Documentos de Académico
Documentos de Profesional
Documentos de Cultura
2003 ENGINE
Engine Mechanical - 2.2L (L61) - Saturn L Series
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Specification
Application
A/C Compressor-to-Block Bolt
Air Pipe Bolts
Air Pipe Nut
Balance Shaft Chain Guide (Adjustable) Bolt
Balance Shaft Chain Guide (Fixed) Bolts
Balance Shaft Chain Guide (Upper) Bolts
Balance Shaft Chain Tensioner Bolts
Balance Shaft Drive Sprockets
Balance Shaft Retaining Bolts
Ball Stud-to-Steering Knuckle Nuts
Battery Terminal Bolts
Cam Cover Bolts-to-Hold J 43649 . See Special Tools and
Equipment.
Camshaft Bearing Cap Bolts
Camshaft Cover Bolts
Camshaft Cover Ground Strap Fastener
Camshaft Sprocket Bolts
First Pass
Metric
25 N.m
25 N.m
16 N.m
10 N.m
10 N.m
10 N.m
10 N.m
55 N.m
10 N.m
100 N.m
17 N.m
English
18 lb ft
18 lb ft
11 lb ft
89 lb in
89 lb in
89 lb in
89 lb in
41 lb ft
89 lb in
74 lb ft
13 lb ft
10 N.m
89 lb in
10 N.m
10 N.m
10 N.m
89 lb in
89 lb in
89 lb in
85 N.m
63 lb ft
30 degrees
Final Pass
Connecting Rod Bolts
25 N.m
First Pass
18 lb ft
100 degrees
Final Pass
Coolant Jacket Plug
20 N.m
15 lb in
Crankshaft Bearing Cap Initial Torque (Lower Crankcase-to-Block Bolts)
20 N.m
15 lb ft
First Pass
70 degrees
Final Pass
Crankshaft Damper Pulley Bolt
First Pass
Final Pass
100 N.m
74 lb ft
75 degrees
steve
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12:51:59 PM
Page 1
First Pass
10 N.m
89 lb in
100 N.m
74 lb ft
75 degrees
Final Pass
Cylinder Head Air Bleed Tube Fastener
Cylinder Head Bolts
First Pass
15 N.m
11 lb in
30 N.m
22 lb ft
155 degrees
Final Pass
Cylinder Head Front Bolts
Cylinder Head Front Chaincase Bolts
Cylinder Head Oil Gallery Plug
Degas Hose Bracket Bolt
Drive Belt Tensioner Bolt
EGR Cover Bolts
Engine Coolant Temperature Sensor
Engine Harness Bracket Bolts
Engine Mount Bracket-to-Engine Bolts
Engine Mount-to-Body Bolts
Engine Mount-to-Engine Mount Bracket Bolts
Exhaust Manifold Heat Shield Bolts
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts
Exhaust Manifold Pipe-to-Resonator Bolts
Exhaust Manifold Studs-to-Cylinder Head
Exhaust Manifold-to-Cylinder Head Nuts
Flywheel Bolt
First Pass
35 N.m
20 N.m
35 N.m
10 N.m
45 N.m
25 N.m
20 N.m
10 N.m
90 N.m
55 N.m
55 N.m
25 N.m
30 N.m
20 N.m
10 N.m
12 N.m
26 lb ft
15 lb ft
26 lb ft
89 lb in
33 lb ft
18 lb ft
15 lb ft
89 lb in
66 lb ft
41 lb ft
41 lb ft
18 lb ft
22 lb ft
15 lb ft
89 lb in
9 lb ft
53 N.m
39 lb ft
25 degrees
Final Pass
Front Cover-to-Block Bolts
Fuel Line Bolt
Fuel Rail Bracket Stud
Ignition Coil-to-Camshaft Cover Bolts
Intake Camshaft Rear Bearing Cap Bolts
Intake Manifold Studs
Intake Manifold-to-Cylinder Head Bolts
Intake Manifold-to-Cylinder Head Nuts
Intake Manifold-to-Cylinder Head Studs
Knock Sensor Bolt
Knock Sensor-to-Engine Block Bolt
Lower Crankcase-to-Block Peripheral Bolts
25 N.m
10 N.m
10 N.m
8 N.m
25 N.m
6 N.m
10 N.m
10 N.m
6 N.m
25 N.m
25 N.m
25 N.m
18 lb ft
89 lb in
89 lb in
71 lb in
18 lb ft
56 lb in
89 lb in
89 lb in
60 lb in
18 lb in
18 lb ft
18 lb ft
steve
Monday, May 09, 2011 12:51:59 PM
Page 2
First Pass
65 N.m
25 N.m
25 N.m
35 N.m
60 N.m
10 N.m
25 N.m
10 N.m
6 N.m
40 N.m
30 N.m
25 N.m
48 lb ft
18 lb ft
18 lb ft
26 lb ft
44 lb ft
89 lb in
18 lb ft
89 lb in
53 lb in
3 lb in
22 lb ft
18 lb ft
12 N.m
9 lb ft
180 degrees
Final Pass
Spark Plugs
Stabilizer Link-to-Strut Assembly
Steering Gear-to-Intermediate Shaft Pinch Bolt
Support Plate-to-Engine Block
Suspension Support Bolts
First Pass
20 N.m
65 N.m
30 N.m
10 N.m
15 lb ft
50 lb ft
22 lb ft
89 lb in
100 N.m
74 lb ft
45 degrees
Final Pass
Thermostat Housing-to-Block Bolts
Throttle Body Bolts
Throttle Body Nuts
Throttle Body Studs-to-Cylinder Head
Tie Rod end Linkage Installer
Tie Rod Nut
Timing Chain Guide (Adjustable) Bolt
Timing Chain Guide (Fixed) Bolts
Timing Chain Guide (Upper) Bolts
Timing Chain Guide Bolt Access Hole Plug
Timing Chain Oil Nozzle Bolt
Timing Chain Tensioner Bolts
Torque Converter Bolts
Transmission Nose Bracket Bolts
Upper Bell Housing Bolts
Water Pump Bolts
Wheel Bolts (Final Torque)
Wheel Bolts (Initial Torque)
10 N.m
10 N.m
10 N.m
6 N.m
45 N.m
60 N.m
10 N.m
10 N.m
10 N.m
40 N.m
10 N.m
75 N.m
75 N.m
35 N.m
65 N.m
25 N.m
125 N.m
63 N.m
89 lb in
89 lb in
89 lb in
60 lb in
35 lb ft
45 lb ft
89 lb in
89 lb in
89 lb in
30 lb ft
89 lb in
55 lb ft
55 lb ft
26 lb ft
48 lb ft
18 lb ft
92 lb ft
46 lb ft
steve
Monday, May 09, 2011 12:51:59 PM
Page 3
Application
Metric
English
General Data
Engine Type
Displacement
RPO
Liter (VIN)
Bore
Inline 4 Cylinder
2.2 L
134 CID
L61
F
85.992-86.008 mm
3.3855-3.3861 in
9.5:01
Compression Ratio
Balance Shaft
0.030-0.063 mm
0.0012-0.0025 in
20.050-20.063 mm
0.7894-0.7899 in
41.975-41.995 mm
1.6526-1.6534 in
20.000-20.020 mm
0.7874-0.7882 in
Bushing Clearance
0.033-0.102 mm
0.0013-0.0040 in
36.776-36.825 mm
1.4479-1.4498 in
36.723-36.743 mm
1.4458-1.4466 in
End Play
0.100-0.300 mm
0.0020-0.0118 in
Bearing Clearance
Block
42.000-42.016 mm
1.6535-1.6542 in
40.763-40.776 mm
1.6048-1.6054 in
64.068-64.082 mm
2.5224-2.5229 in
85.992-86.008 mm
3.3855-3.3861 in
0.010 mm
0.0004 in
0.010 mm
0.0004 in
0.030 mm
0.0012 in
0.050 mm
0.002 in
0.08 mm
0.0031 in
0.040-0.144 mm
0.0016-0.0057 in
26.935-26.960 mm
1.0604-1.0614 in
21.000-21.052 mm
0.8268-0.8252 in
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Page 4
Connecting Rod
0.029-0.069 mm
0.0011-0.0027 in
52.118-52.134 mm
2.0519-2.05252 in
20.007-20.021 mm
0.7877-0.7882 in
0.070-0.370 mm
0.0028-0.0146 in
0.021 mm
0.0083 in
0.04 mm
0.0157 in
49.000-49.014 mm
1.9291-1.9297 in
0.050-0.380 mm
0.0012-0.0150 in
0.031-0.067 mm
0.0012-0.0026 in
55.994-56.008 mm
2.2045-2.2050 in
0.030 mm
0.0012 in
0.050 mm
0.002 in
0.1 mm
0.004 in
6.000-6.012 mm
0.2362-0.2367 in
6.000-6.012 mm
0.2362-0.2367 in
12.013-12.037 mm
0.4730-0.4739 in
344.75-551.60 kPa
50-80 psi
0.20-0.40 mm
0.008-0.016 in
0.35-0.55 mm
0.014-0.022 in
0.25-0.76 mm
0.010-0.030 in
0.04-0.08 mm
0.0015-0.0031 in
0.030-0.069 mm
0.0012-0.0027 in
