< Назад | Содержимое | Далее >

‌ENGINE

Engine Mechanical - 1.5L (L3A) - Volt

SPECIFICATIONS

FASTENER SPECIFICATIONS

Single Use Non-Threaded Fasteners/Components

NOTE:

All fasteners/components listed in this table MUST BE DISCARDED and

replaced with NEW after removal.

Application

Camshaft Cover Gasket

Connecting Rod Bearing

Crankshaft Front Oil Seal

Exhaust Gas Recirculation Cooler Inlet Pipe Gasket

Exhaust Gas Recirculation Cooler Outlet Pipe Gasket

Exhaust Gas Recirculation Pipe Gasket

Exhaust Gas Recirculation Valve Gasket

Fuel Injector Seal

Intake Manifold Gasket

Oil Pan Drain Plug Seal

Positive Crankcase Ventilation Tube with Positive Crankcase Ventilation Valve - Fresh Air

Throttle Body Gasket

Valve Stem Oil Seal

Water Outlet Gasket

Water Pump Housing Gasket

Single Use Threaded Fastener/Component Tightening Specifications

NOTE:

All fasteners/components listed in this table MUST BE DISCARDED and

replaced with NEW after removal.


Application

Specification

Metric (English (USA))

Automatic Transmission Flex Plate Bolt

image First Pass:

30 N.m (22 lb ft)

NOTE:

All fasteners/components listed in this table MUST BE DISCARDED and

replaced with NEW after removal.


Application

Specification

Metric (English (USA))

image Final Pass:

70 Degrees

Camshaft Position Actuator Bolt

image First Pass:

20 N.m (15 lb ft)

image Final Pass:

90 Degrees

Catalytic Converter Stud1

10 N.m (89 lb in)1

Connecting Rod Bolt

image First Pass:

25 N.m (18 lb ft)

image Final Pass:

75 Degrees

Crankshaft Balancer Bolt

image First Pass:

100 N.m (74 lb ft)

image Final Pass:

180 Degrees

Cylinder Head Bolt

image First Pass:

30 N.m (22 lb ft)

image Final Pass:

240 Degrees

Engine Mount Bracket Bolt

image First Pass:

58 N.m (43 lb ft)

image Final Pass:

90 - 105 Degrees

Engine Mount Bolt

image First Pass:

100 N.m (74 lb ft)

image Final Pass:

60 - 75 Degrees

Fuel Feed Intermediate Pipe

30 N.m (22 lb ft)

Fuel Pump Bolt

25 N.m (18 lb ft)

Lower Crankcase Bolt

NOTE:

All fasteners/components listed in this table MUST BE DISCARDED and

replaced with NEW after removal.


Application

Specification

Metric (English (USA))

image First Pass:

15 N.m (11 lb ft)

image Final Pass:

180 Degrees


Oil Filter

3/4 to 1 full turn after gasket makes contact with the sealing surface on the filter mounting flange

Positive Crankcase Ventilation Valve Bolt

10 N.m (89 lb in)

Reusable Threaded Fastener Tightening Specifications


Application

Specification

Metric (English)

NOTE:

All fasteners listed in this table can be reused after removal.

Air Conditioning Compressor Bolt

19 - 25 N.m (14 - 18 lb ft)

Air Conditioning Compressor Bracket Bolt

19 - 25 N.m (14 - 18 lb ft)

Air Conditioning Compressor Bracket Stud

5 - 11 N.m (44 - 97 lb in)

Air Conditioning Compressor Nut

19 - 25 N.m (14 - 18 lb ft)

Air Conditioning Compressor Stud

8 N.m (71 lb in)

Balance Chain Guide Bolt

10 N.m (89 lb in)

Belt Idler Pulley Bracket Bolt

19 - 25 N.m (14 - 18 lb ft)

Camshaft Bearing Cap Bolt

12 N.m (106 lb in)

Camshaft Bearing Front Cap Bolt

12 N.m (106 lb in)

Camshaft Cover Bolt

15 N.m (11 lb ft)

Camshaft Housing Cover Stud

10 N.m (89 lb in)

Camshaft Cover Stud

15 N.m (11 lb ft)

Camshaft Position Actuator Solenoid Valve Bolt

10 N.m (89 lb in)

Camshaft Position Sensor Bolt

10 N.m (89 lb in)

Catalytic Converter Brace Bolt

22 N.m (16 lb ft)

Catalytic Converter Brace Bracket Bolt

22 N.m (16 lb ft)

Catalytic Converter Heat Shield Bolt

9 N.m (80 lb in)

Catalytic Converter Nut

25 N.m (18 lb ft)

Crankshaft Oil Deflector Bolt

10 N.m (89 lb in)


Application

Specification

Metric (English)

Crankshaft Position Sensor Bolt

10 N.m (89 lb in)

Cylinder Head Core Hole Plug

25 N.m (18 lb ft)

Cylinder Head Core Hole Plug

75 N.m (55 lb ft)

Engine Block Oil Gallery Plug

45 N.m (33 lb ft)

Engine Block Oil Gallery Plug

65 N.m (48 lb ft)

Engine Block Coolant Drain Hole Plug

60 N.m (44 lb ft)

Engine Coolant Thermostat Housing Bolt

10 N.m (89 lb in)

Engine Control Module (ECM) Wiring Harness Ground Bolt

10 N.m (89 lb in)

Engine Front Cover Bolt - M6

15 N.m (11 lb ft)

Engine Front Cover Bolt - M10

58 N.m (43 lb ft)

Engine Front Cover Bolt - M14

58 N.m (43 lb ft)

Engine Front Cover Hole Plug

50 N.m (37 lb ft)

Engine Front Cover Stud

15 N.m (11 lb ft)

Engine Lift Bracket Bolt

25 N.m (18 lb ft)

Engine Oil Pressure Sensor

35 N.m (29 lb ft)

Engine Wiring Harness Bracket Bolt

25 N.m (18 lb ft)

Engine Wiring Harness - Wiring Harness Connector Bolt

10 N.m (89 lb in)

Evaporative Emission Canister Purge Solenoid Valve Bolt

10 N.m (89 lb in)

Exhaust Gas Recirculation Cooler Bolt

10 N.m (89 lb in)

Exhaust Gas Recirculation Cooler Inlet Pipe Bolt

10 N.m (89 lb in)

Exhaust Gas Recirculation Cooler Outlet Pipe Bolt

10 N.m (89 lb in)

Exhaust Gas Recirculation Cooler Temperature Sensor

42 N.m (31 lb ft)

Exhaust Gas Recirculation Valve Bolt

10 N.m (89 lb in)

Fuel Feed Intermediate Pipe Bolt

10 N.m (89 lb in)

Fuel Injection Fuel Rail Bolt

10 N.m (89 lb in)

Ignition Coil Bolt

10 N.m (89 lb in)

Intake Manifold Bolt

12 N.m (106 lb in)

Intake Manifold Cover Bolt

7 N.m (62 lb in)

Intake Manifold - Upper Intake Manifold Cover Bolt

8 N.m (71 lb in)

Knock Sensor Bolt

25 N.m (18 lb ft)

Lower Crankcase Bolt - Perimeter

image First Pass:

5 N.m (44 lb in)

image Final Pass:

10 N.m (89 lb in)

Manifold Absolute Pressure Sensor Bolt

10 N.m (89 lb in)

Oil Filter Fitting

55 N.m (41 lb ft)

Oil Pan Drain Plug

25 N.m (18 lb ft)

Oil Pan - Lower Oil Pan Bolt

10 N.m (89 lb in)

Oil Pan - Upper Oil Pan Bolt

10 N.m (89 lb in)

Oil Pump Bolt

10 N.m (89 lb in)

Oil Pump Drive Chain Tensioner Bolt

10 N.m (89 lb in)

Oil Pump Sprocket Bolt


Application

Specification

Metric (English)

image First Pass:

10 N.m (89 lb in)

image Final Pass:

60 Degrees

Oil Pump Suction Pipe Bolt

10 N.m (89 lb in)

Piston Oil Nozzle Bolt

10 N.m (89 lb in)

Positive Crankcase Ventilation Oil Separator Drain Pipe Bolt

10 N.m (89 lb in)

Spark Plug

17 N.m (13 lb ft)

Starter Opening Cover Bolt

25 N.m (18 lb ft)

Thermostat Bypass Pipe Bolt

10 N.m (89 lb in)

Throttle Body Bolt

10 N.m (89 lb in)

Timing Chain Guide Bolt

10 N.m (89 lb in)

Timing Chain Oil Nozzle

15 N.m (11 lb ft)

Timing Chain Tensioner Bolt

25 N.m (18 lb ft)

Timing Chain Tensioner Shoe Bolt

25 N.m (18 lb ft)

Water Outlet Bolt

12 N.m (106 lb in)

Water Pump Bolt

25 N.m (18 lb ft)

APPROXIMATE FLUID CAPACITIES



Application

Specification

Metric

English

L3A, L3G, LE1, LE2, LFV, LV7

Oil Capacity

4.0 L

4.23 quarts

ENGINE MECHANICAL SPECIFICATIONS



Application

Specification

Metric

English

General Data

image Engine Type

4-Cylinder Inline

image Displacement

1.5L

92 CID

image RPO

L3A

image Valves

16

image Bore

74 mm

2.91 in

image Stroke

86.6 mm

3.409 in

image Compression Ratio

12.5:1

image Spark Plug Gap

0.60 - 0.70 mm

0.024 - 0.028 in


Application

Specification

Metric

English

image Firing Order

1 - 3 - 4 - 2

Block

image Crankshaft Main Bearing Bore Diameter

51.868 - 51.882 mm

2.0420 - 2.0426 in

image Cylinder Bore Diameter

73.992 - 74.008 mm

2.913 - 2.914 in

image Cylinder Bore Out-of-Round - Maximum

0.013 mm

0.0005 in

image Cylinder Head Deck Surface Flatness - over 25 mm length


0.025 mm


0.0010 in

image Cylinder Head Deck Surface Flatness - over 150 mm length


0.050 mm


0.0020 in

Engine Block to Bedplate Flatness - overall

0.1 mm

0.004 in

Engine Block to Bedplate Flatness - straightness

0.050 - 0.100 mm

0.0020 - 0.0040 in

Piston Deck Height - Below Deck

0.54 - 0.74 mm

0.021 - 0.029 in

Camshaft

image Camshaft End Play

0.040 - 0.660 mm

0.0016 - 0.0260 in

image Camshaft Journal Clearance

0.040 - 0.085 mm

0.0016 - 0.0033 in

image Camshaft Journal Diameter - Journal 1

30.935 - 30.960 mm

1.2179 - 1.2189 in

image Camshaft Journal Diameter - Journal 2 - 6

23.935 - 23.960 mm

0.9423 - 0.9433 in

image Camshaft Thrust Width - Camshaft with Phaser installed

33.175 - 33.525 mm

1.3061 - 1.3199 in

image Camshaft Thrust Width - Cylinder Head

32.865 - 33.135 mm

1.2939 - 1.3045 in

Connecting Rod

image Connecting Rod Bearing to Crankpin Clearance

0.013 - 0.068 mm

0.0005 - 0.0027 in

image Connecting Rod Bore Diameter - Bearing End

47.186 - 47.202 mm

1.8577 - 1.8583 in

image Connecting Rod Bore Diameter - Pin End w/Bushing

18.007 - 18.017 mm

0.7089 - 0.7093 in

image Connecting Rod Side Clearance

0.090 - 0.350 mm

0.0035 - 0.0138 in

image Connecting Rod Straightness - Bend - Maximum

0.017 mm

0.0007 in

image Connecting Rod Straightness - Twist - Maximum

0.040 mm

0.0016 in

Crankshaft


Application

Specification

Metric

English

image Connecting Rod Journal Diameter

43.992 - 44.008 mm

1.7320 - 1.7326 in

image Connecting Rod Journal Out-of-Round

0.005 mm

0.0002 in

image Crankshaft End Play

0.15 - 0.38 mm

0.0059 - 0.0150 in

image Crankshaft Main Bearing Clearance #1 Bearing

0.011 - 0.070 mm

0.0004 - 0.0028 in

image Crankshaft Main Bearing Clearance # 2, 3, 4 and 5 Bearings


0.012 - 0.067 mm


0.0005 - 0.0026 in

image Crankshaft Main Journal Diameter

46.992 - 47.008 mm

1.8501 - 1.8507 in

image Crankshaft Main Journal Out-of-Round

0.005 mm

0.0002 in

Cylinder Head

image Surface Flatness - Block Deck - in 25 mm

0.025 mm

0.0010 in

image Surface Flatness - Block Deck - in 150 mm

0.050 mm

0.0020 in

image Surface Flatness - Block Deck - between bolts

0.030 mm

0.0012 in

image Surface Flatness - Block Deck - Overall

0.100 mm

0.0039 in

image Valve Guide Bore - Exhaust

5.000 - 5.020 mm

0.1968 - 0.1976 in

image Valve Guide Bore - Intake

5.000 - 5.020 mm

0.1968 - 0.1976 in

image Valve Lifter Bore Diameter - Stationary Lash Adjusters

12.008 - 12.030 mm

0.4728 - 0.4736 in

image Valve Seat Angle - Relief Surface

50 Degrees

image Valve Seat Angle - Seating Surface

90 Degrees

image Valve Seat Angle - Undercut Surface

120 Degrees

image Valve Seat Runout - Maximum

0.080 mm

0.0031 in

Lubrication System

image Oil Pressure - @ 1500 RPM 100°C

200 - 250 kPa

29 - 36 psi

Piston Rings

image Piston Ring End Gap - Top

0.25 - 0.40 mm

0.010 - 0.016 in


Application

Specification

Metric

English

image Piston Ring End Gap - Second

0.40 - 0.60 mm

0.016 - 0.024 in

image Piston Ring End Gap - Oil Control

0.25 - 0.75 mm

0.010 - 0.030 in

image Piston Ring to Groove Clearance - Top

0.03 - 0.08 mm

0.001 - 0.003 in

image Piston Ring to Groove Clearance - Second

0.03 - 0.07 mm

0.001 - 0.003 in

image Piston Ring to Groove Clearance - Oil Control

0.050 - 0.190 mm

0.0020 - 0.0075 in

image Piston Ring Thickness - Top

1.17 - 1.19 mm

0.046 - 0.047 in

image Piston Ring Thickness - Second

1.17 - 1.19 mm

0.046 - 0.047 in

image Piston Ring Thickness - Oil Control - Rail

0.045 - 0.47 mm

0.0018 - 0.0019 in

image Piston Ring Thickness - Oil Control - Spacer

1.67 - 1.79 mm

0.066 - 0.071 in

Pistons and Pins

image Pin - Piston Pin Clearance to Connecting Rod Bore

0.007 - 0.020 mm

0.0003 - 0.0008 in

image Pin - Piston Pin Clearance to Piston Pin Bore

0.002 - 0.010 mm

0.0001 - 0.0004 in

image Pin - Piston Pin Diameter

17.997 - 18.000 mm

0.7085 - 0.7087 in

image Pin - Piston Pin End Play

0.18 - 0.79 mm

0.0071 - 0.0311 in

image Piston - Piston Diameter - @ 38 mm up from crown

73.957 - 73.971 mm

2.9117 - 2.9122 in

image Piston - Piston Pin Bore Diameter

18.002 - 18.010 mm

0.7087 - 0.7091 in

image Piston - Piston Ring Groove Width - Top

1.23 - 1.25 mm

0.0484 - 0.0492 in

image Piston - Piston Ring Groove Width - Second

1.23 - 1.25 mm

0.0484 - 0.0492 in

image Piston - Piston Ring Groove Width - Oil Control

2.03 - 2.05 mm

0.0799 - 0.0807 in

image Piston - Piston to Bore Clearance - w/Polymer

-0.017 mm to +0.029

mm

-0.0007 in to +0.0011

in

Valve System

image Valves - Valve Face Angle

90 Degrees

image Valves - Valve Face Runout - Maximum

0.050 mm

0.0020 in


Application

Specification

Metric

English

image Valves - Valve Seat Runout - Maximum

0.080 mm

0.0031 in

image Valves - Valve Seat Gauge Ball Height - Exhaust

8.85 - 9.09 mm

0.3484 - 0.3579 in

image Valves - Valve Seat Gauge Ball Height - Intake

9.47 - 9.71 mm

0.3728 - 0.3823 in

image Valves - Valve Stem Diameter - Exhaust

4.945 - 4.965 mm

0.1947 - 0.1955 in

image Valves - Valve Stem Diameter - Intake

4.955 - 4.975 mm

0.1951 - 0.1959 in

image Valves - Valve Stem Installed Height

Check and Record

image Valves - Valve Stem to Guide Clearance - Exhaust

0.035 - 0.075 mm

0.0014 - 0.0030 in

image Valves - Valve Stem to Guide Clearance - Intake

0.025 - 0.065 mm

0.0010 - 0.0026 in

image Valve Lash Adjusters - Valve Lash Adjuster Diameter - Stationary Lash Adjuster


11.986 - 12.000 mm


0.4719 - 0.4724 in

image Valve Lash Adjusters - Valve Lash-Adjuster-to-Bore Clearance - Stationary Lash Adjuster


0.008 - 0.044 mm


0.0003 - 0.0017 in

image Valve Springs - Valve Spring Installed Height

34.50 - 35.50 mm

1.358 - 1.398 in

image Valve Springs - Valve Spring Load - Closed - @ 35 mm

215 - 255 N

48 - 57 lb

image Valve Springs - Valve Spring Load - Open - @ 24 mm

405 - 445 N

91 - 100 lb

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS



Application


Type of Material

GM Part Number

United States

Canada

Camshaft Cover1

Sealant

12378521

88901148

Camshaft Lobes

5W-20*

19259486

88863951

Crankshaft Sensor O-Ring

5W-20*

19259486

88863951

Cylinder Bores

5W-20*

19259486

88863951

Cylinder Head Plugs

Threadlocker

19333511

10953489

Engine Block Plugs

Sealant

12346004

10953480

Engine Front Cover1

Sealant

12378521

88901148

Engine Oil

5W-20*

19259486

88863951

Engine Oil - Alternate

0W-20

19259487

19259784

Fuel Injector O-Rings

5W-20*

19259486

88863951

Hydraulic Lash Adjusters

5W-20*

19259486

88863951

Ignition Coils

Lubricant

19260901

19260902


Application


Type of Material

GM Part Number

United States

Canada

Intake and Exhaust Valve Stems

5W-20*

19259486

88863951

Lower Crankcase1

Sealant

12378521

88901148

Lower Crankcase Bolt

Threadlocker

19333511

10953489

Main Bearings

5W-20*

19259486

88863951

Oil Filter

5W-20*

19259486

88863951

Oil Level Indicator Tube O-Ring

Lubricant

88862586

88862827

Oil Pan1

Sealant

12378521

88901148

Oil Pan Bolt

Threadlocker

19333511

10953489

Oil Pump - Pump Elements

5W-20*

19259486

88863951

Oxygen Sensor

Anti-seize

88862477

88862478

Piston Pin to Piston/Rod - Pin Bores of Piston and Rod

5W-20*

19259486

88863951

Rod Bearings - Rod Pins of Crankshaft

5W-20*

19259486

88863951

Thread Repair Cutting Oil

Lubricant

1052864

992881

Thread Repair

Cleaner

88862650

88901247

Timing Chain Guide Bolt Access Hole Plug

Threadlocker

19333511

10953489

Valves

Parts Immersion Solvent

12345368

10953514

Valve Rocker Arm/Valve Tip

5W-20*

19259486

88863951

Water Feed Tube O-Rings

Lubricant

19260901

19260902

Water Pump Drain Plug

Sealant

12346004

10953480

*0W-20 is an approved alternate engine oil for 5W-20, see Engine Oil - Alternate

1 Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

THREAD REPAIR SPECIFICATIONS

Engine Block - Front View

image

Fig. 1: Engine Block - Front View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

420

211

212

213

214

27.0

1.063

27.0

1.063

2

M6x1.0

205

201

202

203

204

20.0

0.787

20.0

0.787

3

Not Serviced

4

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

420

211

212

213

214

27.0

1.063

27.0

1.063

2

M6x1.0

205

201

202

203

204

20.0

0.787

20.0

0.787

3

Not Serviced

4

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

420

211

212

213

214

27.0

1.063

27.0

1.063

2

M6x1.0

205

201

202

203

204

20.0

0.787

20.0

0.787

3

Not Serviced

4

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Courtesy of GENERAL MOTORS COMPANY Engine Block - Front View


Engine Block - Rear View

image

Fig. 2: Engine Block - Rear View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

904

211

212

213

903

36.0

1.417

36.0

1.417

2

M10x1.5

215

211

212

213

214

25.0

0.984

25.0

0.984

3

Not Serviced

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

904

211

212

213

903

36.0

1.417

36.0

1.417

2

M10x1.5

215

211

212

213

214

25.0

0.984

25.0

0.984

3

Not Serviced

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M10x1.5

904

211

212

213

903

36.0

1.417

36.0

1.417

2

M10x1.5

215

211

212

213

214

25.0

0.984

25.0

0.984

3

Not Serviced

Courtesy of GENERAL MOTORS COMPANY Engine Block - Rear View


Engine Block - Right Side View

image

Fig. 3: Engine Block - Right Side View Courtesy of GENERAL MOTORS COMPANY

Engine Block - Right Side View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M14x1.5

735

409

410

411

412

20.0

0.787

20.0

0.787

2

M8x1.25

210

206

207

208

209

37.0

1.457

37.0

1.457

3

M8x1.25

61

206

207

208

209

29.0

1.141

29.0

1.141

Engine Block - Left Side View

image

Fig. 4: Engine Block - Left Side View

Service Call Out


Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M12x1.75

865

856

857

858

859

24.0

0.944

24.0

0.944

2

M10x1.5

420

211

212

213

214

34.0

1.338

34.0

1.338

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out


Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M12x1.75

865

856

857

858

859

24.0

0.944

24.0

0.944

2

M10x1.5

420

211

212

213

214

34.0

1.338

34.0

1.338

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out


Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M12x1.75

865

856

857

858

859

24.0

0.944

24.0

0.944

2

M10x1.5

420

211

212

213

214

34.0

1.338

34.0

1.338

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Courtesy of GENERAL MOTORS COMPANY Engine Block - Left Side View


Engine Block - Bottom View

image

Fig. 5: Engine Block - Bottom View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

Not Serviceable

2

M6x1.0

205

201

202

203

204

22.0

0.866

22.0

0.866

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

Not Serviceable

2

M6x1.0

205

201

202

203

204

22.0

0.866

22.0

0.866

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

Not Serviceable

2

M6x1.0

205

201

202

203

204

22.0

0.866

22.0

0.866

Courtesy of GENERAL MOTORS COMPANY Engine Block - Bottom View


Engine Block - Top View

image


Fig. 6: Engine Block - Top View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-900

MM

(IN)

MM

(IN)

1

M10x1.5

904

901

901

903

904

86.38

3.40

86.38

3.40

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-900

MM

(IN)

MM

(IN)

1

M10x1.5

904

901

901

903

904

86.38

3.40

86.38

3.40

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-900

MM

(IN)

MM

(IN)

1

M10x1.5

904

901

901

903

904

86.38

3.40

86.38

3.40

Courtesy of GENERAL MOTORS COMPANY Engine Block - Top View


Lower Crankcase - Front View

image

Fig. 7: Lower Crankcase - Front View Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase - Front View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

20.0

0.787

20.0

0.787

Lower Crankcase - Bottom View

image

Fig. 8: Lower Crankcase - Bottom View Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase - Bottom View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

23.0

0.905

23.0

0.905

2

M8x1.25

210

206

207

208

209

24.0

0.945

24.0

0.945

Lower Crankcase - Right Side View

image

Fig. 9: Lower Crankcase - Right Side View Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase - Right Side View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

2

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Lower Crankcase - Left Side View


image

Fig. 10: Lower Crankcase - Left Side View Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase - Left Side View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

2

M10x1.5

420

211

212

213

214

34.0

1.338

34.0

1.338

Cylinder Head - Top View

image

Fig. 11: Cylinder Head - Top View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

22.0

0.865

22.0

0.865

2

M6x1.0

63

201

852 core drill as c bore

203

204

22.0

0.865

22.0

0.865

3

Not Serviceable

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

22.0

0.865

22.0

0.865

2

M6x1.0

63

201

852 core drill as c bore

203

204

22.0

0.865

22.0

0.865

3

Not Serviceable

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

22.0

0.865

22.0

0.865

2

M6x1.0

63

201

852 core drill as c bore

203

204

22.0

0.865

22.0

0.865

3

Not Serviceable

Courtesy of GENERAL MOTORS COMPANY Cylinder Head - View


Cylinder Head - Intake Manifold Deck View


image

Fig. 12: Cylinder Head - Intake Manifold Deck View Courtesy of GENERAL MOTORS COMPANY

Cylinder Head - Intake Manifold Deck View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

2

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

3

M8x1.25

210

206

207

208

209

29.0

1.142

29.0

1.142

Cylinder Head - Exhaust Side View


image

Fig. 13: Cylinder Head - Exhaust Side View Courtesy of GENERAL MOTORS COMPANY

Cylinder Head - Exhaust Side View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

2

M8x1.25

906

206

207

208

209

29.0

1.142

29.0

1.142

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Cylinder Head - Front View

image

Fig. 14: Cylinder Head - Front View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

4

M10x1.5

420

211

212

213

214

32.0

1.260

32.0

1.260

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

4

M10x1.5

420

211

212

213

214

32.0

1.260

32.0

1.260

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

4

M10x1.5

420

211

212

213

214

32.0

1.260

32.0

1.260

Courtesy of GENERAL MOTORS COMPANY Cylinder Head - Front View


Cylinder Head - Back View

image

Fig. 15: Cylinder Head - Back View

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Service Call Out

Thread Size


Insert


Drill

Counterbore Tool


Tap


Driver

Drill Depth (Maximum)

Tap Depth (Maximum)

EN 42385-400

MM

(IN)

MM

(IN)

1

M6x1.0

205

201

202

203

204

19.0

0.747

19.0

0.747

2

M6x1.0

63

201

202

203

204

22.0

0.865

22.0

0.865

3

M8x1.25

61

206

207

208

209

29.0

1.142

29.0

1.142

Courtesy of GENERAL MOTORS COMPANY Cylinder Head - Back View


SCHEMATIC WIRING DIAGRAMS

ENGINE MECHANICAL WIRING SCHEMATICS

Engine Oil Pressure Control Solenoid Valve

image

Fig. 16: Engine Oil Pressure Control Solenoid Valve Courtesy of GENERAL MOTORS COMPANY

COMPONENT LOCATOR

DISASSEMBLED VIEWS

Camshaft Cover and Components

image

Fig. 17: Camshaft Cover And Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Positive Crankcase Ventilation Tube

2

Fuel Injection Fuel Rail Bolt (Qty: 4)

3

Fuel Feed Intermediate Pipe

4

Fuel Feed Intermediate Pipe Bolt

5

Fuel Injection Fuel Rail Fuel Pressure Sensor

6

Fuel Injection Fuel Rail

7

Fuel Injection Fuel Rail Bolt (Qty: 4)

8

Ignition Coil Bolt (Qty: 4)

9

Ignition Coil (Qty: 4)

10

Oil Level Indicator

11

Positive Crankcase Ventilation Valve Bolt

12

Positive Crankcase Ventilation Valve

13

Camshaft Position Sensor Bolt

14

Exhaust Camshaft Position Sensor

15

Camshaft Cover Bolt

16

Camshaft Cover

17

Camshaft Cover Locating Pin

Callout

Component Name

18

Camshaft Position Actuator Solenoid Valve Bolt

19

Exhaust Camshaft Position Actuator Solenoid Valve

20

Camshaft Cover Gasket

21

Camshaft Cover Stud (Qty: 2)

22

Intake Camshaft Position Actuator Solenoid Valve

23

Camshaft Position Actuator Solenoid Valve Bolt

24

Positive Crankcase Ventilation Valve

25

Positive Crankcase Ventilation Valve Bolt

26

Camshaft Position Sensor Bolt

27

Intake Camshaft Position Sensor

28

Camshaft Housing Stud

29

Oil Filler Cap

30

Combustion Fuel Injector Seal

31

Fuel Injector (Qty: 4)

32

Fuel Injector Spacer

33

Fuel Injector Seal Ring

34

Fuel Injector Fastener (Qty: 8)


Cylinder Head and Components


image

Fig. 18: Cylinder Head And Components

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Exhaust Camshaft

2

Camshaft Bearing Front Exhaust Cap

3

Camshaft Bearing Cap Bolt - Exhaust (Qty: 12)

4

Intake Camshaft

5

Camshaft Bearing Front Intake Cap

6

Camshaft Bearing Cap Bolt - Intake (Qty: 12)

7

Camshaft Bearing Cap - Intake (Qty: 4)

8

Camshaft Bearing Rear Cap

9

Camshaft Bearing Cap - Exhaust (Qty: 5)

10

Spark Plug (Qty: 4)

11

Cylinder Head Bolt (Qty: 10)

12

Cylinder Head Core Hole Plug

13

Engine Lift Rear Bracket

14

Engine Lift Bracket Bolt (Qty: 2)

15

Cylinder Head Water Jacket Hole Plug (Qty: 4)

16

Catalytic Converter Stud (Qty: 4)

17

Cylinder Head Gasket

18

Exhaust Valve (Qty: 8)

19

Intake Valve (Qty: 8)

20

Cylinder Head Locating Pin

21

Cylinder Head Oil Gallery Restrictor

22

Cylinder Head Core Hole Plug

23

Valve Lifter Follower

24

Fuel Pump O-Ring

25

Fuel Pump

26

Fuel Pump Bolt (Qty: 2)

27

Fuel Pump Insulator

28

Engine Lift Bracket Bolt (Qty: 2)

29

Engine Lift Front Bracket

30

Engine Oil Manifold Check Valve (Qty: 2)

31

Valve Stem Oil Seal - Intake (Qty: 8)

32

Valve Stem Oil Seal - Exhaust (Qty: 8)

33

Valve Spring (Qty: 16)

34

Valve Spring Retainer (Qty: 16)

35

Valve Stem Key (Qty: 32)

36

Hydraulic Valve Lash Adjuster (Qty: 16)

37

Hydraulic Valve Lash Adjuster Arm (Qty: 16)

Engine Block and Components

image

Fig. 19: Engine Block And Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Connecting Rod Bolt (Qty: 8)

2

Connecting Rod Cap

3

Connecting Rod

4

Connecting Rod Bearing (Qty: 4)

5

Piston Pin Retainer

6

Piston Pin

7

Piston

8

Piston Oil Ring Rail

9

Piston Oil Ring Rail Spacer

10

Piston Oil Ring Rail

11

Piston Compression Lower Ring

12

Piston Compression Upper Ring

13

Engine Block Oil Gallery Plug

14

Transmission Locating Pin (Qty: 2)

15

Engine Block

16

Engine Block Oil Gallery Plug (Qty: 2)

17

Cylinder Head Locating Pin (Qty: 2)

Callout

Component Name

18

Engine Block Core Hole Plug (Qty: 2)

19

Engine Block Coolant Drain Hole Plug

20

Knock Sensor

21

Knock Sensor Bolt

22

Engine Oil Pressure Sensor

23

Piston Oil Nozzle (Qty: 4)

24

Piston Oil Nozzle Bolt (Qty: 4)

25

Crankshaft Balancer Key

26

Crankshaft

27

Crankshaft Lower Bearing (Qty: 5)

28

Lower Crankcase Locating Pin (Qty: 4)

29

Lower Crankcase

30

Crankshaft Position Sensor Bolt

31

Crankshaft Position Sensor

32

Oil Filter

33

Oil Filter Fitting

34

Lower Crankcase Bolt (Qty: 10)

35

Lower Crankcase Bolt (Qty: 13)

36

Automatic Transmission Flex Plate Bolt (Qty: 8)

37

Automatic Transmission Flex Plate

38

Crankshaft Position Sensor Reluctor Ring

39

Crankshaft Rear Oil Seal

40

Crankshaft Upper Bearing (Qty: 4)

41

Crankshaft Thrust Upper Bearing


Engine Front Cover and Components

image

Fig. 20: Engine Front Cover and Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Engine Front Cover

2

Engine Front Cover Locating Pin

3

Crankshaft Front Oil Seal

4

Engine Front Cover Bolt - M6 (Qty: 11)

5

Engine Front Cover Bolt - M6 (Qty: 1)

6

Engine Front Cover Hole Plug

7

Engine Front Cover Bolt - M14 (Qty: 1)

8

Engine Front Cover Bolt - M14 (Qty: 1)

9

Engine Front Cover Stud (Qty: 1)

Catalytic Converter and Components

image

Fig. 21: Catalytic Converter And Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Catalytic Converter Gasket

2

Catalytic Converter Heat Shield

3

Catalytic Converter Heat Shield Bolt (Qty: 2)

4

Heated Oxygen Sensor

5

Catalytic Converter Heat Shield

6

Catalytic Converter Heat Shield Bolt (Qty: 6)

7

Heated Oxygen Sensor

8

Catalytic Converter Brace Bracket Nut (Qty: 2)

9

Catalytic Converter Brace Bracket

10

Catalytic Converter

11

Catalytic Converter Nut (Qty: 4)

12

Catalytic Converter Brace Bracket Bolt (Qty: 3)

13

Catalytic Converter Brace Bracket Nut (Qty: 2)

14

Catalytic Converter Brace Bracket

Exhaust Gas Recirculation Components

image

Fig. 22: Exhaust Gas Recirculation Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Thermostat Bypass Hose

2

Exhaust Gas Recirculation Cooler

3

Exhaust Gas Recirculation Cooler Bolt

4

Exhaust Gas Recirculation Cooler Bolt (Qty: 2)

5

Exhaust Gas Recirculation Cooler Temperature Sensor

6

Exhaust Gas Recirculation Cooler Inlet Pipe Gasket

7

Exhaust Gas Recirculation Cooler Water Bypass Outlet Hose

8

Exhaust Gas Recirculation Pipe Gasket

9

Exhaust Gas Recirculation Pipe

10

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)

11

Exhaust Gas Recirculation Pipe Bolt

12

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)

13

Exhaust Gas Recirculation Pipe Gasket

14

Exhaust Gas Recirculation Cooler Outlet Pipe

15

Exhaust Gas Recirculation Cooler Outlet Pipe Bolt (Qty: 2)

16

Exhaust Gas Recirculation Cooler Outlet Pipe Gasket

17

Exhaust Gas Recirculation Cooler Temperature Sensor

Water Pump and Components

image

Fig. 23: Water Pump And Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Water Pump Housing Gasket

2

Water Outlet Gasket

3

Water Outlet

4

Water Outlet Bolt (Qty: 2)

5

Thermostat Bypass Pipe Bolt

6

Water Pump Inlet Hose Fitting

7

Thermostat Bypass Pipe Gasket

8

Water Pump Housing Bolt (Qty: 3)

9

Engine Coolant Thermostat Housing Bolt (Qty: 2)

10

Engine Coolant Thermostat Housing

11

Engine Coolant Thermostat Housing Gasket

12

Water Pump Rear Housing

13

Water Pump Gasket

14

Water Pump Housing

15

Water Pump Bolt (Qty: 5)

Intake Manifold and Components

image

Fig. 24: Intake Manifold And Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Evaporative Emission Canister Purge Solenoid Valve Bolt

2

Evaporative Emission Canister Purge Solenoid Valve

3

Manifold Absolute Pressure Sensor

4

Manifold Absolute Pressure Sensor Bolt

5

Throttle Body Gasket

6

Throttle Body Bolt (Qty: 4)

7

Throttle Body

8

Intake Manifold Gasket

9

Intake Manifold Cover Bolt (Qty: 3)

10

Lower Intake Manifold Cover

11

Intake Manifold Bolt (Qty: 5)

12

Upper Intake Manifold Cover

13

Upper Intake Manifold Cover Bolt (Qty: 3)

Oil Pan and Components

image

Fig. 25: Oil Pan and Components

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Lower Crankcase

2

Crankshaft Oil Deflector

3

Crankshaft Oil Deflector Bolts (Qty: 3)

4

Oil Pump Gasket

5

Oil Pump Assembly Locating Pin

6

Oil Pump Gasket

7

Oil Pump Assembly Bolt (Qty: 4)

8

Oil Pump Assembly

9

Oil Pump Flow Control Solenoid Valve

10

Oil Pump Flow Control Solenoid Valve Retainer

11

Positive Crankcase Ventilation Oil Separator Drain Pipe O-ring

12

Positive Crankcase Ventilation Oil Separator Drain Pipe Bolt

13

Positive Crankcase Ventilation Oil Separator Drain Pipe

14

Upper Oil Pan Locating Pin (Qty: 2)

15

Upper Oil Pan Assembly

16

Lower Oil Pan Locating Pin (Qty: 2)

17

Upper Oil Pan Bolt (Qty: 12)

Callout

Component Name

18

Lower Oil Pan

19

Oil Drain Plug O-ring

20

Oil Pan Drain Plug

21

Lower Oil Pan Bolt (Qty: 12)

22

Upper Oil Pan Bolt (Qty: 2)

23

Upper Oil Pan Bolt (Qty: 2)


Timing Chain and Components


image

Fig. 26: Timing Chain and Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Timing Chain

2

Timing Chain Guide - to Cylinder Head

3

Timing Chain Guide Bolt

4

Camshaft Position Actuator Bolt

5

Camshaft Position Actuator Assembly - Intake

6

Camshaft Position Actuator Assembly - Exhaust

7

Camshaft Position Actuator Bolt

8

Timing Chain Guide - Exhaust Side

Callout

Component Name

9

Crankshaft Sprocket

10

Oil Pump Assembly

11

Oil Pump Drive Chain Tensioner Assembly

12

Oil Pump Drive Chain Tensioner Bolt

13

Oil Pump Drive Chain

14

Timing Chain Guide Bolt (Qty: 3)

15

Timing Chain Oil Nozzle

16

Timing Chain Tensioner Shoe Assembly

17

Timing Chain Tensioner Assembly

18

Timing Chain Tensioner Bolt

19

Timing Chain Tensioner Shoe Bolt

ENGINE IDENTIFICATION


image


Fig. 27: Engine Identification Code

Courtesy of GENERAL MOTORS COMPANY


NOTE: The engine identification number must be stamped to the cylinder block in case of engine replacement.


The engine identification code (1) is stamped on the flattened area of the cylinder block, at the transmission side.

DIAGNOSTIC INFORMATION AND PROCEDURES

DTC P06DA-P06DE: ENGINE OIL PRESSURE CONTROL SOLENOID VALVE

Diagnostic Instructions


image Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check - Vehicle

image Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

image An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions


DTC Descriptor


DTC P06DA

Engine Oil Pressure Control Solenoid Valve Control Circuit

DTC P06DB

Engine Oil Pressure Control Solenoid Valve Control Circuit Low Voltage

DTC P06DC

Engine Oil Pressure Control Solenoid Valve Control Circuit High Voltage

DTC P06DD

Engine Oil Pressure Control Solenoid Valve Stuck Off

DTC P06DE

Engine Oil Pressure Control Solenoid Valve Stuck On

Diagnostic Fault Information



Circuit

Short to Ground

Open/High Resistance

Short to Voltage

Signal Performance

Ignition

P06DA, P06DB*

P06DA, P06DB

-

-

Control

P06DB

P06DA

P06DC

P06DD, P06DE

*Additional DTCs may set.


Circuit/System Description


Circuit

Description

Ignition

Supplied from a fuse.

Control

The output circuit is switched to ground to activate the component.


Component

Description


K20 Engine Control Module

The control module controls a series of actuators to ensure optimal engine performance. The control module does this by reading values from a variety of sensors, interprets the data and adjusts the engine actuators accordingly.

Component

Description

Q44 Engine Oil Pressure Control Solenoid Valve

A solenoid valve is an electro-mechanically operated valve. The valve is controlled by an electric current through the solenoid.

The engine oil pressure control solenoid valve is used to control engine oil pressure inside the mechanical engine oil pump. The control module controls the commanded state of the solenoid valve based on the following inputs:

image Engine Speed

image Calculated Engine Oil Temperature image Engine Oil Pressure

image Engine Run Time

When the solenoid valve is commanded Off, oil pressure is higher. When the solenoid valve is commanded On, oil pressure is lower.

Conditions for Running the DTC


DTC P06DA, P06DB, P06DC

image Ignition Voltage = Greater than 11 V image Engine = Running

DTCs run continuously when the above conditions are met.

DTC P06DD

image DTC P0101, P0102, P0103, P0106, P0107, P0108, P0111, P0112, P0113, P0114, P0117, P0118, P0119, P0128, P0335, P0336, P0521, P0522, P0523, P06DA, P06DB, P06DC, P06DD, P06DE, P111E, P2227, P2228, P2229, P2230 = Not set

image Engine Speed = 1,500 to 2,500 RPM

DTCs run continuously when the above conditions are met.

DTC P06DE

image DTC P0101, P0102, P0103, P0106, P0107, P0108, P0111, P0112, P0113, P0114, P0117, P0118, P0119, P0128, P0335, P0336, P0521, P0522, P0523, P06DA, P06DB, P06DC, P06DD, P06DE, P111E, P2227, P2228, P2229, P2230 = Not set

image Engine = Running - For greater than 1.5 s image Engine Speed = 1,500 to 2,500 RPM

image Engine Oil Pressure Control Solenoid Valve = On - For greater than 1.5 s DTCs run continuously when the above conditions are met.

Conditions for Setting the DTC


DTC P06DA, P06DB, P06DC

Control Circuit = Commanded state does not match the actual state - For 1 s

DTC P06DD

Engine Oil Pressure = Less than a predefined threshold

DTC P06DE

Engine Oil Pressure = Greater than a predefined threshold

Actions Taken When the DTC Sets


image DTCs P06DB, P06DE are Type A DTCs.

image DTCs P06DA, P06DC, P06DD are Type B DTCs.

image Engine Oil Pressure Control Solenoid Valve = Off image Reduced Engine Power = Active

Conditions for Clearing the DTC


image DTCs P06DA, P06DC, P06DD are Type B DTCs. image DTCs P06DB, P06DE are Type A DTCs.

Reference Information


Schematic Reference

Engine Mechanical Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Component View Reference Powertrain Component Views Electrical Information Reference

image Circuit Testing

image Connector Repairs

image Testing for Intermittent Conditions and Poor Connections image Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference Control Module References Circuit/System Verification

NOTE: The engine oil level and condition is critical to the correct operation of the system.


1. Ignition - On/Vehicle - In Service Mode

2. Verify there are no DTCs set related to the following system/component: image B35B Engine Oil Level Sensor

image B37B Engine Oil Pressure Sensor image B37 Engine Oil Pressure Switch

image If other DTCs are set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle image If no other DTCs are set

3. Verify the condition does not exist: image Low Engine Oil Level

image Dirty or contaminated oil

image If a condition exists

Repair as necessary

image If no condition exists

4. Perform the scan tool control function: Engine Oil Pressure Control Solenoid Valve - Low Pressure - High Pressure

Verify the scan tool parameter:

image Engine Oil Pressure Control Solenoid Valve Control Circuit Low Voltage Test Status = OK or Not Run image Engine Oil Pressure Control Solenoid Valve Control Circuit Open Test Status = OK or Not Run

image Engine Oil Pressure Control Solenoid Valve Control Circuit High Voltage Test Status = OK or Not Run

image If not the specified state

Refer to: Circuit/System Testing

image If the specified state

5. Engine running.

6. Perform the following steps:

1. Increase the engine speed slowly to 1,800 RPM.


NOTE: Using the scan tool line graph function may make it easier to identify if the value changes.


