2. Install two bolts (Jack Screws) into the threaded holes (1) to break the seal of the housing.
3. Remove the crankshaft rear oil seal housing.
CRANKSHAFT REAR OIL SEAL REMOVAL
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Fig. 272: View Of Crankshaft Rear Oil Seal Housing, Bolts & Threaded Holes
IMPORTANT: Do not damage the crankshaft or seal bore. Pry out the crankshaft rear oil seal
out using a suitable tool.
Remove the crankshaft rear oil seal.
TIMING CHAIN TENSIONER REMOVAL
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6. Remove the timing chain tensioner bolts.

7. Remove the timing chain tensioner.
ENGINE LIFT BRACKET REMOVAL
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Fig. 277: View Of Engine Lift Bracket & Bolts

1. Remove the engine lift bracket bolts.

2. Remove the engine lift bracket.
CAMSHAFT REMOVAL
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VALVE ROCKER ARM AND VALVE LASH ADJUSTER REMOVAL
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IMPORTANT: Once removed, place the valve rocker arms and valve lash adjusters in an
organized order so the components can be installed into the original
locations.
1. Remove the valve rocker arms.
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2. Remove the valve lash adjusters.
CYLINDER HEAD REMOVAL
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1. Remove the cylinder head bolts.
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2. Remove the cylinder head.
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3. Remove the cylinder head gasket.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
Tools Required:
J 41556 Connecting Rod Guides. See Special Tools and Equipment.
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Fig. 285: View Of Connecting Rod, Cap & Bolts

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap with the cylinder position. Also mark the orientation.
This will ensure the caps and connecting rods are re-assembled properly.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap and bearing half.
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Fig. 286: View Of J 41556

5. Install J 41556 on the connecting rod. See Special Tools and Equipment.
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Fig. 287: View Of Connecting Rod, Piston Assembly & J 41556

6. Remove the connecting rod and piston assembly. Push out the assembly.
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CRANKSHAFT AND BEARINGS REMOVAL
Fig. 288: View Of Crankshaft Main Bearing Cap Bolts

1. Remove the crankshaft main bearing cap bolts.
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Fig. 289: View Of Crankshaft Main Bearing Cap Stiffener

2. Remove the crankshaft main bearing cap stiffener.
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Fig. 290: View Of Crankshaft Main Bearing Caps & Lower Bearings
3. Remove the crankshaft main bearing caps and lower bearings.
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Fig. 291: View Of Crankshaft

4. Remove the crankshaft.
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Fig. 292: View Of Upper Crankshaft Main Bearing Halves

5. Remove the upper crankshaft main bearing halves.
ENGINE BLOCK PLUG REMOVAL
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Fig. 293: View Of Oil Gallery Plugs

1. Remove the engine block oil gallery plugs.
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Fig. 294: View Of Oil Gallery Plug From Rear Of Block

2. Remove the engine block oil gallery plug from rear of block.
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Fig. 295: View Of Crankshaft Position Sensor

3. Remove the crankshaft position sensor.
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Fig. 296: View Of Knock Sensors

4. Remove the knock sensors.
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Fig. 297: View Of EVAP Solenoid

5. Remove the EVAP solenoid.
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Fig. 298: View Of Coolant Temperature Sensor

6. Remove the coolant temperature sensor.
ENGINE BLOCK CLEANING AND INSPECTION
Tools Required
 J 8001 Dial Indicator Set

 J 8087 Cylinder Bore Gauge. See Special Tools and Equipment.
 J 45059 Angle Meter. See Special Tools and Equipment.
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Fig. 299: Cleaning Sealant From Gasket Mating Surface

1. Clean the sealing material from all gasket mating surfaces.

2. Clean the engine block with a cleaning solution.
3. Flush the engine block with clean water.
4. Clean the oil passages.
5. Coat the cylinder bores and the machined surfaces with engine oil.
6. Inspect the threaded holes. Clean the holes with a tap, if needed.
7. Use a straight edge and a feeler gauge to check the deck surface for flatness. Carefully remove any minor
irregularities. Replace the block if there is more than 0.08 mm (0.003 in) gap.
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Fig. 300: Measuring Cylinder Bores With J 8087

8. Replace the engine block if the bores are out of specification.

9. Inspect the cylinder bores. Use J 8087 to measure the cylinder bore. See Special Tools and Equipment.
Inspect the bores for the following conditions:
 Wear
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 Taper
 Runout
 Ridging
IMPORTANT: If the bore is worn beyond the limits, bore the cylinders and refit with the
one oversized piston available.
10. Leave sufficient material to allow finish honing when fitting the pistons.
Fig. 301: Measuring Bolt Hole Bosses

11. Inspect the oil pan rail for nicks. Use a flat file to remove an nicks.
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12. Inspect the front cover attaching area for nicks. Use a flat file to remove any nicks.
13. Inspect the mating surfaces of the transmission case.
14. Use the following procedure to measure the engine block flange runout at the mounting bolt hole bosses:
1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
2. Hold a gauge plate flat against the crankshaft flange.
3. Place J 8001 (dial indicator stem) on the transmission mounting bolt hole boss. Set the indicator to
zero.
4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary
more than 0.25 mm (0.010 in).
5. Recheck the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the
crankshaft flange runout is within the specification, replace the engine block.
15. Remove the crankshaft.
16. Re-install the crankshaft bearing caps, stiffener, and bolts.
Tighten:
1. Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft).
2. Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees. See Special
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Fig. 302: Inspecting Crankshaft Main Bearing Bores With J 8087

IMPORTANT: Perform the following inspections, and reconditioning (if necessary), with
the crankshaft main bearing caps installed and tightened to specification.
17. Inspect the crankshaft main bearing bores. Use J 8087 to measure the bearing bore concentricity and
alignment. See Special Tools and Equipment.
18. Remove the crankshaft main bearing cap stiffener and main bearing caps with bearings.
CYLINDER HONING
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Fig. 303: Identifying Cylinder Bore Cross Hatch Pattern

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use,
cleaning, and lubrication.
 Use only clean sharp stones of the proper grade for the amount of material to be removed.
 Dull, dirty stones cut unevenly and generate excessive heat.
 DO NOT hone to a final grade with a coarse or medium-grade stone.
 Leave sufficient metal so that all the stone marks will be removed with the fine grade stones.
 Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern
at 45-65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore.
 Repeatedly check the cylinder bore fit with the selected piston.
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All measurements of the piston or cylinder bore should be made with the components at normal

room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder
bore.
Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
 The finish marks should be clean but not sharp.

 The finish marks should be free from imbedded particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round
and taper requirements.
5. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and
detergent.
1. Scrub the cylinder bores with a stiff bristle brush.
2. Rinse the cylinder bores thoroughly with clean hot water.
3. Dry the cylinder bores with a clean rag.
4. Do not allow any abrasive material to remain in the cylinder bores.
 Abrasive material may cause premature wear of the new piston rings and the cylinder bores.
 Abrasive material will contaminate the engine oil and may cause premature wear of the
bearings.
6. Perform final measurements of the piston and the cylinder bore.
7. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in order to prevent rusting.
CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION
Tools Required

 J 8087 Cylinder Bore Gauge. See Special Tools and Equipment.
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Fig. 304: Inspecting Crankshaft For Wear

IMPORTANT: Use care when handling the crankshaft. Avoid damaging the crankshaft
reluctor wheel. Nicks, burrs or other damage to the teeth may effect the
On-Board Diagnostics (OBD) II system performance.
1. Clean the crankshaft of all elements.

2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft for the following conditions:
 Damaged threads (1)
 Damaged mounting faces
 Worn crankshaft pin (2)
 Wear without any grooves or scratches (3)
 Grooves or scoring (3)
 Scratches (3)
 Pitting or embedded bearing material (3)
 Overheating (discoloration) (3)
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Fig. 305: Inspecting Crankshaft Bearing Inserts

4. Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of
the material.
IMPORTANT: If cracks, severe gouges or burned spots are found, replace the
crankshaft. Remove slight roughness using a fine polishing cloth soaked
in clean engine oil. Remove any burrs using a fine oil stone.
5. Inspect the outer surfaces of the crankshaft bearings for the following conditions:
 Wear - surface wear indicates either movement of the insert or high spots in the surrounding
material (spot wear)
 Overheating or discoloration
 Looseness or rotation indicated by flattened tangs and wear grooves
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IMPORTANT: Note the location of the crankshaft main bearing high spots. If the spots
are not in line, the crankshaft is bent. Replace the crankshaft.
6. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing
halves also indicate fatigue.
7. Inspect the thrust surfaces of the main thrust bearing for the following conditions:
 Wear
 Grooving - Grooves are caused by irregularities of the crankshaft thrust surface.
8. Inspect the crankshaft bearings for excessive scoring or discoloration.

9. Inspect the crankshaft bearings for dirt or imbedded debris.
10. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections.
11. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a
tapered bearing journal.
IMPORTANT: If crankshaft bearing failure is due to conditions other than normal wear,
investigate the cause of the condition. Inspect the crankshaft or
connecting rod bearing bores.
12. Inspect the connecting rod bearing bores using the following procedure:
1. Tighten the connecting rod bearing cap to specification.
2. Use J 8087 to measure the bearing bore for taper and out-of-round. Record the readings. See
Special Tools and Equipment.
3. No taper or out-of-round should exist.
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Fig. 306: Measuring Diameter Of Crankshaft Bearing Journal

13. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart.
Average the measurements.
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Fig. 307: View Of Crankshaft Bearing Caps

14. Measure the crankshaft bearing journal taper and runout.
IMPORTANT: Refer to the pin stamp on the crankshaft main bearing caps for sequence
and direction of installation. The pin stamp arrow points to the front of the
engine.
15. Install the crankshaft bearing caps.

16. Install the crankshaft main bearing cap stiffener.
17. Install the crankshaft bearing cap bolts.
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Tighten:
1. Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft).
2. Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees. See Special
18. Measure the crankshaft main bearing inside diameter with an inside micrometer.
19. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside
micrometer.
20. If the specified clearances cannot be met, the crankshaft, connecting rods, or block may need to be
replaced.
CRANKSHAFT BALANCER CLEANING AND INSPECTION
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Fig. 308: View Of Crankshaft Balancer Sealing Area & Belt Ribs
1. Inspect the crankshaft balancer sealing area for grooves, nicks, or burs (1).
2. Inspect the crankshaft balancer belt ribs for dents or damage (2).
3. Replace the crankshaft balancer if damage is present.
ENGINE FLYWHEEL CLEANING AND INSPECTION
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Fig. 309: Inspecting Engine Flywheel & Teeth

1. Inspect the engine flywheel for cracks (1).

2. Inspect the engine flywheel teeth for damage (2).
3. Replace the engine flywheel if damage is present.
PISTON AND CONNECTING ROD DISASSEMBLE

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Tools Required
J 43654 Piston Pin Retainer Clip Remover/Installer. See Special Tools and Equipment.
Fig. 310: View Of Piston Rings & Piston Expander

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CAUTION: Handle the piston carefully. Worn piston rings are sharp and may
cause bodily injury.
IMPORTANT: Do not reuse the piston rings.
1. Remove the piston rings using a piston ring expander.
Fig. 311: View Of Piston Pin Retaining Clips

IMPORTANT: Two retainers hold the piston pins in place. Reuse the retainers if they are
not damaged during removal.
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2. Remove the piston pin retaining clips.
Fig. 312: View Of Piston Pin & Connecting Rod

3. Remove the piston pin.
PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION

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J 8087 Cylinder Bore Gage. See Special Tools and Equipment.