0.090-0.106 mm
0.0035-0.0042 in
1.170-1.190 mm
0.0461-0.0469 in
1.471-1.490 mm
0.0579-0.0587 in
0.43 mm
0.0169 in
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Page 5
1.574-1.651 mm
0.0620-0.0650 in
85.967-85.982 mm
3.3845-3.3851 in
20.002-20.007 mm
0.07875-0.7877 in
1.23-1.25 mm
0.0484-0.0492 in
1.52-1.54 mm
0.0598-0.0606 in
2.52-2.54 mm
0.0992-0.1000 in
0.010-0.041 mm
0.0004-0.0016 in
0.007-0.026 mm
0.0003-0.0010 in
0.002-0.012 mm
0.0001-0.0005 in
19.995-20.000 mm
0.7872-0.7874 in
0.19-1.16 mm
0.0075-0.0461 in
0.04 mm
0.0016 in
0.05 mm
0.0020 in
5.955-5.970 mm
0.2344-0.2355 in
5.935-5.950 mm
0.2337-0.2343 in
0.030-0.057 mm
0.0012-0.0022 in
0.050-0.077 mm
0.0020-0.0026 in
11.986-12.000 mm
0.0005-0.0020 in
0.013-0.051 mm
3.2210-3.2299 in
Type of Material
Sealant
Lubricant
Lubricant
Lubricant
Part Number
Permatex Anaerobic Gasket
Maker 51813
5 W 30 or equivalent
Engine Oil Supplement
5 W 30 or equivalent
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Page 6
Engine Oil
Lubricant
Lubricant
Threadlocker
Lubricant
Sealant
Sealant
5 quarts
Lubricant
Engine Oil
Engine Oil
Lubricant
5 W 30 or equivalent
5 W 30 or equivalent
5 W 30 or equivalent
21485277
Engine Oil Supplement
21485278
21019581
5 W 30 or equivalent
Engine Oil Supplement
5 W 30 or equivalent
5 W 30 or equivalent
Engine Oil Supplement
Engine Oil
5 W 30 or equivalent
Sealant
Engine Oil
Antiseize
Lubricant
Lubricant
Threadlocker
Lubricant
Lubricant
Sealant
21019581
5 W 30 or equivalent
12397953
5 W 30 or equivalent
Engine Oil Supplement
21485277
Engine Oil Supplement
Silicone Gel Lubricant
21485278
steve
Monday, May 09, 2011 12:51:59 PM
Page 7
Drill Depth
Tap Driver (Maximum)
MM (IN)
213
214 24.5 0.96
208
209 23.5 0.93
Tap Depth
(Maximum)
MM (IN)
19.5 0.77
18.5 0.73
Engineering
Hole
Number
117
109
858
859
114
208
203
203
203
203
208
203
203
203
203
209
204
204
204
204
209
204
204
204
204
23.5
20
20
20
20
25.5
20
20
20
20
110
129
130
125
126
111
127
122
128
124
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Page 8
14
15
16
17
18
19
20
21
22
M6 x 1
M6 x 1
M6 x 1
M6 x 1
M8 x 1.25
M8 x 1.25
M8 x 1.25
M12 x
1.75
M12 x
1.75
205
205
205
205
210
210
210
201
201
201
201
206
206
206
202
202
202
202
207
207
207
203
203
203
203
208
208
208
204
204
204
204
209
209
209
20
20
20
20
23.5
55
23.5
0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
0.93 18.5 0.73
2.17
THRU
0.93 18.5 0.73
123
131
119
120
106
112
108
855
856
857
858
859
116
855
856
857
858
859
115
Page 9
1
2
3
4
5
6
7
1.75
M16 x 1.5
M10 x 1.5
M8 x 1.25
855
860
215
210
854
M8 x 1.25 No
Flange
M16 x 1.5 860
M12 x
855
1.75
856
861
211
206
857
862
212
207
858
863
213
208
859
864
214
209
39
21
29
18
204
214
206
209
206
207
208
209
18
0.709
208
861
862
863
864
21
0.827
0.59
213
856
857
858
859
39
203
THRU
15
Tap Depth
(Maximum)
MM (IN)
Engineering
Hole
Number
-
12.5 0.49
515
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Monday, May 09, 2011 12:51:59 PM
Page 10
2
3
4
5
6
7
8
9
10
M6 x 1.0
M12 x
1.75
M10 x 1.5
M10 x 1.5
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M12 x
1.75
205
201
202
203
204
865
856
857
858
859
514
215
215
205
205
205
205
211
211
201
201
201
201
212
212
202
202
202
202
213
213
203
203
203
203
214
214
204
204
204
204
23.50
23.50
20.50
20.50
20.50
-
0.73
0.73
0.63
0.63
0.63
521
519
513
512
511
-
865
856
857
858
859
516
0.925
0.925
0.807
0.807
0.807
-
18.5
18.5
16.0
16.0
16.0
-
Page 11
Service
Thread
Call
Size
Out
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
M10 x 1.5
M10 x 1.5
M8 x 1.25
M10 x 1.5
M10 x 1.5
M8 x 1.25
M8 x 1.25
M10 x 1.5
M10 x 1.5
M10 x 1.5
M10 x 1.5
M8 x 1.25
M8 x 1.25
M10 x 1.5
M10 x 1.5
M8 x 1.25
M10 x 1.5
M10 x 1.5
M8 x 1.25
M10 x 1.5
M10 x 1.5
M8 x 1.25
M10 x 1.5
M10 x 1.5
M10 x 1.5
M10 x 1.5
M8 x 1.25
M10 x 1.5
M10 x 1.5
M8 x 1.25
Insert
514
514
210
514
514
210
210
514
514
514
514
210
210
514
514
210
514
514
210
514
514
210
514
514
514
514
210
514
514
210
Counterbore
Drill
Tool
J 42385511
N/A
511
N/A
206
207
511
N/A
511
N/A
206
207
206
207
511
N/A
511
N/A
511
N/A
511
N/A
206
207
206
207
511
N/A
511
N/A
206
207
511
N/A
511
N/A
206
207
511
N/A
511
N/A
206
207
511
N/A
511
N/A
511
N/A
511
N/A
206
207
511
N/A
511
N/A
206
207
Drill Depth
Tap Driver (Maximum)
MM (IN)
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
512
513
60 2.362
512
513
60 2.362
208
209
28 1.102
Tap Depth
(Maximum)
MM (IN)
53.5 2.11
53.5 2.11
22 0.87
53.5 2.11
53.5 2.11
22 0.87
22 0.87
53.5 2.11
53.5 2.11
53.5 2.11
53.5 2.11
22 0.87
22 0.87
53.5 2.11
53.5 2.11
22 0.87
53.5 2.11
53.5 2.11
22 0.87
53.5 2.11
53.5 2.11
22 0.87
53.5 2.11
53.5 2.11
53.5 2.11
53.5 2.11
22 0.87
53.5 2.11
53.5 2.11
22 0.87
Engineering
Hole
Number
1415
1408
1425
1416
1409
1426
1432
1404
1417
1422
1406
1431
1430
1412
1421
1429
1411
1420
1428
1410
1419
1427
1405
1418
1413
1403
1423
1414
1407
1424
steve
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Page 12
Engineering
Hole
Number
-
858
859
613
858
859
612
203
204
610
858
859
606
208
208
208
209
209
209
609
608
607
858
859
617
208
208
208
208
209
209
209
209
30.50
30.50
30.50
30.50
604
605
603
601
1.201
1.201
1.201
1.201
22.5
22.5
22.5
22.5
0.89
0.89
0.89
0.89
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Page 13
13
14
15
M8 x 1.25
M12 x
1.75
M12 x
1.75
210
206
207
208
209
602
855
856
857
858
859
616
865
856
857
858
859
614
Tap Depth
(Maximum)
MM (IN)
107.3 4.22
Engineering
Hole
Number
308
steve
Monday, May 09, 2011 12:51:59 PM
Page 14
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
M12 x
1.75
M11 x 1.5
M11 x 1.5
M11 x 1.5
M11 x 1.5
M11 x 1.5
M11 x 1.5
M11 x 1.5
M8 x 1.25
M8 x 1.25
M8 x 1.25
M11 x 1.5
M8 x 1.25
M11 x 1.5
M12 x
1.75
865
856
857
858
859
317
507
507
507
507
507
507
507
210
210
210
507
210
507
504
504
504
504
504
504
504
206
206
206
504
206
504
N/A
N/A
N/A
N/A
N/A
N/A
N/A
207
207
207
N/A
207
N/A
505
505
505
505
505
505
505
208
208
208
505
208
505
506
506
506
506
506
506
506
209
209
209
506
209
506
113.30
113.30
113.30
113.30
113.30
113.30
113.30