2. Perform the scan tool control function: Engine Oil Pressure Control Solenoid Valve - Low Pressure Verify the scan tool parameter: Engine Oil Pressure = Change is greater than 30 kPa (4 PSI)

image If the change is 30 kPa (4 PSI) or less - Replace the component: Q44 Engine Oil Pressure Control Solenoid Valve

image If the change is greater than 30 kPa (4 PSI)

7. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.

Verify the DTC does not set.

image If the DTC sets

Refer to: Circuit/System Testing

image If the DTC is not set

8. All OK.


Circuit/System Testing


1. Ignition/Vehicle & All vehicle systems - Off

2. Disconnect the appropriate electrical connector: Inline Harness Connector

3. Ignition - On/Vehicle - In Service Mode


NOTE: Testing for steps 4 to 9 is performed on the control module K20 side of the inline harness connector.


4. Verify a test lamp turns On between the test points: Ignition circuit terminal 5 & Ground

image If the test lamp does not turn On and the circuit fuse is OK

1. Ignition/Vehicle - Off & Remove - Test lamp

2. Test for less than 2 ohms between the test points: Ignition circuit terminal 5 & Fuse image If 2 ohms or greater - Repair the open/high resistance in the circuit.

image If less than 2 ohms - Verify the fuse is OK and there is voltage at the fuse.

image If the test lamp does not turn On and the circuit fuse is open

1. Ignition/Vehicle - Off & Remove - Test lamp


NOTE: The ignition circuit supplies voltage to other components. Test all circuits for a short to ground or test all components for being shorted.


2. Test for infinite resistance between the test points: Ignition circuit terminal 5 & Ground image If less than infinite resistance - Repair the short to ground on the circuit.

image If infinite resistance - Refer to: Step 10

image If the test lamp turns On

5. Verify a test lamp does not turn On between the test points: Control circuit terminal 4 & B+

image If the test lamp turns On

1. Ignition/Vehicle - Off & Remove - Test lamp

2. Disconnect the electrical connector: K20 Engine Control Module

3. Test for infinite resistance between the test points: Inline Harness Connector Control circuit terminal 4 & Ground

image If less than infinite resistance - Repair the short to ground on the circuit.

image If infinite resistance - Replace the component: K20 Engine Control Module

image If the test lamp does not turn On

6. Remove - Test Lamp

7. Perform the scan tool control function: Engine Oil Pressure Control Solenoid Valve - Low Pressure

Verify the scan tool parameter: Engine Oil Pressure Control Solenoid Valve Control Circuit High Voltage Test Status = OK or Not Run

image If not the specified state

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector: K20 Engine Control Module

3. Test for less than 1 V between the test points: Inline Harness Connector Control circuit terminal 4 &

Ground

image If 1 V or greater - Repair the short to voltage on the circuit.

image If less than 1 V - Replace the component: K20 Engine Control Module

image If the specified state

8. Connect a 3 A fused jumper wire between the test points: Control circuit terminal 4 & Ignition circuit terminal 5

9. Perform the scan tool control function: Engine Oil Pressure Control Solenoid Valve - Low Pressure

Verify the scan tool parameter: Engine Oil Pressure Control Solenoid Valve Control Circuit High Voltage Test Status = Malfunction

image If not the specified state

1. Ignition/Vehicle - Off & Remove - Jumper wire(s)

2. Disconnect the electrical connector: K20 Engine Control Module

3. Test for less than 2 ohms between the test points: Inline Harness Connector Control circuit terminal 4 & The other end of the circuit

image If 2 ohms or greater - Repair the open/high resistance in the circuit.

image If less than 2 ohms - Replace the component: K20 Engine Control Module

image If the specified state


NOTE: Testing for steps 10 to 12 is performed on the component side of the inline harness connector: Q44 Engine Oil Pressure Control Solenoid Valve


10. Test for 10 to 30 ohms between the test points: Control circuit terminal 4 & Ignition circuit terminal 5

image If not between 10 and 30 ohms

1. Disconnect the electrical connector: Q44 Engine Oil Pressure Control Solenoid Valve

2. Test for less than 2 ohms between the test points:

image Ignition circuit terminal 5 & The other end of the circuit image Control circuit terminal 4 & The other end of the circuit

image If 2 ohms or greater - Repair the open/high resistance in the circuit.

image If less than 2 ohms - Test or replace the component: Q44 Engine Oil Pressure Control Solenoid Valve

image If between 10 and 30 ohms

11. Test for infinite resistance between the test points: image Ignition circuit terminal 5 & Ground

image Control circuit terminal 4 & Ground

image If less than infinite resistance

Repair the short to ground on the circuit.

image If infinite resistance

12. Test for less than 1 V between the test points: image Ignition circuit terminal 5 & Ground

image Control circuit terminal 4 & Ground

image If 1 V or greater

Repair the short to voltage on the circuit.

image If less than 1 V

13. Test or replace the component: Q44 Engine Oil Pressure Control Solenoid Valve


Component Testing


Static Test

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector: Q44 Engine Oil Pressure Control Solenoid Valve

3. Test for 10 to 30 ohms between the test points: Control terminal 2/B & Ignition terminal 1/A

image If not between 10 and 30 ohms

Replace the component: Q44 Engine Oil Pressure Control Solenoid Valve

image If between 10 and 30 ohms

4. Test for infinite resistance between the test points: Each terminal of the component & The component's housing

image If less than infinite resistance

Replace the component: Q44 Engine Oil Pressure Control Solenoid Valve

image If infinite resistance

5. All OK.

Dynamic Test

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector: Q44 Engine Oil Pressure Control Solenoid Valve

3. Connect a 10 A fused jumper wire between the test points: Ignition terminal 1/A & 12 V


CAUTION: Complete the testing as quickly as possible in order to prevent overheating and damaging the component.


4. Momentarily connect a jumper wire between the test points: Control terminal 2/B & Ground

Verify the component turns On and Off when connecting and disconnecting the jumper wire: Q44 Engine Oil Pressure Control Solenoid Valve

image If the component does not turn On and Off

Replace the component: Q44 Engine Oil Pressure Control Solenoid Valve

image If the component turns On and Off

5. All OK.


Repair Instructions


Perform the Diagnostic Repair Verification after completing the repair: Diagnostic Repair Verification

image Refer to Oil Pump Flow Control Solenoid Valve Replacement - Q44 Engine Oil Pressure Control Solenoid Valve

image For control module replacement, programming, and setup refer to: Control Module References

SYMPTOMS - ENGINE MECHANICAL

Strategy Based Diagnostics


Perform the Diagnostic System Check - Vehicle .

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 condition. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection


image Inspect for aftermarket devices which could affect the operation of the engine.

image Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

image Inspect for the correct oil level, proper oil viscosity, and correct filter application.

image 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.

image Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition.


Intermittent


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:

image Engine Noise Under Load

image Base Engine Misfire without Internal Engine Noises

image Base Engine Misfire with Abnormal Internal Lower Engine Noises image Base Engine Misfire with Abnormal Valve Train Noise

image Base Engine Misfire with Coolant Consumption

image Base Engine Misfire with Excessive Oil Consumption

image Engine Noise on Start-Up, but Only Lasting a Few Seconds image Upper Engine Noise, Regardless of Engine Speed

image Lower Engine Noise, Regardless of Engine Speed

image Engine Will Not Crank - Crankshaft Will Not Rotate image Coolant in Engine Oil

image Engine Compression Test

image Oil Consumption Diagnosis

image Oil Pressure Diagnosis and Testing image Oil Leak Diagnosis

OIL PRESSURE DIAGNOSIS AND TESTING

Special Tools


image CH-48027 Digital Pressure Gauge

image EN-21867-850 Oil Pressure Gauge Adapter For equivalent regional tools, refer to Special Tools. Procedure


image


Fig. 28: Engine Oil Pressure Sensor

Courtesy of GENERAL MOTORS COMPANY

1. Remove the engine oil pressure sensor (1).

image


Fig. 29: Adapter And Gauge

Courtesy of GENERAL MOTORS COMPANY

2. Install the EN-21867-850 adapter (1).

3. Install the CH-48027 gauge (2).

4. Start the engine.

5. Check oil pressure.

6. At idling speed, the oil pressure must be greater than 180 kPa (26.11 psi) and the oil temperature must be 85°C (185°F) or more.

7. Remove the CH-48027 gauge (2).

8. Remove the EN-21867-850 adapter (1).

9. Turn off the engine.

image


Fig. 30: Engine Oil Pressure Sensor

Courtesy of GENERAL MOTORS COMPANY

10. Install the engine oil pressure sensor (1).

11. Tighten the sensor to 35 N.m (26 lb ft).

12. Check the engine oil level.

OIL LEAK DIAGNOSIS


Step

Action

Yes

No

DEFINITION: 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 leak and the cause of the leak.


1

1. Operate the vehicle until it reaches normal operating temperature. Refer to Engine Mechanical Specifications.

2. Park the vehicle on a level surface over a large sheet of paper or other clean surface.

3. Wait 15 minutes.

4. Inspect for drippings.

Are drippings present?


Go to Step 2


System OK


Step

Action

Yes

No

2

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 3


3

1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.

2. Inspect for leaks at the following locations: image Sealing surfaces

image Fittings

image Cracked or damaged components

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 4


4

1. Completely clean the entire engine and surrounding components.

2. Operate the vehicle for several miles at normal operating temperature and at varying speeds.

3. Park the vehicle on a level surface over a large sheet of paper or other clean surface.

4. Wait 15 minutes.

5. Identify the type of fluid and the approximate location of the leak.

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 5


5

1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.

2. Inspect for leaks at the following locations: image Sealing surfaces

image Fittings

image Cracked or damaged components

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 6


6

1. Completely clean the entire engine and surrounding components.

2. Apply an aerosol-type powder, for example, baby powder or foot powder, to the suspected area.

3. Operate the vehicle for several miles at normal operating temperature and at varying speeds.

4. Identify the type of fluid and the approximate location of the leak from the discolorations in the powder surface.

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 7


7

1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.


Go to Step 10


Go to Step 8

Step

Action

Yes

No


2. Inspect for leaks at the following locations: image Sealing surfaces

image Fittings

image Cracked or damaged components

Can you identify the type of fluid and the approximate location of the leak?




8

Identify the type of fluid and the approximate location of the leak.

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


Go to Step 9


9

1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.

2. Inspect for leaks at the following locations: image Sealing surfaces

image Fittings

image Cracked or damaged components

Can you identify the type of fluid and the approximate location of the leak?


Go to Step 10


System OK


10

1. Inspect the engine for mechanical damage. Special interest should be shown to the following areas:

image Higher than recommended fluid levels

image Higher than recommended fluid pressures image Plugged or malfunctioning fluid filters or

pressure bypass valves

image Plugged or malfunctioning engine ventilation system

image Improperly tightened or damaged fasteners image Cracked or porous components

image Improper sealants or gaskets, where required image Improper sealant or gasket installation

image Damaged or worn gaskets or seals image 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

11

Repair or replace all damaged or modified components. Did you complete the repair?


Go to Step 1

-

OIL CONSUMPTION DIAGNOSIS

Excessive oil consumption, not due to leaks, is the use of 0.9 L (1 quart) or greater of engine oil within 3,200 kilometers (2,000 miles). The causes of excessive oil consumption include the following conditions:

image External oil leaks

Tighten bolts and/or replace gaskets and oil seals as necessary. image Incorrect oil level or improper reading of oil level indicator

With the vehicle on a level surface, allow adequate drain down time and inspect for the correct oil level. image Improper oil viscosity

Use recommended SAE viscosity for the prevailing temperatures.

image Continuous high speed driving and/or severe usage

image Crankcase ventilation system restrictions or malfunctioning components image Valve guides and/or valve stem oil seals worn, or the seal omitted

Ream guides and install oversize service valves and/or new valve stem oil seals. image Piston rings broken, improperly installed, worn, or not seated properly

Allow adequate time for rings to seat. Replace broken or worn rings, as necessary. image Piston improperly installed or mis-fitted.

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 overheating condition which may cause engine component damage.


NOTE:

While not always conclusive, use of hydrocarbon block test kits may reveal hydrocarbons indicating combustion chamber gases in cooling system. It is important to follow the kit instructions. This is not a substitute for service information.

Combustion

Cause

Correction

leak tests are available from a wide variety of aftermarket suppliers.


1. A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer to

Engine Will Not Crank - Crankshaft Will Not Rotate.

2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder bore.

3. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the coolant may indicate a faulty gasket or damaged component.

4. 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. Refer to

Cylinder Head Replacement.

Cracked cylinder liner

Replace the components as required.

Cylinder head or block porosity

Replace the components as required.

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.

1. 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.

2. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component.

3. 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 Replacement.

Warped cylinder head

Replace the cylinder head and gasket. Refer to

Cylinder Head Replacement.

Cracked cylinder head

Replace the cylinder head and gasket. Refer to

Cylinder Head Replacement.

Cracked cylinder liner

Replace the components as required.

Cylinder head or block porosity

Replace the components as required.

ENGINE NOISE UNDER LOAD


Cause

Correction

Low oil pressure

1. Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing.

2. Repair or replace as required.

Detonation or spark knock

Verify the correct operation of the ignition. Refer to

Symptoms - Engine Controls .

Loose torque converter bolts

1. Inspect the torque converter bolts and flywheel.

2. Repair as required.

Cracked flywheel - automatic transmission

1. Inspect the flywheel bolts and flywheel.

2. Repair as required.

Excessive connecting rod bearing clearance

Inspect the following components and repair as required:

image The connecting rod bearings image The connecting rods

image The crankshaft

Excessive crankshaft bearing clearance

Inspect the following components and repair as required:

image The crankshaft bearings image The crankshaft journals

image The cylinder block crankshaft bearing bore

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.

High valve lash adjuster leak down rate

Replace the lash adjusters as required.

Worn crankshaft thrust bearing

1. Inspect the thrust bearing and crankshaft.

2. Repair or replace as required.

Damaged or faulty oil filter by-pass valve

1. Inspect the oil filter by-pass valve for proper operation.

2. Repair or replace as required.

Malfunctioning camshaft position actuators - improper oil viscosity or contamination. The result is camshaft actuator locking pin does not lock

1. Verify correct engine oil viscosity by changing the engine oil and filter. Reevaluate the concern.

2. Isolate the noise to a specific camshaft position

Cause

Correction


actuator.

3. Replace the camshaft actuator, oil and filter.

BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES


Cause

Correction

Abnormalities, severe cracking, bumps, or missing 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.

Replace the drive belt.

Worn, damaged, or mis-aligned accessory drive components or excessive pulley runout may lead to a misfire DTC.

A misfire code may be present without an actual misfire condition.

Inspect the components, and repair or replace as required.

A loose or improperly installed engine flywheel or crankshaft balancer

A misfire code may be present without an actual misfire condition.

Repair or replace the flywheel and/or balancer as required.

Restricted exhaust system

A severe restriction in the exhaust flow can cause 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.

Repair or replace as required.

Improperly installed or damaged vacuum hoses

Repair or replace as required.

Improper sealing between the intake manifold and cylinder heads or throttle body

Replace the intake manifold, gaskets, cylinder heads, and/or throttle body as required.

Improperly installed or damaged manifold absolute pressure (MAP) sensor

The sealing grommet of the MAP sensor should not be torn or damaged.

Repair or replace the MAP sensor as required.

Damage to the MAP sensor housing

Replace the intake manifold.

Worn rocker arms

Replace the valve rocker arms as required.

Stuck valves

Carbon buildup on the valve stem can cause the valve not to close properly.

Repair or replace as required.

Excessively worn or mis-aligned timing chain

Replace the timing chain and sprockets as required.

Worn camshaft lobes

Replace the camshaft and valve lifters.

Excessive oil pressure

A lubrication system with excessive oil pressure may lead to excessive valve lifter pump up and loss of compression.

image Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing .

image Repair or replace the oil pump as required.

Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages

image Inspect for spark plugs saturated by coolant.

image Inspect the cylinder heads, engine block, and/or head gaskets.

Cause

Correction

Coolant consumption may or may not cause the engine to overheat.

image Repair or replace as required.

Worn piston rings

Oil consumption may or may not cause the engine to misfire.

image Inspect the spark plugs for oil deposits.

image Inspect the cylinders for a loss of compression. Refer to Engine Compression Test .

image Perform cylinder leak down and compression testing to identify the cause.

image Repair or replace as required.

A damaged crankshaft reluctor wheel

A damaged crankshaft reluctor wheel can result in different symptoms depending on the severity and location of the damage.

image Systems with electronic communications, DIS or coil per cylinder, and severe reluctor ring damage may exhibit periodic loss of crankshaft position, stop delivering a signal, and then re-sync the crankshaft position.

image 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 DTC P0300 may be set.

image 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 DTC P0300 or P0336.

Replace the sensor and/or crankshaft as required.

BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES


Cause

Correction

Abnormalities, severe cracking, bumps or missing 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.

Replace the drive belt.

Worn, damaged, or mis-aligned accessory drive components or excessive pulley runout

A misfire code may be present without an actual misfire condition.

Inspect the components, repair or replace as required.

Loose or improperly installed engine flywheel or crankshaft balancer

A misfire code may be present without an actual misfire condition.

Repair or replace the flywheel and/or balancer as required.

Cause

Correction

Worn piston rings

Oil consumption may or may not cause the engine to misfire.

image Inspect the spark plugs for oil deposits.

image Inspect the cylinders for a loss of compression. Refer to Engine Compression Test .

image Perform cylinder leak down and compression testing to determine the cause.

image Repair or replace as required.

Worn crankshaft thrust bearings

Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit fore and aft movement of the crankshaft, and create a DTC without an actual misfire condition.

Replace the crankshaft and bearings as required.

BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE


Cause

Correction

Abnormalities, severe cracking, bumps or missing 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.

Replace the drive belt.

Worn, damaged, or mis-aligned accessory drive components or excessive pulley runout

A misfire code may be present without an actual misfire condition.

Inspect the components, repair or replace as required.

Loose or improperly installed engine flywheel or crankshaft balancer

A misfire code may be present without an actual misfire condition.

Repair or replace the flywheel and/or balancer as required.

Worn piston rings

Oil consumption may or may not cause the engine to misfire.

image Inspect the spark plugs for oil deposits.

image Inspect the cylinders for a loss of compression. Refer to Engine Compression Test .

image Perform cylinder leak down and compression testing to determine the cause.

image Repair or replace as required.

Worn crankshaft thrust bearings

Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit fore and aft movement of the crankshaft, and create a DTC without an actual misfire condition.

Replace the crankshaft and bearings as required.

BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION


Cause

Correction

Faulty cylinder head gasket and/or cracking, or other damage to the cylinder head and engine block cooling

image Inspect for spark plugs saturated by coolant.

Cause

Correction

system passages.

Coolant consumption may or may not cause the engine to overheat.

image Perform a cylinder leak down test.

image Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket.

image Repair or replace as required.

BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION


Cause

Correction

Worn valves, valve guides, and/or valve stem oil seals

image Inspect the spark plugs for oil deposits. image Repair or replace as required.

Worn piston rings

Oil consumption may or may not cause the engine to misfire.

image Inspect the spark plugs for oil deposits.

image Inspect the cylinders for a loss of compression. Refer to Engine Compression Test .

image Perform cylinder leak down and compression testing to determine the cause.

image Repair or replace as required.

UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED


Cause

Correction

Low oil pressure

image Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing .

image Repair or replace as required.

Worn valve rocker arm

Replace the valve rocker arm.

Improper lubrication to the valve rocker arms

Inspect the following components and repair or replace as required:

image The valve rocker arm image The valve lifter

image The oil filter bypass valve

image The oil pump and pump screen image The engine block oil galleries

Broken valve spring

Replace the valve spring.

Worn or dirty valve lifters

Replace the valve lifters.

Stretched timing chain and/or damaged sprocket teeth

Replace the timing chain and sprockets.

Worn, damaged, or faulty timing chain tensioner

Replace the tensioner.

Worn engine camshaft lobes

image Inspect the engine camshaft lobes.

image Replace the camshaft and valve lifters as required.

Cause

Correction

Worn valve guides or valve stems

Inspect the following components, and repair as required:

image The valves

image The valve guides

Stuck valves

Carbon on the valve stem or valve seat may cause the valve to stay open.

Inspect the following components and repair as required:

image The valves

image The valve guides

LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED


Cause

Correction

Low oil pressure

image Perform an oil pressure test. Refer to Oil Pressure Diagnosis and Testing .

image Repair or replace damaged components as required.

Worn accessory drive components - abnormalities, such as severe cracking, bumps, or missing areas in the accessory drive belt and/or misalignment of system components

1. Inspect the accessory drive system.

2. Repair or replace as required.

Loose or damaged crankshaft balancer

1. Inspect the crankshaft balancer.

2. Repair or replace as required.

Detonation or spark knock

Verify the correct operation of the ignition system. Refer to Symptoms - Engine Controls .

Loose torque converter bolts

1. Inspect the torque converter bolts and flywheel.

2. Repair or replace as required.

Loose or damaged flywheel

Repair or replace the flywheel.

Damaged oil pan, contacting the oil pump screen An oil pan that has been damaged, may improperly position the oil pump screen, preventing proper oil flow to the oil pump.

1. Inspect the oil pan.

2. Inspect the oil pump screen.

3. Repair or replace as required.

Oil pump screen loose, damaged or restricted

1. Inspect the oil pump screen.

2. Repair or replace as required.

Excessive piston-to-cylinder bore clearance

1. Inspect the piston and cylinder bore.

2. Repair as required.

Excessive piston pin-to-bore clearance

1. Inspect the piston, piston pin, and the connecting rod.

2. Repair or replace as required.

ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE


Cause

Correction

Seized accessory drive system component

1. Remove accessory drive belts.

2. Rotate crankshaft by hand at the balancer or flywheel location.

Hydraulically locked cylinder

image Coolant/antifreeze in cylinder image Oil in cylinder

image Fuel in cylinder

1. Remove spark plugs and check for fluid.

2. Inspect for broken head gasket.

3. Inspect for cracked engine block or cylinder head.

4. Inspect for a sticking fuel injector.

5. Inspect for cracked cylinder wall.

Seized automatic transmission torque converter

1. Remove the torque converter bolts.

2. Rotate crankshaft by hand at the balancer or flywheel location.

Seized manual transmission

1. Disengage the clutch.

2. Rotate crankshaft by hand at the balancer or flywheel location.

Broken timing chain and/or gears

image Inspect timing chain and gears. image Repair as required.

Seized balance shaft

image Inspect balance shaft. image Repair as required.

Material in cylinder

image Broken valve

image Piston material

image Foreign material

image Cracked cylinder wall

image Inspect cylinder for damaged components and/or foreign materials.

image Inspect for fallen cylinder wall. image Repair or replace as required.

Seized crankshaft or connecting rod bearings

image Inspect crankshaft and connecting rod bearings.

image Inspect for fallen cylinder wall. image Repair as required.

Bent or broken connecting rod

image Inspect connecting rods. image Repair as required.

Broken crankshaft

image Inspect crankshaft. image Repair as required.

Cause

Correction

Seized automatic transmission - hybrid

Seized Engine or Transmission Separation

ENGINE COMPRESSION TEST

Special Tools


EN-51749 Compression Gauge Tester Kit

For equivalent regional tools, refer to Special Tools.

Removal Procedure


NOTE: DO NOT leave vehicle connected to charge port or theft deterrent system will be active and compression test will not run.


1. Bring vehicle into service bay and make sure vehicle has at least 50% charge.

2. Remove the ignition coils. Refer to Ignition Coil Replacement .

3. Remove the spark plugs. Refer to Spark Plug Replacement .


Diagnostic Procedure


NOTE: In order to perform the compression test it will be necessary to use GDS in order to crank engine.


1. Place vehicle into service mode and connect GDS.


NOTE: The drivers door must remain open and vehicle is turned off. This will ensure that the theft deterrent feature is not active.


2. Once vehicle VIN is recorded and you are at the vehicle selection screen select "Enter" and then select "Module Diagnostics" - "Engine Control Module" then "Control Functions" on the menu screens DO NOT select "Compression Test" at this time. When you reach this point stop an turn off vehicle and leave the drivers door open.


NOTE: You must select crank on the compression test diagnostic screen within 10 seconds of turning key on or the theft deterrent feature will be enabled and the compression test will not run. If this occurs it will be necessary to turn off vehicle for at least one minute and then back on to reset this feature.


3. Without compression gauge attached put vehicle back into service mode then select compression test and then select crank on the GDS menu screens. The engine will now crank to allow any foreign substances to be removed from the cylinders. Once vehicle has performed crank function turn vehicle off.

4. After one minute the "Lost Communication with Vehicle" screen will now be displayed.

5. Install EN-51749 gauge in the spark plug bore for the cylinder that is being checked.

6. Put vehicle into service mode then select OK and then select crank on the GDS menu screens. The engine will now crank and then stop. Turn vehicle off.

7. Record the compression reading for the cylinder just tested.


NOTE: It is important to wait at least one minute with key off between checking each cylinder to ensure the theft deterrent feature is not active and the "lost Communication with Vehicle" screen appears.

8. Repeat starting at step 7 for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings.


Installation Procedure


1. Remove EN-51749 gauge.

2. Install the spark plugs. Refer to Spark Plug Replacement .

3. Install the ignition coils. Refer to Ignition Coil Replacement .

CYLINDER LEAKAGE TEST

Special Tools


EN-51749 Compression Gauge Tester Kit

For equivalent regional tools, refer to Special Tools.


NOTE: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate one or more of the following conditions:

image Worn or burnt valves image Broken valve springs image Stuck valve lifters

image Incorrect valve lash image Damaged piston

image Worn piston rings

image Worn or scored cylinder bore

image Damaged cylinder head gasket

image Cracked or damaged cylinder head image Cracked or damaged engine block


WARNING: Refer to Battery Disconnect Warning .


1. Disconnect the battery ground negative cable.

2. Remove the spark plugs. Refer to Spark Plug Replacement .

3. Rotate the crankshaft to place the piston in the cylinder being tested at top dead center (TDC) of the compression stroke.

4. Install the EN-51749 gauge according to the manufacturers instructions.


NOTE: It may be necessary to hold the crankshaft balancer bolt to prevent the crankshaft from rotating.


5. Apply shop air pressure and adjust according to the manufacturers instructions.

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:

image Air leakage noise at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring.

image Air leakage noise at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a

broken valve spring.

image Air leakage noise from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head.

image 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.

CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS


Symptom

Correction

External oil leak

Inspect for any of the following conditions:

image Restricted or kinked PCV hose or engine vent hose

image Damaged, incorrect, or incorrectly installed PCV hose image Excessive crankcase pressure

Rough Idle

Inspect for any of the following conditions:

image Restricted or kinked PCV hose or engine vent hose image Leaking (damaged) PCV hose

image Vacuum hoses worn or not properly installed

Stalling or slow idle speed

Inspect for any of the following conditions:

image Restricted or kinked engine vent hose image Leaking (damaged) PCV hose

High idle speed

Inspect for a leaking (damaged) PCV hose

Sludge in the engine

Inspect for restricted or kinked PCV hose or engine vent hose

REPAIR INSTRUCTIONS - ON VEHICLE

CAMSHAFT COVER REPLACEMENT

Removal Procedure


WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks: image Identify how to disable high voltage.

image Identify how to test for the presence of high voltage.

image Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.

1. Disable the high voltage system. Refer to High Voltage Disabling


image

Fig. 31: Camshaft Cover, Air Cleaner Outlet Duct And Positive Crankcase Ventilation Pipe Courtesy of GENERAL MOTORS COMPANY


CAUTION: The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.


NOTE: If reinstalling the camshaft cover (3), DO NOT cut the PCV line (1). The air cleaner outlet duct (2), camshaft cover (3) and positive crankcase ventilation pipe (1) should be removed together as shown.


2. If replacing the camshaft cover, remove and discard the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Tube Replacement

3. Remove Fuel Feed Intermediate Pipe. Refer to Fuel Feed Intermediate Pipe Replacement

4. Remove Fuel Injection Fuel Rail Assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement

image


Fig. 32: Bolt, Electrical Connectors, Retainer, Nut And Wiring Harness Bracket Courtesy of GENERAL MOTORS COMPANY

5. Remove Bolt (1) @ Camshaft Cover

6. Disconnect Electrical Connector (2) @ Exhaust Gas Recirculation Cooler Temperature Sensor

7. Unclip the exhaust gas recirculation cooler temperature sensor from the camshaft cover retainer (3).

8. Disconnect Electrical Connector (5) @ Camshaft Position Actuator Solenoid Valve

9. Remove Nut (7) @ Engine Wiring Harness Bracket (6)

10. Position aside Engine Wiring Harness Bracket (6)


image


Fig. 33: Bolts, Electrical Connectors, Nut, Fuel Pipe Bracket, Engine Stud, Clip And Engine Wiring Harness

Courtesy of GENERAL MOTORS COMPANY

11. Remove the 3 engine wiring harness support bolts (6, 11)

12. Remove Engine Wiring Harness Bracket Bolt (1)

13. Disconnect Electrical Connector (2) @ Intake Camshaft Position Sensor

14. Remove Nut (4)

15. Lay fuel pipe bracket (3) aside.

16. Remove the engine wiring harness stud (5).

17. Disconnect Electrical Connector (7) @ Exhaust Gas Recirculation Cooler Temperature Sensor

18. Remove the exhaust temperature sensor clip (10).

19. Disconnect Electrical Connector (9) @ Exhaust Camshaft Position Sensor

20. Position aside Engine Wiring Harness (8)


image

Fig. 34: Electrical Connector And Retainer Courtesy of GENERAL MOTORS COMPANY

21. Disconnect Electrical Connector (1) @ Camshaft Position Actuator Solenoid Valve

22. Remove Retainer (2)


image

Fig. 35: Oil Filler Cap And Oil Level Indicator Handle Courtesy of GENERAL MOTORS COMPANY

23. Remove Oil Filler Cap (1)

24. Remove the oil level indicator handle (2).

image

Fig. 36: Camshaft Cover, Studs, Bolts And Gaskets Courtesy of GENERAL MOTORS COMPANY

25. Remove Camshaft Cover Studs (1) (Qty: 2)

26. Remove Camshaft Cover Bolts (4) (Qty: 18)

27. Remove Camshaft Cover (2)

28. Remove and DISCARD the outer camshaft cover gasket (7).

29. Remove and DISCARD the inner camshaft cover gasket (8).

30. Remove and DISCARD the 2 camshaft position actuator solenoid valve gaskets (10).

31. Remove Camshaft Cover Studs (2, 3) (Qty: 2)


Disassemble Procedure


1. Remove Camshaft Position Sensor - Exhaust. Refer to Camshaft Position Sensor Replacement - Exhaust

2. Remove Camshaft Position Sensor - Intake. Refer to Camshaft Position Sensor Replacement - Intake

3. Remove Camshaft Position Actuator Solenoid Valve - Intake. Refer to Camshaft Position Actuator Solenoid Valve Replacement - Intake

4. Remove Camshaft Position Actuator Solenoid Valve - Exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement - Exhaust

5. Remove Positive Crankcase Ventilation Valve - Fresh Air. Refer to Positive Crankcase Ventilation Valve Replacement - Fresh Air

6. Remove Positive Crankcase Ventilation Valve - Secondary. Refer to Positive Crankcase Ventilation Valve Replacement - Secondary


Assemble Procedure


1. Install Positive Crankcase Ventilation Valve - Fresh Air. Refer to Positive Crankcase Ventilation Valve Replacement - Fresh Air

2. Install Positive Crankcase Ventilation Valve - Secondary. Refer to Positive Crankcase Ventilation Valve Replacement - Secondary

3. Install Camshaft Position Actuator Solenoid Valve - Exhaust. Refer to Camshaft Position Actuator Solenoid Valve Replacement - Exhaust

4. Install Camshaft Position Actuator Solenoid Valve - Intake. Refer to Camshaft Position Actuator Solenoid Valve Replacement - Intake

5. Install Camshaft Position Sensor - Intake. Refer to Camshaft Position Sensor Replacement - Intake

6. Install Camshaft Position Sensor - Exhaust. Refer to Camshaft Position Sensor Replacement - Exhaust


Installation Procedure


1. Clean all camshaft cover sealing surfaces.


image

Fig. 37: Camshaft Cover, Studs, Bolts And Gaskets Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


2. Install and tighten Camshaft Cover Studs (2, 3) (Qty: 2) to 10 N.m (89 lb in)


NOTE: Ensure that the gaskets are located in the retaining grooves in the camshaft cover.


3. Apply approximately a 5 mm (0.2 in) thick bead of camshaft cover sealant (11) on both sides between the cylinder head and the engine front cover. Refer to Adhesives, Fluids, Lubricants, and Sealers.

4. Install 2 NEW camshaft position actuator solenoid valve gaskets (10).

5. Install a NEW camshaft cover inner gasket (8).

6. Install a NEW camshaft cover outer gasket (7).


NOTE: If reinstalling the original camshaft cover, install the camshaft cover, air cleaner outlet duct and positive crankcase ventilation tube as an assembly.


7. Install the camshaft cover (5) along with the pins (6, 9).

8. Hand tighten the 2 camshaft cover double end studs (1).

9. Tighten the Camshaft Cover Bolts (4) (Qty: 18) bolts by hand.

image

Fig. 38: Camshaft Cover Stud And Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

10. Tighten the 2 camshaft cover double end studs (1) and the 18 camshaft cover bolts (2) in sequence as shown to 15 N.m (11 lb ft).


image

Fig. 39: Oil Filler Cap And Oil Level Indicator Handle Courtesy of GENERAL MOTORS COMPANY

11. Install the oil level indicator handle (2).

12. Install Oil Filler Cap (1)

image

Fig. 40: Electrical Connector And Retainer Courtesy of GENERAL MOTORS COMPANY

13. Connect Electrical Connector (1) @ Camshaft Position Actuator Solenoid Valve

14. Install Retainer (2)


image


Fig. 41: Bolts, Electrical Connectors, Nut, Fuel Pipe Bracket, Engine Stud, Clip And Engine Wiring Harness

Courtesy of GENERAL MOTORS COMPANY

15. Position the engine wiring harness (8).

16. Connect Electrical Connector (9) @ Exhaust Camshaft Position Sensor

17. Install the exhaust temperature sensor clip (10).

18. Connect Electrical Connector (7) @ Exhaust Gas Recirculation Cooler Temperature Sensor

19. Install the engine wiring harness stud (5) and tighten to 9 N.m (80 lb in).

20. Install fuel pipe bracket (3).

21. Install and tighten Nut (4) to 9 N.m (80 lb in)

22. Install the 3 engine wiring harness support bolts (6, 11) and tighten to 9 N.m (80 lb in).

23. Install and tighten Engine Wiring Harness Bracket Bolt (1) to 9 N.m (80 lb in)

24. Connect Electrical Connector (2) @ Intake Camshaft Position Sensor


image


Fig. 42: Bolt, Electrical Connectors, Retainer, Nut And Wiring Harness Bracket Courtesy of GENERAL MOTORS COMPANY

25. Install the engine wiring harness bracket (6).

26. Connect Electrical Connector (2) @ Exhaust Gas Recirculation Cooler Temperature Sensor

27. Clip in exhaust gas recirculation cooler temperature sensor to the camshaft cover retainer (3).

28. Connect Electrical Connector (5) @ Camshaft Position Actuator Solenoid Valve

29. Install and tighten Nut (7) @ Engine Wiring Harness Bracket (6) to 9 N.m (80 lb in)

30. Install and tighten Bolt (1) @ Camshaft Cover to 9 N.m (80 lb in)

31. Install Positive Crankcase Ventilation Tube. Refer to Positive Crankcase Ventilation Tube Replacement

32. Install Fuel Injection Fuel Rail Assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement

33. Install Fuel Feed Intermediate Pipe. Refer to Fuel Feed Intermediate Pipe Replacement

34. Enable high voltage system. Refer to High Voltage Enabling CAMSHAFT POSITION ACTUATOR REPLACEMENT

Special Tools


image EN-45059 Angle Meter

image EN-51367 Camshaft Holder

image EN-51397-1 Timing Chain Retainer

image EN-51397-2 Timing Chain Retainer Equivalent regional tools: Special Tools Removal Procedure

1. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

2. Drain the cooling system. Refer to Cooling System Draining and Filling -

3. Remove Camshaft Cover. Refer to Camshaft Cover Replacement

4. Remove Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

image


Fig. 43: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

5. Disconnect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

6. Disconnect Heater Inlet Hose (3) @ Heater Coolant Heater (1)

7. Remove Heater Inlet Hose (3)


image

Fig. 44: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

8. Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).

9. Lower the vehicle.

image


Fig. 45: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

10. Install the EN-51367 holder (1).

11. Remove Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement


image


Fig. 46: Camshaft Position Actuator Marks And Timing Chain Marks Courtesy of GENERAL MOTORS COMPANY


NOTE: The actuator marks stands at 12 o'clock, if the cylinder 1 are on top dead center.


12. Check camshaft position actuator marks (1).

13. Apply a color marking to the camshaft timing chain (1) marking to corresponding timing chain link.

image


Fig. 47: Camshaft Timing Chain, Retainers, Thumb Wheels And Bolts Courtesy of GENERAL MOTORS COMPANY

14. Pre-Install the EN-51397-2 retainer (2) to the intake side of the camshaft timing chain (3).

15. Install the EN-51397-1 retainer (5) to the exhaust side of the camshaft timing chain.

16. Hand tighten the thumb wheels (1, 4) securely.


CAUTION: Refer to Fastener Caution


17. Tighten Bolts (6) (Qty: 2) to 5 N.m (44 lb in)


image


Fig. 48: Camshaft Position Actuator Bolts Courtesy of GENERAL MOTORS COMPANY

18. Loosen Bolts (1) (Qty: 2) @ Camshaft Position Actuator

19. Remove the EN-51367 holder.

image

Fig. 49: Engine Front Cover, Hole Plug And Seal Ring Courtesy of GENERAL MOTORS COMPANY

20. Remove Engine Front Cover Hole Plug (1) @ Engine Front Cover

21. Remove Seal Ring (2)


image


Fig. 50: Releasing Tension From Piston Courtesy of GENERAL MOTORS COMPANY


NOTE: Step 22 - 26 explain how to adjust and fix the timing chain tensioner in the service position and should be used for reference.


22. Slightly release tension from the piston (2) until bar (1) can be unlocked by rotating the lever (3) in direction of arrow.

image


Fig. 51: Piston And Tensioner Lever

Courtesy of GENERAL MOTORS COMPANY

23. Entirely push back the piston (1) until the tensioner Lever (2) cannot be locked in this position.


image


Fig. 52: Piston

Courtesy of GENERAL MOTORS COMPANY

24. Release tension from the piston (1) until it releases for three ratchets. The three ratchets can be noticed by the click noises.

image


Fig. 53: Lever And Fixing Pin

Courtesy of GENERAL MOTORS COMPANY

25. Apply tension to the piston until the lever (1) is rotated back into the locking position where the bore in the lever aligns with the bore in the tensioner housing.

26. Fix the lever in this position with a suitable fixing pin (2).


image

Fig. 54: Wrench On Camshaft

Courtesy of GENERAL MOTORS COMPANY


CAUTION: The tightening force must be applied gently to the wrench. Using too much force will lead to an overlap of the timing chain that will cause severe engine damages.


NOTE: A second technician is required.

Follow Step 22 - 26 during rotation of the intake camshaft


27. Install a suitable wrench (1) to the intake camshaft.

28. Apply tension to the chain tensioner by slightly rotating the intake camshaft clockwise.

image

Fig. 55: Timing Chain Tensioner In Lock Position Courtesy of GENERAL MOTORS COMPANY


NOTE: The timing chain tensioner has now the lock position (1).


29. Secure the timing chain tensioner design 1 with a suitable fixing pin 3 mm (0.118 in).


image

Fig. 56: Bolt And Retainer

Courtesy of GENERAL MOTORS COMPANY

30. Fix the EN-51397-2 retainer (1) to the intake side of the camshaft timing chain.

31. Tighten the bolt (2) of the EN-51397-2 retainer to 5 N.m (44 lb in).

32. Remove the wrench.

image


Fig. 57: Checking Chain Slack

Courtesy of GENERAL MOTORS COMPANY


NOTE: The timing chain can be moved up and down between both camshaft position actuators.


33. Check chain slack, if not enough slack is gained, refer to detailed chain tensioner description from step 22 to

26. Apply and release tension to the chain tensioner.


image


Fig. 58: Intake Camshaft Position Actuator And Bolt Courtesy of GENERAL MOTORS COMPANY


NOTE: Only if the timing chain tensioner is fixed in the service position as described above, the timing chain is properly free from tension. Removing the camshaft actuator in another position of the tensioner will make the reinstallation impossible and removal of the engine front cover will be required.


34. Remove and DISCARD the intake camshaft position actuator bolt (1).


NOTE: The camshaft timing chain will be hold by EN-51397-1 retainer.


35. Remove the intake camshaft position actuator (2).

image


Fig. 59: Exhaust Camshaft Position Actuator And Bolt Courtesy of GENERAL MOTORS COMPANY

36. Remove and DISCARD the exhaust camshaft position actuator bolt (1).


NOTE: The camshaft timing chain will be hold by EN-51397-1 retainer.


37. Remove the exhaust camshaft position actuator (2).


Installation Procedure


image


Fig. 60: Camshaft Position Actuator Marks And Timing Chain Marks Courtesy of GENERAL MOTORS COMPANY

1. The marks of the camshaft position actuators (2) must be set to the marks of the camshaft timing chain (1).

image


Fig. 61: Exhaust Camshaft Position Actuator, Dowel Pin, Camshaft And Bolt Courtesy of GENERAL MOTORS COMPANY

2. Install the exhaust camshaft position actuator (1).

3. Readjust the camshaft until the dowel pin (2) engage to camshaft (3).


image


Fig. 62: Intake Camshaft Position Actuator, Dowel Pin, Camshaft And Bolt Courtesy of GENERAL MOTORS COMPANY

4. Install the exhaust camshaft position actuator (1).

5. Readjust the camshaft until the dowel pin (2) engage to camshaft (3).


NOTE: Counterhold the camshaft with a suitable tool.


6. Install the intake camshaft position actuator bolt (4) but do not tighten yet.

image


Fig. 63: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

7. Install the EN-51367 holder (1).


image


Fig. 64: Camshaft Position Actuator Bolts Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution NOTE: Counterhold the camshaft with a suitable tool.

8. Tighten the 2 to camshaft position actuator bolts (1) to:

1. First Pass: 20 N.m (15 lb ft).

2. Final Pass: 90 degrees use the EN-45059 meter.

9. Remove the EN-51367 holder (1).

image


Fig. 65: Camshaft Timing Chain, Retainers, Thumb Wheels And Bolts Courtesy of GENERAL MOTORS COMPANY

10. Loosen the bolts. (6) (Qty: 2)

11. Loosen the bolts. (1, 4) (Qty: 2)

12. Remove EN-51397-2 retainer (2).

13. Remove EN-51397-1 retainer (5).


image

Fig. 66: Timing Chain Tensioner In Lock Position Courtesy of GENERAL MOTORS COMPANY


NOTE: The following step shows the tensioner design 1.