1. Clean and soak the following components in a carburetor cleaning solution to remove carbon, sludge, and
varnish:
 Piston
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 Piston pin
 Connecting rod
Fig. 314: Identifying Twisted Connecting Rod

2. Install the connecting rod cap.

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3. Place the connecting rod assembly on a checking fixture.

4. Inspect the connecting rod assembly for bending or twisting.
5. Replace any bent or twisted connecting rods.
6. If the connecting rod large bore contains minor scratches or abrasions, clean the bore in a circular
direction with light emery paper. DO NOT scrape the connecting rod or cap.
7. Measure the piston pin to connecting rod bore using the following procedure:
 Using an outside micrometer, take two measurements of the piston pin in the area of the connecting
rod contact.
 Using an inside micrometer, measure the connecting rod piston pin bore.
 Subtract the piston pin diameter from the piston pin bore diameter.
 The clearance should not be more than 0.018 mm (0.0007 in).
8. If there is excessive clearance, replace the piston pin.

9. If there is still excessive clearance, replace the connecting rod.
10. If there is evidence of pin bore or pin scoring, replace the rod and pin assembly.
Fig. 315: Inspecting Connecting Rod Cap Bolts

11. Inspect the connecting rod bearings for the following conditions:
 Craters or pockets
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Flattened sections
 Excessive scoring or discoloration.
 Imbedded debris
 bright, polished sections
12. Inspect the inside of the connecting rod bearing and outside diameter of the connecting rod bearing
journal for wear. This indicates high spots.
13. Inspect the connecting rod bearing bore for taper and out-of-round.
14. Inspect the connecting rod bolts for stretching (compare to new or known good bolt). (1) is a stretched
bolt, (2) is a new or good bolt.
15. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
16. Clean the piston ring grooves. Ensure that the oil ring holes and slots are clean.
17. Inspect the pistons for the following conditions:
 Cracked ring lands, skirts, or pin bosses
 Ring grooves for nicks, burrs that may cause binding
 Warped or worn ring lands
 Eroded areas at the top of the piston
 Scuffed or damaged skirts
 Worn piston pin bores
18. Replace pistons that show any signs or damage or excessive wear.
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Fig. 316: Measuring Piston Diameter

IMPORTANT: When fitting pistons, consider both the piston and the cylinder bore
conditions together. Production and service pistons have the same
nominal weight and may be intermixed without affecting engine balance. If
necessary, used pistons may be fitted selectively to any cylinder of the
engine, providing the pistons are in good condition and the same weight.
Do not cut oversize pistons down or the engine balance may be affected.
Finish hone when selecting the piston.
19. Measure the piston diameter for size with a micrometer or caliper at a right angle to the pin center line,
across the skirts, 38 mm (1.50 in) from the top of the piston.
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Fig. 317: Measuring Cylinder Bores With J 8087

20. Replace the piston if worn beyond specifications or if damaged.

21. Use J 8087 to measure the cylinder bore. See Special Tools and Equipment.
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Fig. 318: Honing Cylinder Bore

22. Hone to size if necessary. Use the following procedure to hone the cylinder bore to the correct size.
1. Select a piston.
2. Hone the cylinder bore to obtain the recommended clearance.
3. Clean the piston and cylinder bore with soap and water. Dry the cylinder bore and piston. Lubricate
the cylinder bore with clean engine oil.
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23. Use the following procedure to measure the piston-to-cylinder bore clearance.
1. Subtract the piston diameter from the cylinder bore diameter to determine the piston-to-bore
clearance.
2. Compare the piston-to-bore clearance using the specifications to determine if the clearance is in the
acceptable range.
3. If the used piston is not acceptable, a new service piston may be selected.
24. When a piston has been selected, mark the piston to identify the cylinder for which the piston was fitted.
25. Select a set of new piston rings.
26. Install each ring, one at a time, into the corresponding cylinder.
27. Install the piston for that cylinder, upside down (top of piston pushing on the ring) and push the ring to
approximately 25 mm (1 in) down from the deck surface.
28. Remove the piston.
29. Measure the ring end gap with a feeler gage.
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Fig. 319: Measuring Piston Ring Gap

30. If the ring gap is not within the specification range, replace the rings.
31. Measure the piston ring side clearance - compression rings.
NOTE: The piston ring groove must only be cleaned with a ring groove cleaning
tool. Proper engine performance and durability depends on the
straightness and smoothness of the ring groove. Cleaning the piston ring
groove with an improper tool can damage the piston ring groove and
effect the performance and durability of the engine.
32. Use the following procedure to measure the compression ring side clearance.
1. Roll the piston ring around the groove.
2. Measure the side clearance with a feeler gage.
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3. If the ring is too tight, inspect the piston ring groove for nicks, burrs, or damage. Use emery cloth
to remove any minor burrs.
4. If the ring side clearance is greater than the specification, replace the piston.
CYLINDER SLEEVE REMOVAL
Tools Required
EN-45680-400 Cylinder Sleeve Removal and Installation Kit. See Special Tools and Equipment.
NOTE: Do not chill or heat the cylinder bore sleeve or the cylinder block when
removing or installing a new cylinder bore sleeve. Chilling or heating the
cylinder bore sleeve or the cylinder block will cause engine damage and
will not aid the removal or installation of the new cylinder bore sleeve.
NOTE: Do not damage the crankshaft connecting rod journals or reluctor ring or
engine damage will occur.
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Fig. 320: View Of Cylinder Bore Liner Puller

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the
connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install the cylinder bore sleeve puller EN 45680-402 (1) which is part of EN-45680-400 , through the
cylinder bore. See Special Tools and Equipment.
NOTE: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve
or damage to the cylinder bore sleeve puller will occur.
3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore
sleeve (117).
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Fig. 321: View Of Cylinder Bore Sleeve Puller EN 45680-402

4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the
shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN 456850-401 (4) onto the threaded shaft of the cylinder bore sleeve puller EN
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456850-402 and the engine block.

6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
IMPORTANT: Use four old cylinder head bolts for the attaching bolts.
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.
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Fig. 322: Removing Cylinder Bore Sleeve By Rotating Nut

9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
Fig. 323: Removing Cylinder Bore Sleeve

NOTE: Do not damage the cylinder block surface. Damage to the cylinder block
surface can cause engine failure.
10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve
(117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the
cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and
Bearings Cleaning and Inspection.
CYLINDER SLEEVE INSTALLATION
Tools Required
EN-45680-400 Cylinder Sleeve Removal and Installation Kit. See Special Tools and Equipment.
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NOTE: Do not use assembly aids or lubricants on the cylinder bore sleeve or the
cylinder bore block when installing a new cylinder bore sleeve, or engine
damage will occur. These items will not aid in the installation of the new
cylinder bore sleeve.
NOTE: Do not chill or heat the cylinder bore sleeve or the cylinder block when
removing or installing a new cylinder bore sleeve. Chilling or heating the
cylinder bore sleeve or the cylinder block will cause engine damage and
will not aid the removal or installation of the new cylinder bore sleeve.
Fig. 324: View Of Cylinder Bore Sleeve Fixture

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1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) which is part of
EN-45680-400 , over the cylinder bore sleeve (117) and onto the cylinder block. See Special Tools and
Equipment. Do not apply downward pressure to the cylinder bore sleeve (117).
Fig. 325: Installing Cylinder Bore Sleeve Puller Attachment Bolts

IMPORTANT: Use 4 old cylinder head bolts for the attaching bolts.
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3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401 (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117).
Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
Fig. 326: View Of Proper Liner Alignment

5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
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Fig. 327: View Of Installation Arbor

6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117).
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Fig. 328: View Of Pusher Block

7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN
45680-401 (1).
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Fig. 329: Installing Cylinder Bore Sleeve Into Engine Block Using Tool
NOTE: Do not use any air powered or electric tools to rotate the threaded shaft of
the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403
assembly or damage to the cylinder bore sleeve will occur.
8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN
45680-403 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the
cylinder bore sleeve above the surface of the cylinder block.
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Fig. 330: Seating Cylinder Bore Sleeve Completely Using Tool

10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve
installer EN 45680-403 assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore
sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the
cylinder bore sleeve flange will protrude above the block deck surface.
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Fig. 331: View Of Service Tool Assembly

11. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the
cylinder block (100).
Cylinder Sleeve Trimming
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Fig. 332: Cylinder Liner Trimming Tools View (1 Of 2)

 EN 45680-865 Debris Collector (3)

 EN 45680-411 Trim Tool Assembly (2)
 Air Control Valve (1 - Part of EN 45680-411
 Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational
speed in a clockwise direction
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Fig. 333: Cylinder Liner Trimming Tools View (2 Of 2)

 Trim Tool Preloader (1)

 EN 45680-412 Set Gage Ring (2)
 EN 45680-413 Metal Shavings Catch Plug (3)
 EN 45680-866 Drive Adapter (4)
 EN 45680-414 Bolts (5)
NOTE: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve
inside diameter (I.D) is fully machined and honed to size and is optimally
finished as shipped. Any attempt to modify this factory-produced sizing
and finish with additional boring and honing will lead to engine damage,
excessive noise or abnormal oil consumption.
1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the
cylinder bore sleeve flange.
NOTE: Ensure that all the metal particles are collected in order to prevent internal
damage to the transaxle or bearings.
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Fig. 334: Placing Metal Shaving Catch Plug Into Cylinder Bore Sleeve
2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the
top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore
sleeve.
3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves.
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Fig. 335: Identifying Catch Plug Positioning

NOTE: Installing the metal shaving catch plug deeper than the recommended
depth will create a decrease in vacuum system performance. A decrease in
vacuum system performance will cause metal shavings to enter the engine
and cause engine failure.
NOTE: Installing the metal shaving catch plug above the recommended depth will
cause damage to the metal shaving catch plug.
4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the
cylinder bore sleeve.
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Fig. 336: Identifying Set Gauge Ring Groove

IMPORTANT: Before using trim tool assembly EN 45680-411, the height of the cutting
blades must be set to the proper specification. The proper specification is
that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in)
above the block deck surface.
5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface.
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Fig. 337: View Of Trim Tool Assembly Components And Positioning

IMPORTANT: Ensure that the set gage ring EN 45680-412 surfaces are clean.
6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned
against the top of the flange bearing (3).
IMPORTANT: Once this procedure is done, it is not necessary to reset the trim tool
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assembly EN 45680-411 height until the blades are worn or damaged.
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then
tighten the shaft collar screw.
Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
Fig. 338: Placing Trim Tool Assembly EN 45680-411 Onto The Cylinder
10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1)
pointing in line with the crankshaft centerline and the front of the block.
11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block.
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Fig. 339: Attaching Drill Motor To EN 45680-411