23.50
23.50
23.50
113.30
23.50
113.30
4.22
4.22
4.22
4.22
4.22
4.22
4.22
0.73
0.73
0.73
4.22
0.73
4.22
309
310
302
305
304
303
301
313
311
312
306
314
307
865
856
857
858
859
316
4.461
4.461
4.461
4.461
4.461
4.461
4.461
0.925
0.925
0.925
4.461
0.925
4.461
107.3
107.3
107.3
107.3
107.3
107.3
107.3
18.5
18.5
18.5
107.3
18.5
107.3
Page 15
3
4
M8 x 1.25
M8 x 1.25
210
210
206
206
207
207
208
208
209
209
140
141
steve
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Page 16
Drill Depth
Tap Driver (Maximum)
MM (IN)
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
208
209 23.50 0.925
Tap Depth
(Maximum)
MM (IN)
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
18.5 0.73
Engineering
Hole
Number
415
416
417
418
419
405
406
407
408
409
410
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Monday, May 09, 2011 12:52:00 PM
Page 17
12
13
14
15
M8 x 1.25
M8 x 1.25
M8 x 1.25
M8 x 1.25
210
210
210
210
206
206
206
206
207
207
207
207
208
208
208
208
209
209
209
209
23.50
23.50
23.50
23.50
0.925
0.925
0.925
0.925
18.5
18.5
18.5
18.5
0.73
0.73
0.73
0.73
411
412
413
414
Drill Depth
Tap Driver (Maximum)
MM (IN)
213
214 28.50 1.122
213
214 28.50 1.122
213
214 28.50 1.122
Engineering
Tap Depth
Hole
(Maximum) Number
MM (IN)
22.5 0.89
518
22.5 0.89
517
22.5 0.89
520
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Page 18
Tap Depth
(Maximum)
MM (IN)
Engineering
Hole
Number
-
22.5 0.886
615
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Page 19
Drill Depth
Tap Driver (Maximum)
MM (IN)
203
204
24 0.945
203
204
24 0.945
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
24 0.945
203
204
24 0.945
208
209
203
203
203
203
203
203
204
204
204
204
204
204
THRU
20
20
24
24
16
16
0.787
0.787
0.945
0.945
0.630
0.630
Engineering
Tap Depth
Hole
(Maximum) Number
MM (IN)
20 0.787
2515
20 0.787
2514
16 0.630
2812
16 0.630
2820
16 0.630
2710
20 0.787
2513
20 0.787
2512
THRU
2980
16 0.630
16 0.630
20 0.787
20 0.787
THRU
THRU
2811
2810
2510
2511
2910
2911
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Page 20
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M8 x 1.25
M8 x 1.25
35
M8 x 1.25
36
M8 x 1.25
37
38
39
40
41
42
43
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
205
205
205
205
205
205
205
205
205
205
205
205
205
205
205
205
205
205
210
210
854
No
Flange
854
No
Flange
210
205
205
210
210
205
205
852
852
201
201
852
852
201
852
852
201
852
852
201
201
852
852
201
201
206
206
N/A
N/A
202
202
N/A
N/A
202
N/A
N/A
202
N/A
N/A
202
202
N/A
N/A
202
202
207
207
203
203
203
203
203
203
203
203
203
203
203
203
203
203
203
203
203
203
208
208
204
204
204
204
204
204
204
204
204
204
204
204
204
204
204
204
204
204
209
209
24
24
20
20
24
24
20
24
24
20
24
24
20
20
24
24
20
20
25
25
0.945
0.945
0.787
0.787
0.945
0.945
0.787
0.945
0.945
0.787
0.945
0.945
0.787
0.787
0.945
0.945
0.787
0.787
0.984
0.984
20
20
16
16
20
20
16
20
20
16
20
20
16
16
20
20
16
16
20
20
0.787
0.787
0.630
0.630
0.787
0.787
0.630
0.787
0.787
0.630
0.787
0.787
0.630
0.630
0.787
0.787
0.630
0.630
0.787
0.787
2520
2521
2815
2816
2523
2522
2817
2525
2524
2821
2527
2526
2818
2822
2529
2528
2819
2823
2621
2622
853
N/A
208
209
25
0.984
20
0.787
2541
853
N/A
208
209
25
0.984
20
0.787
2540
206
852
852
206
206
852
852
207
N/A
N/A
207
207
N/A
N/A
208
203
203
208
208
203
203
209
204
204
209
209
204
204
20
24
24
20
20
24
24
0.787
0.945
0.945
0.787
0.787
0.945
0.945
16
20
20
16
16
20
20
0.630
0.787
0.787
0.630
0.630
0.787
0.787
2814
2519
2518
2711
2813
2517
2516
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Page 21
Drill Depth
Tap Driver (Maximum)
MM (IN)
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
203
204
20 0.787
Engineering
Tap Depth
Hole
(Maximum) Number
MM (IN)
16 0.630
4117
16 0.630
4116
16 0.630
4115
16 0.630
4114
16 0.630
4113
16 0.630
4112
16 0.630
4111
16 0.630
4110
16 0.630
4118
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Drill Depth
Tap Driver (Maximum)
MM (IN)
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
N/A N/A
THRU
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
203
204
20 0.78
208
209
25 0.984
208
209
25 0.984
208
209
25 0.984
Tap Depth
(Maximum)
MM (IN)
20 0.78
20 0.78
20 0.78
12 0.78
20 0.78
20 0.78
20 0.78
20 0.78
20 0.78
20 0.78
16 0.630
20 0.78
20 0.78
20 0.78
Engineering
Hole
Number
3118
3119
3210
3810
3110
3111
3112
3113
3114
3115
3310
3116
3610
3117
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Page 23
Tap Depth
(Maximum)
MM (IN)
20 0.787
16 0.630
Engineering
Hole
Number
6310
6210
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Page 24
Engineering
Hole
Number
-
858
859
17
0.670
14
0.551
5011
858
859
17
0.670
14
0.551
5010
208
208
209
209
25
25
0.984
0.984
20
20
0.787
0.787
5031
5030
858
859
17
0.670
14
0.551
5310
858
859
17
0.670
14
0.551
5020
208
209
25
0.984
THRU
5111
208
209
25
0.984
THRU
5110
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Engineering
Drill Depth Tap Depth
Hole
Tap Driver (Maximum) (Maximum) Number
MM (IN) MM (IN)
858
859
17
0.670
14
0.551
1510
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1213
1212
1211
1210
COMPONENT LOCATOR
DISASSEMBLED VIEWS
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Page 27
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
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Page 29
Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Component Name
Thermostat Housing
Thermostat Housing to Engine Block Seal
Water Transfer Pipe
Water Transfer Pipe to Water Pump Seal
Water Pump Bolt
Water Pump
Water Pump to Engine Block Seal
Water Pump Bolt
Oil Filter Cap
Oil Filter
Oil Filter to Engine Block Seal
Cylinder Head Alignment Pin
Intake Balance Shaft Rear Bearing
Intake Balance Shaft
Intake Balance Shaft Bearing Carrier
Intake Balance Shaft Drive Sprocket
Intake Balance Shaft Drive Sprocket Bolt
Exhaust Balance Shaft Drive Sprocket Bolt
Exhaust Balance Shaft Drive Sprocket
Exhaust Balance Shaft Bearing Carrier Bolt
Exhaust Balance Shaft