14. Remove the pin from the timing chain tensioner (1).

15. Install Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement

16. Check the position of the crankshaft, camshaft and camshaft position actuator.

image

Fig. 67: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

17. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt (3).

18. Adjust the engine to cylinder 1 TDC of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).


image


Fig. 68: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

19. Install the EN-51367 holder (1).

20. If the EN-51367 holder (1) can be installed, the engine timing is properly adjusted.

image

Fig. 69: Engine Front Cover, Hole Plug And Seal Ring Courtesy of GENERAL MOTORS COMPANY

21. Install Seal Ring (2)

22. Install and tighten Engine Front Cover Hole Plug (1) to 50 N.m (37 lb ft)

23. Raise the vehicle.


image


Fig. 70: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

24. Install Heater Inlet Hose (3) @ Heater Coolant Heater (1)

25. Connect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

26. Install Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

27. Install Camshaft Cover. Refer to Camshaft Cover Replacement

28. Fill the cooling system. Refer to Cooling System Draining and Filling

29. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement EXHAUST CAMSHAFT REPLACEMENT

Removal Procedure

1. Remove Camshaft Position Actuator. Refer to Camshaft Position Actuator Replacement


image


Fig. 71: Exhaust Camshaft, Bearing Caps And Bolts Courtesy of GENERAL MOTORS COMPANY


NOTE: Many internal engine components will develop specific wear patterns on their friction surfaces.


2. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

3. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

4. Loosen the 12 camshaft bearing cap bolts (1, 2, 7, 8), working from outside to inside in a spiral in steps of 1/2 turn.


NOTE: Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.


5. Remove the 12 camshaft bearing cap bolts (1, 2, 7, 8).

6. Remove Camshaft Bearing Cap (3, 4, 6) (Qty: 6) @ Cylinder Head Assembly

7. Remove Exhaust Camshaft (5)

Installation Procedure


image


Fig. 72: Exhaust Camshaft, Bearing Caps And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Coat the intake camshaft with lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Install Exhaust Camshaft (5)

3. Ensure that the camshaft notch at the front of the camshaft is in the 12 o'clock position before installing the camshaft caps.

4. Rotate the oil seal in the groove of the number one camshaft journal so the split line is at approximately the 12 o'clock position before installing the camshaft caps.


NOTE: Observe the markings on the bearing caps. Each bearing cap is market in order to identify its location. Ensure the caps are installed in the original location and position.


5. Lubricate the 6 camshaft bearing caps (3, 4, 6) and the 12 camshaft bearing cap bolts (1, 2, 7, 8). Refer to

Adhesives, Fluids, Lubricants, and Sealers.

6. Install Camshaft Bearing Caps (4) (Qty: 4)

7. Install the camshaft bearing rear cap (3).

8. Install the camshaft bearing front cap (6).

9. Loosely install the 12 camshaft bearing cap bolts (1, 2, 7, 8).


image


Fig. 73: Exhaust Camshaft Bearing Cap Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


10. Tighten the camshaft bearing cap bolts (1, 2, 7, 8) in increments of 3 turns until they are seated.

11. Tighten the bearing cap bolts in sequence as shown to 12 N.m (106 lb in).

12. Install Camshaft Position Actuator. Refer to Camshaft Position Actuator Replacement INTAKE CAMSHAFT REPLACEMENT

Removal Procedure


1. Remove Camshaft Position Actuator. Refer to Camshaft Position Actuator Replacement

2. Remove Fuel Injection Pump. Refer to Fuel Injection Pump Replacement

image


Fig. 74: Intake Camshaft, Bearing Caps And Bolts Courtesy of GENERAL MOTORS COMPANY


NOTE: Many internal engine components will develop specific wear patterns on their friction surfaces.


3. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

4. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

5. Loosen the 12 camshaft bearing cap bolts (1, 2, 7, 8), working from outside to inside in a spiral in steps of 1/2 turn.


NOTE: Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.


6. Remove the 12 camshaft bearing cap bolts (1, 2, 7, 8).

7. Remove Camshaft Bearing Caps (3, 4, 6) (Qty: 6) @ Cylinder Head Assembly

8. Remove Intake Camshaft (5)


Installation Procedure

image


Fig. 75: Intake Camshaft, Bearing Caps And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Coat the intake camshaft with lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Install Intake Camshaft (5)

3. Ensure that the camshaft notch at the front of the camshaft is in the 12 o'clock position before installing the camshaft caps.

4. Rotate the oil seal in the groove of the number one camshaft journal so the split line is at approximately the 12 o'clock position before installing the camshaft caps.


NOTE: Observe the markings on the bearing caps. Each bearing cap is market in order to identify its location. Ensure the caps are installed in the original location and position.


5. Lubricate the 6 camshaft bearing caps (3, 4, 6) and the 12 camshaft bearing cap bolts (1, 2, 7, 8). Refer to

Adhesives, Fluids, Lubricants, and Sealers.

6. Install the 4 camshaft bearing caps (4).

7. Install the camshaft bearing rear cap (3).

8. Install the camshaft bearing front cap (6).

9. Loosely install the 12 camshaft bearing cap bolts (1, 2, 7, 8).

image


Fig. 76: Intake Camshaft Bearing Cap Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


10. Tighten the camshaft bearing cap bolts (1, 2, 7, 8) in increments of 3 turns until they are seated.

11. Tighten the bearing cap bolts in sequence as shown to 12 N.m (106 lb in).

12. Install Fuel Injection Pump. Refer to Fuel Injection Pump Replacement

13. Install Camshaft Position Actuator. Refer to Camshaft Position Actuator Replacement CAMSHAFT TIMING CHAIN REPLACEMENT

Special Tools


EN-51367 Camshaft Holder

Equivalent regional tools: Special Tools

Removal Procedure


1. Drain the cooling system. Refer to Cooling System Draining and Filling

2. Remove Camshaft Cover. Refer to Camshaft Cover Replacement

3. Remove Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

image


Fig. 77: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

4. Disconnect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

5. Disconnect Heater Inlet Hose (3) @ Heater Coolant Heater (1)


image

Fig. 78: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

6. Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).

image


Fig. 79: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

7. Install the EN-51367 holder (1).

8. Remove Engine Front Cover. Refer to Engine Front Cover Replacement

9. Remove Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement


image

Fig. 80: Timing Chain Tensioner In Service Position Courtesy of GENERAL MOTORS COMPANY

10. Fix the timing chain tensioner (1) in service position:

image


Fig. 81: Releasing Tension From Piston Courtesy of GENERAL MOTORS COMPANY

1. Slightly release tension from the piston (2) until bar (1) can be unlocked by rotating the lever (3) in direction of arrow.


image


Fig. 82: Piston And Tensioner Lever

Courtesy of GENERAL MOTORS COMPANY

2. Entirely push back the piston (1) until the tensioner lever (2) cannot be locked in this position.

image


Fig. 83: Piston

Courtesy of GENERAL MOTORS COMPANY

3. Release tension from the piston (1) until it releases for three ratchets. The three ratchets can be noticed by the click noises.


image


Fig. 84: Lever And Fixing Pin

Courtesy of GENERAL MOTORS COMPANY

4. Apply tension to the piston until the lever (1) is rotated back into the locking position where the bore in the lever aligns with the bore in the tensioner housing.

5. Fix the lever in this position with a suitable fixing pin (2).

image

Fig. 85: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

11. Remove Timing Chain Tensioner Shoe Bolt (1)

12. Remove Timing Chain Tensioner Shoe (2)


image

Fig. 86: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

13. Ensure the correct fixation of the tool (3).

14. Remove Timing Chain Tensioner Bolts (4) (Qty: 2)

15. Remove Timing Chain Tensioner (1)

16. Remove and DISCARD the gasket. (2)

image

Fig. 87: Timing Chain

Courtesy of GENERAL MOTORS COMPANY

17. Remove Timing Chain (1)


Installation Procedure


image

Fig. 88: Timing Chain

Courtesy of GENERAL MOTORS COMPANY


NOTE: Ensure the actuator timing marks are approximately the 12 o'clock position.


1. Install Timing Chain (1) - Install

image

Fig. 89: Timing Chain Marks

Courtesy of GENERAL MOTORS COMPANY

2. Ensure that the colored link (3) matches to the arrow on the crankshaft sprocket.

3. Ensure that the colored links (1, 2) match to the marks on the camshaft position adjuster actuators.


image

Fig. 90: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

4. Install a NEW gasket. (2)

5. Install Timing Chain Tensioner (1)


CAUTION: Refer to Fastener Caution


6. Install and tighten Timing Chain Tensioner Bolts (4) (Qty: 2) to 25 N.m (18 lb ft)

7. Remove the suitable tool (3) from the timing chain tensioner.


image

Fig. 91: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

8. Install Timing Chain Tensioner Shoe (2)

9. Install and tighten Timing Chain Tensioner Shoe Bolt (1) to 25 N.m (18 lb ft)


image


Fig. 92: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

10. Remove the EN-51367 holder (1).

11. Install Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement

12. Check the position of the crankshaft, camshaft and camshaft position actuator adjuster.

1. Install the engine front cover with 4 bolts and the crankshaft balancer.

image

Fig. 93: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

2. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt (2).


image


Fig. 94: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

13. Install the EN-51367 holder (1).

14. If the EN-51367 holder (1) can be installed, the engine timing is properly adjusted.

15. Remove the EN-51367 holder.

16. Remove the engine front cover and crankshaft balancer.

image


Fig. 95: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

17. Install Heater Inlet Hose (3) @ Heater Coolant Heater (1)

18. Connect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

19. Install Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

20. Install Engine Front Cover. Refer to Engine Front Cover Replacement

21. Install Camshaft Cover. Refer to Camshaft Cover Replacement

22. Fill the cooling system. Refer to Cooling System Draining and Filling TIMING CHAIN OIL NOZZLE REPLACEMENT

image

Fig. 96: Timing Chain Oil Nozzle

Courtesy of GENERAL MOTORS COMPANY

Callout

Component Name

Preliminary Procedure

Remove Timing Chain Guide - Right Side. Refer to Timing Chain Guide Replacement - Right Side


1

Timing Chain Oil Nozzle


CAUTION:

Refer to Fastener Caution .


Tighten

15 N.m (11 lb ft)

HYDRAULIC VALVE LASH ADJUSTER ARM REPLACEMENT

Removal Procedure


1. Remove Intake Camshaft. Refer to Intake Camshaft Replacement

2. Remove Exhaust Camshaft. Refer to Exhaust Camshaft Replacement


image


Fig. 97: Hydraulic Valve Lash Adjuster Arms Courtesy of GENERAL MOTORS COMPANY


NOTE: Many internal engine components will develop specific wear patterns on their friction surfaces.


3. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

4. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

5. Remove Hydraulic Valve Lash Adjuster Arms (1) (Qty: 16)


Installation Procedure

image


Fig. 98: Hydraulic Valve Lash Adjuster Arms Courtesy of GENERAL MOTORS COMPANY


NOTE: Used lash adjuster arms must be returned to the original position on the camshaft. If the camshaft is being replaced, the lash adjuster arms actuated by the camshaft must also be replaced.


1. Apply lubricant to the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Position the 16 hydraulic lash adjuster arms (1) on the tip of the valve stems and on the lash adjusters.

3. Apply lubricant to the 16 hydraulic lash adjuster arms (1). Refer to Adhesives, Fluids, Lubricants, and Sealers.

4. Install Exhaust Camshaft. Refer to Exhaust Camshaft Replacement

5. Install Intake Camshaft. Refer to Intake Camshaft Replacement HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT

Removal Procedure


1. Remove Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement

image


Fig. 99: Hydraulic Valve Lash Adjusters Courtesy of GENERAL MOTORS COMPANY


NOTE: Many internal engine components will develop specific wear patterns on their friction surfaces.


2. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

3. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

4. Remove the 16 hydraulic valve lash adjusters (1).


Installation Procedure

image


Fig. 100: Hydraulic Valve Lash Adjusters Courtesy of GENERAL MOTORS COMPANY

1. Install the 16 hydraulic valve lash adjusters (1) in the bores in the cylinder head.

2. Apply lubricant to the 16 hydraulic valve lash adjusters (1). Refer to Adhesives, Fluids, Lubricants, and Sealers.

3. Install Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT

Special Tools


image EN-46116 Valve Stem Seal Remover

image EN-50717 Universal Valve Spring Compressor Kit

image EN-51511 Injector Port Service Plug Equivalent regional tools: Special Tools.

Removal Procedure


1. Remove Camshaft Cover. Refer to Camshaft Cover Replacement

2. Remove Spark Plugs (Qty: 4). Refer to Spark Plug Replacement

3. Remove Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement


image

Fig. 101: Injector Port Service Plug

Courtesy of GENERAL MOTORS COMPANY

4. Install the EN-51511 Plug (2) into the injector bore to prevent air leaks in the cylinder.

5. Tighten Bolt (1)


image

Fig. 102: Valve Spring Compressor Kit, Cross Bars And Locks Courtesy of GENERAL MOTORS COMPANY

6. Install the EN-50717 compressor kit (1) to the front and rear of the cylinder head as shown.

7. Install the cross bars and locks (2) of the EN-50717 compressor kit to the valve spring compressor adapters.

8. Install an air hose adapter into the spark plug hole.

9. Position the EN-50717-2 compressor (3) so that its adapter proper contacts the valve spring retainer and pretension the compressor.


image

Fig. 103: Valve Spring, Retainer And Valve Key Courtesy of GENERAL MOTORS COMPANY


WARNING: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.


10. Apply pressure to the EN-50717-2 compressor to push down the vale spring retainer (2) and compress the valve spring (3) until the valve keys (1) are free from tension.

11. Carefully remove the valve keys then.

12. Release the tension from the EN-50717-2 compressor.


image

Fig. 104: Valve Spring And Retainer

Courtesy of GENERAL MOTORS COMPANY

13. Remove the valve spring retainer (1) and the exhaust valve spring or intake valve spring (2).

image

Fig. 105: Valve Stem Oil Seal And Special Tool Courtesy of GENERAL MOTORS COMPANY

14. Remove and DISCARD the valve stem oil seal (2). Use the EN-46116 remover (1).


Installation Procedure


image

Fig. 106: Valve Stem Oil Seal And Special Tool Courtesy of GENERAL MOTORS COMPANY


NOTE: Valve stem oil seal sets will contain 2 different colored seals, black and green.

The set of 8 seals that are green have to installed to the exhaust valves.


1. Install NEW valve stem oil seal (2). Use the EN-46116 installer (1).

image

Fig. 107: Valve Spring And Retainer

Courtesy of GENERAL MOTORS COMPANY


NOTE: Make sure that the valve springs and the valve spring retainers will be installed in their original position.


2. Install the exhaust or the intake valve spring (2) and the upper valve spring retainer (1). Which valve spring is to be installed, depends on the installation progress.


image

Fig. 108: Valve Spring, Retainer And Valve Key Courtesy of GENERAL MOTORS COMPANY


CAUTION: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly.


3. Using the EN-50717-2 compressor, push down the valve spring retainer (2) and compress the valve spring (3) until the valve keys (1) can be inserted. Carefully insert the valve keys then, so that they are proper installed to the valve stem grooves.

4. Carefully release the tension from the EN-50717-2 compressor.

5. Inspect the valve keys and valve spring retainer for proper seat.

image

Fig. 109: Valve Spring Compressor Kit, Cross Bars And Locks Courtesy of GENERAL MOTORS COMPANY

6. Repeat the procedure with the remaining valves and cylinders.

7. Transfer the EN-50717 compressor kit (1, 2, 3) and the EN-51511 plug as needed.

8. Take care that air pressure is always applied to the combustion chamber of the treated cylinder.

9. Remove EN-50717 compressor kit from the cylinder head.


image

Fig. 110: Injector Port Service Plug

Courtesy of GENERAL MOTORS COMPANY

10. Loosen the bolt. (1)

11. Remove the EN-51511 plug (2) from the injector bores.

12. Install Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement

13. Install Spark Plugs (Qty: 4). Refer to Spark Plug Replacement

14. Install Camshaft Cover. Refer to Camshaft Cover Replacement POSITIVE CRANKCASE VENTILATION TUBE REPLACEMENT

image

Fig. 111: Positive Crankcase Ventilation Tube Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement


1

Positive Crankcase Ventilation Tube


CAUTION:

The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed.

The fittings connected to the PCV line must also be replaced if they are

Callout

Component Name


damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.


Procedure

Using a suitable cutting tool, carefully cut the PCV tube away from the fittings at the air cleaner outlet duct and the camshaft cover. If any damage occurs to either the air cleaner outlet duct or camshaft cover fitting, they must be replaced. Refer to Air Cleaner Outlet Duct Replacement

POSITIVE CRANKCASE VENTILATION VALVE REPLACEMENT - FRESH AIR

Special Tools


EN-50956 Tamper Proof Drive Bit Equivalent regional tools: Special Tools Removal Procedure

image

Fig. 112: Positive Crankcase Ventilation Valve, Tube And Bolt

Courtesy of GENERAL MOTORS COMPANY

1. Remove and DISCARD Positive Crankcase Ventilation Tube (2). Refer to Positive Crankcase Ventilation Tube Replacement

2. Using a suitable tool, cut a slot in the tamper-resistant positive crankcase ventilation fresh air bolt head (1) and remove with a flat-bladed tool. DISCARD the bolt.

3. Remove Positive Crankcase Ventilation Valve (3)


Installation Procedure


image

Fig. 113: Positive Crankcase Ventilation Valve, Tube, Bolt And Special Tool Courtesy of GENERAL MOTORS COMPANY

1. Install Positive Crankcase Ventilation Valve (4)


CAUTION: Refer to Fastener Caution


2. Install the NEW positive crankcase ventilation valve fresh air bolt (1) using EN-50956 bit (2), and tighten to 10 N.m (89 lb in).


NOTE: Install a new tube.


3. Install NEW Positive Crankcase Ventilation Tube (3). Refer to Positive Crankcase Ventilation Tube Replacement

POSITIVE CRANKCASE VENTILATION VALVE REPLACEMENT - SECONDARY

Special Tools


EN-50956 Tamper Proof Drive Bit Equivalent regional tools: Special Tools Removal Procedure

image

Fig. 114: Positive Crankcase Ventilation Valve, Tube And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Remove and DISCARD Positive Crankcase Ventilation Tube (3). Refer to Positive Crankcase Ventilation Tube Replacement

2. Using a suitable tool, cut a slot in the tamper-resistant positive crankcase ventilation fresh air bolt head (1) and remove with a flat-bladed tool. DISCARD the bolt.

3. Remove Positive Crankcase Ventilation Valve (2)


Installation Procedure


image

Fig. 115: Positive Crankcase Ventilation Valve, Tube, Bolt And Special Tool Courtesy of GENERAL MOTORS COMPANY

1. Install Positive Crankcase Ventilation Valve (2)


CAUTION: Refer to Fastener Caution


2. Install the NEW positive crankcase ventilation valve fresh air bolt (1) using EN-50956 bit (4), and tighten to 10 N.m (89 lb in).


NOTE: Install a new tube.


3. Install NEW Positive Crankcase Ventilation Tube (3). Refer to Positive Crankcase Ventilation Tube Replacement

TIMING CHAIN UPPER GUIDE REPLACEMENT


image

Fig. 116: Timing Chain Upper Guide

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

Remove Camshaft Cover. Refer to Camshaft Cover Replacement


1

Timing Chain Guide Fastener (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

Callout

Component Name

2

Upper Timing Chain Guide

TIMING CHAIN GUIDE REPLACEMENT - RIGHT SIDE

Removal Procedure


1. Remove Camshaft Timing Chain. Refer to Camshaft Timing Chain Replacement


image

Fig. 117: Right Side Timing Chain Guide And Bolts Courtesy of GENERAL MOTORS COMPANY

2. Remove the 3 timing chain guide bolts (2).

3. Remove the timing chain guide - right side (1).


Installation Procedure


image

Fig. 118: Right Side Timing Chain Guide And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install the timing chain guide - right side (1).

CAUTION: Refer to Fastener Caution .


2. Install the 3 timing chain guide bolts (2) and tighten to 10 N.m (89 lb in).

3. Install Camshaft Timing Chain. Refer to Camshaft Timing Chain Replacement TIMING CHAIN TENSIONER REPLACEMENT

Special Tools


EN-51367 Camshaft Holder

Equivalent regional tools: Special Tools

Removal Procedure


1. Remove Camshaft Cover. Refer to Camshaft Cover Replacement


image

Fig. 119: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

2. Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).


image

Fig. 120: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

3. Install the EN-51367 holder (1).

4. Remove Engine Front Cover. Refer to Engine Front Cover Replacement

5. Remove Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement


image

Fig. 121: Timing Chain Tensioner In Service Position Courtesy of GENERAL MOTORS COMPANY

6. Fix the timing chain tensioner with design 1 (1) in service position:


image


Fig. 122: Releasing Tension From Piston Courtesy of GENERAL MOTORS COMPANY

1. Slightly release tension from the piston (2) until bar (1) can be unlocked by rotating the lever (3) in direction of arrow.

image


Fig. 123: Piston And Tensioner Lever

Courtesy of GENERAL MOTORS COMPANY

2. Entirely push back the piston (1) until the tensioner lever (2) cannot be locked in this position.


image


Fig. 124: Piston

Courtesy of GENERAL MOTORS COMPANY

3. Release tension from the piston (1) until it releases for three ratchets. The three ratchets can be noticed by the click noises.

image


Fig. 125: Lever And Fixing Pin

Courtesy of GENERAL MOTORS COMPANY

4. Apply tension to the piston until the lever (1) is rotated back into the locking position where the bore in the lever aligns with the bore in the tensioner housing.

5. Fix the lever in this position with a suitable fixing pin (2).


image

Fig. 126: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

7. Remove Timing Chain Tensioner Shoe Bolt (1)

8. Remove Timing Chain Tensioner Shoe (2)

image

Fig. 127: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

9. Ensure the correct fixation of the tool (3).

10. Remove Timing Chain Tensioner Bolts (4) (Qty: 2)

11. Remove Timing Chain Tensioner (1)

12. Remove and DISCARD the gasket. (2)


Installation Procedure


image

Fig. 128: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW gasket. (2)

2. Install Timing Chain Tensioner (1)


CAUTION: Fastener Caution


3. Install and tighten Timing Chain Tensioner Bolts (4) (Qty:) to 25 N.m (18 lb ft)

image

Fig. 129: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

4. Install Timing Chain Tensioner Shoe (2)

5. Install and tighten Timing Chain Tensioner Shoe Bolt (1) to 25 N.m (18 lb ft)

6. Remove the suitable tool from the timing chain tensioner.


image


Fig. 130: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

7. Remove the EN-51367 holder (1).

8. Install Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement

9. Check the position of the crankshaft, camshaft and camshaft position actuator adjuster:

1. Install the engine front cover with 4 bolts and the crankshaft balancer.

image

Fig. 131: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

2. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt (3).


image


Fig. 132: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

10. Install the EN-51367 holder (1).

11. If the EN-51367 holder (1) can be installed, the engine timing is properly adjusted.

12. Remove the EN-51367 holder.

13. Remove the engine front cover and crankshaft balancer.

14. Install Engine Front Cover. Refer to Engine Front Cover Replacement

15. Install Camshaft Cover. Refer to Camshaft Cover Replacement TIMING CHAIN TENSIONER SHOE REPLACEMENT

Removal Procedure


1. Release tension from the timing chain tensioner. Refer to Timing Chain Tensioner Replacement.

image


Fig. 133: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

2. Remove Timing Chain Tensioner Shoe Bolt (1)

3. Remove Timing Chain Tensioner Shoe (2)


Installation Procedure

image


Fig. 134: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Install Timing Chain Tensioner Shoe (2)


CAUTION: Refer to Fastener Caution .


2. Install and tighten Timing Chain Tensioner Shoe Bolt (1) to 25 N.m (18 lb ft)

3. Unlock the timing chain tensioner. Refer to Timing Chain Tensioner Replacement. INTAKE MANIFOLD COVER REPLACEMENT

image

Fig. 135: Intake Manifold Cover

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Upper Intake Manifold Cover Bolt


CAUTION:

Refer to Fastener Caution


Tighten

10 N.m (89 lb in)

2

Engine Oil Filler Cap


3

Upper Intake Manifold Cover

Procedure

Release the upper intake manifold cover retainers by pulling the upper intake manifold cover upwards.

UPPER INTAKE MANIFOLD COVER REPLACEMENT

Removal Procedure


WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

image Identify how to disable high voltage.

image Identify how to test for the presence of high voltage.

image Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling

2. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

3. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

4. Remove Exhaust Gas Recirculation Pipe. Refer to Exhaust Gas Recirculation Pipe Replacement


image

Fig. 136: Upper Intake Manifold Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Remove Upper Intake Manifold Cover Bolts (2) (Qty: 3)

6. Remove Upper Intake Manifold Cover (1)


Installation Procedure

image

Fig. 137: Upper Intake Manifold Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Upper Intake Manifold Cover (1)


CAUTION: Refer to Fastener Caution


2. Install and tighten Upper Intake Manifold Cover Bolts (2) (Qty: 3) to 2.5 N.m (22 lb in)

3. Install Exhaust Gas Recirculation Pipe. Refer to Exhaust Gas Recirculation Pipe Replacement

4. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

5. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

6. Enable the high voltage system. Refer to High Voltage Enabling LOWER INTAKE MANIFOLD COVER REPLACEMENT

Removal Procedure


1. Remove Intake Manifold. Refer to Intake Manifold Replacement

image


Fig. 138: Lower Intake Manifold Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

2. Remove Upper Intake Manifold Cover Bolts (1) (Qty: 3)

3. Remove Lower Intake Manifold Cover (2)


Installation Procedure


image


Fig. 139: Lower Intake Manifold Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Lower Intake Manifold Cover (2)


CAUTION: Refer to Fastener Caution

2. Install and tighten Upper Intake Manifold Cover Bolts (1) (Qty: 3) to 2.5 N.m (22 lb in)

3. Install Intake Manifold. Refer to Intake Manifold Replacement INTAKE MANIFOLD REPLACEMENT

Special Tools


EN-6015 Closure Plugs

Equivalent regional tools: Special Tools (Diagnostic Tools) Special Tools (Repair Tools)

Removal Procedure


WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks: image Identify how to disable high voltage.

image Identify how to test for the presence of high voltage.

image Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling

2. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

3. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

4. Remove Evaporative Emission Canister Purge Solenoid Valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement

5. Remove Throttle Body Assembly. Refer to Throttle Body Assembly Replacement

6. Remove Manifold Absolute Pressure Sensor. Refer to Manifold Absolute Pressure Sensor Replacement

7. Remove Exhaust Gas Recirculation Pipe. Refer to Exhaust Gas Recirculation Pipe Replacement


image

Fig. 140: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

8. Disconnect Fuel Feed Front Pipe (2) @ Fuel Injection Pump (1)

9. Close all open connections with the EN-6015 plugs.


image

Fig. 141: Air Cleaner Resonator Bracket, Retainers And Bolt Courtesy of GENERAL MOTORS COMPANY

10. Unclip Retainers (1) (Qty: 2)

11. Remove Bolt (3)

12. Remove the air cleaner resonator bracket (2).


image

Fig. 142: A/C High Pressure Cutoff Switch, Electrical Connector, Retainer And Engine Wiring Harness Courtesy of GENERAL MOTORS COMPANY

13. Disconnect the electrical connector (2) from the air conditioning high pressure cutoff switch (1).

14. Unclip Retainer (3)

15. Position aside Engine Wiring Harness (4)

image

Fig. 143: Intake Manifold And Bolts

Courtesy of GENERAL MOTORS COMPANY


NOTE: Keep the fasteners in position on the assembly.


16. Loosen Bolts (2) (Qty: 5) @ Intake Manifold (1)


image

Fig. 144: Intake Manifold And Gasket Courtesy of GENERAL MOTORS COMPANY

17. Remove Intake Manifold (1)

18. Remove and DISCARD the gasket. (2)


Disassemble Procedure


1. Remove Upper Intake Manifold Cover. Refer to Upper Intake Manifold Cover Replacement

2. Remove Lower Intake Manifold Cover. Refer to Lower Intake Manifold Cover Replacement


Assemble Procedure


1. Install Upper Intake Manifold Cover. Refer to Upper Intake Manifold Cover Replacement

2. Install Lower Intake Manifold Cover. Refer to Lower Intake Manifold Cover Replacement

Installation Procedure


image

Fig. 145: Intake Manifold And Gasket Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW gasket. (2)

2. Install Intake Manifold (1)


image

Fig. 146: Intake Manifold And Bolts

Courtesy of GENERAL MOTORS COMPANY


NOTE: Keep the fasteners in position on the assembly.


3. Install Bolts (2) (Qty: 5) @ Intake Manifold

image


Fig. 147: Intake Manifold Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to:Fastener Caution


4. Tighten the 5 intake Manifold Bolts to 12 N.m (106 lb in) in the sequence as shown.


image

Fig. 148: A/C High Pressure Cutoff Switch, Electrical Connector, Retainer And Engine Wiring Harness Courtesy of GENERAL MOTORS COMPANY

5. Reposition Engine Wiring Harness (4)

6. Install Retainer (3)

7. Connect the electrical connector (2) to the air conditioning high pressure cutoff switch (1).

image

Fig. 149: Air Cleaner Resonator Bracket, Retainers And Bolt Courtesy of GENERAL MOTORS COMPANY

8. Install the air cleaner resonator bracket (2).

9. Install and tighten Bolt (3) to 9 N.m (80 lb in)

10. Install Retainers (1) (Qty: 2)


image

Fig. 150: Fuel Feed Front Pipe And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

11. Remove all EN-6015 plugs from the connections.

12. Connect Fuel Feed Front Pipe (2) @ Fuel Injection Pump (1)

13. Install Exhaust Gas Recirculation Pipe. Refer to Exhaust Gas Recirculation Pipe Replacement

14. Install Manifold Absolute Pressure Sensor. Refer to Manifold Absolute Pressure Sensor Replacement

15. Install Throttle Body Assembly. Refer to Throttle Body Assembly Replacement

16. Install Evaporative Emission Canister Purge Solenoid Valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement

17. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

18. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

19. Enable the high voltage system. Refer to High Voltage Enabling CATALYTIC CONVERTER BRACE BRACKET REPLACEMENT

Removal Procedure


1. Remove Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement


image


Fig. 151: Catalytic Converter Brace Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

2. Remove Catalytic Converter Brace Bracket Bolts (2) (Qty: 2)

3. Remove Catalytic Converter Brace Bracket (1)


Installation Procedure


image


Fig. 152: Catalytic Converter Brace Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Catalytic Converter Brace Bracket (1)


CAUTION: Refer to Fastener Caution

2. Install and tighten Catalytic Converter Brace Bracket Bolts (2) (Qty: 2) to 22 N.m (16 lb ft)

3. Install Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement CATALYTIC CONVERTER BRACKET REPLACEMENT - LOWER

Removal Procedure


1. Remove Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement


image

Fig. 153: Catalytic Converter, Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

2. Remove the 2 catalytic converter bracket nuts (3).

3. Remove the catalytic converter bracket (2) from the catalytic converter (1).


Installation Procedure


image


Fig. 154: Catalytic Converter, Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

1. Install the catalytic converter bracket (2) to the catalytic converter (1).

CAUTION: Refer to Fastener Caution


2. Install the catalytic converter bracket nuts (3) (Qty: 2) and tighten to 22 N.m (16 lb ft)

3. Install Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement CRANKSHAFT BALANCER REPLACEMENT

Special Tools


image EN-44226 Crankshaft Balancer Remover

image EN-44226-5 Crankshaft Protector

image EN-45059 Angle Meter

image EN-51368 Front Crankshaft Seal Installer Equivalent regional tools: Special Tools Removal Procedure

1. Remove Water Pump Belt. Refer to Water Pump Belt Replacement


image

Fig. 155: Crankshaft Balancer, Special Tools And Bolt Courtesy of GENERAL MOTORS COMPANY

2. Install the EN-44226-1 remover (2) to the crankshaft balancer (1).

3. Loosen the crankshaft balancer bolt (3) by counter holding the crankshaft balancer (1) with the EN-44226-1

remover (3) and suitable tool.

4. Remove the EN-44226-1 remover.

5. Remove Crankshaft Balancer Bolt


image

Fig. 156: Protector And Crankshaft

Courtesy of GENERAL MOTORS COMPANY

6. Install the EN-44226-5 protector (1) to the crankshaft (2).


image


Fig. 157: Remover Plate Assembly And Balancer Courtesy of GENERAL MOTORS COMPANY

7. Install EN-44226-1 remover (2) and EN-44226-2 remover plate (3) onto the balancer (4).

8. Install the EN-44226-3 remover screw (1) through the EN-44226-2 remover plate and against the EN-44226-5

protector.

9. Counter hold the EN-44226-2 remover plate and turn the EN-51368 installer screw to remove the balancer.

10. Remove the EN-44226 remover.

11. Remove the crankshaft balancer (4).

12. Remove the EN-44226-5 protector.


Installation Procedure


image

Fig. 158: Crankshaft Balancer And Installer Tool Courtesy of GENERAL MOTORS COMPANY

1. Install Crankshaft Balancer (1) @ Crankshaft (2)

2. Install the EN-51368 installer (3).

3. Install the crankshaft balancer by screwing the flange from EN-51368 installer.

4. Remove the EN-51368 installer.

image

Fig. 159: Crankshaft Balancer, Special Tools And Bolt Courtesy of GENERAL MOTORS COMPANY

5. Install and hand tighten the crankshaft balancer bolt (3).

6. Install the EN-44226-1 remover (2) to the crankshaft balancer (1).


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution


7. Tighten the crankshaft balancer bolt (3) by counter holding the crankshaft balancer (1) with the EN-44226-1

(3) and torque wrench.

1. First pass to 100 N.m (74 lb ft).

2. Loosen the bolt to 360 degrees.

3. Final pass to an additional 180 degrees, using the EN-45059 meter.

8. Remove EN-44226-1 remover (2) from the crankshaft balancer (1).

9. Install Water Pump Belt. Refer to Water Pump Belt Replacement CRANKSHAFT POSITION SENSOR RELUCTOR RING REPLACEMENT

Removal Procedure

1. Remove Automatic Transmission Flex Plate. Refer to Automatic Transmission Flex Plate Replacement


image

Fig. 160: Crankshaft Position Sensor Reluctor Ring Courtesy of GENERAL MOTORS COMPANY

2. Remove the crankshaft position sensor reluctor ring. (2)


Installation Procedure


image

Fig. 161: Crankshaft Position Sensor Reluctor Ring Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Crankshaft Position Sensor Reluctor Ring Caution .


1. Install the crankshaft position sensor reluctor ring. (2)

2. Install the pin (3) into the correct hole (1).

3. Install Automatic Transmission Flex Plate. Refer to Automatic Transmission Flex Plate Replacement CRANKSHAFT FRONT OIL SEAL REPLACEMENT

Special Tools

image EN-51368 Front Crankshaft Seal Installer

image DT-6125-B Slide Hammer

image DT-23129 Seal Remover Equivalent regional tools: Special Tools Removal Procedure

1. Remove Crankshaft Balancer. Refer to Crankshaft Balancer Replacement


image

Fig. 162: Identifying Crankshaft Front Oil Seal Designs Courtesy of GENERAL MOTORS COMPANY


NOTE: The engine can be equipped with two different front oil seal designs.


2. Check which one of crankshaft front oil seals (1, 2) is installed.


image


Fig. 163: Crankshaft Front Oil Seal And Removal Tool Courtesy of GENERAL MOTORS COMPANY

3. Install the DT-6125-B hammer (3) to DT-23129 seal remover (1).

4. Install the DT-6125-B hammer with the DT-23129 seal remover behind the crankshaft front oil seal (2).

5. Remove the crankshaft front oil seal (2), use the DT-6125-B hammer.


Installation Procedure


image

Fig. 164: Identifying Crankshaft Front Oil Seal Designs Courtesy of GENERAL MOTORS COMPANY


NOTE: The engine can be equipped with two different front oil seal designs.


1. Check which one of crankshaft front oil seals (1, 2) is installed.


image


Fig. 165: Crankshaft Front Oil Seal And Installer Tool (First Design) Courtesy of GENERAL MOTORS COMPANY

2. For front oil seal first design, use the following procedure:


NOTE: The special tool EN-51368 seal installer can be used in two positions, depending which crankshaft front oil seal type is used.


3. Install the crankshaft front oil seal (1) to the EN-51368 seal installer (2) with the notch on the surface (3).

image


Fig. 166: Crankshaft Front Oil Seal And Installer Tool (Second Design) Courtesy of GENERAL MOTORS COMPANY

4. For front oil seal second design, use the following procedure:


NOTE: The special tool EN-51368 seal installer can be used in two positions, depending which crankshaft front oil seal type is used.


5. Install the crankshaft front oil seal (1) to the EN-51368 seal installer (2) with the plane surface (3).


image

Fig. 167: Installing Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS COMPANY


CAUTION: Be careful that the crankshaft front oil seal does not deform while installing.

Failing to do so may reduce the leak-tightness and could cause damage to the crankshaft.


6. Press the crankshaft front oil seal into the correct seat, by tightening the nut (2) from the EN-51368 seal installer (1).

7. Remove the EN-51368 seal installer.

8. Check the correct seat of the crankshaft front oil seal.

9. Install Crankshaft Balancer. Refer to Crankshaft Balancer Replacement CRANKSHAFT REAR OIL SEAL REPLACEMENT

Special Tools


EN-51369 Rear Crankshaft Seal Installer Equivalent regional tools: Special Tools Removal Procedure

1. Remove Crankshaft Position Sensor Reluctor Ring. Refer to Crankshaft Position Sensor Reluctor Ring Replacement


image

Fig. 168: Identifying Crankshaft Rear Oil Seals Courtesy of GENERAL MOTORS COMPANY


NOTE: The engine could be equipped with two different rear oil seal designs.


2. Check which of the crankshaft rear oil seals (1, 2) are installed.


image

Fig. 169: Removing Crankshaft Rear Oil Seal

Courtesy of GENERAL MOTORS COMPANY


CAUTION: Be careful that the crankshaft will not be damaged while the crankshaft rear oil seal is pulled out. Failing to do so may reduce the leak-tightness and could cause damage to the crankshaft.


3. Use a suitable tool to remove the seal.

4. Remove Crankshaft Rear Oil Seal (1)


Installation Procedure


image

Fig. 170: RTV Sealant Application Points Courtesy of GENERAL MOTORS COMPANY

1. Inspect the seal recess (1) for excess sealer material at the lower crankcase to engine block mating location.

2. Remove excess sealer, if present.

3. Add RTV sealer at the 2 locations (1) where the bed plate and block join prior to installing the oil seal. Refer to

Adhesives, Fluids, Lubricants, and Sealers.

image


Fig. 171: Oil Seal And Installer

Courtesy of GENERAL MOTORS COMPANY


NOTE: The oil seal must be installed in the correct direction. The side that faces out will have "this side out" printed on it. Depending on seal design, the way the seal is installed on the EN-51369 installer is opposite. Either the seal is installed over the back of the installer, or the seal is installed over the front of the installer. Match the seal design as shown above and install the seal onto the installer in the correct direction.


4. Install the oil seal (1, 2) in the correct direction on the EN-51369 installer.


NOTE: If the seal is improperly installed on the special tool, it will not install correctly.


5. Inspect the seal on EN-51369 installer, and ensure that the seal lip is not deformed. If necessary, remove the seal and reinstall on the special tool.


NOTE: The special tool installs and establishes the proper depth of the seal in the crankshaft seal bore.


6. Use EN-51369 installer to press the new crankshaft seal into the housing.

image

Fig. 172: Crankshaft Rear Oil Seal Installed Properly Courtesy of GENERAL MOTORS COMPANY

7. Ensure that the crankshaft rear oil seal (1) is installed in the crankshaft seal bore flush to 0.5 mm (0.2 in) depth (2).

CRANKSHAFT SPROCKET REPLACEMENT

Removal Procedure


1. Remove Oil Pump Drive Chain. Refer to Oil Pump Drive Chain Replacement

image


Fig. 173: Crankshaft Sprocket And Balancer Key Courtesy of GENERAL MOTORS COMPANY

2. Remove Crankshaft Sprocket (1)

3. Remove the crankshaft balancer key. (2)


Installation Procedure

image


Fig. 174: Crankshaft Sprocket And Balancer Key Courtesy of GENERAL MOTORS COMPANY

1. Install the crankshaft balancer key (2).

2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.

3. Install Crankshaft Sprocket (1).

4. Install Oil Pump Drive Chain. Refer to Oil Pump Drive Chain Replacement CRANKSHAFT OIL DEFLECTOR REPLACEMENT

Removal Procedure


1. Remove Upper Oil Pan. Refer to Upper Oil Pan Replacement

image


Fig. 175: Positive Crankcase Ventilation Oil Separator Drain Pipe, Bolt And Seal Courtesy of GENERAL MOTORS COMPANY

2. Remove and DISCARD the positive crankcase ventilation oil separator drain pipe bolt (4).

3. Remove the positive crankcase ventilation oil separator drain pipe (2).

4. Remove and the positive crankcase ventilation oil separator seal (1). Check for damage.

image


Fig. 176: Crankshaft Oil Deflector And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Remove and DISCARD the 3 crankshaft oil deflector bolts (3).

6. Remove the crankshaft oil deflector. (1)


Installation Procedure

image


Fig. 177: Crankshaft Oil Deflector And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install the crankshaft oil deflector (1).


CAUTION: Refer to Fastener Caution .


2. Install the 3 NEW crankshaft oil deflector bolts (3) and tighten to 10 N.m (89 lb in).

image


Fig. 178: Positive Crankcase Ventilation Oil Separator Drain Pipe, Bolt And Seal Courtesy of GENERAL MOTORS COMPANY

3. Install the positive crankcase ventilation oil separator seal (1).

4. Install the positive crankcase ventilation oil separator drain pipe (2).

5. Install the NEW positive crankcase ventilation oil separator drain pipe bolt (4) and tighten to 10 N.m (89 lb in).

6. Install Upper Oil Pan. Refer to Upper Oil Pan Replacement ENGINE LIFT FRONT BRACKET REPLACEMENT

Removal Procedure


1. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

image


Fig. 179: Engine Wiring Harness And Retainer Courtesy of GENERAL MOTORS COMPANY

2. Remove the retainer that secures the cable to the bracket. (1)

3. Position aside Engine Wiring Harness (2).


image

Fig. 180: Engine Lift Bracket Bolt And Bolts Courtesy of GENERAL MOTORS COMPANY

4. Remove Engine Lift Bracket Bolts (2) (Qty: 2)

5. Remove Engine Lift Bracket (1)


Installation Procedure

image

Fig. 181: Engine Lift Bracket Bolt And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Lift Bracket (1)


CAUTION: Refer to Fastener Caution


2. Install and tighten Engine Lift Bracket Bolts (2) (Qty: 2) to 25 N.m (18 lb ft)


image


Fig. 182: Engine Wiring Harness And Retainer Courtesy of GENERAL MOTORS COMPANY

3. Reposition Engine Wiring Harness (2)

4. Install the retainer. (1)

5. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement ENGINE LIFT REAR BRACKET REPLACEMENT

image

Fig. 183: Engine Lift Rear Bracket

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

Remove Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement


1

Engine Lift Bracket Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution


Tighten

25 N.m (18 lb ft)

2

Engine Lift Rear Bracket

CYLINDER HEAD REPLACEMENT

Special Tools


image EN-6015 Closure Plugs

image EN-36857 Engine Lift Bracket

image EN-45059 Angle Meter

image EN-51367 Camshaft Holder Equivalent regional tools: Special Tools Removal Procedure

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks: image Identify how to disable high voltage.

image Identify how to test for the presence of high voltage.

image Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling

2. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

3. Remove Exhaust Gas Recirculation Valve. Refer to Exhaust Gas Recirculation Valve Replacement

4. Remove Camshaft Cover. Refer to Camshaft Cover Replacement

5. Remove Intake Manifold. Refer to Intake Manifold Replacement

6. Remove Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement

7. Remove Water Outlet. Refer to Water Outlet Replacement

8. Drain the engine oil. Refer to Draining Fluids and Oil Filter Removal


image


Fig. 184: Electrical Connector And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

9. Disconnect Electrical Connector (1) @ Fuel Injection Pump

10. Remove Water Pump Belt. Refer to Water Pump Belt Replacement

image

Fig. 185: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

11. Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).