NOTE: For proper tool operation, a drill motor with a 1/2 inch chuck, 1 1/8 hp, 7
amps, triple gear reduction, and a 450-600 RPM rotational speed in a
clockwise direction must be used. If the proper drill motor is not used,
damage to the cylinder bore sleeve will occur.
12. Fasten drive adapter EN 45680-866 (1) into the drill chuck.
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NOTE: Ensure that there are no crimps in the air feed hose or the vacuum hose.
Crimps in the hose may cause metal shavings to exit the cutting tool in
any direction, causing engine damage.
13. Connect a compressed air supply (75-125 psi) to the male quick connect (3) located on trim tool assembly
EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum
system that will catch the metal shavings.
14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool
assembly EN 45680-411. Do not apply downward force on the drill until full rotational speed has been
reached. After reaching full rotational speed, gradually apply downward force until the cutting action is
complete in approximately 5 seconds.
15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411.
16. Turn off the compressed air valve (2).
17. Remove trim tool assembly EN 45680-411 from the engine block.
18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413.
19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the
metal shaving catch plug EN 45680-413.
Fig. 340: Checking Cylinder Block Deck Surface With Straight Edge
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20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
21. Using a light, illuminate the backside of the straight edge.
Fig. 341: View Of Improperly Cut Cylinder Bore Sleeve

22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the
straight edge and the top of the cylinder bore sleeve flange. If light is present of either side or both sides
of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve
needs to be installed.
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Fig. 342: View Of For Properly Cut Cylinder Bore Sleeve

23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the
straight edge and the top of the cylinder block deck surface. If light is present on both sides of the
cylinder block, the cylinder bore sleeve is cut correctly.
24. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.
PISTON AND CONNECTING ROD ASSEMBLE
Tools Required
J 43654 Piston Pin Retaining Clip Remover/Installer. See Special Tools and Equipment.
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1. Lubricate the piston pin with clean engine oil.

2. Install one of the piston pin retainers into the retainer groove.
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3. Install the connecting rod and piston pin. Push the piston pin in until it bottoms against the installed
piston pin retainer.
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4. Install the second piston pin retainer.
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Fig. 346: Installing Piston Rings

IMPORTANT: The piston ring end gaps must be staggered 90 degrees apart.
NOTE: Use a piston ring expander to install the piston rings. The rings may be
damaged if expanded more than necessary.
5. Install the following components of the bottom ring assembly (oil control ring).
1. The expander
2. The lower oil control ring
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3. The upper oil control ring
Fig. 347: Installing Middle Ring (Compression Ring)

6. Install the middle ring (compression ring) with the napier groove facing down.
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7. Install the top ring.
CAMSHAFTS CLEANING AND INSPECTION
Tools Required
J 7872 Magnetic Base Dial Indicator Set
Fig. 348: Measuring Camshaft Lobes

1. Clean the camshafts with cleaning solvent.

2. Inspect the camshafts for the following conditions:
 Scored camshaft journals
 Damaged camshaft lobes
 Damaged camshaft sprocket locator pin slots
 Damaged threads
3. Measure the camshaft lobes using a micrometer. The intake camshaft lobes should be a minimum of 41.5
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mm (1.635 in). The exhaust camshaft lobes should be a minimum of 41 mm (1.615 in).
Fig. 349: Measuring Camshaft Runout & Lobe Lift

4. Use J 7872 to measure the camshaft runout.

1. Set the camshaft in V-blocks between the centers.
2. Measure the intermediate camshaft journal.
5. Use J 7872 to measure the camshaft lobe lift.
1. Lubricate the camshaft to V-block contact areas with engine oil.
2. Set the camshaft on V-blocks.
3. Measure the camshaft lobe lift.
6. If the runout or camshaft lobe lift is not within specifications, replace the camshaft.
TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION
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1. Inspect the timing chain sprockets for cracks or teeth that are worn, broken, or chipped.
2. Inspect the timing chain for binding or stretching.
3. Inspect the dowel pins for wear or damage
4. Inspect the crankshaft sprocket keyway and the locating dowel pins in the crankshaft for damage.
5. Inspect the timing chain shoe and guide for excessive wear or cracks.
6. Inspect the timing chain tensioner for damage.
7. Replace the timing chain and sprockets if damaged.
VALVE ROCKER ARM AND VALVE LASH ADJUSTER CLEANING AND INSPECTION
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Fig. 351: View Of Valve Rocker Arm

1. Clean the valve rocker arms and valve lash adjusters in cleaning solvent.
2. Dry the valve rocker arms and valve lash adjusters with compressed air.
3. Inspect the valve rocker arms for the following conditions:
 Excessive wear at the valve contact or valve lash adjuster socket area
 A loose or damaged pin
 A worn or damaged roller. The roller should rotate freely with no binding or roughness.
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Fig. 352: View Of Valve Lash Adjuster

IMPORTANT: Keep the valve rocker arms and valve lash adjusters in the order from
where they where removed.
4. Inspect the valve lash adjusters for the following conditions:

 Excessive wear
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 Clogging of the oil passage

 Damage
 Collapsed or spongy
CYLINDER HEAD DISASSEMBLE
Tools Required

 J 42037 Valve Spring Compressor Adapter. See Special Tools and Equipment.
 J 38820 Valve Stem Seal Remover/Installer. See Special Tools and Equipment.
Fig. 353: View Of Spark Plugs

1. Remove the spark plugs.

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Fig. 354: Compressing Valve Spring Using J 8062 & J 42037

IMPORTANT: Organize the valve train components when disassembling so they can be
reassembled in the same location and matched up with the same
components as previously installed.
2. Use J 8062 and J 42037 to compress the valve spring. See Special Tools and Equipment.
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3. Remove the valve keys.
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4. RemoveJ 8062 and J 42037 . See Special Tools and Equipment.

5. Remove the valve spring retainer and valve spring.
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Fig. 357: View Of Valves

6. Remove the valves.
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7. Use J 38820 to remove the valve seals. See Special Tools and Equipment.
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Fig. 359: View Of Water Jacket Plug

8. Inspect the water jacket plug, for leakage. Replace if necessary.
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Fig. 360: View Of Inner Oil Gallery Plug

9. Inspect the (inner) oil gallery plug, for leakage. Replace if necessary.
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Fig. 361: View Of End Oil Gallery Plugs

10. Inspect the (end) oil gallery plugs, for leakage. Replace if necessary.
CYLINDER HEAD CLEANING AND INSPECTION
Tools Required
J 9666 Valve Spring Tester
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1. Inspect the cylinder head gasket and the mating surface. Inspect for leaks, corrosion, and blowby.
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Fig. 363: Checking For Cylinder Head Warpage

2. If the gasket failed, determine the cause. The following conditions may cause gasket failure:
 Improper installation
 Warped cylinder head
 Missing or not fully seated dowel pins
 Low torque on the cylinder head bolts
 Incorrect length cylinder head bolts
 A warped engine block surface
 Scratched surfaces
 Foreign material
 Cracked engine block threaded holes
3. Clean the following components:

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 The gasket surfaces
Do not use a motorized brush on the head gasket sealing surface.
 Valve stems and valve heads

 The bolt hole threads
Remove all dirt, debris, or threadlocking material from the bolt holes.
4. Inspect the cylinder head mating surfaces for flatness. Use a feeler gauge and a straight edge.
5. Replace the cylinder head if warped more than 0.08 mm (0.003 in).
6. Inspect the cylinder head for cracks.
IMPORTANT: Do not attempt to weld the cylinder head. If the cylinder head is damaged,
replace the cylinder head. Minor nicks may be repaired with a fine flat file
or emery cloth.
7. Inspect the cylinder head deck for corrosion.

8. Inspect the valve springs for squareness.
9. Use J 9666 to measure the valve spring tension. Replace the valve spring if the tension is not within
specification.
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Fig. 364: Measuring Valve Spring Tension

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Fig. 365: Inspecting Valve Guides

10. Inspect the valve guides for wear. The valve guides may be reamed oversized 0.075 mm (0.003 in) and
oversized stemmed valves may be installed. The same size valve seal should be used.
11. Inspect the valve seats for excessive wear, damage, or hot spots.
12. Use the following procedure to measure the valve seat concentricity:
1. Lift the valve off the valve seat.
2. Apply a dab of blue dye to the valve face.
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3. Seat and rotate the valve. The blue dye traces transferred to the valve seat are an indication of
concentricity of the valve seat.
13. Use the following procedure to measure the valve runout:
1. Clean off the blue dye.
2. Apply blue dye to the valve seat.
3. Seat and rotate the valve.
4. The traces of blue dye transferred to the valve indicates valve runout.
14. Replace the head if the valve seats are damaged.
15. Inspect the valves for the following damage:
 Grooving (1, 2)
 Bent valve stem (3). Replace any bent valve.
 Burrs or scratches (4). Minor burrs or scratches may be removed with a fine oil stone.
 Chipped or worn key grooves (5). Replace if damaged.
 Valve tip wear (6). Replace if worn.
CYLINDER HEAD ASSEMBLE
Tools Required

 J 42037 Valve Spring Compressor Adapter. See Special Tools and Equipment.
 J 38820 Valve Stem Seal Remover/Installer. See Special Tools and Equipment.
1. Apply sealant to the threads.
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Fig. 366: View Of End Oil Gallery Plugs

2. Install the (end) oil gallery plugs.
Tighten: Tighten the oil gallery plugs to 38 N.m (28 lb ft).
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Fig. 367: View Of Inner Oil Gallery Plug

3. Apply sealant to the plugs.

4. Install the (inner) oil gallery plugs.
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Fig. 368: View Of Water Jacket Plug

5. Apply sealant to the plug.

6. Install the water jacket plug.
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7. Use J 38820 to install the valve seals. There is only one size valve seal. See Special Tools and
Equipment.
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Fig. 370: View Of Valves

IMPORTANT: Lubricate the valve stems with clean engine oil before installing.
8. Install the valves. 0.075 mm (0.003 in) oversized valves are available if the valve guides needed to be
reamed. Use the same (original size) valve seal.
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9. Install the valve spring and the valve spring retainer.
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Fig. 372: Compressing Valve Springs Using J 8062 & J 42037

10. Use J 8062 and J 42037 to compress the valve spring. See Special Tools and Equipment.
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11. Install the valve keys.