Exhaust Balance Shaft Rear Bearing Engine
Front Cover Alignment Pin
Engine Oil Passage Plug
Engine Oil Passage Plug
Top Compression Piston Ring
Second Compression Piston Ring
Piston Oil Ring Assembly
Piston
Piston Pin
Piston Pin Retainer
Connecting Rod
Connecting Rod Cap Bolt
Connecting Rod Bearing
Crankshaft Thrust Bearing
Crankshaft Bearing
Crankshaft Damper Alignment Key
Crankshaft
Crankshaft Rear Seal
Starter Ring Gear
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42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
Flywheel
Flywheel to Crankshaft Bolt
Engine Oil Pan Baffle
Engine Oil Pan
Pan Drain Plug
Engine Oil Pan Nut
Engine Oil Pan Stud
Engine Oil Pan Bolt
Engine Oil Pickup
Lower Crankcase to Engine Block Bolt
Lower Crankcase to Engine Block Bolt
Crankshaft Bearing Bolt
Lower Crankcase to Engine Block Bolt
Lower Crankcase
Lower Crankcase Alignment Pin
Lower Crankcase Alignment Pin
Engine Block
Water Jacket Plug
Engine Block to Transmission Alignment Pin
Cylinder Head to Engine Block Bolt
Water Jacket Drain Plug
Water Pump to Engine Block Bolt
Thermostat Housing to Engine Block Bolt
Thermostat Housing to Engine Block Bolt
Thermostat Gasket
Thermostat
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Page 32
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
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Page 34
Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Fuel Pressure Regulator Vacuum Line
Accelerator Control Cable Bracket
Throttle Body Nut
Throttle Body Nut
Throttle Body Bolt
Throttle Body
Intake Manifold Bolt
Throttle Body Seal
Intake Manifold
Intake Manifold Gasket
Map Sensor
Throttle Body Stud
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Component Name
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1
2
3
4
5
6
7
8
9
10
11
12
13
Tensioner inoperative.
Wrong belt.
Worn belt.
Tensioner inoperative or broken
internal spring.
Wrong pulley.
Wrong belt.
Belt misaligned.
Belt Chirp
Correction(s)
Replace belt, check belt, and
pulleys for proper belt installation
and
alignment in grooves.
Check pulley diameters against
another vehicle or good parts.
Replace tensioner.
Replace belt.
Replace belt.
Replace tensioner.
(Do not attempt to repair)
Check pulley diameters against
another vehicle or good parts.
Check belt tension.
Check pulley alignment.
Check for belt alignment in
grooves.
Check belt tensioner motion.
Check tensioner movement.
Check belt tension.
Check tensioner/idler pulley
bearings.
Check belt tension.
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Page 39
Worn belt.
Excessive pulley radial/axial
runout.
Belt misaligned.
Water pump, power steering
pump, generator, A/C
compressor, tensioner or idler
bearing/loads.
Oil pump pressure regulator.
IMPORTANT:
Do not disassemble the belt
tensioner.
IMPORTANT: Saturn service tool SA9217NE Chassis Ear Tool (or equivalent) should be used
to locate source(s) of noises caused by vibration(s).
DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views, Engine Component Description,
Lubrication Description, and New Product Information in Engine Unit Repair. Reviewing the description and
operation information will help you determine the correct symptom diagnostic procedure when a malfunction
exists. Reviewing the description and operation information will also help you determine if the condition
described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify
the correct procedure for diagnosing the system and where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
Page 40
Repair.
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
Inspect for aftermarket devices which could affect the operation of the engine.
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
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:
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Page 43
Correction
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Correction
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Replace tensioners
Inspect the engine camshaft lobes.
Replace the camshaft and valve lifters as
required.
Inspect the following components, and repair as
required:
The valves
The valve guides
Inspect the following components, and repair as
required:
Stuck valves
Carbon on the valve stem or valve seat may cause
the valve to stay open.
The valves
The valve guides
Correction
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Page 47
Cause
Low oil pressure
Correction
Perform an oil pressure test. Refer to Oil
Pressure Diagnosis and Testing.
Repair or replace as required.
Verify the correct operation of the ignition. Refer to
DETONATION/SPARK KNOCK in
Troubleshooting No Codes - 2.2L in Engine
Performance.
Coolant/antifreeze in cylinder
Oil in cylinder
Fuel in cylinder
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Page 48
Material in cylinder
Broken valve
Piston material
Foreign material
Cracked cylinder wall
Seized crankshaft or connecting rod bearings
Broken crankshaft
Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an "overtemperature" condition which may cause engine component damage.
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
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Page 50
Normal - Compression builds up quickly and evenly to specified compression on each cylinder.
Piston Rings - Compression low on first stroke. Tends to build up on following strokes but does not reach
normal. Improves considerably with addition of oil.
Valves - Compression low on first stroke. Does not tend to build up on the following strokes. Does not
improve much with the addition of oil. Use approximately three squirts from a plunger-type oiler.
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Page 51
External oil leaks. Tighten bolts and/or replace gaskets and oil seals as necessary.
Incorrect oil level or improper reading of oil level indicator. With the vehicle on a level surface, allow
adequate drain down time and check for the correct oil level.