12. Remove Crankshaft Balancer. Refer to Crankshaft Balancer Replacement

13. Lower the vehicle.

14. Remove Engine Mount Bracket. Refer to Engine Mount Bracket Replacement


image


Fig. 186: Oil Pan Bolts And Upper Oil Pan Courtesy of GENERAL MOTORS COMPANY

15. Remove the 3 oil pan bolts (1) from the upper oil pan.

image

Fig. 187: Engine Front Cover Bolts

Courtesy of GENERAL MOTORS COMPANY

16. Remove Engine Front Cover Bolts (2, 4) (Qty: 12)

17. Remove Engine Front Cover Bolt (1)

18. Remove Engine Front Cover Bolt (3)


image

Fig. 188: Engine Front Cover Pry Points Courtesy of GENERAL MOTORS COMPANY

19. Loosen the engine front carefully from the engine, use a suitable tool at the location as shown to pry (1, 2, 3).

image

Fig. 189: Engine Front Cover And Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS COMPANY

20. Remove Engine Front Cover (1)

21. Remove Crankshaft Front Oil Seal (2)


image


Fig. 190: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

22. Install the EN-51367 holder (1).

23. Remove Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement

image

Fig. 191: Timing Chain Tensioner In Service Position Courtesy of GENERAL MOTORS COMPANY

24. Fix the timing chain tensioner with design (1) in service position:


image


Fig. 192: Releasing Tension From Piston Courtesy of GENERAL MOTORS COMPANY

1. Slightly release tension from the piston (2) until bar (1) can be unlocked by rotating the lever (3) in direction of arrow.

image


Fig. 193: Piston And Tensioner Lever

Courtesy of GENERAL MOTORS COMPANY

2. Entirely push back the piston (1) until the tensioner lever (2) cannot be locked in this position.


image


Fig. 194: Piston

Courtesy of GENERAL MOTORS COMPANY

3. Release tension from the piston (1) until it releases for three ratchets. The three ratchets can be noticed by the click noises.

image


Fig. 195: Lever And Fixing Pin

Courtesy of GENERAL MOTORS COMPANY

4. Apply tension to the piston until the lever (1) is rotated back into the locking position where the bore in the lever aligns with the bore in the tensioner housing.

5. Fix the lever in this position with a suitable fixing pin (2).


image

Fig. 196: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

25. Remove Timing Chain Tensioner Shoe Bolt (1)

26. Remove Timing Chain Tensioner Shoe (2)

image

Fig. 197: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

27. Ensure the correct fixation of the tool (3).

28. Remove Timing Chain Tensioner Bolt (4) (Qty: 2)

29. Remove Timing Chain Tensioner (1)

30. Remove and DISCARD the gasket. (2)


image

Fig. 198: Timing Chain

Courtesy of GENERAL MOTORS COMPANY

31. Remove Timing Chain (1)

image

Fig. 199: Right Side Timing Chain Guide And Bolts Courtesy of GENERAL MOTORS COMPANY

32. Remove Timing Chain Guide Bolts (2) (Qty: 3)

33. Remove Timing Chain Guide (1)


image

Fig. 200: Engine Lift Bracket, Fixture Hook And Bolt Courtesy of GENERAL MOTORS COMPANY


NOTE: Use a device to support the engine while repositioning the lift hook.


34. Install the EN-36857 engine lift bracket (2) then install the fastener (1).

35. Reposition the engine support fixture hook (3) to the newly installed EN-36857 engine lift bracket (2).

image


Fig. 201: Cylinder Head Bolt Loosening/Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

36. Loosen the 10 cylinder head bolts in sequence as shown.


image

Fig. 202: Cylinder Head, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY


CAUTION: In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks.


37. Remove and DISCARD Cylinder Head Bolts (2) (Qty: 10)

38. Remove Cylinder Head (1)

39. Remove and DISCARD Cylinder Head Gasket (3).

40. In case of re-use, then clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.


Disassemble Procedure

1. Remove Fuel Injection Pump. Refer to Fuel Injection Pump Replacement

2. Remove Engine Lift Front Bracket. Refer to Engine Lift Front Bracket Replacement

3. Remove Engine Lift Rear Bracket. Refer to Engine Lift Rear Bracket Replacement

4. Remove Exhaust Camshaft. Refer to Exhaust Camshaft Replacement

5. Remove Intake Camshaft. Refer to Intake Camshaft Replacement

6. Remove Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement

7. Remove Hydraulic Valve Lash Adjuster. Refer to Hydraulic Valve Lash Adjuster Replacement

8. Disassembly cylinder head. Refer to Cylinder Head Disassemble


Assemble Procedure


1. Assemble cylinder head. Refer to Cylinder Head Assemble

2. Install Hydraulic Valve Lash Adjuster. Refer to Hydraulic Valve Lash Adjuster Replacement

3. Install Hydraulic Valve Lash Adjuster Arm. Refer to Hydraulic Valve Lash Adjuster Arm Replacement

4. Install Intake Camshaft. Refer to Intake Camshaft Replacement

5. Install Exhaust Camshaft. Refer to Exhaust Camshaft Replacement

6. Install Engine Lift Rear Bracket. Refer to Engine Lift Rear Bracket Replacement

7. Install Engine Lift Front Bracket. Refer to Engine Lift Front Bracket Replacement

8. Install Fuel Injection Pump. Refer to Fuel Injection Pump Replacement


Installation Procedure


1. Clean all sealing surfaces.

2. Inspect the flatness of cylinder head and the engine block sealing surfaces.


image

Fig. 203: Cylinder Head, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY


NOTE: Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.


3. Install a NEW cylinder head gasket (3).

4. Install Cylinder Head (1)

5. Install, but do NOT tighten NEW Cylinder Head Bolts (2) (Qty: 10) - Use NEW bolts.

image

Fig. 204: Cylinder Head Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution


6. Tighten Cylinder Head Bolts (2) (Qty: 10) in sequence

1. First Pass: 25 N.m (18 lb ft).

2. Second Pass: 30 N.m (22 lb ft)

3. Final Pass: 240 degrees, use the EN-45059 meter.


image

Fig. 205: Engine Lift Bracket, Fixture Hook And Bolt Courtesy of GENERAL MOTORS COMPANY


NOTE: Use a device to support the engine while repositioning the lift hook.


7. Remove Bolt (1)

8. Reposition the lift hook (3) from the EN-36857 engine lift bracket (2) to the cylinder head lift bracket.

9. Remove EN-36857 engine lift bracket

10. Remove the suitable device holding the engine during lift hook repositioning.


image

Fig. 206: Right Side Timing Chain Guide And Bolts Courtesy of GENERAL MOTORS COMPANY

11. Install Timing Chain Guide (1)

12. Install and tighten Timing Chain Guide Bolts (2) (Qty: 3) to 10 N.m (89 lb in)


image

Fig. 207: Timing Chain

Courtesy of GENERAL MOTORS COMPANY


NOTE: Ensure the actuator timing marks are approximately the 12 o'clock position.


13. Install Timing Chain (1)

image

Fig. 208: Timing Chain Marks

Courtesy of GENERAL MOTORS COMPANY

14. Ensure that the colored link (3) matches to the arrow on the crankshaft sprocket.

15. Ensure that the colored links (1, 2) match to the marks on the camshaft position adjuster actuators.


image

Fig. 209: Timing Chain Tensioner Tool, Timing Chain Tensioner, Bolts And Gasket Courtesy of GENERAL MOTORS COMPANY

16. Install a NEW gasket. (2)

17. Install Timing Chain Tensioner (1)

18. Install and tighten Timing Chain Tensioner Bolts (4) (Qty: 2) 25 N.m (18 lb ft)

image

Fig. 210: Timing Chain Tensioner Shoe And Bolt Courtesy of GENERAL MOTORS COMPANY

19. Install Timing Chain Tensioner Shoe (2)

20. Install and tighten Timing Chain Tensioner Shoe Bolt (1) to 25 N.m (18 lb ft)

21. Remove the suitable tool (3) from the timing chain tensioner.


image


Fig. 211: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

22. Remove the EN-51367 holder (1).

23. Install Timing Chain Upper Guide. Refer to Timing Chain Upper Guide Replacement

24. Check the position of the crankshaft, camshaft and camshaft position actuator adjuster:

1. Install the engine front cover with 4 bolts and the crankshaft balancer.

image

Fig. 212: Crankshaft Balancer Markings Courtesy of GENERAL MOTORS COMPANY

2. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt (3).


image


Fig. 213: Camshaft Holder

Courtesy of GENERAL MOTORS COMPANY

25. Install the EN-51367 holder (1).

26. If the EN-51367 holder (1) can be installed, the engine timing is properly adjusted.

27. Remove the EN-51367 holder.

28. Remove the engine front cover and crankshaft balancer.

image

Fig. 214: Coiled Spring Pins And Engine Front Cover Courtesy of GENERAL MOTORS COMPANY

29. Gently tap coiled spring pins (1) back into front cover so they are flush with front cover sealing surface.


image


Fig. 215: Engine Front Cover Sealant Application Areas

Courtesy of GENERAL MOTORS COMPANY


NOTE: The lower crankcase and oil pan mating surfaces must be free of contamination prior to applying the sealer.

Install and align the oil pan to block within 20 minutes of applying the sealer.

The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer.

Additional sealant is necessary to reduce the possibility of leakage where the cylinder head to engine block interface along the bead path flange on the front cover.


30. Apply approximately a 4 mm (0.16 in) thick bead of engine front cover sealant (2) to the engine lower front cover. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.

31. Apply a 3 mm (0.12 in) bead of sealer circling 3 locations (1) on the interior of the engine front cover.


image

Fig. 216: Oil Pan Sealant Application Areas Courtesy of GENERAL MOTORS COMPANY

32. Apply a 3 mm (0.12 in) bead of sealer circling 3 locations (1) on the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.

image

Fig. 217: Engine Front Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

33. Install Engine Front Cover (1)

34. Install Engine Front Cover Bolts (2) (Qty: 2)

35. Hand tighten the bolts.


image

Fig. 218: Coiled Spring Pins And Engine Front Cover Courtesy of GENERAL MOTORS COMPANY

36. Gently tap coiled spring pins (1) back into cover until pins are flush with front cover (2).

image

Fig. 219: Engine Front Cover Bolts

Courtesy of GENERAL MOTORS COMPANY

37. Install Engine Front Cover Bolt (2, 4) (Qty: 10)

38. Install Engine Front Cover Bolt (1)

39. Install Engine Front Cover Bolt (3)


image

Fig. 220: Engine Front Cover Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

40. Tighten the bolts in the sequence shown.

41. Tighten Engine Front Cover Bolt (2) to 58 N.m (43 lb ft)

42. Tighten all other engine front cover bolts to 15 N.m (11 lb ft).

image


Fig. 221: Oil Pan Bolts And Upper Oil Pan Courtesy of GENERAL MOTORS COMPANY

43. Install and tighten Oil Pan Bolts (1) (Qty: 3) to 10 N.m (89 lb in).

44. Install Crankshaft Balancer. Refer to Crankshaft Balancer Replacement

45. Install Water Pump Belt. Refer to Water Pump Belt Replacement

46. Lower the vehicle.

47. Install Engine Mount Bracket. Refer to Engine Mount Bracket Replacement


image


Fig. 222: Electrical Connector And Fuel Injection Pump Courtesy of GENERAL MOTORS COMPANY

48. Connect Electrical Connector (1) @ Fuel Injection Pump

49. Install Water Outlet. Refer to Water Outlet Replacement

50. Install Three-Way Catalytic Converter. Refer to Three-Way Catalytic Converter Replacement

51. Install Intake Manifold. Refer to Intake Manifold Replacement

52. Install Camshaft Cover. Refer to Camshaft Cover Replacement

53. Install Exhaust Gas Recirculation Valve. Refer to Exhaust Gas Recirculation Valve Replacement

54. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

55. Fill the engine oil to the proper level with NEW engine oil. Refer to Approximate Fluid Capacities

56. Enable the high voltage system. Refer to High Voltage Enabling ENGINE FRONT COVER REPLACEMENT

Removal Procedure


1. Remove Camshaft Cover. Refer to Camshaft Cover Replacement

2. Remove Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

3. Remove Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

4. Remove Crankshaft Balancer. Refer to Crankshaft Balancer Replacement


NOTE: Remove the air conditioning and drive motor battery cooling compressor replacement without disconnect any hoses and lines.


5. Reposition away Air Conditioning and Drive Motor Battery Cooling Compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

6. Drain the engine oil. Refer to Draining Fluids and Oil Filter Removal

7. Remove Engine Mount Bracket. Refer to Engine Mount Bracket Replacement


image


Fig. 223: Oil Pan Bolts And Upper Oil Pan Courtesy of GENERAL MOTORS COMPANY

8. Remove Oil Pan Bolts (1) (Qty: 3) @ Upper Oil Pan

image

Fig. 224: Engine Front Cover Bolts

Courtesy of GENERAL MOTORS COMPANY

9. Remove Engine Front Cover Bolts (2, 4) (Qty: 12)

10. Remove Engine Front Cover Bolt (1)

11. Remove Engine Front Cover Bolt (3)


image

Fig. 225: Engine Front Cover Pry Points Courtesy of GENERAL MOTORS COMPANY

12. Loosen the engine front cover carefully from the engine, use a suitable tool at the location as shown to pry (1, 2, 3).

image

Fig. 226: Engine Front Cover And Crankshaft Front Oil Seal Courtesy of GENERAL MOTORS COMPANY

13. Remove Engine Front Cover (1)

14. Remove Crankshaft Front Oil Seal (2)

15. Clean all sealing surfaces.


Installation Procedure


image


Fig. 227: Coiled Spring Pins And Engine Front Cover Courtesy of GENERAL MOTORS COMPANY

1. Gently tap coiled spring pins (1) back into front cover so they are flush with front cover sealing surface.

image


Fig. 228: Engine Front Cover Sealant Application Areas Courtesy of GENERAL MOTORS COMPANY


NOTE: The lower crankcase and oil pan mating surfaces must be free of contamination prior to applying the sealer.

Install and align the oil pan to block within 20 minutes of applying the sealer.

The oil pan must be fastened to final torque specification within 20 minutes of applying the sealer.

Additional sealant is necessary to reduce the possibility of leakage where the cylinder head to engine block interface along the bead path flange on the front cover.


2. Apply approximately a 4 mm (0.16 in) thick bead of engine front cover sealant (2) to the engine lower front cover. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.

3. Apply a 3 mm (0.12 in) bead of sealer circling 3 locations (1) on the interior of the engine front cover.

image

Fig. 229: Oil Pan Sealant Application Areas Courtesy of GENERAL MOTORS COMPANY

4. Apply a 3 mm (0.12 in) bead of sealer circling 3 locations (1) on the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.


image

Fig. 230: Engine Front Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Install Engine Front Cover (1)

6. Install Engine Front Cover Bolts (2) (Qty: 2)

7. Hand tighten the bolts.

image

Fig. 231: Coiled Spring Pins And Engine Front Cover Courtesy of GENERAL MOTORS COMPANY

8. Gently tap coiled spring pins (1) back into cover until pins are flush with front cover (2).


image

Fig. 232: Engine Front Cover Bolts

Courtesy of GENERAL MOTORS COMPANY

9. Install Engine Front Cover Bolts (2, 4) (Qty: 10)

10. Install Engine Front Cover Bolt (1)

11. Install Engine Front Cover Bolt (3)

image

Fig. 233: Engine Front Cover Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution


12. Tighten the bolts in the sequence shown.

13. Tighten Engine Front Cover Bolt (2) to 58 N.m (43 lb ft)

14. Tighten all other engine front cover bolts to 15 N.m (11 lb ft).


image


Fig. 234: Oil Pan Bolts And Upper Oil Pan Courtesy of GENERAL MOTORS COMPANY

15. Install and tighten Oil Pan Bolts (1) (Qty: 3) to 10 N.m (89 lb in)

16. Install Crankshaft Front Oil Seal. Refer to Crankshaft Front Oil Seal Replacement

17. Lower the vehicle.

18. Install Engine Mount Bracket. Refer to Engine Mount Bracket Replacement

19. Install Air Conditioning and Drive Motor Battery Cooling Compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

20. Install Crankshaft Balancer. Refer to Crankshaft Balancer Replacement

21. Install Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

22. Install Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

23. Install Camshaft Cover. Refer to Camshaft Cover Replacement

24. Check and correct the engine oil level. Refer to Approximate Fluid Capacities ENGINE MOUNT BRACKET REPLACEMENT

Special Tools


EN-45059 Angle Meter

Equivalent regional tools: Special Tools

Removal Procedure


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

2. Remove Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

3. Lower the vehicle.

4. Install Engine Support Fixture. Refer to Engine Support Fixture

5. Remove Engine Mount. Refer to Engine Mount Replacement

6. Adjust the engine support fixture to position the engine as necessary to gain access the engine mount bracket bolts.


image

Fig. 235: Engine Mount Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

7. Remove and DISCARD Engine Mount Bracket Bolt (1) @ Engine Mount Bracket (2)

image

Fig. 236: Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

8. Remove and DISCARD Engine Mount Bracket Bolts (2) (Qty: 2)

9. Remove Engine Mount Bracket (1)


Installation Procedure


image

Fig. 237: Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Mount Bracket (1)

2. Install NEW Engine Mount Bracket Bolts (2) (Qty: 2). Use NEW bolts.

image

Fig. 238: Engine Mount Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

3. Install NEW Engine Mount Bracket Bolt (1). Install a NEW bolt.


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution


4. Tighten Engine Mount Bracket Bolts (Qty: 3)

1. First Pass: 58 N.m (43 lb ft).

2. Final Pass: 90 - 105 degrees, use the EN-45059 meter.

5. Install Engine Mount. Refer to Engine Mount Replacement

6. Remove Engine Support Fixture. Refer to Engine Support Fixture

7. Raise the vehicle.

8. Install Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

9. Lower the vehicle.

ENGINE MOUNT REPLACEMENT

Special Tools


J-36857 Engine Lift Bracket

Equivalent regional tools: Special Tools

Removal Procedure


1. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

image

Fig. 239: Engine Lift Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

2. Install the J-36857 Bracket (2) into the engine block bore.


CAUTION: Refer to Fastener Caution


3. Install and tighten Engine Lift Bracket Bolt (1) to 25 N.m (18 lb ft)

4. Using a hydraulic engine lifter, support the engine at the J-36857 Bracket Apply tension to the hydraulic lifter.


image

Fig. 240: Engine Mount, Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Remove and DISCARD the 2 engine mount to engine mount bracket bolts (2).

6. Remove and DISCARD the 3 engine mount to body bolts (1, 3).

7. Remove Engine Mount (4)


Installation Procedure

image

Fig. 241: Engine Mount, Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Engine Mount (4)

2. Install 3 NEW engine mount to body bolts (1, 3) and tighten in two passes:


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution


1. First Pass: 100 N.m (74 lb ft)

2. Final Pass: 60 - 75 degrees - EN-45059 meter

3. Install 2 NEW engine mount to engine mount bracket bolts (2) and tighten in two passes:


CAUTION: Refer to Torque-to-Yield Fastener Caution


1. First Pass: 100 N.m (74 lb ft)

2. Final Pass: 60 - 75 degrees - EN-45059 meter

4. Remove the hydraulic engine lifter from the J-36857 Bracket.


image

Fig. 242: Engine Lift Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

5. Remove Engine Lift Bracket Bolt (1)

6. Remove the J-36857 Bracket (2).

7. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement UPPER OIL PAN REPLACEMENT

Removal Procedure


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

2. Remove Front Compartment Air Deflector. Refer to Front Compartment Air Deflector Replacement

3. Remove Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement


image

Fig. 243: Lower Oil Pan And Locating Pins Courtesy of GENERAL MOTORS COMPANY

4. Remove Lower Oil Pan (2). Refer to Lower Oil Pan Replacement

5. Remove Transmission Mount Strut Bracket. Refer to Transmission Mount Strut Bracket Replacement

6. Remove Exhaust Muffler. Refer to Exhaust Muffler Replacement

7. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement

image


Fig. 244: Drivetrain And Front Suspension Cradle, Brace And Bolts Courtesy of GENERAL MOTORS COMPANY

8. Remove the drivetrain and front suspension brace bolts (3).

9. Remove the drivetrain and front suspension brace (2) from the drivetrain and front suspension cradle (1).


image

Fig. 245: Engine Oil Level Indicator Control Module Wiring Harness And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

10. Disconnect Electrical Connector (1) @ Engine Oil Level Indicator Control Module Wiring Harness (2)

image

Fig. 246: Oil Pump Flow Control Solenoid Valve And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

11. Disconnect Electrical Connector (2) @ Oil Pump Flow Control Solenoid Valve (1)


image

Fig. 247: Engine Oil Level Indicator Control Module, Wiring Harness And Bolt Courtesy of GENERAL MOTORS COMPANY

12. Remove the oil level indicator control module bolt. (1)

13. Remove Engine Oil Level Indicator Control Module Wiring Harness (2)

image


Fig. 248: Transmission Converter Cover And Transmission Bolts Courtesy of GENERAL MOTORS COMPANY

14. Remove Transmission Bolts (1, 2) (Qty: 3)

15. Remove the transmission converter cover (3).


image


Fig. 249: Heater Inlet And Outlet Hose Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

16. Remove Heater Inlet and Outlet Hose Bracket Bolt (1)

17. Position aside Heater Inlet and Outlet Hose Bracket (2)

18. Lower the vehicle.

19. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

20. Install Engine Support Fixture. Refer to Engine Support Fixture

image

Fig. 250: Engine Mount, Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

21. Remove and DISCARD the 2 engine mount to engine mount bracket bolts (2).

22. Remove and DISCARD the 3 engine mount to body bolts (1, 3).

23. Remove Engine Mount (4)

24. Raise the engine with the engine support fixture to gain enough space for the removal of the upper oil pan.

25. Raise the vehicle.


image


Fig. 251: Oil Pan Bolts

Courtesy of GENERAL MOTORS COMPANY


NOTE: Take note that there are different bolt lengths.


26. Remove the oil pan bolts. (4) (Qty: 2)

27. Remove the oil pan bolts. (3) (Qty: 2)

28. Remove the oil pan bolts. (1, 2) (Qty: 12)

image

Fig. 252: Upper Oil Pan

Courtesy of GENERAL MOTORS COMPANY

29. Loosen the upper oil pan (2) carefully from the engine block, use a suitable tool at the location as shown to pry (1, 3).

30. Remove Upper Oil Pan (2)


Installation Procedure


NOTE: The lower crankcase and oil pan mating surfaces must be free of contamination prior to applying the sealer.

Install and align the oil pan to block within 20 minutes of applying the sealer.

The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer.

Additional sealant is necessary to reduce the possibility of leakage where the cylinder head to engine block interface along the bead path flange on the front cover.


1. Clean the oil pan sealing surface.


image

Fig. 253: Upper Oil Pan Sealer Application Areas Courtesy of GENERAL MOTORS COMPANY

2. Apply a 2.25 mm (0.088 in) bead of sealer (1) around the perimeter of the upper oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers.


image

Fig. 254: Upper Oil Pan

Courtesy of GENERAL MOTORS COMPANY

3. Install Upper Oil Pan (2)


image


Fig. 255: Oil Pan Bolts

Courtesy of GENERAL MOTORS COMPANY


NOTE: Take note that there are different bolt lengths.


4. Coat the oil pan bolts (1) (2) (3) and (4) with teflon pipe sealant prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers

5. Hand tighten Oil Pan Bolts (4) (Qty: 2)

6. Hand tighten Oil Pan Bolts (1) (Qty: 2)

7. Hand tighten Oil Pan Bolts (2, 3) (Qty: 12)

image


Fig. 256: Upper Oil Pan Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution


NOTE: Inspect for excessive sealer around the oil filter mounting area. If extra sealer is present remove and clean accordingly.


8. Tighten Oil Pan Bolts in sequence (Qty: 16) to 10 N.m (89 lb in)

9. Lower the vehicle.

10. Move back the engine into original position.


image

Fig. 257: Engine Mount, Engine Mount Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

11. Install Engine Mount (4)

12. Install 3 NEW engine mount to body bolts (1, 3) and tighten in two passes:


CAUTION: Refer to Torque-to-Yield Fastener Caution


1. First Pass: 100 N.m (74 lb ft)

2. Final Pass: 60 - 75 degrees - EN-45059 meter

13. Install 2 NEW engine mount to engine mount bracket bolts (2) and tighten in two passes:

1. First Pass: 100 N.m (74 lb ft)

2. Final Pass: 60 - 75 degrees - EN-45059 meter

14. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

15. Remove Engine Support Fixture. Refer to Engine Support Fixture

16. Raise the vehicle.


image


Fig. 258: Heater Inlet And Outlet Hose Bracket And Bolt Courtesy of GENERAL MOTORS COMPANY

17. Install Heater Inlet and Outlet Hose Bracket (2)

18. Install and tighten Heater Inlet and Outlet Hose Bracket Bolt (1) to 58 N.m (43 lb ft)


image


Fig. 259: Transmission Converter Cover And Transmission Bolts Courtesy of GENERAL MOTORS COMPANY

19. Install the transmission converter cover (3).

20. Install and tighten Transmission Bolts (1, 2) (Qty: 3) to 58 N.m (43 lb ft)

image

Fig. 260: Engine Oil Level Indicator Control Module, Wiring Harness And Bolt Courtesy of GENERAL MOTORS COMPANY

21. Install Engine Oil Level Indicator Control Module Wiring Harness (2)

22. Install and tighten the drivetrain and front suspension brace bolts (3) to 10 N.m (89 lb in)


image

Fig. 261: Oil Pump Flow Control Solenoid Valve And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

23. Connect Electrical Connector (2) @ Oil Pump Flow Control Solenoid Valve (1)

image

Fig. 262: Engine Oil Level Indicator Control Module Wiring Harness And Electrical Connector Courtesy of GENERAL MOTORS COMPANY

24. Connect Electrical Connector (1) @ Engine Oil Level Indicator Control Module Wiring Harness (2)


image


Fig. 263: Drivetrain And Front Suspension Cradle, Brace And Bolts Courtesy of GENERAL MOTORS COMPANY

25. Install the drivetrain and front suspension brace (2) to the drivetrain and front suspension cradle (1).

26. Install and tighten the drivetrain and front suspension brace bolts (3) to 58 N.m (43 lb ft)

27. Install Exhaust Muffler. Refer to Exhaust Muffler Replacement

28. Install Transmission Mount Strut Bracket. Refer to Transmission Mount Strut Bracket Replacement

image

Fig. 264: Lower Oil Pan And Locating Pins Courtesy of GENERAL MOTORS COMPANY

29. Install Lower Oil Pan (2). Refer to Lower Oil Pan Replacement

30. Install Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

31. Install Front Compartment Air Deflector. Refer to Front Compartment Air Deflector Replacement

32. Lower the vehicle.

33. Fill the engine oil to the proper level with NEW engine oil. Refer to Engine Oil and Oil Filter Replacement. LOWER OIL PAN REPLACEMENT

Removal Procedure


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

2. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement


image

Fig. 265: Lower Oil Pan And Bolts

Courtesy of GENERAL MOTORS COMPANY

3. Remove the oil pan bolts. (3) (Qty: 12)

4. Loosen the lower oil pan (1) carefully from the upper oil pan, use a suitable tool to pry at the location as

shown (2).


image

Fig. 266: Lower Oil Pan And Locating Pins Courtesy of GENERAL MOTORS COMPANY

5. Remove and DISCARD Lower Oil Pan (2)


Installation Procedure


NOTE: The complete installation procedure of the lower oil pan should be completed within 20 minutes.


1. Clean the oil pan sealing surface.


image


Fig. 267: Lower Oil Pan Sealer Application Areas Courtesy of GENERAL MOTORS COMPANY

2. Apply a 2.25 mm (0.088 in) bead of sealer (1) around the perimeter of the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers

image

Fig. 268: Lower Oil Pan And Locating Pins Courtesy of GENERAL MOTORS COMPANY


NOTE: Install a NEW oil pan.


3. Install NEW Lower Oil Pan (2)

4. The Pins (1) must fit into the holes.


image

Fig. 269: Lower Oil Pan And Bolts

Courtesy of GENERAL MOTORS COMPANY

5. Install and hand tighten the 12 oil pan bolts (3) to the lower oil pan (1).

image

Fig. 270: Lower Oil Pan Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


6. Tighten the 12 lower oil pan bolts in sequence as shown to 10 N.m (89 lb in).

7. Lower the vehicle.

8. Fill and check the engine oil level. Refer to Engine Oil and Oil Filter Replacement. ENGINE OIL AND OIL FILTER REPLACEMENT

Special Tools


EN-726-A Oil Filter Wrench Equivalent regional tools: Special Tools Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

2. Remove Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

3. Place a drain pan under the vehicle.


image

Fig. 271: Oil Pan Drain Plug And Seal Courtesy of GENERAL MOTORS COMPANY

4. Remove the oil pan drain plug. (2)


NOTE: Inspect the oil drain plug seal ring, replace only if damaged.


5. Remove Oil Pan Drain Plug Seal (1)

6. Drain the engine oil into a suitable container.


image

Fig. 272: Oil Filter And Wrench

Courtesy of GENERAL MOTORS COMPANY

7. Install the EN-726-A wrench (2) to the oil filter (1).


NOTE: Ensure that the old oil filter seal has been removed.


8. Remove and DISCARD the oil filter. (1)


Installation Procedure


image

Fig. 273: Oil Pan Drain Plug And Seal

Courtesy of GENERAL MOTORS COMPANY


NOTE: Clean and inspect the oil pan drain plug, replace if necessary.


1. Install Oil Pan Drain Plug Seal (1)


CAUTION: Refer to Component Fastener Tightening Caution


2. Install and tighten Oil Pan Drain Plug (2) to 25 N.m (18 lb ft)


image

Fig. 274: Oil Filter And Wrench

Courtesy of GENERAL MOTORS COMPANY

3. Clean the engine block sealing surface.

4. Lubricate the NEW oil filter gasket with clean engine oil.

5. Install the EN-726-A wrench (2) to the oil filter (1).

6. Install a NEW oil filter and tighten 3/4 to 1 full turn after the gasket makes contact with the sealing surface on the filter mounting flange. (1)

7. Remove the EN-762-A wrench (2) from the oil filter (1).

8. Install Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

9. Lower the vehicle.


CAUTION: Using engine oils of any viscosity other than those viscosities recommended could result in engine damage.


10. Fill in NEW engine oil. Refer to Approximate Fluid Capacities.

11. Start the engine and allow it to run until the oil pressure control indicator goes off.

12. Check and correct the engine oil level.

13. Reset the GM oil life system. Refer to GM Oil Life System Resetting GM Oil Life System Resetting (With Scan Tool) .

OIL PUMP FLOW CONTROL SOLENOID VALVE REPLACEMENT

Removal Procedure


1. Remove Lower Oil Pan. Refer to Lower Oil Pan Replacement

image


Fig. 275: Oil Pump Flow Control Solenoid Valve, Wiring Harness Plug, Retainer Clamp And Seals Courtesy of GENERAL MOTORS COMPANY

2. Disconnect the wiring harness plug (4) from the oil pump flow control solenoid valve (3)

3. Remove the oil pump flow control solenoid valve retainer clamp (2).

4. Remove the oil pump flow control solenoid valve (3).

5. Remove and DISCARD the 2 oil pump flow control solenoid valve seals (1)


Installation Procedure

image


Fig. 276: Oil Pump Flow Control Solenoid Valve, Wiring Harness Plug, Retainer Clamp And Seals Courtesy of GENERAL MOTORS COMPANY

1. Install 2 NEW oil pump flow control solenoid valve seals (1)

2. Install the oil pump flow control solenoid valve (3).

3. Install the oil pump flow control solenoid valve retainer clamp (2).

4. Connect the wiring harness plug (4) to the oil pump flow control solenoid valve (3)

5. Install Lower Oil Pan. Refer to Lower Oil Pan Replacement OIL PUMP DRIVE CHAIN REPLACEMENT

Removal Procedure


1. Remove Camshaft Timing Chain. Refer to Camshaft Timing Chain Replacement

2. Remove Oil Pump. Refer to Oil Pump Replacement

image


Fig. 277: Oil Pump Drive Chain Tensioner Courtesy of GENERAL MOTORS COMPANY

3. Tension the oil pump drive chain tensioner (1) in direction of the arrow.

4. Install a suitable locking pin tool into the hole of the oil pump drive chain tensioner (1) as shown in pry (2).

image


Fig. 278: Oil Pump Drive Chain And Crankshaft Sprocket Courtesy of GENERAL MOTORS COMPANY

5. Remove the oil pump drive chain (1) from the crankshaft sprocket (2).


Installation Procedure

image


Fig. 279: Oil Pump Drive Chain And Crankshaft Sprocket Courtesy of GENERAL MOTORS COMPANY

1. Install the oil pump drive chain (1) to the crankshaft sprocket (2).

image


Fig. 280: Oil Pump Drive Chain Tensioner Courtesy of GENERAL MOTORS COMPANY

2. Remove the suitable locking pin tool from the oil pump drive chain tensioner (1).

3. Install Oil Pump. Refer to Oil Pump Replacement

4. Install Camshaft Timing Chain. Refer to Camshaft Timing Chain Replacement OIL PUMP DRIVE CHAIN TENSIONER REPLACEMENT

Removal Procedure


1. Remove Engine Front Cover. Refer to Engine Front Cover Replacement

2. Remove Upper Oil Pan. Refer to Upper Oil Pan Replacement

image


Fig. 281: Oil Pump Drive Chain Tensioner Courtesy of GENERAL MOTORS COMPANY

3. Tension the oil pump drive chain tensioner (1) in direction of the arrow.

4. Install a suitable locking pin tool into the hole of the oil pump drive chain tensioner as shown in pry (2).

image


Fig. 282: Oil Pump Drive Chain Tensioner And Bolt Courtesy of GENERAL MOTORS COMPANY

5. Remove the oil pump drive chain tensioner bolt (2).

6. Remove the oil pump drive chain tensioner (1).


Installation Procedure

image


Fig. 283: Oil Pump Drive Chain Tensioner And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Install the oil pump drive chain tensioner (1).


CAUTION: Refer to Fastener Caution .


2. Install the oil pump drive chain tensioner bolt (2) and tighten to 10 N.m (89 lb in).

3. Remove the suitable locking pin tool from the oil pump drive chain tensioner.

4. Install Upper Oil Pan. Refer to Upper Oil Pan Replacement

5. Install Engine Front Cover. Refer to Engine Front Cover Replacement OIL PUMP REPLACEMENT

Removal Procedure


1. Remove Upper Oil Pan. Refer to Upper Oil Pan Replacement

image


Fig. 284: Oil Pump, Bolts, Retainers, Oil Pump Drive Chain And Tensioner Courtesy of GENERAL MOTORS COMPANY

2. Disconnect the wiring harness plug from the oil pump flow control solenoid valve.

3. Remove Oil Pump Bolts (3) (Qty: 4)

4. Remove and DISCARD the 4 oil pump bolt retainers (2, 4).

5. Release the oil pump drive chain tensioner (6).


NOTE: image A second technician is required.

image Inspect the correct seat of the oil pump drive chain on the crankshaft sprocket.


6. Move the oil pump assembly (1) in the arrow direction to separate it from the oil pump drive chain (5).

image


Fig. 285: Oil Pump And Gaskets

Courtesy of GENERAL MOTORS COMPANY

7. Remove and DISCARD the oil pump gasket (2).

8. Remove and DISCARD the oil pump gasket (4).


Disassemble Procedure


Remove Oil Pump Flow Control Solenoid Valve. Refer to Oil Pump Flow Control Solenoid Valve Replacement

Assemble Procedure


Install Oil Pump Flow Control Solenoid Valve. Refer to Oil Pump Flow Control Solenoid Valve Replacement

Installation Procedure

image


Fig. 286: Oil Pump And Gaskets

Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW oil pump gasket (4)

2. Install a NEW oil pump gasket (2)

3. Release the oil pump drive chain tensioner.


NOTE: image A second technician is required.

image Inspect the correct seat of the oil pump drive chain on the crankshaft sprocket.


4. Install the oil pump assembly (3) with the pins (1).

image


Fig. 287: Oil Pump, Bolts, Retainers, Oil Pump Drive Chain And Tensioner Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


5. Install 4 NEW oil pump bolt retainers (2, 4).

6. Install and tighten Oil Pump Bolts (3) (Qty: 4) to 10 N.m (89 lb in).

7. Connect the wiring harness plug to the oil pump flow control solenoid valve.

8. Install Upper Oil Pan. Refer to Upper Oil Pan Replacement ENGINE REPLACEMENT

Special Tools


image CH-42188-B Ball Joint Separator

image CH-51034 Cradle Alignment Guide Pin

image EN-45059 Angel Meter Equivalent regional tools: Special Tools Removal Procedure

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks: image Identify how to disable high voltage.

image Identify how to test for the presence of high voltage.

image Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling

2. Remove Intermediate Steering Shaft Lower Bolt. Refer to Intermediate Steering Shaft Replacement

3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

4. Drain the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling

5. Drain the drive motor generator power inverter module cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling

6. Drain the coolant. Refer to Cooling System Draining and Filling

7. Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement

8. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement

9. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement

10. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement

11. Remove 300-Volt Battery Positive and Negative Cable @ Transmission. Refer to Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Power Inverter Module and A/C Compressor

12. Remove Engine Wiring Harness Junction Block. Refer to Engine Wiring Harness Junction Block Replacement


image

Fig. 288: Ground Cable, Nut, Engine Wiring Harness, Clips And Electrical Connectors

Courtesy of GENERAL MOTORS COMPANY

13. Remove Ground Cable Nut (2)

14. Remove Ground Cable (1)

15. Remove the electrical connector (3) in top direction from the front compartment fuse block housing.

16. Unclip Engine Wiring Harness (5) @ Clips (4) (Qty: 2)

17. Disconnect the electrical connectors. (6, 7) (Qty: 2)


image


Fig. 289: Fuel Feed Pipe, Fuel Feed Front Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

18. Remove Fuel Feed Front Pipe (2) @ Retainer (3)

19. Disconnect Fuel Feed Front Pipe (2) @ Fuel Feed Pipe (1). Refer to Plastic Collar Quick Connect Fitting Service

20. Close all open connections with the EN-6015 plugs.


image


Fig. 290: Evaporative Emission Canister Purge Solenoid Valve And Evaporative Emission Pipe Courtesy of GENERAL MOTORS COMPANY

21. Disconnect Evaporative Emission Pipe (1) @ Evaporative Emission Canister Purge Solenoid Valve (3). Refer to Plastic Collar Quick Connect Fitting Service

22. Close all open connections with the EN-6015 plugs.

23. Remove Heater Water Shutoff Valve Inlet Hose. Refer to Heater Water Shutoff Valve Inlet Hose Replacement


image

Fig. 291: Range Selector Lever Cable And Range Selector Lever Cable Lever Courtesy of GENERAL MOTORS COMPANY

24. Remove Range Selector Lever Cable (1) @ Range Selector Lever Cable Lever


image

Fig. 292: Range Selector Lever Cable And Transmission Range Selector Lever Cable Bracket Courtesy of GENERAL MOTORS COMPANY

25. Remove Range Selector Lever Cable (1) @ Transmission Range Selector Lever Cable Bracket

26. Release the cable from the bracket by pushing the retainer (arrow).

image

Fig. 293: Engine Coolant Thermostat Housing, Radiator Outlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

27. Remove Radiator Outlet Hose Clamp (2)

28. Remove Radiator Outlet Hose (3) @ Engine Coolant Thermostat Housing (1)


image

Fig. 294: Water Outlet, Radiator Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

29. Remove Radiator Inlet Hose Clamp (2)

30. Remove Radiator Inlet Hose (1) @ Water Outlet (3)

31. Install the engine support fixture. Refer to Engine Support Fixture

32. Remove the left side headlamp assembly. Refer to Headlamp Replacement

image

Fig. 295: Engine Wiring Harness And Clips Courtesy of GENERAL MOTORS COMPANY

33. Unclip Engine Wiring Harness (1) @ Wiring Harness Clips (2) (Qty: 2)


image

Fig. 296: Wiring Harness Clip And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

34. Unclip Wiring Harness Clip (2)


CAUTION: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch the connector pins.


35. Disconnect the electrical connectors. (1) (Qty: 3)

36. Place the engine wiring harness at the top of the engine assembly.

image

Fig. 297: Engine Ground Strap Bolt And Retainer Courtesy of GENERAL MOTORS COMPANY

37. Remove the engine ground strap bolt (1).

38. Unclip Wiring Harness Clip (2)

39. Remove Exhaust Muffler. Refer to Exhaust Muffler Replacement


image


Fig. 298: Exhaust Front Pipe, Nuts And Gasket Courtesy of GENERAL MOTORS COMPANY


CAUTION: Do not bend the exhaust flex pipe more than 10 degrees in any direction.

Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.