12. Remove J 8062 and J 42037 . See Special Tools and Equipment.
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Fig. 374: View Of Spark Plugs

IMPORTANT: Do not try to centralize the electrode on the spark plug. The electrode is
offset by design.
13. Install the spark plugs.
CAMSHAFT COVER CLEANING AND INSPECTION
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Fig. 375: View Of Camshaft & Cover Seal

1. Remove and discard the rubber ignition coil seals, and the camshaft cover seal.
2. Clean the camshaft cover with a suitable cleaning solvent.
3. Inspect the camshaft cover for cracks or damage.
4. Inspect the bolt threads for damage.
5. Replace the camshaft cover if necessary.
OIL PUMP CLEANING AND INSPECTION
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Fig. 376: Measuring Inner Oil Pump Gear Tip Clearance

1. Clean all parts of sludge, oil, and varnish by soaking in carburetor cleaner or cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the oil pump housing and engine front cover for the following conditions:
 Cracks or casting imperfections
 Scoring
 Damaged threads
4. Do not attempt to repair the oil pump housing. Replace the oil pump housing if damage is found.
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5. Inspect the oil pump gears for damage.

6. Measure the inner oil pump gear tip clearance in several places.
Fig. 377: Measuring Outer Oil Pump Gear Tip Clearance

7. Measure the outer oil pump gear tip clearance in several places.
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Fig. 378: Measuring Clearance Of Oil Pump Gear Side

IMPORTANT: When deciding oil pump serviceability based on end clearance, consider
depth of the wear pattern in the pump cover.
8. Measure the oil pump gear side clearance.

9. Inspect the pressure regulator valve for the following conditions:
 Scoring
 Sticking
 Burrs - Burrs may be removed using a fine oil stone.
10. Inspect the pressure regulator valve spring for loss of tension or bending. Replace the pressure regulator
spring if damaged.
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11. Inspect the oil pump pipe pickup tube and screen assembly for the following conditions:
 Looseness - If the oil pump pipe pickup tube is loose or bent, replace the oil pump pipe pickup
tube.
 Broken wire mesh or screen
 Inspect the O-ring seal at the base of the oil pump pickup tube for damage.
OIL PAN CLEANING AND INSPECTION
Fig. 379: View Of Oil Pan

1. Clean the oil pan in solvent. Remove all sludge and debris from the oil pan.
IMPORTANT: Do not use a motorized tool or bristle disc to clean this component.
2. Remove all sealing material from the oil pan rails.

3. Inspect the oil pan sealing surfaces for nicks or damage. Remove any minor nicks with a fine flat file.
4. Inspect the threads in the oil drain plug hole.
5. Replace the oil pan if necessary.
ENGINE FRONT COVER CLEANING AND INSPECTION
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Fig. 380: View Of Engine Front Cover

1. Clean the engine front cover with cleaning solvent.
IMPORTANT: Do not use a motorized tool or bristle disc to clean this component.
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2. Remove all sealing material.

3. Inspect the engine front cover sealing surfaces for nicks or damage. Use a fine flat file to remove any
minor nicks.
4. Inspect the engine front cover threaded holes for damage.
5. Repair or replace the engine front cover as necessary.
INTAKE MANIFOLD CLEANING AND INSPECTION
Fig. 381: View Of Intake Manifold

1. Clean the intake manifold gasket mating surface.

2. Inspect the threads on the retaining bolts.
3. Inspect the intake manifold for cracks.
4. Clean the internal ports of all debris.
5. Replace the intake manifold if necessary.
EXHAUST MANIFOLD CLEANING AND INSPECTION
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Fig. 382: View Of Exhaust Manifold

1. Clean the exhaust manifold.

2. Inspect the exhaust manifold for cracks or damage.
3. Inspect the exhaust manifold threads and studs (if necessary).
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Fig. 383: Checking Exhaust Manifold Mating Surface

4. Check the exhaust manifold mating surface for flatness. Use a straight edge and a feeler gauge.
5. Replace the exhaust manifold if necessary.
WATER PUMP CLEANING AND INSPECTION
1. Remove all sealing material from the sealing surface.

2. Inspect the water pump impeller for damage.
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Fig. 384: View Of Water Pump

3. Inspect the water pump shaft for looseness.

4. Inspect the threads for damage.
5. Replace the water pump if necessary.
THREAD REPAIR
Tools Required
 J 42385-400 Thread Repair Kit. See Special Tools and Equipment.

 J 43965 Extension Kit. See Special Tools and Equipment.
The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During
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the insert installation process, the installation driver tool cold-rolls the bottom internal threads and expands the
bottom external threads of the insert into the base material. This action mechanically locks the insert into place.
Fig. 385: View Of J 42385-400 Tool Kit

The tool kit J 42385-400 is designed for use with either a suitable tap wrench or drill motor. See Special Tools
and Equipment. Limited access and larger hole repair may process better using a tap wrench. An extension J
43965 may also be necessary to drive the thread repair tooling dependent on access to the hole being repaired.
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Fig. 386: Drilled Hole Centerline

It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as
the original hole.
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Fig. 387: Identifying Proper Drilling Angle

During the drilling and tapping of the hole being repaired ensure the tooling is consistently machining
perpendicular to the surface of the base material.
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Fig. 388: View Of Tapping Guide

If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are
available to aid in tapping the hole.
Thread Repair
Tap Size Tap Guide Tape Size Tape Guide Tap Size Tape Guide
- J 42385- - J 42385- - J 42385-
6 x 1.0 729 10 x 1.5 731 14 x 1.5 736
8 x 1.25 730 12 x 1.5 732 20 x 1.5 737
Standard Thread Repair - Flush Hole
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Fig. 389: View Of Bushing Type Insert & Base Material

IMPORTANT: The use of a cutting type fluid is recommended when performing the drilling,
counterboring and tapping procedures.
When installed to the proper depth, the flange (1) of the insert will be seated against the counterbore of the
drilled/tapped hole and just below the surface (2) of the base material.
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Fig. 390: Drilling Out Threads Of Damaged Hole

IMPORTANT:  During the drilling process, it is necessary to repeatedly remove the

drill and clean chips from the hole and the flutes of the drill.
 Do NOT drill any further than the original hole depth.
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1. Drill out the threads of the damaged hole.

 M6 inserts require a minimum drill depth of 15 mm (0.59 in).
 M8 inserts require a minimum drill depth of 20 mm (0.79 in).
 M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
Fig. 391: Cleaning Out Metal Chips

IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
2. Using compressed air, clean out any chips.
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Fig. 392: View Of Counterbore Drill

IMPORTANT: A properly counterbored hole will show a slight burnishing on the surface
of the base material for 360 degrees around the drilled hole.
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3. Counterbore the drilled hole to the full depth permitted by the tool (1).

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Fig. 394: Tapping Threads Of Drilled Hole

IMPORTANT:  During the tapping process, it is necessary to repeatedly remove the

tap and clean chips from the hole and the flutes of the tap.
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 Ensure the tap has created full threads at least to the depth equal to
the insert length.
5. Using a suitable tapping wrench, tap the threads of the drilled hole.
 M6 inserts require a minimum tap depth of 15 mm (0.59 in).
 M8 inserts require a minimum tap depth of 20 mm (0.79 in).
 M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).

IMPORTANT: All chips must be removed from the tapped hole prior to insert
installation.
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Fig. 396: Spraying Cleaner Into Tapped Hole

7. Spray cleaner into the tapped hole.
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installation.
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Fig. 398: Lubricating Installer Tool Using Driver Oil

IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter
(OD) of the insert.
9. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
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Fig. 399: View of Bushing Type Insert

10. Install the insert (2) onto the driver installation tool (1).
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Fig. 400: Applying Threadlock To Insert

11. Apply threadlock sealant (1) to the insert OD threads (2).
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Fig. 401: Installing Insert Into Tapped Bolt Hole

12. Install the insert (2) into the tapped hole.
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Fig. 402: Installing Insert - Standard Thread

IMPORTANT: If the insert will not thread down until the flange contacts the
counterbored surface, remove the insert immediately with a screw
extracting tool and inspect the tapped hole for any remaining chips and/or
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improper tapping.
13. Install the insert until the flange (2) of the insert contacts the counterbored surface.
Fig. 403: View Insert And Tool - Standard Thread

IMPORTANT: The driver installation tool will tighten up before screwing completely
through the insert. This is acceptable. The threads at the bottom of the
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insert are being formed and the insert is mechanically locking the insert
into the base material threads.
14. Continue to rotate the driver installation tool (1) through the insert (2).
Fig. 404: View Of Bushing Type Insert & Base Material

15. Inspect the insert for proper installation into the tapped hole. A properly installed insert (1) will be either
flush or slightly below flush with the surface of the base material (2).
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Fig. 405: View Of Restricted Engine Coolant Passages - Standard Thread Repair
16. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or
engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After
drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the
insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.
Recessed Thread Repair
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Fig. 406: Inspecting Insert For Proper Installation - Recessed Thread

IMPORTANT:  The use of a cutting type fluid is recommended when performing the
drilling, counterboring and tapping procedures.
 Do NOT remove the original stop collar from a counterbore drill.
When installed to the proper depth, the flange of the insert (1) will be seated against the counterbore (2) of the
drilled/tapped hole.
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Fig. 407: View Of Stop Collar & Counterbore Drill

1. Install a stop collar (2) on the counterbore drill (1), if required.
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 Drill the hole until the stop collar contacts the surface of the base
material.
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the insert length.

installation.
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installation.
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(OD) of the insert.
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Fig. 417: Installing Insert - Recessed Thread

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Fig. 418: View Of Installed Insert - Recessed Thread

counterbored surface remove the insert immediately with a screw
improper tapping.
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12. Install the insert until the flange (2) of the insert contacts the counterbored surface.
Fig. 419: Installed Insert - Recessed Thread Repair

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13. Continue to rotate the driver installation tool (1) through the insert (2).
Fig. 420: Inspecting Insert For Proper Installation - Recessed Thread

14. Inspect the insert (1) for proper installation (2) into the tapped hole.
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Fig. 421: View Of Restricted Engine Coolant Passage - Recessed Thread Repair
Tapered Pipe Thread Repair
The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.
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Fig. 422: Inspecting Insert For Proper Installation - Tapered Thread

IMPORTANT: The use of a cutting type fluid is recommended when performing the drilling,
counterboring and tapping procedures.
When installed to the proper depth, the flange (1) of the insert will be seated against surface (2) of the base
material of the drilled/tapped hole.
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 Drill the hole until the stop collar contacts the surface of the base
material.
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the insert length.
Fig. 426: View Of Proper Tapping Distance - Tapered Thread

4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.
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installation.
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installation.
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(OD) of the insert.
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Fig. 433: Installing Insert - Tapered Thread

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Fig. 434: Installing Insert - Tapered Pipe Thread Repair

IMPORTANT: If the insert will not thread down until the flange contacts the surface of
the base material remove the insert immediately with a screw extracting
tool and inspect the tapped hole for any remaining chips and/or improper
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tapping.
12. Install the insert until the flange (2) of the insert contacts the surface of the base material.
Fig. 435: Installed Insert - Tapered Pipe Thread Repair

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13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the
top of the insert (3).
Fig. 436: Inspecting Insert For Proper Installation - Tapered Thread

14. Inspect the insert (1) for proper installation (2) into the tapped hole.
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Fig. 437: View Of Restricted Engine Coolant Passages - Tapered Pipe Thread Repair
Cylinder Head Bolt Hole Thread Repair
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Fig. 438: View Of Cylinder Head Bolt Hole Required Tools

The cylinder head bolt hole required tools consist of the following:
 Drill (1) J 42385-402

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 Tap (2) J 42385-403

 Installation driver (3) J 42385-404
 Alignment pin (4) J 42385-303
 Bushing (5) J 42385-302
 Bolts (6) J 42385-421
 Fixture plate (7) J 42385-401
IMPORTANT:  Remove the fixture plate prior to installing the insert with the installer
tool.
 The use of a cutting type fluid is recommended when performing the
When installed to the proper depth, the flange of the insert will be seated against the counterbore of the
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Fig. 439: View Of Bushing, Fixture Plate, Bolts & Bolt Hole
1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired
(4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
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Fig. 440: View Of Alignment Pin & Fixture Retaining Bolts

3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.
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IMPORTANT: During the drilling process, it is necessary to repeatedly remove the drill
and clean chips from the hole and the flutes of the drill.
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Fig. 443: Tapping Out Threads Of Drilled Hole


the insert length.
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Fig. 444: View Of Tap Upper & Lower Marks, Fixture Plate & Bushing
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt
hole until the first mark (1) on the tap aligns with the top of the drill bushing (3).
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Fig. 445: View Of Bushing, Fixture Plate, Bolts & Bolt Hole
IMPORTANT: Remove the fixture plate prior to installing the insert with the installer
tool.
10. Remove the fixture plate bolts (2).