Improper oil viscosity. Use recommended SAE viscosity for the prevailing temperatures.
Continuous high speed driving and/or severe usage.
Crankcase ventilation system restrictions or malfunctioning components.
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.
Piston rings broken, improperly installed, worn, or not seated properly. Allow adequate time for rings to
seat. Replace broken or worn rings as necessary.
Piston improperly installed.
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IMPORTANT: Complaints of high engine oil consumption are not always thoroughly
investigated before major repairs are performed. During initial engine break in,
it is normal for the engine to use from one to three quarts of oil during the first
4,800-9600 kilometers (3,000-6,000miles), depending on driving conditions.
1. Check the engine for external oil leakage and the air intake and PCV systems for excessive oil pull over.
2. Change the engine oil and filter.
3. Warm the engine up and check the oil level after approximately 10 minutes with vehicle on a level
surface. Note exactly where the dipstick reads, relative to the dipstick MAX mark.
4. Inform the customer an oil consumption test is now in progress and any oil added must be documented.
5. Record the vehicle's mileage, date of oil change and exact location of oil level on the Customer Service
Order.
6. Have customer check the engine oil level at each fuel fill and return the vehicle if oil level is at the "MIN"
mark. If the oil level remains in the "CROSS HATCH" area, have the customer continue operating the
vehicle for a minimum of 3,200 kilometers (2,000 miles) before returning the vehicle for final oil
consumption verification.
7. If the engine uses more than one quart of oil in 3,200 kilometers (2,000 miles), after the initial 4,800
kilometers (3,000 miles) break in period, document the oil consumption usage on the Customer Service
Order and continue with the following checks.
8. If the engine is using oil, perform a compression test. Refer to "Engine Compression Test" procedure in
this section of the service manual.
If cylinder compression is found within acceptable limits, replace the valve stem seals.
If compression is not found within acceptable limits, perform an engine cylinder leakage test,
crankcase pressure check, and repair as necessary.
Valve Train Diagnosis
A light tapping at one-half engine speed, or any varying frequency, can indicate a valve train problem. These
tapping noises increase with engine speed.
Before attempting to judge the valve train noises, thoroughly warm up the engine. By doing this you will bring
all engine components to a normal state of expansion. Also, run the engine at various speeds and listen for
engine noises with the hood closed while sitting in the driver's seat. The causes of the valve train noise include
the following conditions:
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Definition: Vehicle speed sensitive vibrations can be heard or felt as the speed of the vehicle (mph) varies.
The operating speed of the engine (rpm) does not effect a vehicle speed sensitive vibration.
OIL PRESSURE DIAGNOSIS AND TESTING
Tools Required
J 44953 Oil Pressure Gage Adapter. See Special Tools and Equipment.
With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low
oil level.
Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil
level indicator.
Run the engine, and verify low, or no oil pressure on the vehicle gage or light. Listen for a noisy valve
train or a knocking noise.
Inspect for the following:
Oil diluted by moisture or unburned fuel mixtures
Improper oil viscosity for the expected temperature
Incorrect or malfunctioning oil pressure sender
Incorrect or malfunctioning oil pressure gage
Plugged oil filter
Malfunctioning oil bypass valve
Remove the oil pressure sender or another engine block oil gallery plug.
Install J 44953 and an oil pressure gage and measure the engine oil pressure. See Special Tools and
Equipment.
Compare the readings to specifications. Refer to Engine Mechanical Specifications.
If the engine oil pressure is below specifications, inspect the engine for one or more of the following:
Oil pump worn or dirty
Refer to Oil Pump Disassemble.
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Page 54
Action
Value(s)
Yes
No
Go to Step 2
System OK
Go to Step 10 Go to Step 3
Page 55
Go to Step 10 Go to Step 4
Go to Step 10 Go to Step 5
Go to Step 10 Go to Step 6
Go to Step 10 Go to Step 7
Go to Step 10 Go to Step 8
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10
11
Go to Step 10 Go to Step 9
Go to Step 10 System OK
Go to Step 11 System OK
Go to Step 1
-
1.
2.
3.
4.
Page 57
6. Remove the engine oil dipstick and install a vacuum gage on the dipstick tube.
7. Block off the PCV system fresh air intake passage.
8. Run the engine at 1500 RPM for 30 seconds, then read the vacuum gage while the engine is running at
1500 RPM.
If a vacuum is present, this indicates that the crankcase ventilation system is functioning properly. No vacuum
indicates that the engine may not be sealed and is drawing in outside air. Check the valve covers, oil pan gasket,
or other sealing areas for leaks. If the vacuum gage registers a positive pressure through the dipstick tube, check
for a plugged hose or engine blow-by.
Results of Incorrect Operation
A rough idle
Stalling or a slow idle speed
Oil leaks
Sludge in the engine
A rough idle
Stalling
A high idle speed
Theory of Operation
The positive crankcase ventilation system (PCV) flows fresh air into the engine crankcase to dilute the
unburned hydrocarbons present and route them into the intake manifold where they are consumed during the
combustion process.
DRIVE BELT EXCESSIVE WEAR DIAGNOSIS
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Fig. 25: Chunking, Cord Breakage Or Separation DO Warrant Drive Belt Replacement
Courtesy of GENERAL MOTORS CORP.
Belts that have chunking longer than 5 mm (13/16 in) in one or more places should be replaced.
Belts should also be replaced if cord breakage or fabric separation is observed.
DRIVE BELT TENSIONER DIAGNOSIS
Drive Belt Tensioner Diagnosis
Step
Action
Remove the drive belt. Inspect the drive belt tensioner
1 pulley.
Is the drive belt tensioner pulley loose or misaligned?
Rotate the drive belt tensioner.
2 Does the tensioner rotate without any unusual resistance
or binding?
Yes
No
Go to Step 4
Go to Step 2
Go to Step 3
Go to Step 4
System OK
Go to Step 4
System OK
REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
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Page 68
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Page 69
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Fig. 34: Removing & Installing Rear Exhaust Manifold Heat Shield
Courtesy of GENERAL MOTORS CORP.
3. Loosen the rear transmission mount through bolt. Do not remove.
4. Position two floor jacks with wood blocks under the engine and transmission to support the powertrain
assembly.
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Page 71
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8. Tighten the transmission mount to transmission bolts using the following sequence:
1. Rear bolt
2. Middle bolt
3. Front bolt
Tighten: Tighten the bolts to 55 N.m (41 lb ft).
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Page 77
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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Page 81
8. Tighten the transmission mount to transmission bolts using the following sequence:
1. Rear bolt
2. Middle bolt
3. Front bolt
Tighten: Tighten the bolts to 55 N.m (41 lb ft).
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Page 85
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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Page 88
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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NOTE:
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Page 97
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Page 98
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IMPORTANT: The isolation must be attached to the engine mount. Replace the isolation
pad if necessary.
1. Assemble the engine mount, engine mount bracket and isolation pad.
Tighten: Tighten the engine mount to bracket bolt to 90 N.m (66 lb ft).
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Page 103
Transaxle).
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Fig. 68: Removing & Installing Oil Level Indicator & Tube
Courtesy of GENERAL MOTORS CORP.
1. Remove the tube bracket to intake manifold bolt.
2. Remove the tube from the engine block.
CRANKCASE VENTILATION HOSES/PIPES REPLACEMENT
Removal Procedure
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Page 107
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NOTE:
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Page 111
9.
10.
11.
12.
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Fig. 75: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
1. Install the J 38122-A onto the damper assembly.
2. Remove and discard the damper retaining bolt and washer. Use the J 38122-A and breaker bar in order to
prevent the crankshaft from rotating when loosening the bolt.