40. Remove Exhaust Front Pipe Nuts (3) (Qty: 2)

41. Remove Exhaust Front Pipe (2)

42. Remove and DISCARD the gasket. (1)

image

Fig. 299: Heater Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

43. Remove Clamp (1)

44. Remove Heater Inlet Hose (2)


image

Fig. 300: Heater Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

45. Remove Clamp (2)

46. Remove Heater Inlet Hose (1)

image


Fig. 301: Heater Inlet Hose, Clamp And Clip Courtesy of GENERAL MOTORS COMPANY

47. Remove Clamp (1)

48. Remove Heater Inlet Hose (2)

49. Unclip Heater Inlet Hose @ Clip (3)

50. Remove Generator Control Module Coolant Pump. Refer to Generator Control Module Coolant Pump Replacement

51. Remove Heater Inlet and Outlet Pipe. Refer to Heater Inlet And Outlet Pipe Replacement

52. Remove Heater Coolant Pump. Refer to Heater Coolant Pump Replacement

53. Remove Heater Coolant Heater. Refer to Heater Coolant Heater Replacement

54. Remove Heater Water Shutoff Valve. Refer to Heater Water Shutoff Valve Replacement


image


Fig. 302: Coolant Hose And Clips

Courtesy of GENERAL MOTORS COMPANY

55. Remove Clip (1) (Qty: 2)

56. Remove Coolant Hose (2)

image


Fig. 303: Drive Motor Battery Coolant Cooler Inlet Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

57. Remove the drive motor battery coolant cooler inlet hose (1) from the retainer (2) and reposition.


image

Fig. 304: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

58. Remove the condenser tube nut (3).

59. Remove the air conditioning evaporator tube (1) along with the condenser tube (2) from the condenser.

image

Fig. 305: Air Conditioning Compressor, Condenser Hose And Bolt Courtesy of GENERAL MOTORS COMPANY

60. Remove the air conditioning compressor and condenser hose bolt (1).

61. Remove the air conditioning compressor and condenser hose (2) from the air conditioning compressor (3).


image

Fig. 306: A/C Compressor And Condenser Hose Tube, Retainer, Wiring Harness And Cycling Switch Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

62. Unclip the retainer (1) holding the air conditioning compressor and condenser hose tube to the engine bracket.

63. Unclip the wiring harness (2) from the air conditioning compressor and condenser hose tube.

64. Disconnect the air conditioning cycling switch electrical connector (3).

65. Remove the air conditioning compressor and condenser hose tube (1).

image

Fig. 307: Air Conditioning Compressor Hose Bolt And Air Conditioning Evaporator Hose Courtesy of GENERAL MOTORS COMPANY

66. Remove the air conditioning compressor hose bolt (1) from the air conditioning evaporator hose (2).

67. Remove Air Conditioning Compressor Hose


image


Fig. 308: Radiator And Lashing Straps Courtesy of GENERAL MOTORS COMPANY

68. Secure the radiator (2) using 2 lashing straps (1)

69. Remove Underbody Front Air Deflector-Left Side. Refer to Underbody Front Air Deflector Replacement - Left Side

70. Drain the transmission. Refer to Transmission Fluid Drain and Fill

image

Fig. 309: Transmission Fluid Cooler Outlet Pipe, Bolt And Sealing Washer Courtesy of GENERAL MOTORS COMPANY

71. Place a container beneath the transmission fluid cooler outlet pipe (2) to catch spilling transmission fluid.

72. Remove Transmission Fluid Cooler Pipe Bolt (1)

73. Disconnect Transmission Fluid Cooler Outlet Pipe (2)

74. Remove and DISCARD Sealing Washer (3)


image

Fig. 310: Transmission Fluid Cooler Inlet Pipe, Bolt And Sealing Washer Courtesy of GENERAL MOTORS COMPANY

75. Place a container beneath the transmission fluid cooler inlet pipe (3) to catch spilling transmission fluid.

76. Remove Transmission Fluid Cooler Pipe Bolt (1)

77. Disconnect Transmission Fluid Cooler Inlet Pipe (3)

78. Remove and DISCARD Sealing Washer (2)

image

Fig. 311: Drive Motor Generator Control Module Cooling Outlet Hose And Bolts Courtesy of GENERAL MOTORS COMPANY

79. Remove Drive Motor Generator Control Module Cooling Outlet Hose Bolt (1) (Qty: 2)

80. Remove and DISCARD Seal (2)


image

Fig. 312: Stabilizer Shaft Link, Stabilizer Shaft And Nut Courtesy of GENERAL MOTORS COMPANY


NOTE: Hold against the hex of the threaded stud to release the nuts. Use a suitable tool.


81. Remove and DISCARD Stabilizer Shaft Link Nuts (2) (Qty: 2)

82. Disconnect Stabilizer Shaft Links (1) (Qty: 2) @ Stabilizer Shaft (3)

image

Fig. 313: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY


NOTE: Support the front suspension under the front lower control arm ball joint with a hydraulic jack to release the nut.


83. Remove and DISCARD Nuts (1) (Qty: 2)

84. Separate the steering knuckle from the lower ball joint. (Qty: 2)

85. Disconnect the outer tie rod from the steering knuckle (Qty: 2). Refer to Steering Linkage Outer Tie Rod Replacement

86. Reposition away Front Wheel Drive Shaft @ Transmission. Refer to Front Wheel Drive Shaft Replacement


image

Fig. 314: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

87. Remove and DISCARD Transmission Mount Strut Bolt (1) @ Transmission Mount Strut (2).

image


Fig. 315: Drivetrain And Front Suspension Cradle Supported With Suitable Hydraulic Jack Courtesy of GENERAL MOTORS COMPANY

88. Support the drivetrain and front suspension cradle (1) with a suitable hydraulic jack (2).


image


Fig. 316: Drivetrain And Front Suspension Cradle, Crossmember Extension And Bolts Courtesy of GENERAL MOTORS COMPANY


NOTE: A second technician is required.


89. Remove and DISCARD Bolts (2, 5, 9) (Qty: 6) @ Drivetrain and Front Suspension Cradle (1)

90. Remove and DISCARD Bolts (4, 7) (Qty: 2) @ Drivetrain and Front Suspension Crossmember Extension (6)

91. Lower the drivetrain and front suspension cradle along with drivetrain and front suspension crossmember extension and both lower control arm (3, 8) as far as necessary to disconnect the wiring harness.

image


Fig. 317: Power Steering Assist Motor, Electrical Connectors And Wiring Harness Clips Courtesy of GENERAL MOTORS COMPANY

92. Disconnect Electrical Connectors (5) (Qty: 2) @ Power Steering Assist Motor (4)

93. Disconnect the electrical connector. (2)

94. Unclip Wiring Harness Clip (1, 3, 6) (Qty: 6)


NOTE: A second technician is required.


95. Carefully lower the drivetrain and front suspension cradle along with drivetrain and front suspension crossmember extension and both lower control arm

96. Remove the drivetrain and front suspension cradle along with drivetrain and front suspension crossmember extension and both lower control arm.

97. Lower the vehicle.

98. Position an engine support table under the powertrain assembly

99. Blocks of wood can be used between the front of the frame and the oil pan in order to level the powertrain during the removal.

100. With the table positioned, fully raise the table to contact with the powertrain assembly.


image

Fig. 318: Transmission Mount And Bolts

Courtesy of GENERAL MOTORS COMPANY

101. Remove and DISCARD Transmission Mount Bolts (1) (Qty: 3) @ Transmission Mount (2)


image

Fig. 319: Engine Mount Bolts

Courtesy of GENERAL MOTORS COMPANY

102. Remove Engine Mount Bolts (1) (Qty: 2)

103. Remove the engine support fixture. Refer to Engine Support Fixture

104. Slowly and carefully raise the vehicle, ensure the powertrain assembly are free from wiring, hoses and other engine compartment components


image

Fig. 320: Starter Opening Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

105. Remove Bolts (2) (Qty: 2)

106. Remove the starter opening cover (1).

image

Fig. 321: Torque Converter Bolts

Courtesy of GENERAL MOTORS COMPANY

107. Remove the torque converter bolts. (1) (Qty: 4)

108. Remove the water outlet. Refer to Water Outlet Replacement

109. Remove Heater Inlet Hose. Refer to Heater Inlet Hose Replacement


image

Fig. 322: Transmission Bolts

Courtesy of GENERAL MOTORS COMPANY

110. Remove the transmission bolts. (1) (Qty: 3)

image

Fig. 323: Transmission Bolt

Courtesy of GENERAL MOTORS COMPANY

111. Remove Transmission Bolt (1)


image

Fig. 324: Transmission Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

112. Remove Transmission Bolts (1) (Qty: 2)

113. Remove Transmission Cover (2)

114. Properly support engine and transmission as necessary.

image

Fig. 325: Transmission Bolts

Courtesy of GENERAL MOTORS COMPANY


NOTE: These are the last transmission bolts.


115. Remove Transmission Bolts (1) (Qty: 2)

116. Separate the engine from the transmission.

117. Disconnect Engine Coolant Hose as necessary.

118. Disconnect all electrical connectors.

119. Transfer components as necessary.


Installation Procedure


1. Connect all electrical connectors.

2. Connect engine coolant hoses as necessary


Do not tighten bell housing bolts at this time. There must be a small 1 mm (0.039 in) to 2 mm IMPORTANT: (0.079 in) mm gap between the engine and transmission to allow rotation for input flange

alignment


3. Install two appropriate guide pins into the engine to aid aligning the transmission to the engine.


NOTE: A second technician is required.


4. Align the transmission to the engine leaving a 2 millimeter gap between both.

image

Fig. 326: Transmission Bolts

Courtesy of GENERAL MOTORS COMPANY

5. Remove the guide pin, then install the 2 transmission bolt (1) and hand tighten, allowing a small 1 mm (0.039 in) to 2 mm (0.079 in) gap between the engine and transmission.


image

Fig. 327: Transmission Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

6. Install Transmission Cover (2)

7. Install and hand tighten Transmission Bolts (1) (Qty: 2)

image

Fig. 328: Transmission Bolt

Courtesy of GENERAL MOTORS COMPANY

8. Install and hand tighten Transmission Bolt (1)


image

Fig. 329: Transmission Bolts

Courtesy of GENERAL MOTORS COMPANY

9. Install and hand tighten Transmission Bolts (1) (Qty: 3)

image

Fig. 330: Torque Converter Bolts

Courtesy of GENERAL MOTORS COMPANY

10. Set the engine to TDC allowing the master oblong flexplate bolt hole to appear in the starter hole opening.

11. Install and perform final tightening of the ALL remaining torque convertor bolts and transmission housing to engine bolts as specified in the transmission replacement procedure. Refer to Transmission Replacement


image

image

Fig. 331: Starter Opening Cover And Bolts Courtesy of GENERAL MOTORS COMPANY

12. Install the starter opening cover (1).

image

13. Install and tighten Bolts (2) (Qty: 2). Refer to Transmission Replacement

14. Install the water outlet. Refer to Water Outlet Replacement

15. Install Heater Inlet Hose. Refer to Heater Inlet Hose Replacement

16. Slowly and carefully lower the vehicle, ensure the powertrain assembly are free from wiring, hoses and other engine compartment components

image

Fig. 332: Engine Mount Bolts

Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution


CAUTION: Refer to Torque-to-Yield Fastener Caution


17. Install and tighten Engine Mount Bolts (1) (Qty: 2). Refer to Engine Mount Replacement


image

Fig. 333: Transmission Mount And Bolts Courtesy of GENERAL MOTORS COMPANY

18. Install and tighten Transmission Mount Bolts (1) (Qty: 3) @ Transmission Mount (2). Refer to Transmission Mount Replacement

19. Install the engine support fixture. Refer to Engine Support Fixture

20. Raise the vehicle.

image


Fig. 334: Drivetrain And Front Suspension Cradle Supported With Suitable Hydraulic Jack Courtesy of GENERAL MOTORS COMPANY


NOTE: A second technician is required.


21. Raise the drivetrain and front suspension cradle along with drivetrain and front suspension crossmember extension and both lower control arm (1) with a suitable jack (2) as far as necessary to connect the wiring harness.


image


Fig. 335: Power Steering Assist Motor, Electrical Connectors And Wiring Harness Clips Courtesy of GENERAL MOTORS COMPANY

22. Install Wiring Harness Clips (1, 3, 6) (Qty: 6)

23. Connect the electrical connector. (2)

24. Connect Electrical Connectors (5) (Qty: 2) @ Power Steering Assist Motor (4)

image


Fig. 336: Drivetrain And Front Suspension Cradle, Crossmember Extension And Bolts Courtesy of GENERAL MOTORS COMPANY


NOTE: A second technician is required.


25. Install the drivetrain and front suspension cradle (1) along with the drivetrain and front suspension crossmember extension (6) and the lower control arm (3, 8) to the vehicle. Refer to Drivetrain and Front Suspension Cradle Replacement


image

Fig. 337: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY


WARNING: Refer to Torque-to-Yield Fastener Warning


26. Install and tighten NEW Transmission Mount Strut Bolt (1) @ Transmission Mount Strut (2). Refer to

Transmission Mount Strut Bracket Replacement

27. Install Front Wheel Drive Shaft @ Transmission. Refer to Front Wheel Drive Shaft Replacement

28. Connect the outer tie rod to the steering knuckle (Qty: 2). Refer to Steering Linkage Outer Tie Rod Replacement

image

Fig. 338: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY


NOTE: Support the lower control arm under the ball joint with a hydraulic jack to tighten the nut.


29. Install the 2 lower ball joint (3) to the steering knuckle (2).

30. Install and tighten Nuts (1) (Qty: 2). Refer to Lower Control Arm Replacement


image

Fig. 339: Stabilizer Shaft Link, Stabilizer Shaft And Nut Courtesy of GENERAL MOTORS COMPANY


NOTE: Hold against the hex of the threaded stud to tighten the nuts. Use a suitable tool.


31. Connect Stabilizer Shaft Links (1) (Qty: 2) @ Stabilizer Shaft (3)

32. Install and tighten Stabilizer Shaft Link Nuts (2) (Qty: 2) @ Stabilizer Shaft Link (1). Refer to Lower Control Arm Replacement

image

Fig. 340: Drive Motor Generator Control Module Cooling Outlet Hose And Bolts Courtesy of GENERAL MOTORS COMPANY

33. Install NEW Seal (2). Install a NEW seal.

34. Install and tighten Drive Motor Generator Control Module Cooling Outlet Hose Bolts (1) (Qty: 2). Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet)


image

Fig. 341: Transmission Fluid Cooler Inlet Pipe, Bolt And Sealing Washer Courtesy of GENERAL MOTORS COMPANY

35. Install NEW Sealing Washer (2). Install a NEW seal.

36. Connect Transmission Fluid Cooler Inlet Pipe (3)

37. Install and tighten Transmission Fluid Cooler Pipe Bolt (1). Refer to Transmission Fluid Cooler Inlet Pipe Replacement

image

Fig. 342: Transmission Fluid Cooler Outlet Pipe, Bolt And Sealing Washer Courtesy of GENERAL MOTORS COMPANY

38. Install NEW Sealing Washer (3). Install a NEW seal.

39. Connect Transmission Fluid Cooler Outlet Pipe (2)

40. Install and tighten Transmission Fluid Cooler Pipe Bolt (1). Refer to Transmission Fluid Cooler Outlet Pipe Replacement

41. Fill Transmission. Refer to Transmission Fluid Drain and Fill

42. Install Underbody Front Air Deflector-Left Side. Refer to Underbody Front Air Deflector Replacement - Left Side


image


Fig. 343: Radiator And Lashing Straps Courtesy of GENERAL MOTORS COMPANY

43. Loosen the radiator (2) from the body and remove the ropes (1).

image

Fig. 344: Air Conditioning Compressor Hose Bolt And Air Conditioning Evaporator Hose Courtesy of GENERAL MOTORS COMPANY

44. Install Air Conditioning Compressor Hose

45. Install the air conditioning compressor hose bolt (1) to the air conditioning evaporator hose (2) and tighten. Refer to Air Conditioning Compressor Hose Replacement


image

Fig. 345: A/C Compressor And Condenser Hose Tube, Retainer, Wiring Harness And Cycling Switch Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

46. Install the air conditioning compressor and condenser hose tube (1).

47. Connect the air conditioning cycling switch electrical connector (3).

48. Install the wiring harness (2) to the air conditioning compressor and condenser hose tube.

49. Install the retainer (1).

image

Fig. 346: Air Conditioning Compressor, Condenser Hose And Bolt Courtesy of GENERAL MOTORS COMPANY

50. Install the air conditioning compressor and condenser hose (2) to the air conditioning compressor (3).

51. Install the air conditioning compressor and condenser hose bolt (1) and tighten. Refer to Air Conditioning Compressor and Condenser Hose Replacement


image

Fig. 347: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

52. Install the air conditioning evaporator tube (1) along with the condenser tube (2) to the condenser.

53. Install the condenser tube nut (3) and tighten. Refer to Air Conditioning Compressor and Condenser Hose Replacement

image


Fig. 348: Drive Motor Battery Coolant Cooler Inlet Hose And Retainer Courtesy of GENERAL MOTORS COMPANY

54. Install the drive motor battery coolant cooler inlet hose (1) to the retainer (2).


image


Fig. 349: Coolant Hose And Clips

Courtesy of GENERAL MOTORS COMPANY

55. Install Coolant Hose (2)

56. Install Clips (1) (Qty: 2)

57. Install Heater Water Shutoff Valve. Refer to Heater Water Shutoff Valve Replacement

58. Install Heater Coolant Heater. Refer to Heater Coolant Heater Replacement

59. Install Heater Coolant Pump. Refer to Heater Coolant Pump Replacement

60. Install Heater Inlet and Outlet Pipe. Refer to Heater Inlet And Outlet Pipe Replacement

61. Install Generator Control Module Coolant Pump. Refer to Generator Control Module Coolant Pump Replacement

image


Fig. 350: Heater Inlet Hose, Clamp And Clip Courtesy of GENERAL MOTORS COMPANY

62. Install Heater Inlet Hose (2)

63. Install Clamp (1)

64. Install Heater Inlet Hose @ Clip (3)


image

Fig. 351: Heater Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

65. Install Heater Inlet Hose (1)

66. Install Clamp (2)

image


Fig. 352: Exhaust Front Pipe, Nuts And Gasket Courtesy of GENERAL MOTORS COMPANY

67. Install a NEW gasket. (1)

68. Install Exhaust Front Pipe (2)

69. Install and tighten Exhaust Front Pipe Nuts (3) (Qty: 2). Refer to Exhaust Front Pipe Replacement

70. Install Exhaust Muffler. Refer to Exhaust Muffler Replacement


image

Fig. 353: Engine Ground Strap Bolt And Retainer Courtesy of GENERAL MOTORS COMPANY

71. Install the engine ground strap bolt (1) and tighten to 25 N.m (18 lb ft).

72. Install Wiring Harness Clip (2)

image

Fig. 354: Wiring Harness Clip And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

73. Connect the electrical connectors. (1) (Qty: 3)

74. Install Wiring Harness Clip (2)


image

Fig. 355: Engine Wiring Harness And Clips Courtesy of GENERAL MOTORS COMPANY

75. Install Engine Wiring Harness (2) @ Wiring Harness Clips (1) (Qty: 2)

76. Install Headlamp Left Side. Refer to Headlamp Replacement

77. Lower the vehicle.

78. Remove the engine support fixture. Refer to Engine Support Fixture

image

Fig. 356: Water Outlet, Radiator Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

79. Install Radiator Inlet Hose (1) @ Water Outlet (3)

80. Install Radiator Inlet Hose Clamp (2)


image

Fig. 357: Engine Coolant Thermostat Housing, Radiator Outlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

81. Install Radiator Outlet Hose (3) @ Engine Coolant Thermostat Housing (1)

82. Install Radiator Outlet Hose Clamp (2)

image

Fig. 358: Range Selector Lever Cable And Transmission Range Selector Lever Cable Bracket Courtesy of GENERAL MOTORS COMPANY

83. Install the range selector lever cable (1) to the range selector lever cable bracket. The retainer snaps automatically in.

image

Fig. 359: Range Selector Lever Cable And Range Selector Lever Cable Lever Courtesy of GENERAL MOTORS COMPANY

84. Install Range Selector Lever Cable (1) @ Range Selector Lever Cable Lever

85. Install Heater Water Shutoff Valve Inlet Hose. Refer to Heater Water Shutoff Valve Inlet Hose Replacement

image


Fig. 360: Evaporative Emission Canister Purge Solenoid Valve And Evaporative Emission Pipe Courtesy of GENERAL MOTORS COMPANY

86. Remove all EN-6015 plugs from the connections.

87. Connect Evaporative Emission Pipe (1) @ Evaporative Emission Canister Purge Solenoid Valve (3). Refer to

Plastic Collar Quick Connect Fitting Service


image


Fig. 361: Fuel Feed Pipe, Fuel Feed Front Pipe And Retainer Courtesy of GENERAL MOTORS COMPANY

88. Remove all EN-6015 plugs from the connections.

89. Connect Fuel Feed Front Pipe (2) @ Fuel Feed Pipe (1). Refer to Plastic Collar Quick Connect Fitting Service

90. Install Fuel Feed Front Pipe (2) @ Retainer (3)

image

Fig. 362: Ground Cable, Nut, Engine Wiring Harness, Clips And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

91. Install the electrical connector (3) to the front compartment fuse block housing.

92. Install Ground Cable (1)

93. Install and tighten Ground Cable Nut (2) to 9 N.m (80 lb in)

94. Connect the electrical connectors. (6, 7) (Qty: 2)

95. Install Engine Wiring Harness (5) @ Clips (4) (Qty: 2)

96. Install Engine Wiring Harness Junction Block. Refer to Engine Wiring Harness Junction Block Replacement

97. Install 300-Volt Battery Positive and Negative Cable @ Transmission. Refer to Battery 300-Volt Positive and Negative Cable Replacement - High Voltage Battery to Power Inverter Module and A/C Compressor

98. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement

99. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement

100. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement

101. Install Intake Manifold Cover. Refer to Intake Manifold Cover Replacement

102. Adjust Range Selector Lever Cable. Refer to Range Selector Lever Cable Adjustment

103. Install Intermediate Steering Shaft Lower Bolt. Refer to Intermediate Steering Shaft Replacement

104. Fill the cooling system. Refer to Cooling System Draining and Filling

105. Fill the drive motor generator power inverter module cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling

106. Fill the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling -

107. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

108. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging

109. Enable the high voltage system. Refer to High Voltage Enabling AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT

Special Tools


image EN-45059 Angle Meter

image EN-51398 Flywheel Holder

Equivalent regional tools: Special Tools

Removal Procedure


1. Remove Transmission. Refer to Transmission Replacement


image

Fig. 363: Flywheel Holder And Bolts

Courtesy of GENERAL MOTORS COMPANY

2. Install the EN-51398 holder (1), lock the automatic transmission flex plate via the starter ring gear.

3. Ensure that the EN-51398 holder is engaged into a robust portion of the flex plate (3).

4. Install and tighten the 2 starter opening cover bolts (2).


image

Fig. 364: Automatic Transmission Flex Plate And Bolts Courtesy of GENERAL MOTORS COMPANY

5. Remove and DISCARD the 8 automatic transmission flex plate bolts (1).

6. Remove Automatic Transmission Flex Plate (2)


Installation Procedure

image

Fig. 365: Automatic Transmission Flex Plate And Bolts Courtesy of GENERAL MOTORS COMPANY

1. Install Automatic Transmission Flex Plate (2)

2. Install 8 NEW automatic transmission flex plate bolts (1).

3. Hand tighten the bolts.


image


Fig. 366: Automatic Transmission Flex Plate Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Fastener Caution .


CAUTION: Refer to Torque-to-Yield Fastener Caution .


NOTE: The bolts have adhesive patch and must be tightened to final torque within 5 minutes.


4. Tighten Automatic Transmission Flex Plate Bolts in the sequence shown.

1. First Pass: 20 N.m (15 lb ft).

2. Second Pass: 30 N.m (22 lb ft).

3. Final Pass: 70 degrees, using the EN 45059 meter.


image

Fig. 367: Flywheel Holder And Bolts

Courtesy of GENERAL MOTORS COMPANY

5. Remove the 2 starter opening cover bolts (2).

6. Remove the EN-51398 holder (1).

7. Install Transmission. Refer to Transmission Replacement ENGINE SUPPORT FIXTURE

image

Fig. 368: Engine Support Fixture Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Callout

Component Name

Preliminary Procedures

1. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

2. To gain access for the engine support fixture installation, remove the wiring harness from the front compartment upper side rail.

3. To gain access for the engine lift bracket installation, unclip the engine wiring harness from the intake manifold.

Special Tools

image EN-43405 Engine Support Fixture Adapter

image EN-28467-1A Cross Bracket

image EN-28467-5A Strut Tower Support Assembly

image EN-28467-8A Hook Assembly

image EN-28467-2A Radiator Tube Shelf Assembly

image EN-36857 Engine Lift Bracket

Equivalent regional tools: Special Tools


1

Engine Support Fixture Adapter Leg (Qty: 2)

Procedure

Install the bracket to fender frame. Do not install on top of fender lip.

2

Main Support Beam

3

Cross Bracket (Qty: 2)


4

Strut Tower Support Assembly (Qty: 2)

Procedure

Adjust the length of the strut tower support assembly.

5

Radiator Tube Shelf Assembly (Qty: 2)


6

Engine Lift Bracket

Procedure

Use a grade 10.9 bolt to install the EN-36857 Engine Lift Bracket.

7

Hook Assembly (Qty: 2)

REPAIR INSTRUCTIONS - OFF VEHICLE

DRAINING FLUIDS AND OIL FILTER REMOVAL

image

Fig. 369: Draining Fluids and Oil Filter Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Oil Pan Drain Plug


CAUTION:

Refer to Fastener Caution .


NOTE:

Place a drip pan underneath. Allow the oil to drain completely.


2

Oil Filter

Special Tools

EN-726-A Oil Filter Wrench

For equivalent regional tools, refer to Special Tools.

3

Oil Filter Fitting

CRANKSHAFT BALANCER REMOVAL

image


Fig. 370: Crankshaft Balancer

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Remove the starter opening cover. Refer to Engine Block Disassemble.

2. Install the EN-51760 holder, lock the automatic transmission flex plate via the starter ring gear.

Special Tools EN-51760 Flywheel HolderFor equivalent regional tools, refer to Special Tools.

1

Crankshaft Balancer Bolt


2

Crankshaft Balancer

Procedure

1. Install the EN-44226-5 protector onto the crankshaft.

2. Install EN-44226-1 holding body and EN-44226-2 remover plate with remover bolt onto the balancer.

3. Counter hold the EN-44226-2 remover plate and turn the remover screw to remove the balancer.

Special Tools

image EN-44226 Crankshaft Balancer Remover

image EN-44226-5 Crankshaft Protector

AUTOMATIC TRANSMISSION FLEX PLATE REMOVAL

image


Fig. 371: Automatic Transmission Flex Plate Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Remove the starter opening cover. Refer to Engine Block Disassemble.

2. Install EN-51760 holder, lock the automatic transmission flex plate via the starter ring gear.

Special Tools EN-51760 Flywheel HolderEquivalent regional tools: Special Tools.


1

Automatic Transmission Flex Plate Bolt (Qty: 8)


NOTE:

Discard the bolts.

2

Automatic Transmission Flex Plate


3

Crankshaft Position Sensor Reluctor Ring


CAUTION:

Refer to Crankshaft Position Sensor Reluctor Ring Caution

.

EXHAUST GAS RECIRCULATION PIPE REMOVAL

image


Fig. 372: Exhaust Gas Recirculation Pipe Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)

2

Exhaust Gas Recirculation Pipe Bolt

3

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)

4

Exhaust Gas Recirculation Pipe


5

Exhaust Gas Recirculation Pipe Gasket


NOTE:

Discard the gasket.


6

Exhaust Gas Recirculation Pipe Gasket


NOTE:

Discard the gasket.

EXHAUST GAS RECIRCULATION COOLER OUTLET PIPE REMOVAL

image

Fig. 373: Exhaust Gas Recirculation Cooler Outlet Pipe Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Cooler Temperature Sensor

Procedure

Disconnect the temperature sensor nut at the outlet pipe.

2

Exhaust Gas Recirculation Cooler Outlet Pipe Bolt (Qty: 2)

3

Exhaust Gas Recirculation Cooler Outlet Pipe


4

Exhaust Gas Recirculation Cooler Outlet Pipe Gasket


NOTE:

Discard the gasket.

EXHAUST GAS RECIRCULATION COOLER REMOVAL

image

Fig. 374: Exhaust Gas Recirculation Cooler Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Cooler Temperature Sensor

Procedure

Disconnect the temperature sensor nut at the inlet pipe.


2

Exhaust Gas Recirculation Cooler Water Bypass Outlet Hose

Procedure

Disconnect the bypass outlet hose at the water pump.


3

Thermostat Bypass Hose

Procedure

Disconnect the bypass hose at the water outlet.

4

Exhaust Gas Recirculation Cooler Bolt (Qty: 2)

5

Exhaust Gas Recirculation Cooler Bolt

6

Exhaust Gas Recirculation Cooler


7

Exhaust Gas Recirculation Cooler Inlet Pipe Gasket


NOTE:

Discard the gasket.

EXHAUST GAS RECIRCULATION VALVE REMOVAL


image

Fig. 375: Exhaust Gas Recirculation Valve Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Valve Cooling Return Hose

Procedure

Disconnect the cooling return hose at the water pump inlet adapter.

2

Exhaust Gas Recirculation Valve Bolt (Qty: 3)

3

Exhaust Gas Recirculation Valve

4

Exhaust Gas Recirculation Valve Gasket

WATER PUMP REMOVAL

image

Fig. 376: Water Pump

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Thermostat Bypass Pipe Bolt (Qty: 2)

2

Water Pump Inlet Hose Fitting

3

Thermostat Bypass Pipe Gasket

4

Water Pump Bolt (Qty: 2)

5

Water Pump Bolt

6

Water Pump

7

Water Pump Housing Gasket

ENGINE WIRING HARNESS ASSEMBLY REMOVAL

image

Fig. 377: Engine Wiring Harness Assembly Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Wiring Harness Connector Bolt

2

Engine Wiring Harness Bracket Bolt (Qty: 2)

3

Engine Wiring Harness

THROTTLE BODY ASSEMBLY REMOVAL

image

Fig. 378: Throttle Body Assembly

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Throttle Body Bolt (Qty: 4)

2

Throttle Body

3

Throttle Body Gasket

INTAKE MANIFOLD REMOVAL

image

Fig. 379: Intake Manifold

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Intake Manifold Bolt (Qty: 5)


NOTE:

Bolt retainers keep the bolts in position on the assembly.


Procedure

Loosen bolts until disengaged from mount location.

2

Intake Manifold

3

Intake Manifold Gasket

FUEL PUMP REMOVAL

image

Fig. 380: Fuel Pump

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Fuel Feed Intermediate Pipe Bolt (Qty: 1)


2

Fuel Feed Intermediate Pipe


WARNING:

Fuel that flows out at high pressure can cause serious injury to the skin and eyes.

ALWAYS

depressurize the fuel system before removing


Callout

Component Name


components that are under high fuel pressure.


NOTE:

Discard the pipe.


3

Fuel Pump Insulator


WARNING:

The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids.

Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.


4

Fuel Pump Bolt (Qty: 2)


CAUTION:

Alternately loosen the fuel pump bolts one turn at a

Callout

Component Name


time until the pump is fully disengaged from fuel pump lifter follower.

Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage


Procedure:

Remove the fuel injection pump bolts alternating in steps of one turn each.


NOTE:

Discard the bolts.

5

Fuel Pump

6

Valve Lifter Follower

ENGINE LIFT AND SIGHT SHIELD BRACKET REMOVAL


image

Fig. 381: Engine Lift And Sight Shield Bracket Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Engine Lift Bracket Bolt (Qty: 2)

2

Engine Lift Rear Bracket

3

Engine Lift Bracket Bolt (Qty: 2)

4

Engine Lift Front Bracket

WATER OUTLET REMOVAL


image

Fig. 382: Water Outlet

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Water Outlet Bolt (Qty: 2)

2

Water Outlet

3

Water Outlet Gasket

IGNITION COIL REMOVAL

image

Fig. 383: Ignition Coil

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Ignition Coil Assembly (Qty: 4)

FUEL RAIL AND INJECTORS REMOVAL

Special Tools

image EN-51146 Fuel Injector Removal/Installation Kit

image EN-51146-100 Fuel Injector Removal Plate

image EN-51146-150 Fuel Injector Removal Adapters For equivalent regional tools, refer to Special Tools.

WARNING: Refer to Diesel/Gasoline Vapors Warning . WARNING: Refer to Safety Goggles and Fuel Warning .

NOTE: Maintain a clean work surface when working with fuel rail and fuel injectors.

Use care to avoid contaminants on the injector seals.


image


Fig. 384: Fuel Injector Screw And Adapters Courtesy of GENERAL MOTORS COMPANY


NOTE: Remove only one fuel injector screw (2) to perform the length check.


1. Ensure the EN-51146-150 fuel injector removal adapters (1) are used with non-turbocharger applications. Match the length (a) of the EN-51146-150 adapters (1) to the length of the fuel injector screw (2). If the length does not match, refer to the Turbocharger procedure.


image


Fig. 385: Adapters And Supports

Courtesy of GENERAL MOTORS COMPANY

2. Install the EN-51146-150 adapters (2) to the EN-51146-1-1 supports (1) and tighten to 7 N.m (62 lb in).

image


Fig. 386: Inner Fuel Injector Screw

Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not loosen or remove both fuel injector screws for an individual fuel injector at the same time. Ensure the EN-51146-150 adapter and EN-51146-1-1 support is properly installed on the inner fuel injector screw location before removing the remaining outer fuel injector screw. Ensure the screws do not fall into the cylinder head slot.


3. Remove the inner fuel injector screw (1).

4. Install one EN-51146-150 adapter and EN-51146-1-1 support (2) and tighten to 5 N.m (44 lb in).

image


Fig. 387: Outer Fuel Injector Screw

Courtesy of GENERAL MOTORS COMPANY

5. Remove the outer fuel injector screw (1).

6. Install a second EN-51146-150 adapter and EN-51146-1-1 support (2) and tighten to 5 N.m (44 lb in).


image


Fig. 388: Supports

Courtesy of GENERAL MOTORS COMPANY

7. Using the same procedure, install the remaining EN-51146-150 adapters and EN-51146-1-1 supports (1) for each fuel injector and tighten to 5 N.m (44 lb in).

image


Fig. 389: Upper And Lower Fuel Rail Assembly Bolts Courtesy of GENERAL MOTORS COMPANY


NOTE: The fuel rail bolts may remain with the decoupling elements and retainer at the fuel rail assembly.


8. Loosen the 4 upper fuel rail assembly bolts (1) completely from the cylinder head, but do not remove the bolts.

9. Loosen the 4 lower fuel rail assembly bolts (2) completely from the cylinder head, but do not remove the bolts.

image


Fig. 390: Plate, Supports, Bolts And Slide Hammers Courtesy of GENERAL MOTORS COMPANY

10. Install EN-51146-100 plate (2) to the EN-51146-1-1 supports (1) using the eight plate bolts (3). Counterhold each support with a wrench while tightening the bolt.

11. Install the EN-51146-1-3 slide hammers (4) onto the EN-51146-100 plate (2) using the outer holes.

image


Fig. 391: Removing Fuel Injectors

Courtesy of GENERAL MOTORS COMPANY


NOTE: The alignment of the fuel injectors within the cylinder bores is critical for fuel injection system function. Use equal force on each slide hammer to ensure the fuel injectors are removed without tilting in the injector bore.


12. Using the EN-51146-1-3 slide hammers (1, 2), begin to remove the fuel injectors by applying slight force equally on both hammers. Observe the alignment of the fuel injectors, and allocate force on the hammers as necessary.


NOTE: After removing the fuel rail and injector assembly, position the assembly on a clean work surface with the fuel injectors on top. Do not allow the weight of the assembly to rest on the fuel injectors.


13. Complete the removal of the fuel rail and injector assembly with the EN-51146 remover. The slide hammers may then be removed from the plate.

14. Install the EN-51146-2-5 calibration tools onto the fuel injector tips to protect the injectors.

15. Cover the fuel injector bores at the cylinder head to prevent contamination.

CAMSHAFT COVER REMOVAL

Camshaft Cover and Gasket Removal

image

Fig. 392: Camshaft Cover And Gasket Courtesy of GENERAL MOTORS COMPANY

Camshaft Cover and Gasket Removal

Callout

Component Name

1

Oil Level Indicator

2

Camshaft Cover Stud (Qty: 2)

3

Camshaft Cover Bolt (Qty: 18)


4

Camshaft Cover

Procedure

Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

5

Camshaft Cover Gasket

Camshaft Cover Components Removal

image


Fig. 393: Camshaft Cover Components Courtesy of GENERAL MOTORS COMPANY

Camshaft Cover Components Removal

Callout

Component Name


1

Positive Crankcase Ventilation Valve Bolt (Qty: 2)


NOTE:

Bolts are tamper- proof.

Remove the bolts only if inspection of the PCV tube or valves indicates replacement is necessary.


Procedure

1. Using a suitable tool, cut a slot in the tamper-proof PCV bolt heads and remove with a

Callout

Component Name


flat-bladed tool.

2. Discard the bolts.


2

Positive Crankcase Ventilation Tube with Positive Crankcase Ventilation Valve - Fresh Air


NOTE:

These components have tamper- proof connections and cannot be disassembled. Remove this component only if inspection indicates replacement is necessary. The PCV tube to fresh air inlet duct connection is tamper-proof, and the inlet duct must be replaced when servicing PCV valve components.


Procedure

1. Inspect all PCV components and the fresh air inlet duct prior to removal. Do not remove the PCV components or inlet duct unless a diagnostic or inspection procedure indicates replacement is necessary.

2. Complete all camshaft cover inspections prior to inspecting or removing PCV components. If inspection indicates the camshaft cover requires replacement, all PCV components and inlet duct will be replaced with the cover.

3

Camshaft Position Sensor Bolt

4

Intake Camshaft Position Sensor

5

Camshaft Position Sensor Bolt

6

Exhaust Camshaft Position Sensor

7

Camshaft Cover Locating Pin (Qty: 2)

8

Camshaft Position Actuator Solenoid Valve Bolt

9

Camshaft Position Actuator Solenoid Valve

10

Camshaft Position Actuator Solenoid Valve Bolt

Callout

Component Name

11

Camshaft Position Actuator Solenoid Valve

OIL PAN REMOVAL


image

Fig. 394: Oil Pan

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Lower Oil Pan Bolt (Qty: 12)


2

Lower Oil Pan

Procedure

Remove the oil pan drain plug, if applicable. Discard the lower oil pan.

3

Oil Pan Bolt (Qty: 2)

4

Oil Pan Bolt (Qty: 12)

5

Oil Pan Bolt (Qty: 2)

6

Wiring Harness Connector Bolt


7

Wiring Harness Connector

Procedure

Disconnect the oil pump control valve connector, then remove through the upper oil pan.

8

Upper Oil Pan Assembly

ENGINE FRONT COVER REMOVAL

image

Fig. 395: Engine Front Cover

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Engine Front Cover Bolt (Qty: 1)

2

Engine Front Cover Bolt (Qty: 1)

3

Engine Front Cover Bolt (Qty: 11)

4

Engine Front Cover Stud (Qty: 1)


5

Engine Front Cover

Procedure

1. Locate pry-points on the engine front cover to loosen the cover from the engine block.

2. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

3. Clean and inspect the engine front cover mating surface.


6

Crankshaft Front Oil Seal

Procedure Discard the seal. Special Tools

EN-51096 Crankshaft Seal Remover

For equivalent regional tools, refer to Special Tools.

Callout

Component Name

7

Engine Front Cover Hole Plug

CAMSHAFT TIMING CHAIN REMOVAL


image

Fig. 396: Camshaft Timing Chain

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Timing Chain Guide Bolt (Qty: 2)

2

Timing Chain Guide - to Cylinder Head

3

Timing Chain Tensioner Bolt (Qty: 2)

4

Timing Chain Tensioner Assembly

5

Timing Chain Tensioner Gasket

6

Timing Chain Tensioner Shoe Bolt (Qty: 1)

7

Timing Chain Tensioner Shoe Assembly

8

Timing Chain Guide Bolt (Qty: 3)

9

Timing Chain Guide - Exhaust Side

10

Timing Chain

11

Timing Chain Oil Nozzle

INTAKE AND EXHAUST CAMSHAFT, BEARING CAP, AND LASH ADJUSTER REMOVAL

Camshaft Actuator Removal


image

Fig. 397: Camshaft Actuator

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

2

Camshaft Position Actuator - Intake


3

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

4

Camshaft Position Actuator - Exhaust

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

2

Camshaft Position Actuator - Intake


3

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

4

Camshaft Position Actuator - Exhaust

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

2

Camshaft Position Actuator - Intake


3

Camshaft Position Actuator Bolt


NOTE:

Discard bolt.

4

Camshaft Position Actuator - Exhaust

Courtesy of GENERAL MOTORS COMPANY Camshaft Actuator Removal

Camshaft Bearings and Camshaft Removal


image

Fig. 398: Camshaft Bearings and Camshaft Courtesy of GENERAL MOTORS COMPANY

Camshaft Bearings and Camshaft Removal

Callout

Component Name

Preliminary Procedure


NOTE:

Many internal engine components will develop specific wear patterns on their friction surfaces.


1. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

Callout

Component Name

2. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.


1

Camshaft Bearing Cap Bolt - Intake Side (Qty: 12)

Procedure

Loosen each bolt 1/2 turn to reduce spring pressure.

2

Camshaft Bearing Front Intake Cap


3

Camshaft Bearing Cap - Intake Side (Qty: 4)


NOTE:

Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.

4

Camshaft Bearing Rear Cap - Intake Side

5

Intake Camshaft Assembly


6

Camshaft Bearing Cap Bolt - Exhaust Side (Qty: 12)

Procedure

Loosen each bolt 1/2 turn to reduce spring pressure.

7

Camshaft Bearing Front Exhaust Cap.


8

Camshaft Bearing Cap - Exhaust Side (Qty: 5)


NOTE:

Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.

9

Exhaust Camshaft Assembly


Valve Rocker Arm and Lash Adjuster Removal

image

Fig. 399: Valve Rocker Arm and Lash Adjuster Courtesy of GENERAL MOTORS COMPANY

Valve Rocker Arm and Lash Adjuster Removal

Callout

Component Name

Preliminary Procedure


NOTE:

Many internal engine components will develop specific wear patterns on their friction surfaces.


1. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

2. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

CYLINDER HEAD REMOVAL


image

Fig. 400: Cylinder Head (With Loosening/Tightening Sequence) Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Cylinder Head Bolt (Qty: 10)

Procedure

Remove the bolts in sequence. Discard the bolts.

2

Cylinder Head Assembly

3

Cylinder Head Gasket

OIL PUMP DRIVE CHAIN AND OIL PUMP REMOVAL

Oil Pump Drive Chain and Crankshaft Sprocket Removal

image

Fig. 401: Oil Pump Drive Chain and Crankshaft Sprocket Courtesy of GENERAL MOTORS COMPANY

Oil Pump Drive Chain and Crankshaft Sprocket Removal

Callout

Component Name

1

Oil Pump Drive Chain Tensioner Bolt

2

Oil Pump Drive Chain Tensioner


3

Oil Pump Drive Chain

Procedure

Loosen the oil pump assembly bolts and tilt the oil pump assembly in order to remove the drive chain.