11. Remove the fixture plate (3) and bushing (1).
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installation.
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installation.
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(OD) of the insert.
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Fig. 452: View Of Installation Driver

18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole.
improper tapping.
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20. Install the insert until the flange of the insert contacts the counterbored surface.
21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the tapped hole.
Crankshaft Main Bolt Hole Thread Repair
Fig. 453: View Of Crankshaft Main Bearing Bolt Hole Required Tools
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IMPORTANT:  In order to repair some crankshaft main bolt holes it will be necessary to
mount the fixture plate upside down.
 Do NOT remove the fixture plate prior to installing the insert with the
installation driver. The fixture plate remains in position throughout the
thread repair process.
The crankshaft main bearing bolt hole required tools consist of the following:
 Drill (1) J 42385-417

 Tap (2) J 42385-418
 Installation driver (3) J 42385-419
 Fixture plate (4) J 42385-401
 Bushing (5) J 42385-307
 Alignment pin (6) J 42385-308
 Bolts (7) J 42385-510
IMPORTANT:  Ensure the fixture plate is installed during the machining and installation
processes of the insert.
 The use of a cutting type fluid is recommended when performing the
When installed to the proper depth, the flange of the insert will be seated against the counterbore of the
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Fig. 454: View Of Fixture Plate, Bolts & Bushing

1. Position the fixture plate (3) with the bushing (2), installed over the crankshaft main cap bolt hole to be
repaired.
2. Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.
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Fig. 455: View Of Alignment Pin & Fixture Retaining Bolts

3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.
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Fig. 456: Drilling Bushing


 Drill the crankshaft main bolt hole until the mark (1) on the drill
aligns with the top of the drill bushing (2).
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Fig. 458: Tapping Out Threads Of Crankshaft Main Bolt Hole

IMPORTANT:  Do not remove the fixture plate, ensure the fixture plate is installed
during the machining and installation processes of the insert.
 During the tapping process, it is necessary to repeatedly remove the
the insert length.
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Fig. 459: View Of Fixture Plate, Drill Bushing & Tool Marking
9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main
cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
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installation.
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installation.
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IMPORTANT:  Do not remove the fixture plate, ensure the fixture plate is installed
during the installation process of the insert.
 Do not allow oil or other foreign material to contact the outside
diameter (OD) of the insert.
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Fig. 466: Tapping Out Threads Of Crankshaft Main Bolt Hole

16. Install the insert and installation driver (1) into the tapped hole.
17. Start the insert into the threaded hole.
improper tapping.
18. Install the insert until the flange of the insert contacts the counterbored surface.
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19. Continue to rotate the driver installation tool through the insert.
Fig. 467: View Of Fixture Plate, Drill Bushing & Tool Marking
20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of
the drill bushing (2).
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21. Inspect the insert for proper installation into the tapped hole.
Fig. 468: View Of Fixture Plate, Bolts & Bushing

22. Remove the fixture plate bolts (1).

23. Remove the fixture plate (3) and bushing (2).
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SERVICE PRIOR TO ASSEMBLY
Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order
to measure components when inspecting for excessive wear. Repair or replace the components that are not
within the manufacturers specification. When components are reinstalled into an engine, return the components
to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean
engine oil or engine assembly lubricant (unless otherwise specified). This will provide initial lubrication when
the engine is first started.
ENGINE PRELUBING
Tools Required
J 45299 Engine Preluber. See Special Tools and Equipment.
IMPORTANT: A constant/continuous flow of clean engine oil is required to properly

prime the engine. Be sure to use an approved engine oil as specified in
the owners manual.
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Fig. 469: View Of Engine Block Oil Gallery Plug

1. Remove the engine oil filter, fill with clean engine oil, and reinstall.
Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Remove the engine block oil gallery plug (1).

3. Install the M16 x 1.5 adapter P/N 509375.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine
oil through the flexible hose and into the engine assembly. See Special Tools and Equipment
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Fig. 470: Identifying Engine Preluber J 45299

6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine block oil gallery plug (1).
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Tighten: Tighten the oil pressure sensor to 35 N.m (26 lb ft).
8. Top-off the engine oil to the proper level.
ENGINE BLOCK PLUG INSTALLATION
1. Add sealer to the plug threads.
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Fig. 471: View Of Oil Gallery Plug From Rear Of Block

2. Install the engine block oil gallery plug to rear of block.
Tighten: Tighten the engine block oil gallery plug to 80 N.m (40 lb ft).
Fig. 472: View Of Front Engine Block Oil Gallery Plug

3. Add sealer to the plug threads.

4. Install the engine block oil gallery plugs to front and left of block.
Tighten:
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 Tighten the side engine block oil gallery plugs to 35 N.m (26 lb ft).
 Tighten the front (1) engine block oil gallery plug to 80 N.m (40 lb ft).
Fig. 473: View Of Coolant Temperature Sensor

5. Add sealer to the coolant temperature sensor threads.

6. Install the coolant temperature sensor.
Tighten: Tighten the coolant temperature sensor to 20 N.m (15 lb ft).
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Fig. 474: View Of EVAP Solenoid

7. Add sealer to the EVAP solenoid bolt threads.
Tighten: Tighten the EVAP solenoid bolt to 10 N.m (89 lb in).
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Fig. 475: View Of Knock Sensors

8. Install the knock sensors.
Tighten: Tighten the knock sensors to 25 N.m (18 lb ft).
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Fig. 476: View Of Crankshaft Position Sensor

9. Add sealer to the crankshaft position sensor bolt.

10. Install the crankshaft position sensor and bolt.
Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
CRANKSHAFT AND BEARINGS INSTALLATION
Tools Required
J 45059 Angle Meter. See Special Tools and Equipment.
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Fig. 477: View Of Upper Crankshaft Main Bearing Halves

1. Install the upper crankshaft main bearings into the block.
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Fig. 478: View Of Crankshaft

2. Lubricate the upper crankshaft main bearing surface with clean engine oil.
3. Install the crankshaft.
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Fig. 479: View Of Crankshaft Main Bearing Caps & Lower Bearings
IMPORTANT: Refer to the pin stamp on the crankshaft main bearing caps for sequence
and direction of installation. The pin stamp arrow points to the front of the
engine.
4. Install the lower crankshaft main bearings into the main bearing caps.
5. Lubricate the lower crankshaft main bearing surface with clean engine oil.
6. Install the crankshaft main bearing caps.
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Fig. 480: View Of Crankshaft Main Bearing Cap Stiffener

IMPORTANT: The crankshaft main bearing cap stiffener is directional. The end marked
front goes to the front.
7. Install the crankshaft main bearing cap stiffener.
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Fig. 481: View Of Crankshaft Main Bearing Cap Bolts

8. Install new crankshaft main bearing bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the
bottom of the crankshaft main bearing cap is parallel to the block surface.
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Fig. 482: Tightening Sequence For Crankshaft Main Bearing Cap Bolts
9. Tighten the crankshaft main bearing cap bolts in equal increments.
Tighten:
1. Tighten the crankshaft main bearing cap bolts to 25 N.m (18 lb ft) in sequence.
2. Use J 45059 to tighten the crankshaft main bearing cap bolts an additional 180 degrees. See
Special Tools and Equipment.
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Fig. 483: Measuring Crankshaft End Play

10. Measure the crankshaft end play.

1. Thrust the crankshaft forward or rearward.
2. Insert a feeler gage between the thrust crankshaft bearing and the bearing surface of the crankshaft
and measure the bearing clearance. Refer to Engine Mechanical Specifications for the proper
clearance.
3. If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or
raised metal. Minor imperfections may be removed with a fine stone.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Tools Required
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 J 8037 Piston Ring Compressor. See Special Tools and Equipment.
 J 41556 Connecting Rod Guide. See Special Tools and Equipment.
Fig. 484: View Of Connecting Rods & Caps

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at Bottom Dead
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Center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Install J 8037 onto the piston and ring assembly to compress the rings. See Special Tools and
Equipment.
6. Install the connecting rod bearings into the connecting rods and caps (1).
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Fig. 485: Lubricating Connecting Rod Bearing Contact Surface

7. Lubricate the connecting rod bearing contact surfaces with engine oil (2).
8. Install the J 41556 into the connecting rod. See Special Tools and Equipment.
Fig. 486: View Of Piston Alignment Mark & Flat Casting Boss
IMPORTANT: The piston and cylinder bore have been measured and the bore has been
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sized for the proper clearance. Install the piston and connecting rod
assembly into the proper cylinder bore. The piston alignment mark MUST
face the front of the engine block (1) or the flat casting boss (2).
9. Install the connecting rod and piston into the proper cylinder bore.
Fig. 487: Tapping Piston Rings Into Cylinder Bore

10. 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. See Special Tools and Equipment.
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Fig. 488: View Of Connecting Rod, Cap & Bolts

11. Guide the connecting rod end onto the crankshaft journal.
Use J 41556 to pull the connecting rod into place. See Special Tools and Equipment.
12. Install the connecting rod bearing, cap, and bolts.
Tighten:
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1. Tighten the connecting rod bearing cap bolts on the first pass to 25 N.m (18 lb ft).
2. Use J 45059 to tighten the connecting rod bearing cap bolts on the second pass an additional 110
degrees. See Special Tools and Equipment.
Fig. 489: Tapping Connecting Rod Assembly Parallel To Crankshaft

13. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod
assembly parallel to the crankshaft.
14. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be
between 0.05-0.35 mm (0.0019-0.0137 in).
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CYLINDER HEAD INSTALLATION
Tools Required

1. Install the dowel pins (cylinder head locator) (if necessary).

2. Install a new cylinder head gasket.
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3. Install the cylinder head.
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4. Install new cylinder head bolts.
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Fig. 493: View Of Tightening Sequence For Cylinder Head Bolts

5. Tighten the new cylinder head bolts in the following sequence:
Tighten:
1. Tighten the (14) long cylinder head bolts in sequence to 30 N.m (22 lb ft).
2. Use J 45059 to tighten the cylinder head bolts in sequence an additional 155 degrees. See Special
3. Tighten the (2 Short) end bolts to 7 N.m (62 lb in).
Use J 45059 to tighten the short cylinder head end bolts an additional 60 degrees. See Special
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4. Tighten the (1 Long) end bolt to 7 N.m (62 lb in).
Use J 45059 to tighten the long cylinder head end bolt an additional 120 degrees. See Special
VALVE ROCKER ARM AND VALVE LASH ADJUSTER INSTALLATION

1. Lubricate and fill the valve lash adjusters with engine oil.
2. Install the valve lash adjusters in their original locations.
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3. Lubricate the valve rocker arm roller, needle bearings, valve pallet, and lash adjuster pocket.
4. Install the valve rocker arms in their original locations.
CAMSHAFT INSTALLATION
Tools Required
J 44221 Camshaft Holding Tool. See Special Tools and Equipment.
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1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil.
2. Install the exhaust camshaft.
3. Install the intake camshaft.
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Fig. 497: Installing J 44221 Onto Camshafts

4. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See Special Tools
and Equipment.
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IMPORTANT: Install the same camshaft cap onto the same camshaft journal from which
it was removed. The camshaft caps are pin stamped for direction and
numerical order.
5. Install the exhaust camshaft caps.