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2. Install the damper onto the crankshaft indexing keyway. Use care to properly align the keyway and flats
on the damper with the oil pump drive.
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Fig. 78: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
NOTE:
3. Install the new retaining bolt and washer using the J 38122-A and a breaker bar to hold the crankshaft.
Tighten: Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) plus 75 degrees.
ENGINE FRONT COVER REPLACEMENT (WITH OIL PUMP ASSEMBLY)
Tools Required
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Removal Procedure
Page 117
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Fig. 82: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
7. Install the J 38122-A .
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Page 122
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Fig. 92: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
6. Install the crankshaft damper pulley.
1. Lubricate the front seal and sealing surface of the damper pulley with clean motor oil.
2. Install the damper onto the crankshaft indexing keyway. Use care to properly align the flats on the
damper with the flats on the oil pump drive.
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Fig. 97: Pulling Camshafts Straight Up To Avoid Damaging The Cylinder Head Thrust Surfaces
Courtesy of GENERAL MOTORS CORP.
1. Disconnect the negative battery cable.
2. Remove the front cover. Refer to Engine Front Cover Replacement (With Oil Pump Assembly).
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Page 146
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Page 147
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Page 148
Fig. 111: Rotating Assembly 90 Degrees To Allow The Chain To Fall Between The Cylinder Block
Bosses
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: When lowering the timing chain rotate the assembly 90 degrees to allow
the chain to fall between the cylinder block bosses, then rotate the
assembly back so that the camshaft sprocket is facing forward.
4. Lower the assembly through the chain housing opening on top of the cylinder head. Use care to make
sure that the chain goes around both sides of the cylinder block bosses.
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Fig. 112: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The crankshaft sprocket timing mark will be at approximately the 5 o'clock
position.
5. Route the chain around the crankshaft sprocket and align the silver link to the timing mark.
IMPORTANT: The camshaft sprocket bolt is not reusable. It is a torque-to-yield (TTY)
bolt, and must be discarded to prevent premature failure.
6. Install the intake camshaft sprocket loosely onto the intake camshaft and install the new camshaft
sprocket bolt finger tight. It is not necessary to align the sprocket-to-camshaft offset notch at this time.
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Fig. 115: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The camshaft sprocket bolt is not reusable. It is a torque-to-yield (TTY)
bolt, and must be discarded to prevent premature failure.
9. Align the camshaft sprocket-to-camshaft and tighten the camshaft bolt using the following procedure:
NOTE:
Do not rotate either camshaft more than half turn in either direction with
crankshaft at top dead center (TDC). To do so may cause valve to piston
contact resulting in a damaged valve and/or a damaged piston.
Page 153
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Page 159
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Page 171
13.
14.
15.
16.
Inspect the balance shaft drive chain and sprockets for wear.
Inspect the camshaft sprocket faces for signs of movement.
Inspect the alignment notch in the camshaft for cracking or damage.
Inspect the water pump, crankshaft, and balance shaft sprocket teeth and chain for signs of excessive
wear, chipping, or seizure of the balance shaft drive chain links.
Installation Procedure
Page 172
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J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment.
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Page 181
The L61 engine camshafts, rocker arms, lash adjusters, valve springs, and seals can be serviced without
removing the exhaust system, vibration damper, front mount, or front cover. The following procedure must be
followed to prevent damage to the camshafts, lash adjusters, cylinder head, and lower timing chain guides.
Removal Procedure
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Page 184
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Page 185
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Fig. 147: Pulling Camshafts Straight Up To Avoid Damaging The Cylinder Head Thrust Surfaces
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Camshafts are spring loaded and may rotate.
14. Carefully pull the camshafts straight up to avoid damaging the cylinder head thrust surface when
removing the camshafts.
Installation Procedure
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Fig. 148: Aligning Camshaft Slot In Line With The Notch On The Sprockets
Courtesy of GENERAL MOTORS CORP.
1. Lubricate the camshaft bearing journals with clean engine oil and install both camshafts and all bearing
caps, except the front cap on each camshaft.
2. When installing camshafts, attempt to position the camshaft slot up with the notches on the camshaft
sprockets.
NOTE:
3. Install all bearing caps except the front caps and the rear intake camshaft cap, if serviced. Tighten down
the bearing caps uniformly.
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Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
Page 189
Fig. 150: Applying LOCTITE 242 & Installing Upper Timing Chain Guide Bolts
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Apply LOCTITE 242 to the upper timing chain guide bolts.
8. Install the upper timing chain guide.
Tighten: Tighten the timing chain guide (upper) bolts to 10 N.m (89 lb in).
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Page 190
J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment.
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Page 191
Fig. 151: Pulling Camshafts Straight Up To Avoid Damaging The Cylinder Head Thrust Surfaces
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The J 43655 Camshaft Sprocket Holding Tool must be used to remove one or
both camshafts at the same time. The engine's crankshaft can not be rotated
with the camshafts removed.
The L61 engine camshafts, rocker arms, valve lash adjusters, valve springs, and seals can be serviced without
removing the exhaust system, vibration damper, front mount, or front cover. The following procedure must be
followed to prevent damage to the camshafts, lash adjusters, cylinder head, and lower timing chain guides.
Removal Procedure
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Page 193
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Page 194
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Fig. 156: Pulling Camshafts Straight Up To Avoid Damaging The Cylinder Head Thrust Surfaces
Courtesy of GENERAL MOTORS CORP.
NOTE:
Page 197
Removal Procedure
Page 198
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Fig. 159: Installing Hose Over Radiator Drain Tube & Loosening Radiator Drain Valve
Courtesy of GENERAL MOTORS CORP.
8. Drain the coolant at the radiator and at the water pump drain plug.
9. Lower the vehicle.
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Fig. 160: Proper Connection Of Pressure Adapter & Gage Bar Set To Fuel Rail
Courtesy of GENERAL MOTORS CORP.
10. Relieve the fuel system pressure.
11. Remove the fuel line bracket bolts.
12. Disconnect the fuel lines at the quick disconnects using the SA9805E . See Special Tools and
Equipment.
13. Secure the lines away from the engine.
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Be careful not to damage the aluminum the aluminum cylinder head and
block gasket sealing surfaces when removing the cylinder head or during
cleaning.
32. Lift the cylinder head from the dowels on the engine block and place the cylinder head on wooden blocks
or a bench. If the cylinder head is difficult to lift off, use a pry bar at the designated pry points.
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Fig. 175: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
38. Remove the suction liquid A/C line retaining clips from underneath the right side frame rail and position
the line away to allow clearance to the crankshaft pulley bolt.
39. Position the crankshaft 60 degrees before top dead center (BTDC).
40. Install the J 38122-A .
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Page 217
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Page 218
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Page 219
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Page 222
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Page 223
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Page 224
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Page 225
Fig. 185: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
Courtesy of GENERAL MOTORS CORP.
NOTE:
1. Set the crankshaft to 60 degrees before or after top dead center (TDC).
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Page 227
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Page 228
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Fig. 189: Aligning Camshaft Slot In Line With The Notch On The Sprockets
Courtesy of GENERAL MOTORS CORP.
8. Position the exhaust camshaft with the offset slot at the 2 o'clock position.
9. Position the intake camshaft with the offset slot at the 11 o'clock position.
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Fig. 191: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: There is a 2nd design adjustable guide with a contact pad for the 2nd
design notched tensioner. A 2nd design guide should be used only with a
2nd design tensioner.
13. Route the chain around the crankshaft sprockets and align the silver link to the timing mark.
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Page 234
IMPORTANT: Ensure that all the timing marks and colored links are aligned properly
before proceeding to the next step.