4

Crankshaft Balancer Key

5

Crankshaft Sprocket

Oil Pump Assembly Removal

image

Fig. 402: Oil Pump Assembly

Callout

Component Name

1

Oil Pump Flow Control Solenoid Valve Retainer

2

Oil Pump Flow Control Solenoid Valve

3

Oil Pump Assembly Bolt (Qty: 4)

4

Oil Pump Assembly

5

Oil Pump Gasket

6

Oil Pump Gasket

Callout

Component Name

1

Oil Pump Flow Control Solenoid Valve Retainer

2

Oil Pump Flow Control Solenoid Valve

3

Oil Pump Assembly Bolt (Qty: 4)

4

Oil Pump Assembly

5

Oil Pump Gasket

6

Oil Pump Gasket

Callout

Component Name

1

Oil Pump Flow Control Solenoid Valve Retainer

2

Oil Pump Flow Control Solenoid Valve

3

Oil Pump Assembly Bolt (Qty: 4)

4

Oil Pump Assembly

5

Oil Pump Gasket

6

Oil Pump Gasket

Courtesy of GENERAL MOTORS COMPANY Oil Pump Assembly Removal


CRANKSHAFT OIL DEFLECTOR REMOVAL

image

Fig. 403: Crankshaft Oil Deflector

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Positive Crankcase Ventilation Oil Separator Drain Pipe Bolt

2

Positive Crankcase Ventilation Oil Separator Drain Pipe

3

Crankshaft Oil Deflector Bolt (Qty: 3)

4

Crankshaft Oil Deflector

LOWER CRANKCASE REMOVAL

image

Fig. 404: Lower Crankcase (With Bolt Removal Sequence) Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Lower Crankcase Bolt - Perimeter (Qty: 13)


2

Lower Crankcase Bolt (Qty: 10)

Procedure

Remove bolts in sequence. Discard the bolts.

3

Lower Crankcase

PISTON, CONNECTING ROD, AND BEARING REMOVAL

image

Fig. 405: Piston, Connecting Rod and Bearing Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure


NOTE:

Many internal engine components will develop specific wear patterns on their friction surfaces.


1. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

2. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

3. Before removing the connecting rods, check the connecting rod side clearance using the following

Callout

Component Name

procedure:

1. Tap the connecting rod to one end of the crankshaft journal with a dead-blow or wooden hammer.

2. Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.

3. The connecting rod side clearance should not exceed specifications. Refer to Engine Mechanical Specifications

4. If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection.

5. If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.

6. If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.


NOTE:

An arrow/dot showing proper piston orientation is located on the top of the piston.


4. Using a marker, number each piston face. Draw an arrow along the centerline of the piston pointing toward the front of the engine.


CAUTION:

Do not use a stamp, punch or any other method that may distort or stress the connecting rod or connecting rod cap.

Extensive engine damage may result from a connecting rod that is distorted or stressed.


5. Mark the cylinder number on the connecting rod and the connecting rod cap with a scribe, paint stick or permanent marker.


Callout

Component Name


1

Connecting Rod Bolt (Qty: 8)


CAUTION:

Powdered metal connecting rods have rod bolts which yield when torqued. If the rod bolts are loosened or removed the rod bolts must be replaced.

Rod bolts that are not replaced will not torque to the correct clamp load and can lead to serious engine damage.


Procedure

DO NOT use the bolts for reinstallation. The bolts may be used to keep the parts together and for inspection and specification measurements.


2

Connecting Rod Assembly (Qty: 4)


NOTE:

The connecting rod caps must remain with the original connecting rod. The caps must be oriented identical to original installation.


Procedure


Callout

Component Name


Mark the side of the rod with a line that crosses the interface of the rod and cap. Use this line to ensure that the cap and rod are reinstalled in the same orientation.


3

Connecting Rod Bearing (Qty: 4)


NOTE:

If the connecting rod bearings have been used in a running engine, you must replace them with NEW

connecting rod bearings for reassembly.


4

Connecting Rod Bearing (Qty: 4)


NOTE:

If the connecting rod bearings have been used in a running engine, you must replace them with NEW

connecting rod bearings for reassembly.


5

Connecting Rod Assembly (Qty: 4)


NOTE:

Piston assembly attached.


Procedure

Using the EN-51454 guides, push the connecting rod and piston assembly through the top of the cylinder. DO NOT scratch the crankshaft journal or cylinder wall and DO NOT damage the oil jets when removing the connecting rod and piston assembly.

Special Tools

EN-51454 Connecting Rod Guides

Callout

Component Name


For equivalent regional tools, refer to Special Tools.

CRANKSHAFT AND BEARING REMOVAL


image

Fig. 406: Crankshaft and Bearing

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Crankshaft Lower Bearing (Qty: 5)


NOTE:

image Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original

Callout

Component Name


location and position, when suitable for use.

image If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced.

2

Crankshaft Assembly

3

Crankshaft Rear Oil Seal

4

Crankshaft Upper Bearing (Qty: 4)

5

Crankshaft Thrust Upper Bearing

CYLINDER HEAD DISASSEMBLE

Special Tools


image EN-8062 Valve Spring Compressor

image EN-43963 Valve Spring Compressor - Off-Car Adapter

image EN-46116 Valve Seal Remover

image EN-46122 Camshaft Position Actuator Check-Ball Valve Remover/Installer For equivalent regional tools, refer to Special Tools.

Intake and Exhaust Valve Components Removal


image

Fig. 407: Spark Plugs

Courtesy of GENERAL MOTORS COMPANY

1. Remove the spark plugs (1).


image

Fig. 408: Special Tool To Remove/Install Valve Stem Keys Courtesy of GENERAL MOTORS COMPANY


WARNING: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.


CAUTION: Do not compress the valve springs less than 25.0 mm (0.984 in). Contact between the valve spring retainer and the valve stem oil seal can cause potential valve stem oil seal damage.


NOTE: image Many internal engine components will develop specific wear patterns on their friction surfaces.

image Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

image Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.


2. Using EN-8062 compressor and EN-43963 adapter, compress the upper valve spring retainer down until the valve stem keys are discharged from spring load. Use a suitable tool and a bit of grease to remove the valve stem keys (1).

image

Fig. 409: Valve Spring Retainer, Valve Spring And Oil Seal Courtesy of GENERAL MOTORS COMPANY

3. Slowly release the EN-8062 compressor from the valve spring assembly. Remove the valve spring retainer (1) and the valve spring (2).

4. Repeat the procedure for all valve stem keys, valve spring retainers, and valve springs.


CAUTION: Do not damage the valve guide. Remove any burrs that have formed at the key groove by chamfering the valve stem with an oil stone or a file.


5. Using EN-46116 remover, remove the valve stem oil seals (3). Discard all used seals and replace with new.


image


Fig. 410: Exhaust And Intake Valves

Courtesy of GENERAL MOTORS COMPANY


NOTE: Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.


6. Remove the 8 exhaust valves (1) and the 8 intake valves (2) from the cylinder head.


Engine Oil Manifold Check Valve Removal

1. Inspect the oil manifold check valves. Damaged, restricted or clogged check valves must be replaced. If check valves are OK, disregard the remaining steps which detail replacing the check valves.


image

Fig. 411: Oil Manifold Check Valve, Check Ball Spring And Check Ball Courtesy of GENERAL MOTORS COMPANY

2. Insert a punch or drift into the check valve. With moderate pressure, seat the punch into the inner body of the check valve, and remove the upper part of the valve (1).

3. Remove the check ball spring (2) and check ball (3) from inside of the check valve.


image

Fig. 412: Setting Depth Gauge On Drill Bit Courtesy of GENERAL MOTORS COMPANY

4. Using EN-46122-3 drill bit (1), drill the remainder of check valve sleeve to a depth of approximately 19 mm (0.75 in) (a) by placing tape on drill bit as a depth gauge. It is not necessary or desirable to drill completely through the bottom of the check valve.

image

Fig. 413: Tapping Drilled Out Portion Of Oil Manifold Check Valve Courtesy of GENERAL MOTORS COMPANY

5. Lubricate EN-46122-4 tap (1) with lubricant. Tap drilled out portion of check valve remaining in cylinder head. Tap to full depth possible until tap bottoms out in head.


image

Fig. 414: Special Tool To Remove Oil Manifold Check Valve Sleeve From Cylinder Head Courtesy of GENERAL MOTORS COMPANY

6. Assemble EN-46122-2 bolt, nut, washers, and collar (1). Position collar with slightly-larger inside diameter DOWN toward the cylinder head.

7. Screw bolt by hand fully down into threaded check valve sleeve, then lightly tighten nut against washer.

8. Hold bolt with one wrench, and use another to tighten the nut until the check valve sleeve is removed from the cylinder head.

9. Clean check valve bore and related passages thoroughly to remove any drilling chips or other debris.


Cylinder Head Disassemble

image

Fig. 415: Cylinder Head Core Hole Plugs, Oil Gallery Plugs And Oil Gallery Restrictor Courtesy of GENERAL MOTORS COMPANY

1. Remove 4 cylinder head core hole plugs (1) from the top of the cylinder head.

2. Remove 2 cylinder head oil gallery plugs (3).

3. Remove the cylinder head oil gallery restrictor (2).

4. Remove the cylinder head core hole plug (4) from the front of the cylinder head.


image


Fig. 416: Side Cylinder Head Oil Gallery Plugs And Studs Courtesy of GENERAL MOTORS COMPANY

5. Remove 2 cylinder head oil gallery plugs (1) from the side of the cylinder head.

6. Remove 4 catalytic converter studs (2). Discard the studs.

image


Fig. 417: Cylinder Head Core Hole Plugs Courtesy of GENERAL MOTORS COMPANY

7. Remove the 2 cylinder head core hole plugs (1) from the rear of the cylinder head.

CYLINDER HEAD CLEANING AND INSPECTION

Special Tools


image EN-22738-B Valve Spring Tester

image EN-28410 Gasket Remover

image GE-7872 Magnetic Base Dial Indicator

For equivalent regional tools, refer to Special Tools.

Valve Cleaning and Inspection

image


Fig. 418: Valve Inspection Areas

Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not use a wire brush on any part of the valve stem.


NOTE: Do not grind or condition the intake valve. If the intake valve is out of specification, replace the valve.


1. Clean the valves of carbon, oil and varnish. Use a soft bristle wire brush to clean any carbon build-up from the valve head. Varnish can be removed by soaking in Parts Immersion Solvent or equivalent. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Clean the valve guides.

3. Inspect the valve stem for pitting or wear (4).

4. Inspect the valve key groove for chipping or wear (5). Replace the valve if chipped or worn.

5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.

6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.

7. Inspect the valve stem for straightness (3) and the valve head for bending or distortion using V blocks. Bent or distorted valves must be replaced.

8. Clean the deposits from the valve face. Inspect the valve face for grooving.

9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must

be replaced.

10. Replace the valve if the valve head O.D. and chamfer (2) is worn or out of specification. Refer to Valve and Seat Grinding.

11. The valves may be lightly lapped to the valve seats.

12. Replace the valve if the valve tip (6) is worn.

13. If no apparent wear, pitting, grooving, or distortion is present, perform the valve measurement and reconditioning procedure to verify valve specification. Refer to Valve and Seat Grinding.


Valve Guide Measurement


image


Fig. 419: Inspecting For Excessive Valve Stem To Guide Clearance Courtesy of GENERAL MOTORS COMPANY

1. Measure the valve stem (1) to-guide (2) clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.

2. Clamp the GE-7872 indicator to the cylinder head at the camshaft cover rail.

3. Locate the dial indicator so that the movement of the valve stem from side to side, crossways to the cylinder head, will cause a direct movement of the indicator stem. The dial indicator stem must contact the side of the valve stem just above the valve guide.

4. Drop the valve head about 0.064 mm (0.0025 in) off the valve seat.

5. Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading. Refer

to Engine Mechanical Specifications for proper clearance.


NOTE: Valve guide wear at the bottom 10 mm (0.390 in) of the valve guide is not significant to normal operation.


6. If the clearance for the valve is greater than specifications and a new standard diameter valve stem will not bring the clearance within specifications, replace the cylinder head.


Valve Spring Cleaning and Inspection


1. Clean the valve springs in solvent.


WARNING: Refer to Safety Glasses Warning .


2. Dry the valve springs with compressed air.

3. Inspect the valve springs for broken coils or coil ends.


image


Fig. 420: Measuring Valve Spring Tension Courtesy of GENERAL MOTORS COMPANY

4. Measure the valve spring tension using the EN-22738-B tester. Refer to Engine Mechanical Specifications

5. If low valve spring load is found, replace the valve springs. DO NOT use shims to increase spring load. The use of shims can cause the valve spring to bottom out before the camshaft lobe is at peak lift.

Valve Rocker Arm Cleaning and Inspection


image


Fig. 421: Inspecting Valve Rocker Arms Courtesy of GENERAL MOTORS COMPANY

1. Inspect the camshaft follower roller (1) for the following: image Flat spots

image Excessive scoring and pitting image Ensure the roller spins freely

2. Inspect the camshaft follower valve tip area (2).

3. Inspect the camshaft follower stationary hydraulic lash adjuster (SHLA) pivot area (3).

4. Replace the camshaft follower or followers as necessary.


Cylinder Head and Gasket Surface Cleaning and Inspection


1. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults to determine the cause:

1. Improper installation

2. Loose or warped cylinder head

3. Missing, off location or not fully seated dowel pins

4. Corrosion in the seal area around the coolant passages

5. Chips or debris in the cylinder head bolt holes

6. Bolt holes in the cylinder block not drilled or tapped deep enough


image


Fig. 422: Inspecting Fuel Injector Bores Courtesy of GENERAL MOTORS COMPANY

2. Inspect the fuel injector bores and clean, if required. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection.

3. Inspect the cylinder head gasket surface.

image Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1).

image Replace the cylinder head if the area between the valve seats is cracked (2).

image Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).

4. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant


NOTE: Do not use a wire brush on any gasket sealing surface.


5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.

6. Remove any old thread sealant, gasket material or sealant using EN-28410 remover.

7. Clean all cylinder head surfaces with non-corrosive solvent.

8. Blow out all the oil galleries using compressed air.

9. Clean any debris or build-up from the lifter pockets.

10. Clean the valve guides.

11. Clean the threaded holes. Use a nylon bristle brush.

12. Clean the remains of the sealer from the plug holes.

13. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.


NOTE: Do not attempt to weld the cylinder head, replace it.


14. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.

15. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.

16. Inspect the sealing surfaces.

17. Inspect the cylinder head plugs and verify the oil orifice is clear and free of debris.


Cylinder Head Deck Flatness Inspection


image


Fig. 423: Inspecting Cylinder Head Deck Surface For Flatness Courtesy of GENERAL MOTORS COMPANY

1. Ensure the cylinder head decks are clean and free of gasket material.

2. Inspect the surface for any imperfections or scratches that could inhibit proper cylinder head gasket sealing.

3. Using a straight-edge placed diagonally across the deck surface, inspect the cylinder head deck surface for flatness.

4. Measure the clearance between the straight-edge and the cylinder head deck face using a feeler gauge at 4 points along the straight-edge.

5. Refer to Engine Mechanical Specifications If the cylinder head deck flatness is more than the specified amount, replace the cylinder head.


Camshaft Journal Clearance


1. Install the camshaft bearing cap in the cylinder head without the camshaft.


CAUTION: Refer to Fastener Caution .


2. Install the camshaft cap bolts and tighten to 10 N.m (89 lb in).

3. Measure the camshaft bearings using an inside micrometer.

4. Subtract the camshaft journal diameter from the camshaft bearing diameter. This will provide the running clearance. If the running clearance exceeds specifications and the camshaft journals are within specification, replace the cylinder head. Refer to Engine Mechanical Specifications

5. Remove the camshaft bearing caps when measurement is complete.


Camshaft Journal Alignment


1. Ensure the camshafts are serviceable.

2. Inspect the cylinder head camshaft bearing surfaces for any imperfections or scratches that could inhibit proper camshaft clearances. Repair minor imperfections or scratches.

3. Install the camshafts in the cylinder head.

4. Install the camshaft bearing caps.

5. Install the camshaft cap bolts and tighten to 10 N.m (89 lb in).

6. Ensure the camshafts spin freely in the cylinder head. If the camshaft does not run freely, replace the cylinder head.

VALVE AND SEAT GRINDING

Valve Measurement and Reconditioning Overview


image Proper valve service is critical to engine performance. Therefore, all detailed measurement procedures must be followed to identify components that are out of specification.

image If the measurement procedures reveal that the valve or valve seat must be reconditioned, it is critical to perform the measurement procedures after reconditioning.


Valve Seat Width Measurement Procedure

image


Fig. 424: Measuring Valve Seat Width In Cylinder Head Courtesy of GENERAL MOTORS COMPANY

1. Measure the valve seat width in the cylinder head using a proper scale.


image


Fig. 425: Measuring Valve Length Using Slide Gauge Courtesy of GENERAL MOTORS COMPANY

2. Measure the valve length (2). Use a slide gauge (1). Refer to Engine Mechanical Specifications.

image


Fig. 426: Measuring Valve Stem Diameter Using Micrometer Gauge Courtesy of GENERAL MOTORS COMPANY

3. Measure the valve stem diameter (1). Use a micrometer gauge (2). Refer to Engine Mechanical Specifications.

image


Fig. 427: Valve Face Seat Width

Courtesy of GENERAL MOTORS COMPANY

4. Measure the seat width (b) on the valve face (1) using a proper scale.


NOTE: The seat contact area must be at least 0.5 mm (0.020 in) from the outer diameter, margin (a), of the valve. If the contact area is too close to the margins, the seat must be reconditioned to move the contact area away from the margin.


5. Compare your measurements with the specifications listed in Engine Mechanical Specifications.

6. If the seat widths are acceptable, check the valve seat roundness using the Valve Seat Roundness Measurement Procedure.

7. If the seat width is not acceptable, you must grind the valve seat using the Valve and Seat Reconditioning Procedure to bring the width back into specification. Proper valve seat width is critical to providing the correct amount of valve heat dissipation.


Valve Seat Roundness Measurement Procedure


1. Measure the valve seat roundness using a dial indicator attached to a tapered pilot installed in the guide. The pilot should have a slight bind when installed in the guide.


CAUTION: The correct size pilot must be used. Do not use adjustable diameter pilots.

Adjustable pilots may damage the valve guides.


2. Compare your measurements with the specifications listed in Engine Mechanical Specifications.

3. If the valve seat exceeds the roundness specification, you must grind the valve and valve seat using the Valve and Seat Reconditioning Procedure.

4. If new valves are being used, the valve seat roundness must be within 0.05 mm (0.002 in).


Valve Head O.D. and Chamfer Measurement Procedure


image


Fig. 428: View Of Valve Head O.D. & Chamfer Courtesy of GENERAL MOTORS COMPANY

1. Measure the valve head O.D. and chamfer (a) using an appropriate scale. Refer to Engine Mechanical Specifications.

2. If the valve head O.D. and chamfer is within specification, test the valve (1) for seat concentricity using the Valve-to-Seat Concentricity Measurement Procedure. Reinspect the valve head O.D. and chamfer after completing the concentricity measurement if valve seat reconditioning is performed.


Valve-to-Seat Concentricity Measurement Procedure


NOTE: image Checking the valve-to-seat concentricity determines whether the valve and seat are sealing properly.

image You must measure the valve face and the valve seat to ensure proper

valve sealing.


image


Fig. 429: Inspecting Valve Face

Courtesy of GENERAL MOTORS COMPANY

1. Coat the valve face (3) lightly with blue dye (1).

2. Install the valve in the cylinder head.

3. Turn the valve against the seat with enough pressure to wear off the dye.

4. Remove the valve from the cylinder head.

5. Inspect the valve face.

image If the valve face is concentric, providing a proper seal, with the valve stem, a continuous mark (2) will be made around the entire face.


NOTE: The wear mark MUST be at least 0.5 mm (0.020 in) from the outer diameter, the margin (a), of the valve. If the wear mark is too close to the margin, the seat must be reconditioned to move the contact area away from the margin.


NOTE: Do not grind or condition the intake valve. If the intake valve is out of specification, replace the valve.


image If the face is not concentric with the stem, the mark will NOT be continuous around the valve face. The

valve should be refaced or replaced and the seat must be reconditioned using the Valve and Seat Reconditioning Procedure.

Valve and Seat Reconditioning Procedure


image


Fig. 430: Valve Seating Surface Angle

Courtesy of GENERAL MOTORS COMPANY


NOTE: image If the valve seat width, roundness or concentricity is beyond specifications, you must grind the seats in order to ensure proper heat dissipation and prevent the build up of carbon on the seats.

image It is necessary to reface the valve if seat reconditioning is required unless a new valve is used.


1. Grind the valve seating surface (a) to the proper angle specification (2). Refer to Engine Mechanical Specifications.

2. Grind the valve relief surface to the proper angle specification (1) to correctly position the valve seating surface (a) to the valve. Refer to Engine Mechanical Specifications.

3. Grind the valve undercut surface to the proper angle specification (3) to narrow the valve seating surface width

(a). Refer to Engine Mechanical Specifications.


NOTE: Do not grind or condition the intake valve. If the intake valve seat has been

reconditioned, replace the corresponding intake valve.


4. Replace the intake valve if it is out of specification. Refer to Engine Mechanical Specifications.

5. If the original exhaust valve is being used, grind the valve to the specifications listed in Engine Mechanical Specifications. Measure the valve head O.D. and chamfer again after grinding using the Valve Head O.D. and Chamfer Measurement Procedure. Replace the exhaust valve if it is out of specification. New valves do not require grinding.

6. When grinding the valves and seats, grind off as little material as possible. Cutting valve seat results in lowering the valve spring pressure.

7. Install the valve in the cylinder head.

image If you are using refaced exhaust valves, lap the valves into the seats with a fine grinding compound. The refacing and reseating operations should leave the refinished surfaces smooth and true so that minimal lapping is required. Excessive lapping will groove the valve face and prevent a good seat when hot.

image Be sure to clean any remaining lapping compound from the valve and seat with solvent and compressed air prior to final assembly.

8. After obtaining the proper valve seat width in the cylinder head, you must re-measure the valve stem height using the Valve Stem Height Measurement Procedure.

9. If the valve stem height is acceptable, test the seats for concentricity using the Valve-to-Seat Concentricity Measurement Procedure.


Valve Stem Height Measurement Procedure


image

Fig. 431: Valve Stem Height Measurement Courtesy of GENERAL MOTORS COMPANY


NOTE: To determine the valve stem height measurement, measure from the valve spring seat to the valve spring retainer.


1. Install the valve (1) into the valve guide in the cylinder head (2).

2. Ensure the valve is seated to the cylinder head valve seat.

3. Install the valve stem oil seal.

4. Install the valve spring retainer and valve stem locks.

5. Measure the distance (a) between the valve seal lip to the bottom of the valve spring retainer. Refer to Engine Mechanical Specifications.

6. If the maximum height specification is exceeded, a new valve should be installed and the valve stem height re- measured.


CAUTION: DO NOT grind the valve stem tip. The tip of the valve is hardened and grinding the tip will eliminate the hardened surface causing premature wear and possible engine damage.


CAUTION: DO NOT use shims in order to adjust valve stem height. The use of shims will cause the valve spring to bottom out before the camshaft lobe is at peak lift and engine damage could result.


7. If the valve stem height still exceeds the maximum height specification, the cylinder head must be replaced.

CYLINDER HEAD ASSEMBLE

Special Tools


image EN-8062 Valve Spring Compressor

image EN-43963 Valve Spring Compressor - Off-Car Adapter

image EN-46116 Valve Seal Remover

image EN-46122 Camshaft Position Actuator Check-Ball Valve Remover/Installer For equivalent regional tools, refer to Special Tools.

Cylinder Head Assemble


1. Apply sealant to all plugs prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers.

image


Fig. 432: Cylinder Head Core Hole Plugs Courtesy of GENERAL MOTORS COMPANY


CAUTION: Refer to Component Fastener Tightening Caution .


2. Install 2 NEW cylinder head core hole plugs (1) in the rear of the cylinder head. Tighten the plug to 25 N.m (18 lb ft).


image


Fig. 433: Side Cylinder Head Oil Gallery Plugs And Studs Courtesy of GENERAL MOTORS COMPANY

3. Install 2 NEW cylinder head oil gallery plugs (1) in the side of the cylinder head.


CAUTION: Refer to Torque-to-Yield Fastener Caution .


4. Install 4 NEW catalytic converter studs (2). Tighten the studs to 10 N.m (89 lb in)

image

Fig. 434: Cylinder Head Core Hole Plugs, Oil Gallery Plugs And Oil Gallery Restrictor Courtesy of GENERAL MOTORS COMPANY

5. Install 4 NEW cylinder head core hole plugs (1) in the top of the cylinder head. Tighten the plugs to 25 N.m (18 lb ft).

6. Install a NEW cylinder head oil restrictor (2).

7. Install 2 NEW cylinder head oil gallery plugs (3).

8. Install a NEW cylinder head core hole plug (4). Tighten the plug to 75 N.m (55 lb ft).


image

Fig. 435: Engine Oil Manifold Check Valve Courtesy of GENERAL MOTORS COMPANY

9. If necessary, install new engine oil manifold check valves (3):

1. Use lubricant included with EN-46122 remover/installer to lubricate the outside of the new check valve (3).

2. With the check ball end of the check valve facing DOWN, towards the head, insert the NEW check valve into the check valve bore in the cylinder head.

3. Place EN-46122-2 collar (2) over the new check valve with the slightly-larger inside diameter of the collar DOWN toward the cylinder head.

4. Using the EN-46122-1 driver (1), lightly tap the new check valve into place until the driver stops against

the top of the collar.

Intake and Exhaust Valve Components Installation


image


Fig. 436: Exhaust And Intake Valves

Courtesy of GENERAL MOTORS COMPANY


NOTE: Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.


1. Ensure that the valve train components will be installed in their original position.

2. Lubricate the valve guides and the valve stems with engine oil.

3. Install the exhaust valves (1) and the intake valves (2) in the cylinder head.


image

Fig. 437: Valve Spring Retainer, Valve Spring And Oil Seal Courtesy of GENERAL MOTORS COMPANY


NOTE: image Valve stem oil seal sets will contain 2 different colored seals, black and green. The set of 8 seals that are green go on the exhaust valves.

image Ensure the valve stem oil seals do not deform during installation.

image Force should only be applied to the valve spring contact area of the new valve stem oil seal during installation.


4. Using EN-46116 installer, carefully push the NEW valve stem oil seals (3) into position, until the seal positively locks on the guide.

5. Lubricate the valve stem and valve guide ID with clean engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers.

6. Install the valve spring (2) and the valve spring retainer (1).


image

Fig. 438: Special Tool To Remove/Install Valve Stem Keys Courtesy of GENERAL MOTORS COMPANY

7. Using EN-8062 compressor, position EN-43963 adapter properly to the valve spring retainer.


WARNING: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.


CAUTION: Do not compress the valve springs less than 25.0 mm (0.984 in). Contact between the valve spring retainer and the valve stem oil seal can cause potential valve stem oil seal damage.


8. Using EN-8062 compressor, compress the valve spring and scale the upper valve spring retainer down until the valve stem keys can be installed. Use a suitable tool and a bit of grease to install the valve stem keys (1).

9. Slowly release the tension on the valve spring.

10. Inspect for proper valve key seating.

11. Repeat the procedure for the remaining valves.

image

Fig. 439: Spark Plugs

Courtesy of GENERAL MOTORS COMPANY

12. Install the spark plugs (1) and tighten to 17 N.m (13 lb ft).

ENGINE BLOCK DISASSEMBLE

Upper Engine Block Disassemble


image


Fig. 440: Upper Engine Block Components Courtesy of GENERAL MOTORS COMPANY

Upper Engine Block Disassemble 1

Callout

Component Name

1

Transmission Locating Pin (Qty: 2)

Callout

Component Name

2

Engine Block Oil Gallery Plug

3

Cylinder Head Locating Pin (Qty: 2)

4

Engine Block Coolant Drain Hole Plug

5

Knock Sensor Bolt

6

Knock Sensor

7

Engine Oil Pressure Sensor

8

Starter Opening Cover Bolt

9

Starter Opening Cover


Upper Engine Block Disassemble


image


Fig. 441: Upper Engine Block Components Courtesy of GENERAL MOTORS COMPANY

Upper Engine Block Disassemble 2

Callout

Component Name

1

Engine Block Core Hole Plug

2

Engine Block Oil Gallery Plug (Qty: 2)

3

Lower Crankcase Locating Pin (Qty: 4)

4

Piston Oil Nozzle Bolt (Qty: 4)

Callout

Component Name

5

Piston Oil Nozzle (Qty: 4)


Lower Crankcase Disassemble


image


Fig. 442: Lower Crankcase Components Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase Disassemble

Callout

Component Name

1

Crankshaft Position Sensor Bolt

2

Crankshaft Position Sensor

ENGINE BLOCK CLEANING AND INSPECTION

Special Tools


image EN-8087 Cylinder Bore Gauge

image EN-28410 Gasket Remover

For equivalent regional tools, refer to Special Tools.

Cleaning Procedure


1. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

2. Remove any old thread sealant, gasket material or sealant using EN-28410 remover.

3. Clean all the following areas with solvent: image Sealing surfaces

image Cooling passages

image Oil passages

image Bearing journals

4. Clean all threaded and through holes with solvent.


WARNING: Refer to Safety Glasses Warning .


5. Dry the engine block with compressed air.


Visual Inspection


image


Fig. 443: Block

Courtesy of GENERAL MOTORS COMPANY

1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced.

2. Inspect the primary camshaft drive chain tensioner mounting surface on the engine block for burrs or any defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.

3. Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if necessary.

4. Inspect all threaded and through holes for damage or excessive debris.

5. Inspect all bolts for damage, if damaged replace with NEW bolts only.

6. Check the cylinder condition. Some light vertical marks may be visible on the cylinder wall. In these areas, check that the honing marks are still visible in this marked area. If they are, the cylinder surface has not been

compromised and the engine block can be used.

7. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.

8. Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.

9. Repair any damaged threaded holes. Refer to Thread Repair Specifications and Thread Repair.


Measuring Cylinder Bore Diameter


image


Fig. 444: Measuring Cylinder Bore

Courtesy of GENERAL MOTORS COMPANY

1. Measure the cylinder bore diameter 37 mm (1.457 in) from the deck face using the EN-8087 gauge.

2. Compare your results with the Engine Mechanical Specifications. If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.


Measuring Cylinder Bore Taper


1. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 10 mm (0.397 in) below the deck surface and record your measurement.

2. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centerline, at 100 mm (3.976 in) below the deck surface and record your measurement.

3. Calculate the difference between the 2 measurements. The result will be the cylinder taper.

4. Compare your results with the Engine Mechanical Specifications. If the cylinders exceed the specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.


Measuring Cylinder Bore Out-of-Round


1. Measure both the thrust and non-thrust cylinder diameter at 10 mm (0.397 in) below the deck. Record your measurements.

2. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the upper end of the cylinder.

3. Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.976 in) below the deck surface. Record your measurements.

4. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.

5. Compare your results with the Engine Mechanical Specifications. If the cylinders exceed these specifications, the cylinder block may be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.


Deck Flatness Inspection


image


Fig. 445: Checking Deck Flatness

Courtesy of GENERAL MOTORS COMPANY

1. Ensure the engine block decks are clean and free of gasket material.

2. Inspect the surface for any imperfections or scratches that could inhibit proper cylinder head gasket sealing.

3. Place a straight-edge diagonally across the cylinder block deck face surface.

4. Measure the clearance between the straight-edge and the cylinder block deck face using a feeler gauge at 4 points along the straight-edge.

5. If the warpage is less than 0.05 mm (0.002 in), the cylinder block deck surface does not require resurfacing.

6. If the warpage is between 0.05 - 0.20 mm (0.002 - 0.008 in) or any imperfections or scratches that could inhibit proper cylinder head gasket sealing are present, the cylinder block deck surface requires resurfacing.

7. If resurfacing is required the maximum amount that can be removed is 0.25 mm (0.010 in).

8. If the cylinder block deck surface requires more than 0.25 mm (0.010 in) material removal the block must be replaced.

ENGINE BLOCK ASSEMBLE

Lower Crankcase Assemble


image


Fig. 446: Lower Crankcase Components Courtesy of GENERAL MOTORS COMPANY

Lower Crankcase Assemble

Callout

Component Name

1

Crankshaft Position Sensor


2

Crankshaft Position Sensor Bolt


CAUTION:

Refer to Fastener Caution .

Callout

Component Name



Tighten

10 N.m (89 lb in)


Upper Engine Block Assemble


image


Fig. 447: Upper Engine Block Components Courtesy of GENERAL MOTORS COMPANY

Upper Engine Block Assemble 1

Callout

Component Name

Preliminary Procedure

Apply sealant to all plugs prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers.

1

Engine Block Core Hole Plug (Qty: 2)


2

Engine Block Oil Gallery Plug (Qty: 2)

Tighten

65 N.m (48 lb ft)

3

Lower Crankcase Locating Pin (Qty: 4)

4

Piston Oil Nozzle (Qty: 4)

Callout

Component Name


5

Piston Oil Nozzle Bolt (Qty: 4)

Tighten

10 N.m (89 lb in)


Upper Engine Block Assemble


image


Fig. 448: Upper Engine Block Components Courtesy of GENERAL MOTORS COMPANY

Upper Engine Block Assemble 2

Callout

Component Name

Preliminary Procedure

Apply sealant to all plugs prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers.


1

Transmission Locating Pin (Qty: 2)

Procedure

Ensure Transmission locating pins are properly seated and not damaged.


2

Engine Block Oil Gallery Plug


CAUTION:

Refer to Component Fastener Tightening Caution .


Tighten

65 N.m (48 lb ft)

3

Cylinder Head Locating Pin (Qty: 2)

Callout

Component Name


4

Engine Block Coolant Drain Hole Plug

Tighten

60 N.m (44 lb ft)

5

Knock Sensor


6

Knock Sensor Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

25 N.m (18 lb ft)


7

Engine Oil Pressure Sensor

Tighten

35 N.m (29 lb ft)

8

Starter Opening Cover


9

Starter Opening Cover Bolt (Qty: 2)

Tighten

25 N.m (18 lb ft)

FUEL INJECTOR AND FUEL INJECTOR BORE CLEANING AND INSPECTION

image

Fig. 449: Fuel Injector and Fuel Injector Bore Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Use EN-47909 cleaning kit to clean the fuel injector bores.


NOTE:

Do not soak or immerse the fuel rail or injectors in solvent.


2. Clean the exterior of the fuel rail and injectors with solvent.

Special Tools EN-47909 Injector Bore and Sleeve Cleaning KitFor equivalent regional tools, refer to Special Tools.


1

Fuel Rail Assembly


NOTE:

Callout

Component Name


Do not remove the EN-51146

remover unless fuel injector replacement is necessary.


Procedure

1. Inspect for damage, debris, or restrictions to the fuel rail and fuel ports.

2. Inspect for damage to the mounting area for the fuel rail.

3. Inspect for damage to the fuel rail mounting bolts.

4. Inspect for damage to the threads on the fuel rail fuel feed fitting.

5. Inspect the fuel rail pressure sensor for damage.

6. Inspect the fuel injector for damage to the harness connector.

7. Inspect the fuel injector tip, tolerance ring, and seal locations.


2

Fuel Injector Combustion Seal


NOTE:

Discard the seals and use NEW seals upon installation.


Procedure

1. If present, remove the calibration tool on the fuel injector tip.

2. Remove and discard the fuel injector combustion seals.

3. Reinspect each fuel injector tip once the seals are removed.

PISTON AND CONNECTING ROD DISASSEMBLE

image

Fig. 450: Piston and Connecting Rod

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure


NOTE:

Many internal engine components will develop specific wear patterns on their friction surfaces.


1. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

2. Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.

PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION

Piston Cleaning Procedure


NOTE: DO NOT wire brush any part of the piston.


1. Clean the piston skirts and the pins with a cleaning solvent.

2. Clean the piston ring grooves with a groove cleaner. Ensure that the oil ring holes and slots are clean.


WARNING: Refer to Safety Glasses Warning .


3. Dry the piston with compressed air.


Piston Inspection Procedure


image


Fig. 451: Identifying Piston Inspection Areas Courtesy of GENERAL MOTORS COMPANY

1. Inspect the pistons for the following conditions: image Cracked ring lands, skirts or pin bosses

image Ring grooves for nicks, burrs that may cause binding (5) image Warped or worn ring lands (5)

image Piston pin retainer grooves for burrs (2)

image Eroded areas at the top of the piston (1) image Scuffed or damaged skirt coating (4)

image Worn piston pin bores or worn piston pins (3)

2. Replace pistons that show any signs of damage or excessive wear.


Piston Measurement Procedure


image


Fig. 452: Measuring Piston Width

Courtesy of GENERAL MOTORS COMPANY

1. Measure piston width using the following procedure:

1. Using an outside micrometer, measure the width of the piston at 30 mm (1.181 in) below the crown, top,

(1) at the thrust surfaces of the piston, perpendicular to the piston pin centerline.

2. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter.

3. Check your measurements. Refer to Engine Mechanical Specifications.

4. If the clearance obtained through measurement is greater than the provided specifications and the cylinder bores are within specification, replace the piston.

image


Fig. 453: Measuring Piston Pin Diameter Courtesy of GENERAL MOTORS COMPANY

2. Measure the piston pin bore to piston pin clearances using the following procedure:

1. Piston pin bores and pins must be free of varnish or scuffing.

2. Use an outside micrometer to measure the piston pin in the piston contact areas.


image


Fig. 454: Measuring Piston Pin Bore

Courtesy of GENERAL MOTORS COMPANY

3. Using an inside micrometer, measure the piston pin bore. Compare your result with the piston pin diameter and piston pin to piston pin bore clearance specification. Refer to Engine Mechanical Specifications.

4. If the clearance is excessive, determine which piece is out of specification and replace as necessary.

5. You must replace the piston if any of its dimensions are out of specification.

6. If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 mm (0.010 in). There is only one size of oversized pistons and rings available for service.


Piston Ring Measurement Procedure

image


Fig. 455: Measuring Piston Ring End Gap Courtesy of GENERAL MOTORS COMPANY

1. Measure the piston ring end gap using the following procedure:

1. Place the piston ring in the area of the bore where the piston ring will travel approximately 25 mm (1 in) down from the deck surface. Ensure that the ring is square with the cylinder bore by positioning the ring with the piston head.

2. Measure the end gap of the piston ring with feeler gauges. Refer to Engine Mechanical Specifications.

3. If the clearance exceeds the provided specifications, the piston rings must be replaced.

4. Repeat the procedure for all the piston rings.


image


Fig. 456: Measuring Piston Ring Side Clearance Courtesy of GENERAL MOTORS COMPANY

2. Measure the piston ring side clearance using the following procedure:

1. Roll the piston ring entirely around the piston ring groove. If any binding is caused by the ring groove, dress the groove with a fine file. If any binding is caused by a distorted piston ring, replace the ring.

2. With the piston ring on the piston, use feeler gauges to check clearance at multiple locations.

3. Compare the measurements with piston ring side clearance specification. Refer to Engine Mechanical Specifications.

4. If the clearance is greater than specifications, replace the piston rings.


image


Fig. 457: Compression Ring Locating Dimple Courtesy of GENERAL MOTORS COMPANY

3. There is a locating dimple (1) on the compression rings near the end for identification. Install the compression rings with the dimple facing up.

4. If the new ring does not reduce the clearance to the proper specification, install a new piston.

5. If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 mm (0.010 in). There is only 1 size of oversized pistons and rings available for service.


Connecting Rod Cleaning Procedure


1. Clean the connecting rods in solvent.


WARNING: Refer to Safety Glasses Warning .


2. Dry the connecting rod using compressed air.

3. Remove the connecting rod cap and clean the threads.

4. Remove the connecting rod bearing and discard. Never reuse a connecting rod bearing used in a running engine.


Connecting Rod Visual Inspection Procedure

image


Fig. 458: Inspecting Connecting Rod Components Courtesy of GENERAL MOTORS COMPANY

1. Inspect the piston pin bushing (4) for scoring or damage.

2. Inspect the connecting rod beam (1) for twisting or bending.

3. Inspect the rod cap (2) for any nicks or damage caused by possible interference.

4. Inspect for scratches or abrasion on the rod bearing seating surface.


NOTE: DO NOT scrape the rod or rod cap.


5. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. Thoroughly clean the parts and perform a high-pressure wash if an abrasive is used on the bores.


Connecting Rod Measurement Procedure


Piston Pin End

image


Fig. 459: Measuring Piston Pin Diameter Courtesy of GENERAL MOTORS COMPANY


NOTE: Measurements of all components should be taken with the components at normal room temperature.


1. Using an outside micrometer, take 2 measurements of the piston pin in the area of the connecting rod contact.

image


Fig. 460: Checking Connecting Rod Piston Pin Bore Dimensions Courtesy of GENERAL MOTORS COMPANY

2. Using an inside micrometer, measure the connecting rod piston pin bore.

3. Subtract the piston pin diameter from the piston pin bore.

4. Compare the clearance measurements to the proper specifications. Refer to Engine Mechanical Specifications.

5. If the clearance is excessive, replace the piston pin. If a new pin does not resolve the clearance problem, replace the connecting rod.

Connecting Rod Crankshaft Bearing End

image


Fig. 461: Measuring Connecting Rod Crankshaft Bearing Bore Courtesy of GENERAL MOTORS COMPANY


NOTE: Measurements of all components should be taken with the components at normal room temperature.


NOTE: The bore specifications are based on connecting rod bolts at full torque specification.


1. Using the old bolts, tighten the connecting rod cap bolts to 25 N.m (18 lb ft) plus 75 degrees.

2. Using an inside micrometer, measure the connecting rod crankshaft bearing bore.

3. Compare the bore measurements to the proper specifications. Refer to Engine Mechanical Specifications.

4. Replace the connecting rod if the bore is out of specifications. DO NOT recondition the connecting rod.

PISTON AND CONNECTING ROD ASSEMBLE

image

Fig. 462: Piston and Connecting Rod

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Connecting Rod


NOTE:

Align the connecting rod and piston with the features used to identify the orientation of the component relative to the front of the engine.


Callout

Component Name


2

Piston

Procedure

1. Locate the alignment feature or marks on the connecting rod.

2. Locate the alignment feature or marks on the piston.

3. Ensure that the alignment features are in the correct location when assembling the components.

3

Piston Pin


4

Piston Pin Retainer


CAUTION:

Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage.


Procedure

1. Coat the piston pin with oil.

2. Install one side of one piston pin retainer into the retaining groove using EN-49941

installer. Rotate the retainer until it is fully seated in the groove.

3. Install the piston pin. Push the piston pin until it bottoms in the previously installed retainer.

4. Install the second piston pin retainer, using EN-49941 installer.

5. Ensure that the piston moves freely.


Special Tools

EN-49941 Piston Pin Retainer Remover and Installer For equivalent regional tools, refer to Special Tools.


5

Piston Oil Ring Rail


CAUTION:

Use a piston ring expander to install the piston rings. The rings may be damaged if

Callout

Component Name


expanded more than necessary.


6

Piston Oil Ring Spacer


NOTE:

Properly orient the oil ring spacer as shown before installation. The ends of the spacer must be facing toward the top of the piston.

7

Piston Oil Ring Rail

8

Piston Compression Lower Ring


9

Piston Compression Upper Ring

Procedure

Once the rings are installed, set the ring gaps as shown. Use the piston location arrow for reference.

CAMSHAFT CLEANING AND INSPECTION

Special Tools


GE-7872 Magnetic Base Dial Indicator

For equivalent regional tools, refer to Special Tools.

Cleaning Procedure


1. Clean the camshaft in solvent.


WARNING: Refer to Safety Glasses Warning .