6. Install the intake camshaft caps.
7. Install the camshaft cap bolts.
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ENGINE LIFT BRACKET INSTALLATION
Fig. 499: View Of Engine Lift Bracket Bolts

1. Install the engine lift bracket.
2. Install the engine lift bracket bolts in sequence.
Tighten: Tighten the engine lift bracket bolts in sequence to 50 N.m (37 lb ft)
TIMING CHAIN TENSIONER INSTALLATION

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1. Install the timing chain tensioner.
2. Install the timing chain tensioner bolts.
Tighten: Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
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3. Install the timing chain tensioner guide.

4. Install the timing chain tensioner guide bolts.
Tighten: Tighten the timing chain tensioner guide bolts to 14 N.m (124 lb in).
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5. Install the timing chain tensioner shoe.

6. Install the timing chain tensioner shoe bolt.
Tighten: Tighten the timing chain tension shoe bolt to 25 N.m (18 lb ft).
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7. 7. Install the cylinder head access hole plugs.
Tighten: Tighten the cylinder head access hole plugs to 5 N.m (44 lb in).
TIMING CHAIN AND SPROCKETS INSTALLATION
Tools Required
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Fig. 504: View Of J 44221 Installed To Camshafts

1. Install J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. See Special Tools
and Equipment.
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Fig. 505: Installing Timing Chain & Sprockets

2. Compress the tensioner and lock in place.

3. Install the crankshaft sprocket.
4. Install the intake camshaft sprocket into the timing chain.
5. Align the (dark) link of the timing chain with the timing mark on the intake camshaft sprocket (1).
6. Feed the timing chain down through the opening in the head.
7. Install the timing chain onto the crankshaft sprocket. Align the (dark) link of the timing chain with the
timing mark on the crankshaft sprocket (2).
Equipment.
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8. Install the intake camshaft sprocket onto the intake camshaft.
Fig. 506: View Of Intake Camshaft Sprocket Washer & Bolt

9. Install the intake camshaft sprocket washer and new bolt.
Tighten:
 Tighten the new intake camshaft sprocket bolt the first pass to 20 N.m (15 lb ft).
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 Use J 45059 to tighten the intake camshaft sprocket bolt the final pass an additional 100 degrees.
Fig. 507: Aligning Exhaust Camshaft Position Actuator

11. Align the (dark) link of the timing chain with the timing mark on the exhaust camshaft actuator (1).
Equipment.
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13. Install the new exhaust camshaft actuator bolt.
Tighten:
 Tighten the new exhaust camshaft actuator bolt the first pass to 25 N.m (18 lb ft).
 Use J 45059 to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees.
14. Unlock the tensioner.

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IMPORTANT: Rotate the camshaft actuator clockwise relative to the camshaft prior to
tightening the bolt.
16. Rotate the camshaft actuator clockwise (as seen from the front of the vehicle).
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Fig. 509: View Of Timing Chain Aligning Marks

17. The dark links (1) on the chain should be aligned with marks on sprockets as shown.
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19. Add threadlock to the top chain guide bolt threads.
Tighten: Tighten the top chain guide bolts to 10 N.m ( 89 lb in).
CAMSHAFT COVER INSTALLATION
1. Install a new camshaft cover seal.
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2. Install the camshaft cover and bolts.
Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
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Fig. 512: View Of Ignition Control Modules & Bolts

3. Install new ignition control module seals.

4. Install the ignition control modules and bolts.
Tighten: Tighten the ignition control module bolts to 10 N.m (89 lb in).
CAMSHAFT POSITION ACTUATOR VALVE INSTALLATION
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Fig. 513: View Of Camshaft Position Actuator Valve & Bolt

1. Apply clean engine oil to the camshaft position actuator valve hole.
2. Install the camshaft position actuator valve.
3. Add sealant to the camshaft position actuator valve bolt threads.
4. Install the camshaft position actuator valve bolt.
Tighten: Tighten the camshaft position actuator valve bolt to 10 N.m (89 lb in).
CRANKSHAFT FRONT OIL SEAL INSTALLATION

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Tools Required
J 44218 Seal Installer. See Special Tools and Equipment.
Fig. 514: Installing Crankshaft Front Oil Seal Using J 44218

1. Apply engine oil to the outside diameter of the crankshaft front oil seal.
2. Use J 44218 to install the crankshaft front oil seal. See Special Tools and Equipment.
OIL PUMP INSTALLATION
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1. Install the oil pump pressure relief valve and spring.
2. Install the oil pump pressure relief valve plug.
Tighten: Tighten the oil pump pressure relief valve plug to 14 N.m (124 lb in).
3. Install the oil pump outer and inner gears as removed.

4. Install the oil pump cover.
5. Install the oil pump cover bolts.
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Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
ENGINE FRONT COVER INSTALLATION
Tools Required
J 44219 Engine Cover Alignment Pins. See Special Tools and Equipment.
Fig. 516: View Of Crankshaft Snout, Balancer Friction Washer & Bolt
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1. Install the engine front cover spacer bolt.
Tighten: Tighten the engine front cover spacer bolt to 10 N.m (89 lb in).
2. Install the crankshaft balancer friction washer over the crankshaft snout, up against the crankshaft gear.
Fig. 517: Installing J 44219 Into Engine Block

3. Install J 44219 . See Special Tools and Equipment.
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Fig. 518: View Of Engine Front Cover

IMPORTANT: The engine front cover must be installed within 10 minutes from when the
sealer was applied.
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4. Apply a 3 mm (0.12 in) bead of sealer to the back side of the engine front cover (1).
5. Align the oil pump to the crankshaft sprocket splines.
6. Install the engine front cover.
8. Install the engine front cover bolts.
Tighten:
1. Tighten the engine front cover bolts to 10 N.m (89 lb in).
2. Tighten the small center bolt (1) last to 10 N.m (89 lb in).
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WATER PUMP INSTALLATION
Tool Required
J 41240 Fan Clutch Remover and Installer. See Special Tools and Equipment.
Fig. 520: View Of Water Pump & Bolts

1. Install the water pump gasket.

2. Install the water pump.
3. Install the water pump bolts.
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Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
Fig. 521: Tightening Water Pump Pulley Bolts

4. Install the water pump pulley.

5. Install the water pump pulley bolts.
6. Install J 41240 to hold pulley. See Special Tools and Equipment.
7. Tighten the water pump pulley bolts.
Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
CRANKSHAFT REAR OIL SEAL AND HOUSING INSTALLATION
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Tools Required
J 44219 Housing Alignment Pins. See Special Tools and Equipment.
Fig. 522: View Of Rear Oil Seal Housing

1. Apply a 3 mm (0.12 in) bead of to the rear oil seal housing (1).
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Fig. 523: View Of J 44219 Installed In Engine Block

2. Install J 44219 into the block. See Special Tools and Equipment.
IMPORTANT: With the help of the plastic installation aid (supplied with the new seal), be
sure the lip of the seal faces inward.
3. Slide the crankshaft rear oil seal housing over the alignment pins (J 44219 ) and crankshaft. See Special
4. Install the crankshaft rear oil seal housing bolts (except the two in place of the guide pins).
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6. Install the remaining two crankshaft rear oil seal housing bolts.
Tighten: Tighten the crankshaft rear oil seal housing bolts to 10 N.m (89 lb in).
Fig. 524: View Of Oil Pan Sealing Area

7. Wipe off any excess material from the bottom of the oil pan sealing area (1).
OIL PUMP PIPE AND SCREEN ASSEMBLY INSTALLATION
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Fig. 525: View Of Oil Pump Pipe, O-Ring & Bolts

1. Install a new oil pump pipe O-ring/gasket (419) - model dependent.

2. Install the oil pump pipe and screen assembly.
3. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil pump pipe bolt threads.
4. Install the oil pump pipe and screen assembly bolts.
Tighten: Tighten the oil pump pipe and screen assembly bolts to 10 N.m (89 lb in).
OIL PAN INSTALLATION
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Fig. 526: Applying Sealant To Block

1. Apply a 3 mm (0.12 in) bead of sealer to the block.
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Fig. 527: View Of Oil Pan & Bolts

IMPORTANT: The oil pan must be installed within 10 minutes from when the sealer was
applied.
2. Install the oil pan.

3. Install the oil pan bolts.
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Fig. 528: Inspecting Oil Pan Alignment

IMPORTANT: When installing the oil pan, it could be shifted front or back a little which
could cause a transmission alignment problem. The back of the oil pan
needs to be flush with the block.
4. Check the oil pan alignment. Use a straight edge on the back of the block and oil pan (transmission
mounting surface).
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5. Tighten the oil pan bolts.
Tighten:
 Tighten the (side) oil pan bolts to 25 N.m (1 lb ft).
 Tighten the (end) oil pan bolts to 10 N.m (89 lb in).
6. Install the oil level sensor.