18. Tighten the intake and exhaust camshaft sprocket bolts.
Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) plus 30 degrees.
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Page 235
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Page 236
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Page 238
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Page 239
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Page 241
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Page 242
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Page 243
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Page 246
Fig. 206: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: It may be necessary to lower the engine slightly with a crow bar so that
the bolt-head clears the frame rail.
39. Install the new crankshaft damper pulley bolt.
Tighten: Tighten the crankshaft damper pulley bolt to 100 N.m (74 lb ft) plus 75 degrees.
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Page 250
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Page 253
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Page 254
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Page 255
Fig. 215: Removing & Installing Oil Level Indicator & Tube
Courtesy of GENERAL MOTORS CORP.
54. Attach the wiring harness to the brackets located under the intake manifold.
55. Install the oil indicator tube assembly.
Tighten: Tighten the oil level indicator tube-to-intake manifold bolt to 10 N.m (89 lb in).
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Page 257
Fig. 217: Removing & Installing Surge Tank Coolant Air Bleed Hose
Courtesy of GENERAL MOTORS CORP.
61. Attach the cylinder head degas hose onto the coolant reservoir and attach to the harness retainers.
Tighten: Tighten the degas hose bracket bolts to 10 N.m (89 lb in).
62. Attach the hoses.
1. Upper radiator hose
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Page 258
2.
3.
4.
5.
NOTE:
63. Install the fuel lines. Ensure that the lines are routed correctly.
64. Clip the lines into place and install the fuel line bracket and bolt.
Tighten: Tighten the fuel line bolt to 10 N.m (89 lb in).
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Page 259
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Page 261
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Page 265
NOTE:
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Page 267
Page 268
Tools Required
Removal Procedure
1. Remove the steering gear-to-intermediate shaft pinch bolt. Access is from the inside of the vehicle at the
front of the dash.
2. Remove the battery.
3. Disconnect the main wire feed to the fuse block.
4. Disconnect the main ground on the left fender well.
5. Remove the intake air temperature (IAT) electrical connector.
6. Remove the air cleaner lid and the inlet duct.
7. Remove the air box.
8. Disconnect the purge hose from the throttle body and route away from the engine.
9. Disconnect the following electrical connections:
1. The purge solenoid
2. The rear HO2S sensor
3. The main harness connector by the master cylinder
4. The transaxle back-up switch
10. Remove the front-of-dash cover.
11. Remove the PCM boot from the front of the dash.
12. Disconnect the PCM electrical connectors and secure to the engine.
13. Remove the fuse block.
14. Disconnect the engine harness main connector from the bottom of the fuse block.
15. Remove the battery tray and the fuse block tray.
16. Remove the cruise control and throttle cables.
17. Disconnect the brake assist vacuum line from the throttle body and route away from the engine.
18. Loosen the pinch bolt securing the control assembly rod to the control shaft lever assembly.
NOTE:
The control shaft lever retaining pin has a spring loaded locking feature
securing the pin in place. If this spring is not depressed before attempting
to remove the pin, damage to the pin will result.
19. Remove the pin retaining control shaft lever to shift control shaft of the transaxle.
20. Remove the retaining clips holding the control shaft lever assembly to the transaxle and frame assembly
brackets.
21. Remove the control shaft lever assembly by pulling straight up from the pivot pins.
22. Drain the coolant.
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Page 269
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
42.
43.
44.
45.
46.
47.
Do not attempt to separate the joint using a wedge-type tool because seal
may be damaged.
Remove the lower ball stud bolt and separate the ball from the steering knuckle assembly.
Remove the suspension support assemblies.
Remove the suspension support cage nuts from the body. Discard the cage nuts.
Support the powertrain and frame with the powertrain lifting table and the J 43628 .
Remove the remaining 4 frame-to-body attachment fasteners.
Carefully lower the powertrain and frame assembly from the vehicle.
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Page 271
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23.
24.
25.
26.
Install the upper and lower radiator hoses from the radiator.
Install the heater hose.
Connect the brake assist vacuum lines to the brake booster.
Install and adjust the shift control rod as follows:
1. Install the shift rod into the shift linkage assembly.
2. Rotate the transaxle shift control shaft clockwise, toward the passenger side of the vehicle, and
depress the spring loaded transaxle shift linkage lock pin on the transaxle case.
3. Pull up the shift lever boot.
4. Move the shift lever to 5th (reverse gate) using a 3/8 in. punch to hold in place.
5. Tighten the pinch bolt.
Tighten: Tighten the shift control rod pinch bolt to 12 N.m (9 lb ft) plus 180 degrees.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Page 273
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Page 274
28. Disconnect the lower engine to transmission bell housing bolts. Do not remove the upper bolts at this
time.
29. Lower the vehicle.
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Page 275
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Installation Procedure
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Page 276
4. Install the engine mount bracket onto the engine and install the bolts.
Tighten: Tighten the engine mount bracket-to-engine bolts to 90 N.m (66 lb ft).
5. Install the right front engine mount and install the bolts.
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Page 277
23. Connect the EVAP purge solenoid and EVAP purge hose.
24. Connect the fuel lines.
25. Connect the brake assist vacuum hose.
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Page 278
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Page 279
Do not use a universal type oil filter wrench to remove oil filter cap.
Damage to the oil cap and the engine may result.
NOTE:
The cylinder block sealing surface can be damaged if the oil filter cap is
removed using a chisel or screwdriver.
IMPORTANT: Either a 68 mm (2.68 in) (14 Flute Oil Filter Wrench) or a 32 mm (.26 in)
socket must be used to loosen the oil filter cap assembly.
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Page 280
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Page 281
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Page 282
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Page 283
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Page 284
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Page 285
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Page 286
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Page 287
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Page 288
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Page 289
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Page 290
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Page 291
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Page 292
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Page 293
NOTE:
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Page 294
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Page 295
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Page 296
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Page 297
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Page 298
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Page 299
Removal Procedure
Fig. 249: Properly Installed Camshaft Support Holding Tool & Valve Spring Compressor
Courtesy of GENERAL MOTORS CORP.
1. Remove the spark plugs, cam cover, and camshaft. Refer to Camshaft Cover Replacement.
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Page 300
Care should be used when servicing the valve spring, the retainer and the
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Page 301
valve. If air pressure is lost, the valve(s) will drop into the cylinder.
4. Pressurize the cylinder being serviced to 690 kPa (100 psi).
5. Position the compressor assembly cover over the valve spring to be removed and turn the T-handle to
compress the spring.
Page 302
Installation Procedure
IMPORTANT: Before each valve stem seal is installed, oil the valve stem seal and guide.
If a valve stem seal is removed, it must be discarded.
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Page 303
1. Inspect the valve stem for scratches, scores, and scuffs. Spray the valve stem and guide with clean
lubricating oil to remove any debris that may be present on the valve stem or the top of the guide.
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Page 304
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Page 305
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Page 306
Page 307
Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water
pump.
6. Apply sealant P/N 21485278 to the water pump drain plug.
7. Install the water pump drain plug.
Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.
ENGINE FLYWHEEL REMOVAL
Tools Required
IMPORTANT: It may be necessary to remove the chamfer (bevel) from the edge of an 18
mm socket in order to get full socket engagement on the thin headed
flywheel bolts.
IMPORTANT: It is not necessary to orientate the flywheel to the crankshaft. It is
balanced separately from the engine.
1. Remove the flywheel attaching bolts. Use the J 43653 to prevent crankshaft rotation. See Special Tools
and Equipment.