2. Dry the camshaft with compressed air.


Visual Inspection


image


Fig. 463: Identifying Camshaft Inspection Areas Courtesy of GENERAL MOTORS COMPANY

1. Inspect the camshaft oil feed holes (1) to the camshaft position actuator for dirt, debris or blockage.

2. Inspect the threaded hole (2) for damage.

3. Inspect the camshaft position actuator locating notch (3) for damage or wear.

4. Inspect the camshaft sealing grooves (4) for damage.

5. Inspect the camshaft thrust surface (5) for damage.

6. Inspect the camshaft lobes (6) and journals (7) for the following conditions: image Excessive scoring or pitting

image Discoloration from overheating

image Deformation from excessive wear, especially the camshaft lobes

7. If any of the above conditions exist on the camshaft, replace the camshaft.


Camshaft Measurement


image


Fig. 464: Supporting Camshaft In Fixture Courtesy of GENERAL MOTORS COMPANY

1. With the camshaft in a suitable fixture, measure the camshaft for wear.


image


Fig. 465: Measuring Camshaft Journals Courtesy of GENERAL MOTORS COMPANY

2. Measure the camshaft journals for diameter and out-of-round using an outside micrometer. Refer to Engine Mechanical Specifications.

image If the diameter is smaller than specifications, replace the camshaft. image If the out-of-round exceeds specifications, replace the camshaft.


image


Fig. 466: Checking Camshaft Runout

Courtesy of GENERAL MOTORS COMPANY

3. Measure the camshaft runout using the GE-7872 indicator. Refer to Engine Mechanical Specifications.

image


Fig. 467: Measuring Camshaft Thrust Width Courtesy of GENERAL MOTORS COMPANY

4. Measure the camshaft thrust width for wear using a depth micrometer. Refer to Engine Mechanical Specifications.


image


Fig. 468: Measuring Camshaft Thrust Wall Surface For Runout Courtesy of GENERAL MOTORS COMPANY

5. Measure the camshaft thrust wall surface for runout using GE-7872 indicator. Refer to Engine Mechanical Specifications.

6. If the camshaft is damaged or worn beyond specifications, replace the camshaft. No machining of the camshaft is allowed.


image


Fig. 469: Measuring Camshaft Lobes For Wear Courtesy of GENERAL MOTORS COMPANY

7. Measure the camshaft lobes for wear using the GE-7872 indicator.

image


Fig. 470: Measuring Lift Of Camshaft Lobe Courtesy of GENERAL MOTORS COMPANY

8. Place the GE-7872 indicator with the indicator tip on the base circle (1) of the camshaft lobe.

1. Place the GE-7872 indicator at zero.

2. Rotate the camshaft until the indicator tip is at the highest point (3) on the lobe. This reading is the lift of the camshaft lobe. Refer to Engine Mechanical Specifications.

3. If the indicated measurement is significantly lower than these specifications, replace the camshaft or engine performance will be reduced.

CAMSHAFT TIMING CHAIN AND SPROCKET CLEANING AND INSPECTION

image

Fig. 471: Camshaft Timing Chain and Sprocket Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Timing Chain

Procedure

1. Inspect the timing chain for binding or worn links.

2. Inspect the timing chain for loose links.

3. Inspect the timing chain for loose pins.

4. Replace the timing chain if binding, excessive wear, or a loose condition is present.


2

Timing Chain Guide

Procedure

1. Inspect the guide for worn guide surface. Replace the timing chain guides if wear exceeds

1.12 mm (0.045 in) depth on the chain guide surface.

2. Inspect the guide for a cracked or broken guide surface.

3. Inspect the guide for a cracked or damaged guide base.

4. Replace the guide if damage is present.


Callout

Component Name


3

Camshaft Position Actuator Assembly - Exhaust

Procedure

1. Inspect the camshaft actuator faces for signs of movement.

2. Inspect the camshaft actuator for sprocket damage.

3. Inspect the actuator bolt seating and sealing inner hub flange for damage.

4. Inspect the back of the actuator for locating pin damage.

5. Ensure the actuator housing bolts are not loose or missing.

6. Inspect the back of the actuator for blockage to the oil passages.

7. Replace the actuator if any of these conditions are present.


4

Timing Chain Guide

Procedure

1. Inspect the guide for wear to the guide surface.

2. Inspect the guide for cracked or broken guide surface or base.

3. Replace the guide if these conditions are present.


5

Timing Chain Oil Nozzle

Procedure

1. Inspect the oil nozzle body for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body if it is damaged.

2. Verify oil nozzle oil flow with compressed air.

3. Replace the nozzle if damage or oil flow restriction is present.


6

Timing Chain Tensioner Shoe

Procedure

1. Inspect for worn, cracked, or broken shoe surface.

2. Inspect the shoe for wear at the tensioner contact pad.

3. Replace the shoe if any of these conditions are present.


7

Timing Chain Tensioner

Procedure

1. Inspect the tensioner for damage to the plunger-to-shoe contact surface.

2. Inspect the tensioner for a locked or binding condition. Reset the plunger and ensure the plunger moves freely in and out of the tensioner body.

image If the tensioner has a lever on the front, press down on the lever and depress the plunger. Insert a suitable tool into the hole in the tensioner body to hold the plunger in the retracted position.

image If the tensioner has a retaining clip, press the clip and depress the plunger. Insert a suitable tool into the hole in the tensioner body to hold the plunger in the retracted

Callout

Component Name


position.

3. Inspect the timing chain tensioner gasket for damage.

4. Replace the tensioner if any of these conditions are present.


8

Camshaft Position Actuator Assembly - Intake

Procedure

1. Inspect the camshaft actuator faces for signs of movement.

2. Inspect the camshaft actuator for sprocket damage.

3. Inspect the actuator bolt seating and sealing inner hub flange for damage.

4. Inspect the back of the actuator for locating pin damage.

5. Ensure the actuator housing bolts are not loose or missing.

6. Inspect the back of the actuator for blockage to the oil passages.

7. Replace the actuator if any of these conditions are present.

INTAKE MANIFOLD CLEANING AND INSPECTION


image


Fig. 472: Intake Manifold

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Remove all components prior to cleaning and inspection.

2. Inspect each component.


1

Manifold Absolute Pressure Sensor Bolt


CAUTION:

Refer to Fastener Caution .

Callout

Component Name



Tighten

10 N.m (89 lb in)

2

Manifold Absolute Pressure Sensor


3

Evaporative Emission Canister Purge Solenoid Valve Bolt

Tighten

10 N.m (89 lb in)

4

Evaporative Emission Canister Purge Solenoid Valve


5

Upper Intake Manifold Cover Bolt (Qty: 3)

Tighten

8 N.m (71 lb in)

6

Upper Intake Manifold Cover


7

Intake Manifold Cover Bolt (Qty: 3)

Tighten

7 N.m (62 lb in)

8

Lower Intake Manifold Cover

CRANKSHAFT AND BEARING CLEANING AND INSPECTION

Special Tools

image EN-8087 Cylinder Bore Checking Gauge

image EN-45059 Angle Meter

image GE-7872 Magnetic Base Dial Indicator Set For equivalent regional tools, refer to Special Tools. Crankshaft Cleaning and Inspection


image


Fig. 473: Crankshaft

Courtesy of GENERAL MOTORS COMPANY


NOTE: Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring. Damage to the teeth of the crankshaft position reluctor ring may affect on-board diagnostic (OBD) II system performance.


1. Clean the crankshaft (1) with solvent.

2. Thoroughly clean all oil passages and inspect for restrictions or burrs.


WARNING: Refer to Safety Glasses Warning .


3. Dry the crankshaft with compressed air.


NOTE: Reluctor ring teeth should not have imperfections on the rising or falling edges. Imperfections of the reluctor ring teeth may effect OBD II system performance.


4. Perform a visual inspection of the crankshaft for damage.


image


Fig. 474: Identifying Different Crankshaft Journal Wear Patterns Courtesy of GENERAL MOTORS COMPANY

5. Inspect the crankshaft journals for wear (1). The journals should be smooth, with no signs of scoring, wear, or damage.

6. Inspect the crankshaft journals for grooves or scoring (2).

7. Inspect the crankshaft journals for scratches or wear (3).

8. Inspect the crankshaft journals for pitting or imbedded bearing material (4).

Crankshaft Measurements

image


Fig. 475: Measure Crankshaft Journals For Out-Of-Round Courtesy of GENERAL MOTORS COMPANY

1. Measure the crankshaft journals (1) for out-of-round.

2. Measure the crankshaft journals for taper.


image


Fig. 476: Measuring Crankshaft Runout Courtesy of GENERAL MOTORS COMPANY

3. Measure the crankshaft runout.

Using wooden V-blocks, support the crankshaft on the front and rear journals.

4. Use the GE-7872 indicator (1) in order to measure the crankshaft runout at the front and rear intermediate journals.

5. Use the GE-7872 indicator in order to measure the runout of the crankshaft rear flange.

6. Replace the crankshaft if the measurements are not within specifications. Refer to Engine Mechanical Specifications.

Crankshaft Bearings Cleaning and Inspection

image


Fig. 477: Identifying Crankshaft Bearing Damage Courtesy of GENERAL MOTORS COMPANY


NOTE: image Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for use.

image If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.


1. Inspect crankshaft bearings for craters or pockets (1). Flattened sections on the bearing halves also indicate fatigue.

2. Inspect the crankshaft bearings for excessive scoring or discoloration (2).

3. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.

4. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing (3). If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

image


Fig. 478: Measuring Crankshaft Main Bearing Bores Courtesy of GENERAL MOTORS COMPANY

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

1. Tighten the bedplate to specification using the EN-45059 meter.

2. Measure the bearing bore for taper and out-of-round using the EN-8087 gauge (1).

3. No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2 methods to measure bearing clearance. Method A gives more reliable results and is preferred.

image Method A yields measurement from which the bearing clearance can be computed.

image Method B yields the bearing clearance directly. Method B does not give any indication of bearing run- out.


image


Fig. 479: Measuring Crankshaft Bearing Journal Using Method A Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not mix inserts of different nominal size in the same bearing bore.


2. To measure bearing clearance using Method A, use the following procedure:

1. Measure the crankshaft bearing journal diameter with a micrometer (1) in several places, 90 degrees apart. Average the measurements.

2. Measure the crankshaft bearing journal taper and runout.

3. Install the lower crankcase and tighten the bearing cap bolts to specification.

4. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements.

5. Subtract journal measurement from bearing ID measurement to determine clearance.

6. Determine whether clearance is within specification.

7. If out of specification, choose different inserts.

8. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.

9. Measure the crankshaft main bearing inside diameter with an inside micrometer.

image


Fig. 480: Measuring Bearing Clearance With Gaging Plastic Using Method B Courtesy of GENERAL MOTORS COMPANY

3. To measure bearing clearance using Method B, use the following procedure:

1. Clean the used bearing inserts.

2. Install the used bearing inserts.

3. Place a piece of gaging plastic across the entire bearing width.

4. Install the bearing caps.


CAUTION: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.


5. Install the bearing cap bolts to specification.


NOTE: Do not rotate the crankshaft.


6. Remove the bearing cap, leaving the gauging plastic in place. It does not matter whether the gauging plastic adheres to the journal or to the bearing cap.

7. Measure the gauging plastic at its widest point with the scale (1) printed on the gauging plastic package.

8. Remove the gauging plastic.

OIL PUMP DRIVE CHAIN TENSIONER AND OIL PUMP DRIVE CHAIN CLEANING AND INSPECTION


image

Fig. 481: Oil Pump Drive Chain Tensioner and Oil Pump Drive Chain Cleaning and Inspection Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Clean all components.

2. Inspect each component.

1

Oil Pump Drive Chain

2

Oil Pump Drive Chain Tensioner Bolt

3

Oil Pump Drive Chain Tensioner

OIL PUMP CLEANING AND INSPECTION

image

Fig. 482: Oil Pump Cleaning and Inspection Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Clean all components.

2. Inspect each component.

1

Oil Pump

2

Oil Pump Gasket

3

Oil Pump Gasket

4

Oil Pump Flow Control Solenoid Valve Retainer

5

Oil Pump Flow Control Solenoid Valve

OIL PAN CLEANING AND INSPECTION

image

Fig. 483: Oil Pan Cleaning and Inspection Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Remove all components prior to cleaning.

2. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

3. Clean all components.

4. Inspect each component.

1

Upper Oil Pan Locating Pin (Qty: 2)

2

Upper Oil Pan

3

Lower Oil Pan Locating Pin (Qty: 2)


4

Lower Oil Pan


NOTE:

Use a NEW lower oil pan.

5

Oil Pan Drain Plug

THREAD REPAIR

Special Tools


image EN 42385-307 Drill Bushing

image EN 42385-308 Alignment Pin

image EN 42385-510 Main Attachment Bolt

image EN 42385-900 Head Bolt Thread Repair Kit

image EN 42385-904 Thread Insert

For equivalent regional tools, refer to Special Tools.

General Thread Repair


image


Fig. 484: Bushing Type Insert And Base Material Courtesy of GENERAL MOTORS COMPANY

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material

(2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

image


Fig. 485: Drilling And Tapping Threads Courtesy of GENERAL MOTORS COMPANY


NOTE: The use of a cutting fluid, WD 40®, or equivalent, is recommended when performing the drilling, counterboring, and tapping procedures. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a suitable tap wrench or drill motor.


1. Drill out the threads of the damaged hole (1).

image M6 inserts require a minimum drill depth of 15 mm (0.59 in). image M8 inserts require a minimum drill depth of 20 mm (0.79 in).

image M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).


WARNING: Refer to Safety Glasses and Compressed Air Warning .


2. Using compressed air, clean out any chips.

image


Fig. 486: Identifying Tool Used To Counterbore Hole Courtesy of GENERAL MOTORS COMPANY

3. Counterbore the hole to the full depth permitted by the tool (1).

4. Using compressed air, clean out any chips.

image


Fig. 487: Drilling And Tapping Threads Courtesy of GENERAL MOTORS COMPANY

5. Using a tap wrench (2), tap the threads of the drilled hole.

image M6 inserts require a minimum tap depth of 15 mm (0.59 in). image M8 inserts require a minimum tap depth of 20 mm (0.79 in).

image M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).

WARNING: Refer to Safety Glasses and Compressed Air Warning . WARNING: Refer to Cleaning Solvent Warning .

6. Using compressed air, clean out any chips.

7. Spray cleaner into the hole. Refer to Adhesives, Fluids, Lubricants, and Sealers.

8. Using compressed air, clean any cutting oil and chips out of the hole.

image


Fig. 488: Lubricating Installer Tool Threads Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.


9. Lubricate the threads of the installer tool (2) with the driver oil (1).

image


Fig. 489: Driver Tool And Insert

Courtesy of GENERAL MOTORS COMPANY

10. Install the insert (2) onto the driver tool (1).

image


Fig. 490: Applying Threadlock To Insert OD Threads Courtesy of GENERAL MOTORS COMPANY

11. Apply threadlock LOCTITE™ 277, EN 42385 - 109 (1) loctite, or equivalent to the insert OD threads (2).

image


Fig. 491: Installing Insert Into Bolt Hole Using Installer Tool Courtesy of GENERAL MOTORS COMPANY

12. Install the insert (2) into the hole.

Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert.

The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

image


Fig. 492: Bushing Type Insert And Base Material Courtesy of GENERAL MOTORS COMPANY

13. Inspect the insert for proper installation into the hole.

A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).


Cylinder Head Bolt Hole Thread Repair

image


Fig. 493: Cylinder Head Bolt Hole Thread Repair Kit Courtesy of GENERAL MOTORS COMPANY


NOTE: The tools listed may not necessarily represent the exact tools used for the procedure.


1. The cylinder head bolt hole thread repair kit consists of the following items: image Drill (1)

image Tap (2)

image Installer (3)

image Sleeve (4)

image Alignment Pin (5)

image Bushing (6)

image Bolts (7)

image Fixture Plate (8)


image


Fig. 494: Fixture Plate, Bolts And Bushing Courtesy of GENERAL MOTORS COMPANY


WARNING: Refer to Safety Glasses and Compressed Air Warning .


NOTE: The use of a cutting fluid, WD 40®, or equivalent, is recommended when performing the drilling and tapping procedures. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a suitable tap wrench or drill motor.


2. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck.

Position the fixture plate and bushing over the hole that is to be repaired (4).


image


Fig. 495: Alignment Pin & Fixture Retaining Bolts Courtesy of GENERAL MOTORS COMPANY

3. Position the alignment pin (1) through the bushing and into the hole.

4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).

5. Remove the alignment pin from the hole.

image


Fig. 496: Installing Sleeve Onto Drill

Courtesy of GENERAL MOTORS COMPANY

6. Install the sleeve (2) onto the drill (1), if required.

image


Fig. 497: Drilling Out Threads Of Damaged Hole Courtesy of GENERAL MOTORS COMPANY


NOTE: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole.


7. Drill out the threads of the damaged hole.

Drill the hole until the stop collar of the drill bit or the sleeve contacts the bushing.


WARNING: Refer to Safety Glasses and Compressed Air Warning .


8. Using compressed air, clean out any chips.

image


Fig. 498: Tapping Threads Of Drilled Hole With Tap Wrench Courtesy of GENERAL MOTORS COMPANY

9. Using a tap wrench, tap the threads of the drilled hole.

image


Fig. 499: Fixture Plate, Drill Bushing And Tool Marking Courtesy of GENERAL MOTORS COMPANY

10. Using a TAP wrench, tap the threads of the drilled hole.

In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap align with the top of the drill bushing (2).

11. Remove the fixture plate (1), bushing (2), and bolts.

WARNING: Refer to Safety Glasses and Compressed Air Warning . WARNING: Refer to Cleaning Solvent Warning .

12. Using compressed air, clean out any chips.

13. Spray cleaner into the hole. Refer to Adhesives, Fluids, Lubricants, and Sealers.

14. Using compressed air, clean any cutting oil and chips out of the hole.

image


Fig. 500: Lubricating Installer Tool Threads Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.


15. Lubricate the threads of the installer tool (2) with the driver oil (1).

image


Fig. 501: Driver Tool And Insert

Courtesy of GENERAL MOTORS COMPANY

16. Install the insert (2) onto the driver tool (1).

image


Fig. 502: Applying Threadlock To Insert OD Threads Courtesy of GENERAL MOTORS COMPANY

17. Apply threadlock LOCTITE™ 277, EN 42385 - 109 loctite (1), or equivalent to the insert OD threads (2).

image


Fig. 503: Installing Insert And Driver Into Hole Courtesy of GENERAL MOTORS COMPANY

18. Install the insert and driver (1) into the hole.

Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block.

The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

SERVICE PRIOR TO ASSEMBLY

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

CRANKSHAFT AND BEARING INSTALLATION

image

Fig. 504: Crankshaft and Bearing

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Crankshaft Upper Bearing (Qty: 4)


NOTE:

image Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for

Callout

Component Name


use.

image For vehicles equipped with Start/Stop and Hybrid vehicles, the #1 upper bearing is specifically coated for durability and has a blue coloration.


Procedure

Ensure that the guide lug on the bearing is properly seated to the notch in the engine block for each bearing. Coat the crankshaft bearing shell with engine oil.


2

Crankshaft Thrust Bearing

Procedure

Ensure that the guide lug on the bearing is properly seated to the notch in the engine block. Coat the crankshaft bearing shell with engine oil.

3

Crankshaft

LOWER CRANKCASE INSTALLATION

image

Fig. 505: Lower Crankcase With Bolt Tightening Sequences Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Crankshaft Lower Bearing (Qty: 5)

Procedure

Install the bearings in the lower crankcase, and ensure that the guide lug on the bearing is properly seated to the notch in the lower crankcase for each bearing. Coat the crankshaft bearing shell with engine oil.


2

Lower Crankcase

Procedure

1. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant


NOTE:

image The block assembly surface must be free of contamination prior to

Callout

Component Name


applying the sealer.

image Install and align the bedplate to block within 20 minutes of applying the sealer.

image The bedplate must be fastened to final torque specification within 60 minutes of applying the sealer.


2. Apply a 3 mm bead of sealer directly in the groove of the block to bedplate mating surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers.

3. Install the lower crankcase, ensure the lower crankcase is aligned properly on the dowels. Tap gently into place with a suitable tool, if necessary.


3

Lower Crankcase Bolts (Qty: 10)


CAUTION:

Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


Procedure

Tighten the NEW lower crankcase bolts in the sequence shown.

1. Tighten the bolts in sequence a first pass to 15 N.m (11 lb ft).

2. Using the EN 45059 angle meter, tighten the bolts in sequence a final pass to 180 degrees.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

Callout

Component Name


4

Lower Crankcase Bolts (Qty: 13)

Procedure

1. Apply sealant to the lower crankcase perimeter bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Tighten the lower crankcase bolts in the sequence shown.

3. Tighten the bolts in sequence a first pass to 5 N.m (44 lb in).

4. Tighten the bolts in sequence a final pass to 10 N.m (89 lb in).

PISTON, CONNECTING ROD, AND BEARING INSTALLATION


image

Fig. 506: Piston, Connecting Rod and Bearing Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure


NOTE:

Many internal engine


Callout

Component Name

components will develop specific wear patterns on their friction surfaces.


1. Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.

2. Ensure all components are adequately marked with location, direction, or orientation when necessary.


1

Connecting Rod Bearing (Qty: 4)


NOTE:

The connecting rod bearing anti-rotation tab grooves are to point toward the right-hand side of the engine.


Procedure

Install NEW bearings to the connecting rods and lubricate each bearing with engine oil.


2

Piston and Connecting Rod Assembly (Qty: 4)


NOTE:

The connecting rods and caps must be installed in the same order and orientation in which they were removed. If new connecting rods are required, the connecting rod is provided as an assembly,


Callout

Component Name


and the upper rod will need to be disassembled from the lower cap.


Procedure

1. Install the EN-51454 guides into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.


NOTE:

Ensure to stagger each piston ring end gap equally around the piston.


NOTE:

When installing a piston into a cylinder, use a ring compressor sleeve or equivalent for best results. The following features should be looked for when selecting a ring compressor sleeve:

image Hard anodized and Teflon coated for low friction and prolonged wear resistance.

image Smooth radius that tapers down to the specific bore size.


Callout

Component Name


image Sleeve should compress the piston rings smoothly and evenly.

image Using a ring compressor sleeve greatly reduces the difficulty with installing thin high- performance oil rings.

If a ring compressor sleeve is unavailable, a universal ring compressor will work, but is more difficult to use.


2. Install the ring compressor on the piston.

3. Ensure each piston ring end gap is spaced equally around the piston as shown.

4. Lubricate the piston and the piston rings with engine oil. Do not disturb the piston ring end gap location.

5. Lubricate the correct engine bore for the piston.


NOTE:

The piston must be installed oriented correctly to the front of the engine.


6. Position the piston so that the arrow mark on the top of the piston points to the front of the engine.

7. Install the ring compressor, the piston, and the connecting rod to the correct bore.

8. Tap the piston into the bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place.

9. Hold the ring compressor against the engine block until all the rings have entered the cylinder bore.

Callout

Component Name


10. Remove the connecting rod guides from the connecting rod bolt holes.


Special Tools

EN-51454 Connecting Rod Guides

For equivalent regional tools, refer to Special Tools.


3

Connecting Rod Bearing (Qty: 4)

Procedure

Install NEW bearings to the connecting rod caps and lubricate each bearing with engine oil.


4

Connecting Rod Cap (Qty: 4)

Procedure

Ensure that the connecting rod cap is properly oriented on the connecting rod.


5

Connecting Rod Bolts (Qty: 8)


CAUTION:

Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


Procedure

1. Install NEW connecting rod bolts and tighten using the EN 45059 angle meter.

1. Tighten the bolts a first pass to 25 N.m (18 lb ft).

2. Tighten the bolts a final pass 75 degrees using EN 45059 angle meter.


NOTE:

Rotate the crankshaft to ensure that it moves freely and does not bind.


2. Measure the connecting rod side clearance with a feeler gauge. Refer to Engine Mechanical Specifications.

3. Measure the piston deck height. Refer to Engine Mechanical Specifications.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

CRANKSHAFT OIL DEFLECTOR INSTALLATION


image

Fig. 507: Crankshaft Oil Deflector (With Bolt Tightening Sequence) Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Crankshaft Oil Deflector


2

Crankshaft Oil Deflector Bolt (Qty: 3)


CAUTION:

Refer to Fastener Caution .


Procedure

Tighten the bolts in the sequence shown.

Tighten

10 N.m (89 lb in)

3

Positive Crankcase Ventilation Oil Separator Drain Pipe


4

Positive Crankcase Ventilation Oil Separator Drain Pipe Bolt

Tighten

10 N.m (89 lb in)

CRANKSHAFT REAR OIL SEAL INSTALLATION


image

Fig. 508: Crankshaft Rear Oil Seal

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Crankshaft Rear Oil Seal

Procedure

1. Inspect the seal recess for excess sealer material at the lower crankcase to engine block mating location. Remove excess sealer, if present.

2. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

3. Add RTV sealer at 2 locations where the bedplate and block join prior to installing the oil seal. Refer to Adhesives, Fluids, Lubricants, and Sealers.


NOTE:

The oil seal must be installed in the correct direction.


Callout

Component Name


The side that faces out will have "this side out" printed on it.

Depending on seal design, the way the seal is installed on the

EN-51369

installer is opposite. Either the seal is installed over the back of the installer, or the seal is installed over the front of the installer.

Match the seal design as shown above and install the seal onto the installer in the correct direction.


4. Install the oil seal in the correct direction on EN-51369 seal installer.


NOTE:

If the seal is improperly installed on the special tool, it will not install correctly.


5. Inspect the seal on EN-51369 seal installer, and ensure that the seal lip is not deformed. If necessary, remove the seal and reinstall on the special tool.

6. Assemble the EN-51369 seal installer components.

Callout

Component Name


NOTE:

The special

7. UtoseolEiNns-5t1a3ll6s9 seal installer to press the new crankshaft seal into the housing. Ensure that tahne dseal is installed in the crankshaft seal bore flush to 0.5 mm depth.

establishes the proper

Speciadl eTpoothls of the

EN-51s36e9alSienalthInestaller

For equcirvaanleknst hreagfitonal tools, refer to Special Tools.

seal bore.

OIL PUMP DRIVE CHAIN AND OIL PUMP INSTALLATION

Oil Pump Assembly Installation


image

Fig. 509: Oil Pump Assembly

Callout

Component Name

1

Oil Pump Gasket

2

Oil Pump Gasket

3

Oil Pump Assembly

Callout

Component Name

1

Oil Pump Gasket

2

Oil Pump Gasket

3

Oil Pump Assembly

Callout

Component Name

1

Oil Pump Gasket

2

Oil Pump Gasket

3

Oil Pump Assembly

Courtesy of GENERAL MOTORS COMPANY Oil Pump Assembly Installation

Callout

Component Name


4

Oil Pump Assembly Bolt (Qty: 4)


NOTE:

Install the oil pump assembly and bolts loosely onto the engine block. Final torque must be performed after the drive chain is installed.

5

Oil Pump Flow Control Solenoid Valve

6

Oil Pump Flow Control Solenoid Valve Retainer


Crankshaft Sprocket and Oil Pump Drive Chain Installation


image

Fig. 510: Crankshaft Sprocket and Oil Pump Drive Chain

Courtesy of GENERAL MOTORS COMPANY

Crankshaft Sprocket and Oil Pump Drive Chain Installation

Callout

Component Name

1

Crankshaft Sprocket

2

Crankshaft Balancer Key


3

Oil Pump Drive Chain


CAUTION:

Refer to Fastener Caution .


Procedure

1. Tilt the oil pump assembly in order to install the drive chain over the oil pump and crankshaft sprockets.

2. Once the drive chain is correctly positioned on the sprockets, tighten the oil pump assembly bolts to 10 N.m (89 lb in).


4

Oil Pump Drive Chain Tensioner Assembly


NOTE:

Ensure the tensioner spring is retained in the correct position prior to installation.


5

Oil Pump Drive Chain Tensioner Bolt

Tighten

10 N.m (89 lb in)


6

Oil Pump Assembly Bolt

Tighten

10 N.m (89 lb in)

CYLINDER HEAD INSTALLATION

image

Fig. 511: Cylinder Head With Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Cylinder Head Gasket


NOTE:

Ensure that the cylinder head and the engine block sealing surfaces are clear of oil, grease, and old gasket material.

2

Cylinder Head Assembly


3

Cylinder Head Bolt (Qty: 10)


CAUTION:

Callout

Component Name


Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


Procedure

Tighten the NEW cylinder head bolts in the sequence shown.

1. Tighten the bolts a first pass to 30 N.m (22 lb ft).

2. Using the EN-45059 angle meter, tighten the bolts a final pass to 240 degrees.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

INTAKE AND EXHAUST CAMSHAFT, BEARING CAP, AND LASH ADJUSTER INSTALLATION

Valve Rocker Arm and Lash Adjuster Installation

image

Fig. 512: Valve Rocker Arm and Lash Adjuster Courtesy of GENERAL MOTORS COMPANY

Valve Rocker Arm and Lash Adjuster Installation

Callout

Component Name


1

Hydraulic Valve Lash Adjuster Assembly

Procedure

Install the lash adjusters in the bores in the cylinder head. Apply lubricant to the lash adjusters, refer to Adhesives, Fluids, Lubricants, and Sealers.


2

Hydraulic Valve Lash Adjuster Arm Assembly


NOTE:

Used lash adjuster arms must be returned to the original position on the camshaft. If the camshaft is being

Callout

Component Name


replaced, the lash adjuster arms actuated by the camshaft must also be replaced.


Procedure

1. Apply lubricant to the valve tips, refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Position the lash adjuster arm on the tip of the valve stem and on the lash adjuster.

3. Apply lubricant to the lash adjuster arms, refer to Adhesives, Fluids, Lubricants, and Sealers.


Camshaft Bearings and Camshaft Installation


image


Fig. 513: Camshaft Bearings and Camshaft Courtesy of GENERAL MOTORS COMPANY

Camshaft Bearings and Camshaft Installation

Callout

Component Name


1

Exhaust Camshaft Assembly

Procedure

1. Coat the exhaust camshaft with lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Install the exhaust camshaft in the cylinder head.

3. Ensure that the camshaft notch at the front of the camshaft is in the 12 o'clock position.

4. Rotate the oil seal in the groove of the number one camshaft journal so the split line is at approximately the 12 o'clock position before installing the camshaft caps.


2

Camshaft Bearing Cap - Exhaust Side (Qty: 5)


NOTE:

Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.

Ensure the caps are installed in the original location and position.


Procedure

Install the cap and start the cap bolts by hand.


3

Camshaft Bearing Front Exhaust Cap

Procedure

Install the cap and start the cap bolts by hand.


4

Camshaft Bearing Cap Bolt - Exhaust Side (Qty: 12)


CAUTION:

Refer to Fastener Caution .


Procedure

1. Lubricate the cap bolts.

2. Tighten the bearing cap bolts in sequence three turns each until the caps are seated.


Tighten

12 N.m (106 lb in)

Callout

Component Name


5

Intake Camshaft Assembly

Procedure

1. Coat the intake camshaft with lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Install the intake camshaft in the cylinder head.

3. Ensure that the camshaft notch at the front of the camshaft is in the 12 o'clock position.

4. Rotate the oil seal in the groove of the number one camshaft journal so the split line is at approximately the 12 o'clock position before installing the camshaft caps.


6

Camshaft Bearing Cap - Intake Side (Qty: 4)


NOTE:

Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.

Ensure the caps are installed in the original location and position.


Procedure

Install the cap and start the cap bolts by hand.


7

Camshaft Bearing Rear Cap - Intake Side

Procedure

Install the cap and start the cap bolts by hand.


8

Camshaft Bearing Front Intake Cap

Procedure

Install the cap and start the cap bolts by hand.


9

Camshaft Bearing Cap Bolt - Intake Side (Qty: 12)

Procedure

1. Lubricate the cap bolts.

2. Tighten the bearing cap bolts in sequence three turns each until the caps are seated.


Tighten

12 N.m (106 lb in)


Camshaft Actuator Installation

image

Fig. 514: Camshaft Actuator

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool. Remove when the camshaft actuator bolts are tightened to specification.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator - Intake


NOTE:

Align the actuator with the notch in the camshaft.


2

Camshaft Position Actuator Bolt


CAUTION:

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool. Remove when the camshaft actuator bolts are tightened to specification.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator - Intake


NOTE:

Align the actuator with the notch in the camshaft.


2

Camshaft Position Actuator Bolt


CAUTION:

Callout

Component Name

Preliminary Procedure

Install the EN-51367 camshaft locking tool. Remove when the camshaft actuator bolts are tightened to specification.

Special Tools

EN-51367 Camshaft Locking Tool

For equivalent regional tools, refer to Special Tools.


1

Camshaft Position Actuator - Intake


NOTE:

Align the actuator with the notch in the camshaft.


2

Camshaft Position Actuator Bolt


CAUTION:

Courtesy of GENERAL MOTORS COMPANY Camshaft Actuator Installation

Callout

Component Name


Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


Procedure

Tighten the NEW camshaft position actuator bolt in the sequence shown.

1. Tighten the bolt a first pass to 20 N.m (15 lb ft).

2. Using the EN 45059 angle meter, tighten the bolt a final pass to 90 degrees.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.


3

Camshaft Position Actuator - Exhaust


NOTE:

Align the actuator with the notch in the camshaft.


4

Camshaft Position Actuator Bolt

Procedure

Tighten the NEW camshaft position actuator bolt in the sequence shown.

1. Tighten the bolt a first pass to 20 N.m (15 lb ft).

2. Using the EN-45059 angle meter, tighten the bolt a final pass to 90 degrees.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

CAMSHAFT TIMING CHAIN INSTALLATION

image

Fig. 515: Camshaft Timing Chain Components Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Timing Chain Oil Nozzle


CAUTION:

Refer to Component Fastener Tightening Caution .


Tighten

15 N.m (11 lb ft)


2

Timing Chain


NOTE:

Ensure the actuator timing marks and the

Callout

Component Name


crankshaft sprocket keyway are at the 12 O'Clock position.


Procedure


NOTE:

Ensure the correct timing link is aligned with the timing mark. The color of the actuator timing links are the same, and the color of the crankshaft sprocket timing link is unique.


1. Align the first timing chain link with the intake actuator timing mark.

2. Align the second timing chain link with the exhaust actuator timing mark.

3. Align the final timing chain link with the crankshaft sprocket timing mark.

3

Timing Chain Guide - Exhaust Side


4

Timing Chain Guide Bolt (Qty: 3)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

5

Timing Chain Tensioner Shoe Assembly


6

Timing Chain Tensioner Shoe Bolt

Tighten

25 N.m (18 lb ft)

7

Timing Chain Tensioner Gasket

Callout

Component Name


8

Timing Chain Tensioner Assembly


NOTE:

Ensure the tensioner is fully retracted prior to installation. Depending on tensioner model, the procedure to depress and lock the plunger is different.


Procedure

1. If the tensioner has a lever on the front, press down on the lever and depress the plunger. Insert a suitable tool into the hole in the tensioner body to hold the plunger in the retracted position.

2. If the tensioner has a retaining clip, press the clip and depress the plunger. Insert a suitable tool into the hole in the tensioner body to hold the plunger in the retracted position.


9

Timing Chain Tensioner Bolt (Qty: 2)

Tighten

25 N.m (18 lb ft)

10

Timing Chain Upper Guide - to Cylinder Head


11

Timing Chain Upper Guide Bolt (Qty: 2)

Tighten

10 N.m (89 lb in)

ENGINE FRONT COVER INSTALLATION

Engine Front Cover and Components Installation

image

Fig. 516: Engine Front Cover and Components With Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

Engine Front Cover and Components Installation

Callout

Component Name


1

Engine Front Cover Hole Plug


CAUTION:

Refer to Fastener Caution .


Tighten

50 N.m (37 lb ft)


2

Engine Front Cover

Procedure

1. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant


NOTE:


Callout

Component Name


image The engine front cover surface must be free of contamination prior to applying the sealer.

image Install and align the cover within 20 minutes of applying the sealer.

image The cover must be fastened to final torque specification within 20 minutes of applying the sealer.

image Additional sealant is necessary to reduce the possibility of leakage where the cylinder head to engine block interface along the bead path flange on the front cover.


2. Apply a 4 mm bead of sealer directly in the flange of the engine front cover perimeter mating surface.

3. Apply a 3 mm bead of sealer circling 3 locations on the interior of the engine front cover.

4. Apply a 3 mm bead of sealant at the 2 horizontal groove locations along the flange where the cylinder head and engine block mate. Refer to Adhesives, Fluids, Lubricants, and Sealers.


3

Engine Front Cover Bolt - M6 (Qty: 11)


NOTE:

Callout

Component Name


Hand start the engine front cover bolts.

Torque to specification when all front cover bolts and the stud are installed hand-tight.


Tighten

15 N.m (11 lb ft)


4

Engine Front Cover Stud (Qty: 1)

Tighten

15 N.m (11 lb ft)


5

Engine Front Cover Bolt - M6 (Qty: 1)


NOTE:

This interior M6 bolt is longer than the perimeter M6 bolts.


Tighten

15 N.m (11 lb ft)


6

Engine Front Cover Bolt - M14 (Qty: 1)

Tighten

58 N.m (43 lb ft)

Procedure

Tighten all the engine front cover bolts in the sequence shown.

1. Tighten the bolts a first pass to 5 N.m (44 lb in).

2. Tighten the bolts a final pass to final torque specification.


Crankshaft Front Oil Seal Installation

image

Fig. 517: Crankshaft Front Oil Seal

Callout

Component Name


1

Crankshaft Front Oil Seal

Procedure


NOTE:

The oil seal must be installed in the correct direction.

The side that faces out will have "this side out" printed on it. The design of the seal determines which end of the EN 51368 installer is used. Use the end of the installer that matches

Callout

Component Name


1

Crankshaft Front Oil Seal

Procedure


NOTE:

The oil seal must be installed in the correct direction.

The side that faces out will have "this side out" printed on it. The design of the seal determines which end of the EN 51368 installer is used. Use the end of the installer that matches

Callout

Component Name


1

Crankshaft Front Oil Seal

Procedure


NOTE:

The oil seal must be installed in the correct direction.

The side that faces out will have "this side out" printed on it. The design of the seal determines which end of the EN 51368 installer is used. Use the end of the installer that matches

Courtesy of GENERAL MOTORS COMPANY Crankshaft Front Oil Seal Installation

Callout

Component Name


the design of the seal, as shown.


1. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.

2. Determine which end of the EN-51368 installer will be used and install the seal on it.

3. Install the EN-51368 installer over the crankshaft.

4. Install the EN-51368 screw, large washer, bearing, and nut.

5. Counter-hold the screw, and tighten the nut to install the seal.


Special Tools

EN-51368 Front Crankshaft Seal Installer

For equivalent regional tools, refer to Special Tools.

OIL PAN INSTALLATION


image


Fig. 518: Oil Pan With Bolt Tightening Sequences Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


Callout

Component Name

1

Engine Oil Level Indicator Control Wiring Harness


2

Wiring Harness Connector Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)


3

Upper Oil Pan Assembly

Procedure

1. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant


NOTE:

image The lower crankcase and oil pan mating surfaces must be free of contamination prior to applying the sealer.

image Install and align the oil pan to block within 20 minutes of applying the sealer.

image The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer.

image Additional sealant is necessary to reduce the possibility of

Callout

Component Name


leakage where the cylinder head to engine block interface along the bead path flange on the front cover.


2. Apply a 3 mm bead of sealer around the perimeter of the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers.

3. Install the oil pan on the lower crankcase, ensure the oil pan locating pins align with the lower crankcase.


4

Oil Pan Bolt (Qty: 12)

Procedure

1. Apply sealant to the oil pan bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Hand start the oil pan bolts. Torque to specification when all oil pan bolts are installed hand-tight.


Tighten

10 N.m (89 lb in)


5

Oil Pan Bolt (Qty: 2)

Procedure

1. Apply sealant to the oil pan bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Hand start the oil pan bolts. Torque to specification when all oil pan bolts are installed hand-tight.


Tighten

10 N.m (89 lb in)


6

Oil Pan Bolt (Qty: 2)

Procedure

1. Apply sealant to the oil pan bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2. Tighten all the oil pan bolts in sequence.

3. Inspect for excessive sealer around the oil filter mounting area when final torque is achieved. If extra sealer is present, remove and clean accordingly.


Tighten

10 N.m (89 lb in)

Callout

Component Name


7

Lower Oil Pan

Procedure

1. Connect the oil pump control valve wiring harness connector.

2. Use a NEW lower oil pan.

3. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

4. Apply a 5 mm bead of sealer around the perimeter of the lower oil pan. Refer to

Adhesives, Fluids, Lubricants, and Sealers.

5. Install the lower oil pan on the upper oil pan, ensure the oil pan locating pins align with the lower oil pan.


8

Lower Oil Pan Bolt (Qty: 12)

Procedure

Tighten the oil pan bolts in sequence.

Tighten

10 N.m (89 lb in)

CAMSHAFT COVER INSTALLATION

Camshaft Cover Components Installation - Bottom


image


Fig. 519: Camshaft Cover Components - Bottom Courtesy of GENERAL MOTORS COMPANY

Camshaft Cover Components Installation - Bottom

Callout

Component Name

1

Camshaft Position Actuator Solenoid Valve

Callout

Component Name


2

Camshaft Position Actuator Solenoid Valve Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

3

Camshaft Cover Locating Pin (Qty: 2)

4

Intake Camshaft Position Sensor


5

Camshaft Position Sensor Bolt

Tighten

10 N.m (89 lb in)


Camshaft Cover Components Installation - Top


image


Fig. 520: Camshaft Cover Components - Top Courtesy of GENERAL MOTORS COMPANY

Camshaft Cover Components Installation - Top

Callout

Component Name

1

Exhaust Camshaft Position Sensor


2

Camshaft Position Sensor Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

3

Camshaft Position Actuator Solenoid Valve


4

Camshaft Position Actuator Solenoid Valve Bolt

Tighten

10 N.m (89 lb in)


5

Positive Crankcase Ventilation Tube with Positive Crankcase Ventilation Valve - Fresh Air


NOTE:

These components have tamper- proof connections and cannot be disassembled. The fresh air inlet duct is connected to the PCV Tube with a tamper- proof connection.

All components must be replaced once removed.


Procedure

1. Assemble a NEW PCV tube with NEW PCV valves and a NEW fresh air inlet duct.

2. Install the PCV valves to the camshaft cover.

Callout

Component Name


6

Positive Crankcase Ventilation Valve Bolt (Qty: 2)


NOTE:

Bolts are tamper- proof.


Procedure

Using EN-50956 bit, install NEW bolts.

Tighten

10 N.m (89 lb in)

Special Tools

EN-50956 Tamper-Proof Drive Bit Equivalent regional tools: Special Tools


Camshaft Cover Installation


image

Fig. 521: Camshaft Cover With Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

Camshaft Cover Installation

Callout

Component Name


1

Camshaft Cover Gasket


NOTE:

Use a NEW gasket.


Procedure

Assemble the camshaft cover and a NEW gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.


2

Camshaft Cover

Procedure

1. Ensure proper use of room temperature vulcanizing (RTV) sealant. Refer to Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

2. Apply approximately a 5 mm (0.2 in) thick bead of camshaft cover sealant on both sides between the cylinder head and the engine front cover. Refer to Adhesives, Fluids, Lubricants, and Sealers.


3

Camshaft Cover Bolt (Qty: 18)

Procedure:

Tighten the engine front cover bolts and studs in sequence.