7. Install the oil level sensor bolt.
Tighten: Tighten the oil level sensor bolt to 10 N.m (89 lb in).
CRANKSHAFT BALANCER INSTALLATION
Tools Required

 J 41478 Crankshaft Balancer Installer. See Special Tools and Equipment.
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Fig. 529: Installing Crankshaft Balancer Using J 41478

1. Install the crankshaft balancer using J 41478 . See Special Tools and Equipment.
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Fig. 530: View Of Crankshaft Balancer

3. Hold the flywheel or back of the crankshaft. The crankshaft balancer does not have a keyway so the
crankshaft could turn when tightening, causing an improper torque.
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IMPORTANT: Be sure the crankshaft balancer friction washer, was installed prior to the
engine front cover installation.
4. Install the crankshaft balancer washer and new bolt.
Tighten:
1. Tighten the new crankshaft balancer bolt while holding the back to 150 N.m (110 lb ft).
2. Use J 45059 to tighten the crankshaft balancer bolt an additional 180 degrees. See Special Tools
and Equipment.
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FUEL RAIL AND INJECTORS INSTALLATION
Fig. 532: View Of Fuel Injector Rail & Bolts

1. Lubricate the lower injector O-rings with mineral oil.

2. Install the fuel injector rail.
3. Install the fuel injector rail bolts.
Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
INTAKE MANIFOLD INSTALLATION
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1. Install a new intake manifold gasket.
2. Install the intake manifold and bolts.
Tighten: Tighten the intake manifold bolts from the inside out to 16 N.m (12 lb ft).
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3. Lubricate the inner diameter of the ends of PCV hose with lubricant.
4. Install the PCV hose.
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Fig. 535: View Of Throttle Control Module & Bolts

5. Install a new throttle control module gasket.

6. Install the throttle control module.
7. Add sealer to the throttle control module bolt threads.
NOTE: Refer to in Cautions and Notices.
8. Install the throttle control module bolts.
Tighten: Tighten the throttle control module bolts to 10 N.m (89 lb in).
THERMOSTAT HOUSING INSTALLATION
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Fig. 536: View Of Thermostat Housing & Bolts

1. Install the thermostat housing.
2. Install the thermostat housing bolts.
Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).
HEATER INLET HOSE FITTING INSTALLATION

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Fig. 537: View Of Heater Inlet Hose Fitting

1. Apply sealant to the heater inlet hose fitting threads.
2. Install the heater inlet hose fitting.
Tighten: Tighten the heater inlet hose fitting to 45 N.m (33 lb ft).
HEATER OUTLET HOSE FITTING INSTALLATION
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Fig. 538: View Of Heater Outlet Hose Fitting

1. Apply sealant to the heater outlet hose fitting threads.
2. Install the heater outlet hose fitting.
Tighten: Tighten the heater outlet hose fitting to 45 N.m (33 lb ft).
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WATER OUTLET INSTALLATION
Fig. 539: View Of Water Outlet

1. Install the water outlet.
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2. Install the water outlet bolts.
Tighten: Tighten the water outlet bolts to 10 N.m (89 lb in).
OIL FILTER ADAPTER INSTALLATION

1. Install the oil filter bypass valve.
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2. Install the oil filter adapter.
Tighten: Tighten the oil filter adapter to 50 N.m (37 lb ft).
EXHAUST MANIFOLD INSTALLATION
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Fig. 542: View Of Exhaust Manifold Gasket

1. Install the exhaust manifold gasket.
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Fig. 543: View Of Exhaust Manifold & Bolts

2. Install the exhaust manifold.

3. Add threadlock to the exhaust manifold bolt threads.
4. Install the exhaust manifold bolts.
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Fig. 544: Tightening Exhaust Manifold Bolts

5. Tighten the exhaust manifold bolts.
Tighten:
1. Tighten the exhaust manifold bolts a first pass in sequence to 25 N.m (18 lb ft).
2. Tighten the exhaust manifold bolts a second pass in sequence to 25 N.m (18 lb ft).
3. Tighten the exhaust manifold bolts a final pass in sequence to 25 N.m (18 lb ft).
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Fig. 545: View Of Exhaust Manifold Studs

6. Install the exhaust manifold heat shield studs (if required).
Tighten: Tighten the exhaust manifold heat shield studs to 10 N.m (89 lb in).
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Fig. 546: View Of Exhaust Manifold Heat Shield & Nuts

7. Install the exhaust manifold heat shield.

8. Add anti-seize to the exhaust manifold heat shield nuts.
9. Install the exhaust manifold heat shield nuts.
Tighten: Tighten the exhaust manifold heat shield nuts to 10 N.m (89 lb in).
OIL LEVEL INDICATOR AND TUBE INSTALLATION
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1. Install the oil level indicator tube.

2. Add sealant to the oil level indicator tube stud threads.
3. Install the oil level indicator tube stud.
Tighten: Tighten the oil level indicator tube stud to 10 N.m (89 lb in).
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4. Install the oil level indicator.
POWER STEERING PUMP BRACKET INSTALLATION
Fig. 548: View Of Power Steering Pump Bracket & Bolts

1. Install the power steering pump bracket.
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2. Install the power steering pump bracket bolts.
Tighten: Tighten the power steering pump bracket bolts to 50 N.m (37 lb ft).
DRIVE BELT TENSIONER INSTALLATION
Fig. 549: View Of Drive Belt Tensioner & Bolt

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt.

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Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
DRIVE BELT IDLER PULLEY INSTALLATION
Fig. 550: View Of Drive Belt Idler Pulley & Bolts

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolts.
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Tighten: Tighten the drive belt idler pulley bolts to 50 N.m (37 lb ft).
CRANKSHAFT REAR OIL SEAL INSTALLATION
Tools Required
J 44227 Rear Seal Installer. See Special Tools and Equipment.
Fig. 551: Installing Crankshaft Rear Oil Seal Using J 44227

1. Use the plastic installation sleeve supplied with the new seal when installing a new seal.
Use J 44227 to install the crankshaft rear oil seal. See Special Tools and Equipment.
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ENGINE FLYWHEEL INSTALLATION
Tools Required

1. Install the flywheel.

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2. Install new flywheel bolts.
Tighten:
1. Tighten the new flywheel bolts to 25 N.m (18 lb ft).
2. Use J 45059 to tighten the flywheel bolts an additional 50 degrees. See Special Tools and
Equipment.
DESCRIPTION AND OPERATION

CRANKCASE VENTILATION SYSTEM DESCRIPTION
A closed crankcase ventilation system is used in order to provide a more complete scavenging of crankcase
vapors. Fresh air from the throttle body is supplied to the crankcase, mixed with blow-by gases, and then passed
through a crankcase ventilation pipe/passage into the intake manifold.
Results of Incorrect Operation
A plugged PCV Pipe/passage way may cause:
 Rough idle
 Stalling or slow idle speed
 Oil leaks
 Sludge in engine
DRIVE BELT SYSTEM DESCRIPTION
The drive belt system consists of the following components:
 The drive belt

 The drive belt tensioner
 The drive belt idler pulley
 The crankshaft balancer pulley
 The accessory drive component mounting brackets
 The accessory drive components
 The power steering pump, if belt driven
 The generator
 The A/C compressor, if equipped
 The engine cooling fan, if belt driven
 The water pump, if belt driven
 The vacuum pump, if equipped
 The air compressor, if equipped
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The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has
several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain
accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and
have different layers or plys containing either fiber cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When the back side
of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The
spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from
slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive
components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the
accessory.
ENGINE COMPONENT DESCRIPTION
Engine Block
The lost foam all aluminum engine block utilizes a deep skirt design for increased rigidity. The cylinders are
positioned in a straight in-line 6 cylinder orientation. The crankshaft bearing caps have a bearing beam or
"ladder" for enhanced structural rigidity and vibration reduction.
Oil Pan
A single piece cast aluminum oil pan contributes to crankshaft and block rigidity while reducing overall weight.
The oil pan bolts to the bell housing as well as the block. This eliminates points of vibration and makes the
complete powertrain act as a single casting. Jack screws are used to remove the oil pan.
Crankshaft
The crankshaft is a nodular iron design with seven main bearings.
Connecting Rods
The connecting rods are forged powdered metal. The connecting rods and caps are of a fractured split design to
improve durability and reduce internal friction. Care must be taken to ensure the mating surfaces are not
damaged during service procedures.
Pistons
The pistons are a full-floating design. The piston pins are a slip fit in the bronze bushed connecting rod and are
retained in the piston by round wire retainers. There are two compression rings and one oil control ring.
Cylinder Head
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The cylinder head is also made of the lost foam aluminum for lighter weight and rapid heat dissipation. There
are 4 valves per cylinder and the ports are of a high swirl design for improved combustion. The cylinder head
gasket consist of a steel laminated construction.
Valve Train
The engine utilizes dual overhead camshafts and roller followers for reduced friction, which results in improved
gas mileage.
Fuel System
A new electronic throttle control system is used on the engine. A throttle actuator control or TAC system
eliminates cable linkage from the pedal to the throttle control module. All throttle movements are controlled by
the PCM.
Oil Pump
The oil pump is gear driven directly from the crankshaft. The oil pump drive gear is a slip fit to the crankshaft.
Engine Covers
There is a front engine cover and a rear engine cover, both are made of aluminum. The front engine cover and
rear engine cover have "T" sealing joints and need to be removed after the oil pan. The front and rear covers
need to be installed before the oil pan. Jack screws are used to remove the covers. Guide pins are used to aid in
the installation of both covers.
EXHAUST CAMSHAFT POSITION ACTUATOR DESCRIPTION
The camshaft position actuator is bolted to the front of the exhaust camshaft and is integral with the sprocket.
The actuator and sprocket can only be replaced as one unit. The actuator has a hydraulically actuated piston
located in the hub. The piston has an internal helical spline that slides in mesh with the gear. As the piston
moves, the piston and gear mechanism changes the timing of the exhaust camshaft, relative to the cam drive
sprocket. When oil pressure is applied to one side of the piston, the cam moves clockwise and timing is
advanced. When oil pressure is applied to the other side of the piston the cam moves counter-clockwise to
retard timing. The total range of actuator rotation is 0 to 25 camshaft degrees. At idle, the exhaust camshaft
position actuator is at full advance or 0 degrees.
NEW PRODUCT INFORMATION
The purpose of New Product Information is to highlight or indicate important new features for the service
community.
Changes may include one or more of the following items:
 Torque values and/or fastener tightening strategies

 Engine specifications
 New sealants and/or adhesives
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 Disassembly and assembly procedure revisions

 Engine mechanical diagnostic procedure revisions
 Special tools required
New Features on the LL8 Engine
 Pan-axle design oil pan

 Exhaust camshaft position actuator
 Exhaust camshaft position actuator valve
 Jack bolts on the front cover, rear cover, and oil pan
Engine Features
 Powder metal connecting rods

 Full floating piston pins
 Lost foam casted aluminum block and head
 Composite plastic camshaft cover
 Electronic Throttle Control - ETC
 Composite intake manifold
 Bridge/bearing beam - stiffener ladder
 Stainless steel fuel rail
 Coil-on-plug ignition system
 Inlet side thermostat
 No EGR
 No AIR
New Special Tools Required
 J 44217 Timing chain holding tool

 J 44218 Front seal installation tool
 J 44219 Cover alignment pins
 J 44220 Engine lift bracket
 J 44221 Camshaft holding tool
 J 44222 Camshaft actuator and sprocket holding tool
 J 44226 Crankshaft damper holding and removal tool
 J 22227 Rear main seal installation tool
LUBRICATION DESCRIPTION
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Fig. 553: View Of Engine Lubrication System