4

Camshaft Cover Stud (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Procedure:

Tighten the engine front cover bolts and studs in sequence.

Tighten

15 N.m (11 lb ft)

5

Oil Level Indicator

FUEL RAIL AND INJECTORS INSTALLATION

Special Tools


image EN-49245 Fuel Injector Seal Installer/Sizer

image EN-51105 Injector Seal Installer Adapters

image EN-51146 Fuel Injector Removal/Installation Kit

image EN-51146-100 Fuel Injector Removal Plate

image EN-51146-150 Fuel Injector Removal Adapters For equivalent regional tools, refer to Special Tools. Fuel Injector Installation Procedure

image


Fig. 522: Installing Fuel Injectors Using Removal/Installation Kit Courtesy of GENERAL MOTORS COMPANY


NOTE: Do not remove the fuel injectors unless inspection indicates replacement is necessary. Do not remove the EN-51146-150 adapter and EN-51146-1-1 support unless the fuel injector is being replaced.


1. If one or more fuel injectors are being replaced, remove the EN-51146-100 plate (2) and bolts (1).

2. Remove the EN-51146-150 adapters and EN-51146-1-1 supports (3) for all fuel injectors that are being replaced.

3. Remove and discard the fuel injectors (5) that are being replaced.

4. Lubricate the O-ring with one drop of clean engine oil. Install a new fuel injector (5).


CAUTION: Refer to Fastener Caution .


5. Install the NEW fuel injector screws (4) to the NEW fuel injectors (5) and tighten to 5 N.m (44 lb in).

6. Connect the fuel injector wiring harness plugs.


Fuel Injector Combustion Seal Installation Procedure

image


Fig. 523: Installing Combustion Seals

Courtesy of GENERAL MOTORS COMPANY


NOTE: DO NOT use any type of lubricant when installing the NEW combustion seals on the fuel injector tip.


NOTE: The injector tip protectors in the EN-49245 set are too small for some injectors.

Ensure EN-51105 is used on injector tips during seal installation. The pusher and final sizer work for all injectors.


1. Install EN-51105-1 long protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-51105-1 long protector (1).

2. Using EN-49245-3 pusher (3), install the seal (2) into the recessed area of the fuel injector.

3. Compress the seal (2) with your fingers.

4. Install EN-51105-2 short protector (4) onto the fuel injector tip. Place a NEW seal (5) on EN-51105-2 short protector (4).

5. Using EN-49245-3 pusher (3), install the seal (5) into the last recessed area of the fuel injector.

6. Compress the seal (5) with your fingers.

image


Fig. 524: Pre-Sizing Tool

Courtesy of GENERAL MOTORS COMPANY

7. Push the EN-51146-2-4 pre-sizing tool (1) over the fuel injector tip.

8. Tighten the nut (2) and counterhold at the spanner flat (3) of the EN-51146-2-4 pre-sizing tool (1) until the measure (a) of 4.5 mm (0.177 in) is reached.

9. Loosen the nut (2) of the EN-51146-2-4 pre-sizing tool.

10. Install the EN-51146-2-4-7 take off chassis (4) to the EN-51146-2-4 pre-sizing tool (1).

11. Install the EN-51146-2-4-6 screw M10 (5) to the EN-51146-2-4-7 take off chassis (4) and tighten until the

EN-51146-2-4 pre-sizing tool (1) is loosened.

image


Fig. 525: Sizer

Courtesy of GENERAL MOTORS COMPANY

12. Install the EN-49245-4 sizer (1) in a rotary motion to the fuel injector tip in order to complete the combustion seal final sizing.


image

Fig. 526: Ensure Seals Are Installed Correctly Courtesy of GENERAL MOTORS COMPANY

NOTE: The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided.


13. Check both of the fuel injector combustion seals on each fuel injector for correct seat: image The seal must not be too large, buckled, or corrugated (1)

image The seal must be fixed tight and accurate (2)

14. If the seals are not installed correctly, remove the incorrect seal and replace with a NEW seal.


Fuel Rail Assembly Installation Procedure


image


Fig. 527: Installing Fuel Rail Assembly Using Special Tools Courtesy of GENERAL MOTORS COMPANY

1. If any components of EN-51146 remover are installed to the fuel rail, perform the following procedure:


NOTE: If the plate is not installed on the supports, it is likely one or more fuel injectors have been replaced. Disregard the following steps for fuel injectors that have already been replaced.


1. Remove the bolts (1) and EN-51146-100 plate (2).

2. Remove only the front EN-51146-150 adapter and EN-51146-1-1 support (3) for the first fuel injector.

CAUTION: Refer to Fastener Caution .


3. Install the fuel injector screw (4) and tighten to 5 N.m (44 lb in).

4. Remove the rear EN-51146-150 adapter and EN-51146-1-1 support (6) for the first fuel injector.

5. Install the fuel injector screw (5) and tighten to 5 N.m (44 lb in).

6. Repeat the same procedure for the remaining fuel injectors with EN-51146-150 adapters and

EN-51146-1-1 supports still attached.

7. Connect the fuel injector wiring harness plugs, if necessary.

2. Ensure the fuel rail assembly and fuel injector bores have been cleaned prior to installation.


image


Fig. 528: Fuel Rail Assembly

Courtesy of GENERAL MOTORS COMPANY


NOTE: During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.


3. Carefully install the fuel rail assembly (1).

4. Push the fuel injectors slightly in their seats.


image


Fig. 529: Fuel Rail Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY

5. Tighten the 4 lower fuel rail bolts in increments of 1 turn until they are seated.

6. Tighten the 4 lower fuel rail bolts in sequence to 10 N.m (89 lb in).

7. Tighten the 4 upper fuel rail bolts in sequence to 10 N.m (89 lb in).

IGNITION COIL INSTALLATION

image

Fig. 530: Ignition Coil

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Inspect the inside of the ignition coil rubber boot for a thin, even coat of grease.

2. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease evenly to the inside of the ignition coil rubber boot, up to a depth of 15 mm from the end of the boot. Refer to Adhesives, Fluids, Lubricants, and Sealers.

3. Remove any excess grease from around the end of the boot, and ensure there is not an excessive amount within the boot.


1

Ignition Coil Assembly (Qty: 4)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

WATER OUTLET INSTALLATION


image

Fig. 531: Water Outlet

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Water Outlet Gasket


NOTE:

Use a NEW gasket.

Ensure the mating surfaces are clean and free of debris.

2

Water Outlet


3

Water Outlet Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

12 N.m (106 lb in)

ENGINE LIFT AND SIGHT SHIELD BRACKET INSTALLATION

image

Fig. 532: Engine Lift And Sight Shield Bracket Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Engine Lift Rear Bracket


2

Engine Lift Bracket Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

25 N.m (18 lb ft)

3

Engine Lift Front Bracket


4

Engine Lift Bracket Bolt (Qty: 2)

Tighten

25 N.m (18 lb ft)

FUEL PUMP INSTALLATION

image

Fig. 533: Fuel Pump

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Valve Lifter Follower


NOTE:

The camshaft must be in the base circle position before the high pressure fuel pump is installed.


Procedure

1. Lubricate the valve lifter follower with engine oil, refer to Adhesives, Fluids, Lubricants, and Sealers.


Callout

Component Name


NOTE:

At the base circle position, the EN-51365

alignment gauge will sit flush with the cylinder head.


2. Install the valve lifter follower. Ensure that the guide pin on the follower is aligned with the groove in the fuel pump bore. Install EN-51365 alignment gauge and rotate the camshaft until the special tool is flush with the cylinder head. This indicates the camshaft lobe is at base circle position.

3. Remove EN-51365 alignment gauge and the valve lifter follower.

4. Lubricate the valve lifter follower again with engine oil.

5. Install the valve lifter follower. Ensure that the guide pin on the follower is aligned with the groove in the fuel pump bore.


Special Tools

EN-51365 Fuel Pump Installation Gauge

For equivalent regional tools, refer to Special Tools.


2

Fuel Pump


NOTE:

If the fuel pump is not new, replace the fuel pump O-ring seal.

Lubricate the O-ring with one drop of clean engine oil.


3

Fuel Pump Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


CAUTION:

Refer to Torque-to-


Callout

Component Name


Yield Fastener Caution .


CAUTION:

Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated.

Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.


Procedure

Install NEW fuel injection pump bolts alternating in steps of one turn each until seated to specified torque.

Tighten

25 N.m (18 lb ft)


4

Fuel Pump Insulator


WARNING:

The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids.

Failure to replace the noise cancelling foam component that has been


Callout

Component Name


exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.


5

Fuel Feed Intermediate Pipe


NOTE:

Use a NEW pipe.


Procedure


NOTE:

Do not remove shipping caps from the fuel rail fitting or fuel pump fitting until installation of pipe. Do not remove the fuel pump inlet shipping cap at any time.


1. Remove any fuel pipe shipping caps, if applicable.

2. Finger start the fuel pipe nuts to pump and fuel rail.

3. Finger start the fuel feed intermediate pipe assembly bolt through the pipe bracket.

4. Snug the fuel pipe nut at the pump by hand, 5 full turns minimum.

5. Snug the fuel pipe nut at the fuel rail by hand, 5 full turns minimum.


NOTE:

Tightening the bracket bolt prior to final torque for the pipe

Callout

Component Name


nuts helps to align the fuel feed pipe.


6. Tighten the fuel feed intermediate pipe assembly bracket bolt to 10 N.m (22 lb ft).

7. Torque the pipe nut to fuel rail to specification.

8. Torque the pipe nut to pump to specification.


Tighten

30 N.m (22 lb ft)


6

Fuel Feed Intermediate Pipe Bolt (Qty: 1)

Tighten

10 N.m (89 lb in)

INTAKE MANIFOLD INSTALLATION


image

Fig. 534: Intake Manifold With Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Intake Manifold Gasket


NOTE:

Use a NEW gasket.

Ensure the mating

Callout

Component Name


surfaces are clean and free of debris.

2

Intake Manifold


3

Intake Manifold Bolt (Qty: 5)


CAUTION:

Refer to Fastener Caution .


NOTE:

Bolt retainers keep the bolts in position on the assembly.


Procedure:

Tighten the bolts in sequence.

Tighten

12 N.m (106 lb in)

THROTTLE BODY ASSEMBLY INSTALLATION

image

Fig. 535: Throttle Body Assembly

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Throttle Body Gasket


NOTE:

Use a NEW gasket.

Ensure the mating surfaces are clean and free of debris.

2

Throttle Body


3

Throttle Body Bolt (Qty: 4)


NOTE:

Tighten the 4 bolts in a criss-cross

Callout

Component Name


pattern.


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

ENGINE WIRING HARNESS ASSEMBLY INSTALLATION


image

Fig. 536: Engine Wiring Harness Assembly Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Engine Wiring Harness


2

Engine Wiring Harness Bracket Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

25 N.m (18 lb ft)

Callout

Component Name


3

Wiring Harness Connector Bolt

Tighten

10 N.m (89 lb in)

WATER PUMP INSTALLATION


image

Fig. 537: Water Pump

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Water Pump Housing Gasket


NOTE:

Use a NEW gasket.

Ensure the mating surfaces are clean and free of debris.

2

Water Pump

Callout

Component Name


3

Water Pump Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

25 N.m (18 lb ft)


4

Water Pump Bolt (Qty: 2)

Tighten

25 N.m (18 lb ft)

5

Thermostat Bypass Pipe Gasket

6

Water Pump Inlet Hose Fitting


7

Thermostat Bypass Pipe Bolt (Qty: 2)

Tighten

10 N.m (89 lb in)

EXHAUST GAS RECIRCULATION VALVE INSTALLATION


image

Fig. 538: Exhaust Gas Recirculation Valve Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Valve Gasket


NOTE:

Use a NEW Gasket.

2

Exhaust Gas Recirculation Valve


3

Exhaust Gas Recirculation Valve Bolt (Qty: 3)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)


4

Exhaust Gas Recirculation Valve Cooling Return Hose

Procedure

1. Inspect the hose, and replace if necessary. Connect the cooling return hose at the exhaust gas recirculation valve.

2. Connect the cooling return hose at the water pump inlet adapter.

EXHAUST GAS RECIRCULATION COOLER INSTALLATION

image

Fig. 539: Exhaust Gas Recirculation Cooler Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Cooler Inlet Pipe Gasket


NOTE:

Use a NEW gasket.

2

Exhaust Gas Recirculation Cooler


3

Exhaust Gas Recirculation Cooler Bolt


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)

Callout

Component Name


4

Exhaust Gas Recirculation Cooler Bolt (Qty: 2)

Tighten

10 N.m (89 lb in)


5

Thermostat Bypass Hose

Procedure

1. Inspect the bypass hose, and replace if necessary. Connect the bypass hose at the exhaust gas recirculation cooler.

2. Connect the bypass hose at the water outlet.


6

Exhaust Gas Recirculation Cooler Water Bypass Outlet Hose

Procedure

1. Inspect the bypass outlet hose, and replace if necessary. Connect the outlet hose at the exhaust gas recirculation cooler.

2. Connect the bypass outlet hose at the water pump.


7

Exhaust Gas Recirculation Cooler Temperature Sensor

Procedure

Connect the temperature sensor nut at the inlet pipe and tighten.

Tighten

42 N.m (31 lb ft)

EXHAUST GAS RECIRCULATION COOLER OUTLET PIPE INSTALLATION


image

Fig. 540: Exhaust Gas Recirculation Cooler Outlet Pipe Courtesy of GENERAL MOTORS COMPANY

Callout

Component Name


1

Exhaust Gas Recirculation Cooler Outlet Pipe Gasket


NOTE:

Use a NEW gasket.

2

Exhaust Gas Recirculation Cooler Outlet Pipe


3

Exhaust Gas Recirculation Cooler Outlet Pipe Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)


4

Exhaust Gas Recirculation Cooler Temperature Sensor

Procedure

Connect the temperature sensor nut at the outlet pipe and tighten.

Tighten

42 N.m (31 lb ft)

EXHAUST GAS RECIRCULATION PIPE INSTALLATION

image


Fig. 541: Exhaust Gas Recirculation Pipe Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Exhaust Gas Recirculation Pipe Gasket


NOTE:

Use NEW gasket.


2

Exhaust Gas Recirculation Pipe Gasket


NOTE:

Use NEW gasket.

3

Exhaust Gas Recirculation Pipe

Callout

Component Name


4

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)


CAUTION:

Refer to Fastener Caution .


Tighten

10 N.m (89 lb in)


5

Exhaust Gas Recirculation Pipe Bolt

Tighten

10 N.m (89 lb in)


6

Exhaust Gas Recirculation Pipe Bolt (Qty: 2)

Tighten

10 N.m (89 lb in)

AUTOMATIC TRANSMISSION FLEX PLATE INSTALLATION


image


Fig. 542: Automatic Transmission Flex Plate With Bolt Tightening Sequence Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Crankshaft Position Sensor Reluctor Ring


CAUTION:

Refer to Crankshaft


Callout

Component Name


Position Sensor Reluctor Ring Caution

.


2

Automatic Transmission Flex Plate

Procedure

1. Install the flex plate, and install the flex plate bolts hand tight to hold in place.

2. Remove the starter opening cover. Refer to Engine Block Disassemble.

3. Install EN-51760 holder to lock the flywheel via the starter ring gear.


Special Tools

EN-51760 Flywheel Holder

Equivalent regional tools: Special Tools.


3

Automatic Transmission Flex Plate Bolt (Qty: 8)


CAUTION:

Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


NOTE:

Bolts have adhesive patch and must be tightened to final torque within 5 minutes.


Procedure

Tighten the NEW flex plate bolts in the sequence shown.

1. Tighten the bolts a first pass to 20 N.m (15 lb ft).

2. Tighten the bolts a second pass to 30 N.m (22 lb ft).

3. Using the EN-45059 angle meter, tighten the bolt a final pass 70 degrees.

4. Remove EN-51760 holder once final torque is achieved.

Callout

Component Name


5. Install the starter opening cover. Refer to Engine Block Assemble.


Special Tools

EN-45059 Angle Meter

Equivalent regional tools: Special Tools.

CRANKSHAFT BALANCER INSTALLATION


image


Fig. 543: Crankshaft Balancer

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

Preliminary Procedure

1. Remove the starter opening cover. Refer to Engine Block Disassemble.

2. Install EN-51760 holder, lock the automatic transmission flex plate via the starter ring gear.

Special Tools EN-51760 Flywheel HolderFor equivalent regional tools, refer to Special Tools.


1

Crankshaft Balancer

Procedure:

Using the screw, washer, bearing, and nut from the EN-51368 installer, seat the crankshaft balancer.

Special Tools

EN-51368 Front Crankshaft Seal Installer

For equivalent regional tools, refer to Special Tools.


2

Crankshaft Balancer Bolt


CAUTION:

Callout

Component Name


Refer to Fastener Caution .


CAUTION:

Refer to Torque-to- Yield Fastener Caution .


Procedure:

Tighten the NEW crankshaft balancer bolt in the sequence shown.

1. Tighten the bolt a first pass to 100 N.m (74 lb ft).

2. Loosen the bolt 360 degrees.

3. Tighten the bolt a second pass to 100 N.m (74 lb ft).

4. Tighten the bolt a final pass 180 degrees using EN-45059 angle meter.

5. Install the starter opening cover. Refer to Engine Block Assemble.


Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

OIL FILTER INSTALLATION


image

Fig. 544: Oil Filter, Fitting Adapter And Drain Plug

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name


1

Oil Pan Drain Plug


CAUTION:

Refer to Component Fastener Tightening Caution .


NOTE:

Use a NEW gasket.


Tighten

25 N.m (18 lb ft)


2

Oil Filter Fitting

Tighten

55 N.m (41 lb ft)


3

Oil Filter

Tighten

3/4 to 1 full turn after gasket makes contact with the sealing surface on the filter mounting flange.

Special Tools

EN-726-A Oil Filter Wrench

For equivalent regional tools, refer to Special Tools.

ENGINE PRELUBING

Special Tools

EN-45299 Engine Preluber

For equivalent regional tools, refer to Special Tools.

image


Fig. 545: Oil Pressure Switch

Courtesy of GENERAL MOTORS COMPANY


NOTE: A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Ensure an approved engine oil is used, as specified in the owners manual.


1. Remove the oil pressure switch.

2. Install the M12 x 1.75 adapter (1) P/N 509376.

image


Fig. 546: Flexible Hose, Adapter And Preluber Courtesy of GENERAL MOTORS COMPANY

3. Install the flexible hose to the adapter and open the valve.

4. Pump the handle on the EN-45299 preluber (1) in order to flow a minimum of 1 - 1.9 liters (1 - 2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.

5. Close the valve and remove the flexible hose and adapter from the engine.


CAUTION: Refer to Fastener Caution .


6. Install the oil pressure switch to the engine and tighten to 26 N.m (19 lb ft).

7. Top-off the engine oil to the proper level.

DESCRIPTION AND OPERATION

CRANKCASE VENTILATION SYSTEM DESCRIPTION

Positive Crankcase Ventilation System


The crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting vapors to the atmosphere. Fresh air from the intake system is supplied to the crankcase and mixed with blow-by gases inside the crankcase. Blow-by gases rise to the top of the engine and are picked up into the oil separation chamber in the camshaft cover, where oil is separated from the gases. Blow-by gases are then passed to the intake

manifold to be consumed by normal combustion, through a calibrated orifice inside of the camshaft cover.

Operation


image

Fig. 547: Crankcase Ventilation System Diagram Courtesy of GENERAL MOTORS COMPANY

Fresh air is brought into the engine through the positive crankcase ventilation (PCV) valve (4) as long as the crankcase is under vacuum. The primary control is through the PCV orifice (3) which meters the flow into intake manifold, at a rate depending on manifold vacuum. The PCV orifice is an integral part of the camshaft cover. Under certain operating conditions, the system is designed to allow excessive amounts of blow by gases to flow through the PCV valves (1 or 2) depending on if the engine is in boost mode or excessive crankcase pressure is detected and then routed into the intake system to be consumed by normal combustion.

Turbo Applications:

During normal operating conditions the PCV gases are routed using PCV valve (3) and the internal passage within the camshaft cover. When the Turbo is active, check valve (3) is closed and check valve (1) opens and PCV gases are routed back to the turbocharger to be consumed by normal combustion. If the engine sees excessive positive crankcase pressure check valve (2) opens and the pressure is routed to the air inlet to be reintroduced into the engine.

Non-Turbo Applications:

During normal operating conditions the PCV gases are routed using check valve (3) and the internal passage within the camshaft cover. If the engine sees excessive positive crankcase pressure check valve (2) opens and the pressure is

routed to the air inlet. Also for non-turbo applications check valve (1) does not exist.

In any application check valve (2) is only used if the engine sees excessive crankcase pressure.

Results of Incorrect Operation

A plugged orifice may cause the following conditions: image Rough idle

image Stalling or slow idle speed image Oil leaks

image Sludge in engine

A leaking orifice may cause the following conditions: image Rough idle

image Stalling

image High idle speed

ENGINE COMPONENT DESCRIPTION

Engine Description


Cylinder Block

The cylinder block is constructed of aluminum alloy by high-pressure die casting with 4 cast-in-place iron cylinder liners arranged in-line. The block has 5 crankshaft bearings with the thrust bearing located on the second bearing from the rear of the engine. The cylinder block incorporates a bedplate design that forms an upper and lower crankcase. This design promotes cylinder block rigidity and reduced noise and vibration.

Crankshaft

The crankshaft is forged micro alloy steel. It is supported in 5 main journals with main bearings which have oil clearance for lubricating. The thrust bearing is located in the 4th position which controls proper crankshaft axial end play. The crankshaft is also comprised of 8 counterweights that have been scalloped for mass reduction and topped for precise engine balance. A harmonic balancer is used to control torsional vibration.

Piston and Connecting Rod

The pistons are cast aluminum. The pistons use 2 compression rings and 1 oil control ring assembly. The piston is a low friction, lightweight design with a recessed top and barrel shaped skirt. The piston pins are chromium steel and are a full-floating design. The connecting rods are powdered metal. The connecting rods are fractured at the connecting rod journal and then machined for the proper clearance. All applications use a piston with a graphite coated skirt. The piston and pin are to be serviced as an assembly.

Upper Oil Pan

The oil pan is a structural aluminum oil pan with transmission attachment. It includes the oil suction pipe, this pipe is connected with the oil pump. The oil pan is attached at the lower crankcase.

Oil Pump

The oil pump is a crankshaft driven oil pump integrated in pump module. The oil pump draws engine oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted before the inlet of the oil pump to remove impurities which could clog or damage the oil pump or other engine components. When the

crankshaft rotates, the oil pump driven gear rotates. This causes the space between the gears to constantly open and narrow, pulling oil in from the oil pan when the space opens and pumping the oil out to the engine as it narrows. At high engine speeds, the oil pump supplies a much higher amount of oil than required for lubrication of the engine. The oil pressure regulator prevents too much oil from entering the engine lubrication passages.

Cylinder Head

This cylinder head is double over head camshaft (DOHC) type and has 2 camshafts that open 4 valves per cylinder with hydraulic valve lash adjuster. The camshaft sprocket wheels are installed in front of the camshafts. The cylinder head is made of cast aluminum alloy for better strength in hardness with light weight. The combustion chamber of the cylinder head is designed for increasing of squish and swirl efficiency and then this is maximized to gasoline combustion efficiency. The exhaust manifold is integrated into the cylinder head.

Valves

There are 2 intake and 2 exhaust valves per cylinder. Positive valve stem seals are used on all valves.

Valve Lash Adjusters

The valve train uses a roller finger follower acted on by a hydraulic lash adjuster. The roller finger follower reduces friction and noise.

Camshaft Cover

The camshaft cover has a steel crankcase ventilation baffling incorporated. The camshaft cover has mounting locations for the ignition system.

Camshaft/Camshaft Drive

Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are assembled with steel lobes.

This engine design uses a chain to drive the dual overhead camshafts. The chain is an inverted tooth or silent design with a 6.35 mm pitch to ensure quiet operation and is hydraulically tensioned to be maintenance-free. The tensioner has a ratchet mechanism to reduce chain movement during engine starts to eliminate noise. The lightweight plastic/composite chain guides have a unique grooved face design to reduce friction for optimum efficiency. Both the crank sprocket and cam sprockets are hardened to prevent wear even with extended oil change intervals.

Intake Manifold

The intake manifold is the air flow passage to the cylinder combustion chamber through the throttle body and has an effect on engine torque, power, noise, driveability, emission, fuel economy and performance. It is made of composite plastic. The intake manifold incorporates a distribution and control system for positive crankcase ventilation (PCV) gases.

Turbocharger, If Equipped

The turbocharger consists of turbine and compressor on a common shaft. The shaft bearing is constructed to higher rotation speed and lubricated by engine oil. The turbocharger is water cooled for improved durability. The turbine wheel is driven by exhaust emissions. The compressor wheel compresses the intake air. A wastegate bypass valve regulates the charging pressure for generating a high pressure at low speed as well. At a defined charging pressure it regulates the way of the exhaust emission on bypassing the turbine wheel. The wastegate valve is controlled pneumatic and electric from the pressure in the intake manifold. The pressure of exhaust emission is reduced by opening the wastegate thereby reducing the intake pressure.

Fuel Injection System

The engine is equipped with a central direct injection system. The fuel system consists of 4 separate direct injection fuel injectors, one high pressure fuel rail, and a high pressure fuel feed pipe that connects the high pressure fuel pump to the fuel rail. The injectors are each seated into their individual bores in the cylinder head with two combustion seals to provide sealing. The high pressure fuel pump mounts to the rear of the cylinder head and is driven by the intake camshaft. Motion is transmitted to the pump from a tri-lobe on the rear of the camshaft through a hydraulic roller lifter. Due to the location of the central direct injection system injector location this provides an increase in fuel economy and performance.

SEPARATING PARTS


NOTE: image Disassembly of the piston, press fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore. If the piston, pin, and connecting rod have been disassembled, replace the components as an assembly.

image Many internal engine components will develop specific wear patterns on their friction surfaces.

image When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure installation to their original location and position.


Separate, mark, or organize the following components: image Piston and the piston pin

image Piston to the specific cylinder bore image Piston rings to the piston

image Connecting rod to the crankshaft journal image Connecting rod to the bearing cap

A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.

image Crankshaft main and connecting rod bearings image Camshaft and valve lash adjusters

image Valve lash adjusters, lash adjuster guides, pushrods and rocker arm assemblies image Valve to the valve guide

image Valve spring and shim to the cylinder head location

image Engine block main bearing cap location and direction image Oil pump drive and driven gears

LUBRICATION DESCRIPTION

image


Fig. 548: Cutaway View Of Lubrication System Courtesy of GENERAL MOTORS COMPANY

Engine lubrication is supplied by a variable displacement two-stage vane-type oil pump assembly. An oil control solenoid valve, controlled by the engine control module (ECM), mounted to the oil pump provides two stage functionality. The oil pump is mounted off-axis on the front of the engine.

All oil passing through the oil pump goes through the oil filter, where contaminants are removed. The oil filter is located on the left front side of the engine block. The oil filter is a spin-on type that mounts directly to the engine block. A bypass valve is incorporated into the oil filter, which permits oil flow in the event the filter becomes restricted.

Oil then enters the gallery where it is distributed to the crankshaft, piston oil nozzles, and timing chain oil nozzle. For turbo applications, oil is also distributed through the turbocharger oil feed and return pipes (3) and engine oil cooler. The connecting rod bearings are oiled by passages through the crankshaft connecting the main journals to the rod journals. A groove around each upper main bearing furnishes oil to the drilled crankshaft passages. The pressurized oil passes through the cylinder head restrictor orifice into the cylinder head and then into each camshaft feed gallery. Passages feed each hydraulic lash adjuster.

The front feed off the main oil gallery also feeds the timing chain tensioner (1) and the intake and exhaust side phasers and oil control valves.


NOTE: A mechanical vacuum pump is not used on hybrid engine.

On the exhaust side, drilled passages feed each camshaft journal surface and the exhaust side head gallery feeds the mechanical vacuum pump. On the intake side, the oil is fed through the hollow camshaft to each camshaft journal surface, and a separate connected gallery feeds the intake side hydraulic lash adjusters.

An engine oil pressure sensor (2) is located on the intake rear side of the engine just below the head gasket interface. Oil returns to the oil pan through passages cast into the cylinder head. The phasers and timing chain drive lubrication drains directly into the oil pan behind the front cover.

CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

REPLACING ENGINE GASKETS

Special Tools


J 28410 Gasket Remover

For equivalent regional tools, refer to Special Tools.

Gasket Use and Applying Sealants


image Do not use any gasket again unless specified.

image Gaskets that can be used again will be identified in the service procedure.

image Do not apply sealant to any gasket or sealing surface unless called out in the service information.


Separating Components


image Use a rubber mallet to separate components.

image Bump the part sideways to loosen the components.

image Bumping should be done at bends or reinforced areas to prevent distortion of parts.


Cleaning Gasket Surfaces


image Remove all gasket and sealing material from the part using the J 28410 remover or equivalent. image Care must be used to avoid gouging or scraping the sealing surfaces.

image Do not use any other method or technique to remove sealant or gasket material from a part. image Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces.

image These methods of cleaning can cause damage to the component sealing surfaces.

image Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. image This grit is abrasive and has been known to cause internal engine damage.

Assembling Components


CAUTION: Refer to Sealant Caution .

image When assembling components, use only the sealant specified or equivalent in the service procedure. image Sealing surfaces should be clean and free of debris or oil.

image Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.

image Components requiring lubrication will be identified in the service procedure.

image When applying sealant to a component, apply the amount specified in the service procedure. image Tighten bolts to specifications. Do not overtighten.

USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALANT

Cleaning Mating Part Surfaces for RTV Joints


RTV sealant depends greatly on adhesion to the mating parts in order to form and maintain a robust sealed joint. As with any adhesion system, proper surface preparation of the bonded parts is extremely important to ensure good adhesion over the life of the product.


CAUTION: When cleaning the sealing surfaces of engine components, DO NOT use bristle discs, abrasive pads, wire wheels or surface conditioning discs. These types of devices should not be used because they produce a very fine grit that is abrasive and known to cause internal engine damage. The bristle discs and pads are embedded with abrasive material and wear down as they clean, continually exposing fresh abrasive to the surface of the component.


Abrasive pads, wire wheels and bristle discs can remove enough metal to affect the engine front cover, cylinder head, engine block, oil pan rail, and intake manifold runner surface flatness, which can then result in engine coolant leaks, engine oil leaks and air leaks. It takes about 15 seconds to remove 0.203 mm (0.008 in) of metal with an abrasive pad.

Abrasive pads, wire wheels and bristle discs used with high speed grinders produce airborne debris that can travel throughout the shop contaminating other work being performed outside of the immediate work area.

When cleaning engine gasket sealing surfaces and/or cleaning parts from an engine that are to be reused, surface conditioning discs, typically constructed of woven fiber or molded bristles that contain abrasives, such as a high amount of aluminum oxide, should NOT be used. The use of such surface conditioning discs dislodges aluminum oxide from the disk and metal component particles, which can lead to premature engine bearing failure. The presence of aluminum oxide in engine oil has been shown to cause premature engine bearing failure. In some cases, this failure occurs in as little as 1,600 km (1,000 mi) or less after the repair has been made.

Surface conditioning discs may grind the component material and embed it into the disc. This can result when more aggressive grinding of the gasket surface takes place.

General Motors strongly recommends using a plastic razor blade, plastic gasket scraper, a wood scraper or a non- metallic scraper to remove all sealer/gasket material on the surface of engine components that are to be reused. Do not use any other method or technique to remove the sealant or the gasket material from a part.

image Do not gouge or scratch any engine sealing surface during the cleaning process. image It is not necessary to remove every speck of the old sealer.

To remove the old RTV sealant from the sealing surface, spray GM Low VOC Cleaner or an equivalent, on the mating surfaces and allow it to soak to loosen the old gasket material. Use care to avoid getting GM Low VOC Cleaner in any area other than the mating surface to be cleaned.

Use a plastic razor blade, that mounts in a scraper device or a hand held plastic razor blade, to remove old RTV

sealant from a sealing surface. Use a new blade for each corresponding engine component surface. Hold the blade as parallel to the flat surface as possible.

To properly clean the sealing surfaces prior to reassembly, spray GM Low VOC Cleaner on a folded lint free shop cloth. Wipe the mating surfaces on the engine and front cover and rotate the shop cloth until there are no more visible signs of contamination on the cloth.

After the final cleaning of the parts, allow up to 5 minutes for the components to dry before applying new RTV sealant.


NOTE: After the final cleaning with GM Low VOC Cleaner and before reassembly, DO NOT touch the cleaned surfaces with your hand. Oils from your skin WILL CONTAMINATE the surface and prevent proper bonding of the new RTV sealant.


Typical Applications


This procedure is intended for use in the following operations:

image Building of engines in a manual low volume build process where the use of assembly lubricants and other typical conditions exist which may contaminate the component sealing surfaces in an RTV joint.

image Cleaning of surfaces contaminated with oil or other substance during the assembly operation as a special case event.

In the typical situation, both the part being assembled, and the assembly to which it is to be sealed will be cleaned. An example is an oil pan assembled to a block/front cover/rear cover assembly using an RTV seal applied to the pan or the block. Both the pan and the block assembly should be cleaned prior to RTV application.

Any loose gaskets that are part of the RTV joint should not be cleaned unless it is known that they have been contaminated during the build process. Examples of loose gaskets are intake side and end seals which contact RTV used to seal a T-joint.

Assemblies supplied to GM with gaskets in place should not be cleaned unless they are known to be contaminated during the build process. Examples are rocker/cam covers with press in place gaskets using RTV at corners or

T-joints.

Materials Needed

Use clean dry lint free cloths to wipe surface with approved solvent based cleaner. Examples are: image GM Good Wrench Service Low VOC Brake Parts Cleaner

image AC Delco Non-Chlorinated Brake Parts Cleaner image Loctite ODC - Free Cleaner & Degreaser

Procedure:

1. Identify the surfaces to which the RTV will come into contact in the assembled joint.

2. Using an approved solvent based cleaner, thoroughly soak an appropriate portion of a clean, dry cloth. Immediately wipe the surfaces with the cloth to remove any residue of oil, soap, etc.

3. Repeat step 2 using a clean portion of the cloth as many times as required until the cleanliness of the cloth after wiping the surface becomes constant in appearance. There is typically some discoloration of the cloth after wiping however a clean surface should produce the same level of discoloration with successive wiping with a clean cloth and solvent.

4. If crevices exist in the joint such that wiping the surface would not be sufficient to clean the crevice, the approved solvent based cleaner should be directly sprayed on the joint to ensure wetting of the surfaces and

removal of the contaminant. DO NOT spray rubber components directly. Care must be used to avoid getting solvent in areas other than necessary to clean the joint. Then continue with step 3.

5. Allow the surfaces to dry for a minimum of 1 minute or longer if necessary for the solvent to evaporate from the surface.

6. Do not touch the cleaned surface with anything prior to RTV application.

7. The surface is now prepared for RTV application.


Sealant Types


NOTE: 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.

The following two major types of sealant are commonly used in engines: image Room Temperature Vulcanizing (RTV)

image Anaerobic sealant, which include the following: image Gasket Eliminator

image Pipe Sealant image Threadlock

Room Temperature Vulcanizing (RTV) Sealer

This type of sealant is used where two components, such as the intake manifold and the engine block, are assembled together.

Use the following information when using RTV sealant:

image Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: image The exhaust manifold

image The head gasket

image Any other surfaces where a different type of sealant is specified in the service procedure

image Do not use RTV sealant unless the ambient air temperature is at least 18°C (65°F) degrees or higher. image Always follow all the safety recommendations and the directions that are on the RTV sealant container. image Use a plastic or wood scraper in order to remove all the RTV sealant from the components.

CAUTION: Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.


image The surfaces to be sealed must be clean and dry.


NOTE: The bead size is critical and is easier to maintain consistency and application

with a RTV dispensing tool. This also helps to eliminate waste.


image Use a RTV sealant bead size as specified in the service procedure. image Apply the RTV sealant bead to the inside of any bolt holes areas.

NOTE: Do not wait for the RTV sealant to skin over.


image Assemble the components while the RTV sealant is still wet to the touch, within 10 minutes.


NOTE: Do not overtighten the fasteners.


image Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

Anaerobic Type Gasket Eliminator Sealant

Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used where two rigid parts, such as castings, are assembled together. When two rigid parts are disassembled and no sealant or gasket is readily noticeable, then the two parts were probably assembled using an anaerobic type gasket eliminator sealant.

Use the following information when using gasket eliminator sealant:

image Always follow all the safety recommendations and directions that are on the gasket eliminator sealant container.

image Apply a continuous bead of gasket eliminator sealant to one flange. image The surfaces to be sealed must be clean and dry.

CAUTION: Do not allow the sealant to enter a blind hole. The sealant may prevent the fastener from achieving proper clamp load, cause component damage when the fastener is tightened, or lead to component failure.


image Do not allow the gasket eliminator sealed joint to cure more than 5 minutes before torquing to specification. This will result in an incorrect clamp load of assembled components.

image Do not overtighten the fasteners.

image Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface.

image Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

image After properly tightening the fasteners, remove the excess gasket eliminator sealant from the outside of the joint.

Anaerobic Type Threadlock Sealant

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 two close fitting metal surfaces.

Use the following information when using threadlock sealant:

image Always follow all safety recommendations and directions that are on the threadlock sealant container. image The threaded surfaces to be sealed must be clean and dry.

image Apply the threadlock sealant as specified on the threadlock sealant container.

NOTE: image Do not allow the threadlock sealant to cure more than 5 minutes before torquing to specification. This will result in an incorrect clamp load of assembled components.

image Do not overtighten the fasteners.


image Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

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 two parts are assembled together and require a leak proof joint.

Use the following information when using pipe sealant:

image Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: image The exhaust manifold

image The head gasket

image Surfaces where a different sealant is specified

image Always follow all the safety recommendations and the directions that are on the pipe sealant container. image The surfaces to be sealed must be clean and dry.

image Use a pipe sealant bead of the size or quantity as specified in the service procedure.


CAUTION: Do not allow the sealant to enter a blind hole. The sealant may prevent the fastener from achieving proper clamp load, cause component damage when the fastener is tightened, or lead to component failure.


image Apply the pipe sealant bead to the inside of any bolt hole areas. image Apply a continuous bead of pipe sealant to one sealing surface.

NOTE: Do not overtighten the fasteners.


image Tighten the fasteners in sequence, if specified, and to the proper torque specifications.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS



Illustration

Tool Number/Description


Illustration

Tool Number/Description


image


CH-42188-B J-42188-B

Ball Joint Separator


Illustration

Tool Number/Description


image


CH-48027

Digital Pressure Gauge


Illustration

Tool Number/Description


image


CH-51034

Cradle Alignment Guide Pins


Illustration

Tool Number/Description


image


DT-6125-1B J-6125-1B

Slide Hammer with Adapter


Illustration

Tool Number/Description


image


DT-23129 J-23129 KM-586

Universal Seal Remover


Illustration

Tool Number/Description


image


DT-45866 J-45866

Input Shaft Seal Installer


Illustration

Tool Number/Description


image


EN-498-B

Oil Pressure Gauge


Illustration

Tool Number/Description


image


EN-8062 J-8062 KM-348

Valve Spring Compressor - Head Off


Illustration

Tool Number/Description


image


EN-8087 J-8087

Cylinder Bore Gauge


Illustration

Tool Number/Description


image


EN-21867-850 J-21867-850 KM-498-B KM-6106

83 93 852

Oil Pressure Gauge Adapter


Illustration

Tool Number/Description


image


EN-22738-B GE-22738-B J-22738-B

J-9666

Valve Spring Tester


Illustration

Tool Number/Description


image


EN-23951 J-23951

Valve Manometer


Illustration

Tool Number/Description


image


EN-28410 J-28410

Gasket Remover


Illustration

Tool Number/Description


image


EN-28467-B J-28467-B

Universal Engine Support Fixture


Illustration

Tool Number/Description


image


EN-28467-501 J-28467-501

Engine Support Fixture Adapters


Illustration

Tool Number/Description


image


EN-36462-A J-36462-A

Engine Support Adapter Leg Set


Illustration

Tool Number/Description


image


EN-36857 J-36857

Engine Lift Bracket


Illustration

Tool Number/Description


image


EN-38185

Hose Clamp Pliers


Illustration

Tool Number/Description


image


EN-41816 J-41816

Crankshaft Balancer Remover


Illustration

Tool Number/Description


image


EN-42385-850 J-42385-850

Thread Repair Kit


Illustration

Tool Number/Description


image


EN-43963 J-43963 KM-6149

Valve Spring Compressor (off car)


Illustration

Tool Number/Description


image


EN-44226 J-44226

Crankshaft Balancer Remover


Illustration

Tool Number/Description


image


EN-44226-5

Crankshaft Protector


Illustration

Tool Number/Description


image


EN-45059 J-45059

Angle Meter


Illustration

Tool Number/Description


image


EN-45299 J-45299

Engine Pre-Luber


Illustration

Tool Number/Description


image


EN-46116

Valve Stem Seal Remover


Illustration

Tool Number/Description


image


EN-46122

Camshaft Position Actuator Check-Ball Valve Remover/Installer


Illustration

Tool Number/Description


image


EN-47909

Injector Bore and Sleeve Cleaning Kit


Illustration

Tool Number/Description


image


EN-48248

Cylinder Compression Pressure Gauge


Illustration

Tool Number/Description


image


EN-49245

Fuel Injector Seal Installer/Sizer


Illustration

Tool Number/Description


image


EN-49941

Piston Pin Clip Remover/Installer


Illustration

Tool Number/Description


image


EN-50717

Valve Spring Compressor - Head On


Illustration

Tool Number/Description


image


EN-50956

Tamper Proof Drive Bit


Illustration

Tool Number/Description


image


EN-51007

Engine Support Fixture


Illustration

Tool Number/Description

image


EN-51096

Crankshaft Rear Oil Seal Remover


Illustration

Tool Number/Description


image


EN-51105

Injector Seal Installer Adapters


Illustration

Tool Number/Description


image


EN-51146

Injector Remover/Installer


Illustration

Tool Number/Description


image


EN-51146-100

Fuel Injector Removal Plate


Illustration

Tool Number/Description


image


EN-51146-150

Injector Remover/Installer Adapters


Illustration

Tool Number/Description


image


EN-51365

Fuel Pump Installation Gauge


Illustration

Tool Number/Description


image


EN-51367

Camshaft Locking Tool


Illustration

Tool Number/Description


image


EN-51368

Front Crankshaft Seal Installer


Illustration

Tool Number/Description


image


EN-51369

Rear Crankshaft Seal Installer


Illustration

Tool Number/Description


image


EN-51397

Timing Chain Retainer


Illustration

Tool Number/Description


image


EN-51454

Connecting Rod Guides


Illustration

Tool Number/Description


image


EN-51749

Compression Gauge Tester Kit


Illustration

Tool Number/Description


image


EN-51760

Flywheel Holding Tool


Illustration

Tool Number/Description


image


GE-7872 J-7872

Magnetic Base Dial Indicator Set


Illustration

Tool Number/Description


image


GE-42220 J-28428-E J-42220

Universal 12V Leak Detection Lamp


image


image


  

 

< Назад | Содержимое | Далее >