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The engine lubrication system is of the force-feed type. The oil is supplied under full pressure to the crankshaft,
connecting rods, valve lash adjusters, and cam phasing system. A controlled volume of oil is supplied to the
camshaft and valve rocker arms. Gravity flow or splash lubricates all other parts. The engine oil is stored in the
oil pan, which is filled through a fill cap in the camshaft cover. A removable oil level indicator, on the right side
of the engine block, is provided to check the oil level. The oil pump is located in the engine front cover and is
driven by the crankshaft. It is a gerotor-style pump, which is a combination of a gear, and a rotor pump.
It is connected by a passage in the cylinder block to an oil screen and pipe assembly. The screen is submerged
in the oil supply and has ample volume for all operating conditions. Oil is drawn into the pump through the
screen and pipe assembly, and a passage in the crankcase, connecting to the passages in the engine front cover.
Oil is discharged from the oil pump to the oil filter. The oil pressure relief valve limits the oil pressure. The oil
filter bypass valve opens when the oil filter is restricted to approximately 68.95 kPa (10 psi) of pressure
difference between the oil filter inlet and discharge. The oil will then bypass the oil filter and channel unfiltered
oil directly to the main oil galleries of the engine. A full-flow oil filter is mounted to the oil filter adapter on the
lower right front side of the engine. The main oil galleries run the full length of the engine block and cut into
the valve lash adjuster holes to supply oil at full pressure to the valve lash adjusters. Holes are drilled from the
crankshaft bearings to the main oil gallery. Oil is transferred from the crankshaft bearings to the connecting rod
bearings through holes drilled in the crankshaft. Pistons, piston pins, and cylinder walls are lubricated by oil
splash from the crankshaft and connecting rods. The camshafts and valve rocker arms are supplied with oil from
the oil passages drilled into the camshaft mounting areas.
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:
 Machined
 Honed
 Polished
 Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal
engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during
assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice
proper cleaning and protection procedures to the machined surfaces and to the friction areas.
NOTE: Engine damage may result if an abrasive paper, pad, or motorized wire brush is
used to clean any engine gasket surfaces.
Whenever you remove the valve train components, keep the components in order. Follow this procedure in
order to install the components in the same locations and with the same mating surfaces as when removed.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
Disconnect the negative battery cables before you perform any major work on the engine. For more information
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on the disconnection of the battery, refer to Engine Electrical.
SEPARATING PARTS
The components of an internal combustion engine develop wear patterns with their mating components. During
disassembly of the engine, parts should be separated and kept in order so they may be reinstalled in the same
location from which they were removed.
REPLACING ENGINE GASKETS
1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service
procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service
procedure.
2. Use jack screws to separate components.
IMPORTANT: Do not use any other method or technique in order to remove the gasket
material from a components.
Do not use the following items in order to clean the gasket surfaces:
 Abrasive pads
 Sand paper
 Power tools
These methods of cleaning may damage the component.

Abrasive pads also produce a fine grit that the oil filter cannot remove
from the oil. This grit is abrasive and may cause internal engine damage.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper.
Do not gouge or scrape the sealing surfaces.
IMPORTANT: Do not allow the sealant to enter any blind threaded holes. The sealant
may cause the following conditions:
 Prevent you from properly seating the bolt

 Cause damage when you tighten the bolt
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the
sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead
size as specified in the service procedure.
5. Tighten the bolts to the specifications.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALER
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IMPORTANT: The correct sealant and amount of sealant must be used in the proper location
to prevent oil leaks, coolant leaks, or the loosening of the fasteners. DO NOT
interchange the sealants. Use only the sealant (or equivalent) as specified in
the service procedure.
Sealant Types
The following 2 major types of sealant are commonly used in engines:
 Aerobic sealant (Room Temperature Vulcanizing (RTV))

 Anaerobic sealant, which include the following:
 Gasket eliminator
 Pipe
 Threadlock
Aerobic Type Room Temperature Vulcanizing (RTV) Sealant
Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is
used where 2 components (such as the intake manifold and the engine block) are assembled together.
Use the following information when using RTV sealant:
 Do not use RTV sealant in areas where extreme temperatures are expected. These areas include:
 The exhaust manifold
 The head gasket
 Any other surfaces where a different type of sealant is specified in the service procedure
 Always follow all the safety recommendations and the directions that are on the RTV sealant container.
 Use a plastic or wood scraper in order to remove all the RTV sealant from the components.
IMPORTANT: Do not allow the RTV sealant to enter any blind threaded holes, as it may
prevent the fasteners from clamping properly or cause damage when the
fastener is tightened.
 The surfaces to be sealed must be clean and dry.

 Use a RTV sealant bead size as specified in the service procedure.
 Apply the RTV sealant bead to the inside of any bolt holes areas.
 Assemble the components while the RTV sealant is still wet to the touch. Do not wait for the RTV sealant
to skin over.
 Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT
overtighten the fasteners.
Anaerobic Type Threadlock Sealant
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Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for threadlocking and
sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when confined between 2 close fitting
metal surfaces.
Use the following information when using threadlock sealant:
 Always follow all safety recommendations and directions that are on the threadlock sealant container.
 The threaded surfaces to be sealed must be clean and dry.
 Apply the threadlock sealant as specified on the threadlock sealant container.
IMPORTANT: Fasteners that are partially torqued and then the threadlock sealant
allowed to cure more than five minutes, may result in incorrect clamp load
of assembled components.
Anaerobic Type Pipe Sealant
Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is
used where 2 parts are assembled together and require a leak proof joint.
Use the following information when using pipe sealant:
 Do not use pipe sealant in areas where extreme temperatures are expected. These areas include:
 The exhaust manifold
 The head gasket
 Surfaces where a different sealant is specified
 Always follow all the safety recommendations and the directions that are on the pipe sealant container.
 The surfaces to be sealed must be clean and dry.
 Use a pipe sealant bead of the size or quantity as specified in the service procedure.
IMPORTANT: Do not allow the pipe sealant to enter any of the blind threaded holes, as
the pipe sealant may prevent the fastener from clamping properly, or
cause component damage when the fastener is tightened.
 Apply the pipe sealant bead to the inside of any bolt hole areas.
 Apply a continuous bead of pipe sealant to 1 sealing surface.
TOOLS AND EQUIPMENT
Work in a clean and well-lit area. Have the following components available before you begin to work:
Microsoft
 A suitable parts cleaning tank

 A compressed air supply
 Trays, in order to keep the parts and the fasteners organized
 An adequate set of hand tools
An approved engine repair stand will prevent personal injury or damage to the engine components. The special
tools are designed in order to quickly and safely accomplish the operations for which the tools are intended.
Using the tools will minimize possible damage to the engine components. Precision measuring tools are
required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly
of various parts.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration Tool Number/Description
EN45680-400
Cylinder Sleeve Removal and Installation Kit
J 7872
Magnetic Base Dial Indicator Set
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J 8001
Dial Indicator Set
J 8037
Piston Ring Compressor
J 8062
Valve Spring Compressor (Head-Off)
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J 8087
Cylinder Bore Gage
J 9666
Valve Spring Tester
J 21867
Pressure Gage and Hose
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J 28428-E
High Intensity Black Light
J 35667-A
Cylinder Head Leakdown Tester
Microsoft
J 38722
Compression Tester
J 38820
Valve Stem Seal Remover/Installer
J 41240
Fan Clutch Remover and Installer
J 41478
Crankshaft Front Oil Seal Installer
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J 41556
Connecting Rod Guides
J 41816-2
Crankshaft End Protector
J 42037
Valve Spring Compressor Adapter
Microsoft
J 42385-400
Thread Repair Kit
J 42907
Oil Pressure Tester
J 43654
Piston Pin Retainer Clip Remover/Installer
J 43965
Thread Repair Extension Kit
Microsoft
J 44217
Timing Chain Retention Tool
J 44218
Seal Installer
J 44219
Cover Alignment Pins
Microsoft
J 44220
Engine Lift Bracket
J 44221
Camshaft Holding Tool
J 44222
Camshaft Sprocket Holding Tool
J 44226
Crankshaft Balancer Remover
Microsoft
J 44227
Rear Seal Installer
J 44228
Valve Spring Compressor
Microsoft
J 44299
Engine Preluber
J 45059
Angle Meter
Microsoft

2004 ENGINE Engine Mechanical - 4.2L

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2004 ENGINE Engine Mechanical - 4.2L

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2004 Isuzu Ascender LS

2004 ENGINE Engine Mechanical - 4.2L - Ascender

Engine Mechanical - 4.2L - Ascender

Fastener Tightening Specifications

Cylinder Head End Bolts - 1 Long

 First Pass 20 N.m 15 lb ft

ENGINE MECHANICAL SPECIFICATIONS

Engine Mechanical Specifications

 Piston Ring to Groove Clearance - Oil 0.059-0.215 mm 0.0023-0.0085 in

SEALERS, ADHESIVES, AND LUBRICANTS

Sealers, Adhesives, and Lubricants

Oil Level Indicator Tube Stud Sealant

THREAD REPAIR SPECIFICATIONS

Engine Block - Top View

Fig. 1: Engine Block Thread Repair - Top View

Engine Block - Top View

3 M 11 x 2 402 n/a n/a 403 404 108 59 2.324 51 2.009

Engine Block - Bottom View

Fig. 2: Engine Block Thread Repair - Bottom View

Engine Block - Bottom View

Hole Thread Counterbore Stop Drill Depth Tap Depth

Engine Block - Left Side View

Fig. 3: Engine Block Thread Repair - Left Side View

Engine Block - Left Side View

Engine Block - Right Side View

Fig. 4: Engine Block Thread Repair - Right Side View

Engine Block - Right Side View

16 16 x 1.5 206 207 n/a 208 209 210 32 1.260 23 0.906

Engine Block - Front View

Fig. 5: Engine Block Thread Repair - Front View

Engine Block - Front View

10 6x1 405 n/a 407 203 204 205 30 1.182 26 1.024

Engine Block - Rear View

Fig. 6: Engine Block Thread Repair - Rear View

Engine Block - Rear View

Cylinder Head - Top View

Fig. 7: Cylinder Head Thread Repair - Top View

Cylinder Head - Top View

37 M6x1 405 n/a 406 203 204 205 28 1.103 24 0.945

Cylinder Head - End View (Front)

Fig. 8: Cylinder Head Thread Repair - End View (Front)

Cylinder Head - End View (Front)

Cylinder Head - End View (Rear)

Fig. 9: Cylinder Head Thread Repair - End View (Rear)

Cylinder Head - End View (Rear)

Cylinder Head - Intake Manifold Deck View

Cylinder Head - Intake Manifold Deck View

Cylinder Head - Exhaust Manifold Deck View

Cylinder Head - Exhaust Manifold Deck View

Oil Pan - Top View

Fig. 12: Oil Pan Thread Repair - Top View

Oil Pan - Top View

Oil Pan - Left Side View

Fig. 13: Oil Pan Thread Repair - Left Side View

Oil Pan - Left Side View

Oil Pan - Right Side View

Fig. 14: Oil Pan Thread Repair - Right Side View

Oil Pan - Right Side View

Oil Pan - Rear View