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Page 308
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Page 309
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Page 310
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Page 311
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Page 312
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Page 313
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Page 314
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Page 315
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Page 316
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Page 317
Page 318
Tools Required
Fig. 267: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
1. Install the J 38122-A onto the damper assembly.
2. Remove and discard the damper retaining bolt and washer. Use the J 38122-A and breaker bar in order to
prevent the crankshaft from rotating when loosening the bolt.
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Page 319
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Page 320
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Page 321
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Page 322
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Page 323
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Page 324
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Page 325
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Page 326
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Page 327
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Page 328
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Page 329
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Page 330
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Page 331
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Page 332
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Page 333
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Page 334
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Page 335
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Page 336
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Page 337
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Page 338
Mark the bearing caps to ensure they are installed in the same position.
Remove the intake camshaft bearing cap bolts.
Remove the camshaft bearing caps.
Remove the intake camshaft.
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Page 339
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Page 340
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Page 341
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Page 342
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Page 343
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Page 344
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Page 345
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Page 346
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Page 347
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Page 348
Page 349
J 43650 Balance Shaft Bearing Remover/Installer. See Special Tools and Equipment.
Removal Procedure
Page 350
Proper centering of the tool is required on the balance shaft bushing. If the
tool is not properly centered, then damage to the bearing bore and block
will occur.
3. Install the J 43650 into the balance shaft hole. Insert the tool with the foot parallel to the shaft. See
Special Tools and Equipment.
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Page 351
Assure the special tool J43650 is properly installed. It the bearing removal
is attempted and the tool is not positioned properly, block damage may
result.
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Page 352
7. To assure the J 43650 is properly installed, measure from one end of the front side of the nut to the end of
the threaded shaft. See Special Tools and Equipment. The measurement should be between 74-77 mm
(2.91-3.03 in). If the measurement is less than 73 mm (2.87 in) the tool is not properly installed and
should be reinstalled.
Page 353
Removal Procedure
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Page 354
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Page 355
Page 356
J 38188 Cylinder Head Broken Bolt Extractor Kit. See Special Tools and Equipment.
Removal Procedure
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Page 357
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Page 358
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Page 359
Use a new razor blade for each cylinder head and cylinder block.
IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not
gouge or scrape the combustion chamber surfaces. The feel of the
gasket surface is important, not the appearance. There will be
indentations from the gasket left in the cylinder head after all the
gasket material is removed. These small indentations will be filled in
by the new gasket.
IMPORTANT: Do not use a tap to clean the cylinder head bolt holes. Use a nylon bristle
brush.
7. Clean the old sealer/lube and dirt from bolts, studs, and cylinder head bolt holes.
8. Clean the bolt holes with a nylon bristle brush.
CAUTION: Wear safety glasses to avoid injury when using compressed air or
any cleaning solvent. Bodily injury may occur if fumes are inhaled or
if skin is exposed to chemicals.
9. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and
compressed air from an extended-tip blow gun to reach the bottom of the holes.
10. Remove any broken long cylinder head bolts using the J 38188 . See Special Tools and Equipment.
OIL PAN REMOVAL
Removal Procedure
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Page 360
Page 361
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Page 362
Page 363
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Page 364
Fig. 312: View Of Oil Passage Plug, Oil Flow Check Valve & Water Jacket Drain Plug
Courtesy of GENERAL MOTORS CORP.
1.
2.
3.
4.
5.
6.
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Page 365
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Page 366
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Page 367
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Page 368
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Page 369
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Page 370
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Page 371
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Page 372
13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole
bosses:
1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
2. Hold the gage plate flat against the crankshaft flange.
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Page 373
3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary
more than 0.203 mm (0.008 in).
5. Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
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Page 374
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Page 375
Page 376
A crankshaft balancer hub seal surface with excessive scoring, grooves, rust, or other damage must
be replaced.
Worn, clunking, or deteriorated rubber between the pulley and damper ring
IMPORTANT: In order for the belt to track properly, the belt grooves should be free
of all dirt or debris.
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Page 377
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Page 378
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Page 379
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Page 380
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Page 381
Page 382
Page 383
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
CAUTION: Refer to SAFETY GLASSES CAUTION in Cautions and Notices.
Page 384
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Page 385
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Page 386
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Page 387
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Page 388
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Page 389
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Page 390
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Page 391
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Page 392
Page 393
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction
with a light emery paper. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure:
1. Using an outside micrometer, take two measurements of the piston pin in the area of the connecting
rod contact.
2. Using an inside micrometer, measure the connecting rod piston pin bore.
3. Subtract the piston pin diameter from the piston pin bore diameter.
4. The clearance should not be more than 0.021 mm (0.0008 in).
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.
Piston Measurement
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Page 394
Page 395
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Page 396
Page 397
2. Measure the end gap of the piston ring with feeler gages. Compare the measurements with those
provided below:
The top compression ring end gap should be 0.20-0.40 mm (0.0060-0.015 in).
The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in).
The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in).
3. If the clearance exceeds the provided specifications, the piston rings must be replaced.
4. Repeat the procedure for all the piston rings.
Page 398
new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the 2nd
compression ring near the end for identification of the top side. Install the 2nd compression ring with the
dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than
0.069 mm (0.0026 in).
10. If the new ring does not reduce the clearance to 0.069 mm (0.0026 in) or less, install a new piston.
Page 399
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores
are within specification, replace the piston.
Piston Selection
Page 400
Page 401
4. Measure the bore gauge with a micrometer and record the reading.
Page 402
Tools Required
J 43654 Piston Pin Clip Installer. See Special Tools and Equipment.
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Page 403
Install the piston pin retainers correctly in the retaining groove during
assembly in order to avoid engine damage.
2. Use the following procedure in order to assemble the piston pin and the retainer:
1. Coat the piston pin with oil.
2. Using the J 43654 , install one side of one piston pin retainer into the retaining groove. See Special
Tools and Equipment. Rotate the retainer until it is fully seated in the groove.
3. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously
installed retainer.
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Page 404
Use a piston ring expander to install the piston rings. The rings may be
damaged if expanded more than necessary.
3. Install the following components of the oil control ring assembly (bottom ring):
1. Expander
2. Lower oil control ring
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Page 405
Inspect the valve lifters for scoring where they contact the camshaft.
Inspect the camshaft journals and lobes for wear or scoring.
Inspect camshaft sprocket alignment notch for damage.
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Page 406
Inspect the camshaft cover for damage or loose oil control baffles.
Clean the camshaft cover.
Wash the camshaft in solvent.
Inspect the camshaft cover for cracks or other signs of damage.
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Page 407
Page 408
4. Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide
surface.
5. Inspect the timing chain and sprockets for wear.
6. Inspect the camshaft sprocket faces for signs of movement.
7. Inspect the camshaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the
timing chain links.
8. Inspect the oil nozzle body for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body
if it is damaged.
9. Remove the old oil from the timing chain tensioner.
10. Inspect the timing chain tensioner for the scoring or free movement.
11. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
BALANCE SHAFT CLEANING AND INSPECTION
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Page 409
5. Measure the rear bearing journals on the balance shafts, the journals should be 36.723-36.743 mm
(1.4458-1.4466 in) in diameter.
6. Measure the front bearing journals on the balance shafts, the front bearing journals should be 20.02020.000 mm (0.7881-0.7874 in) in diameter.
7. When the balance shafts have been installed in the engine block, check for smooth rotation, sticking,
binding, or roughness.
BALANCE SHAFT DRIVE CHAIN AND SPROCKETS CLEANING AND INSPECTION
Fig. 353: Exploded View Of Balance Shaft Drive Chain & Sprockets
Courtesy of GENERAL MOTORS CORP.
1. Inspect the balance shaft drive chain guides for cracking or wear.
2. Replace the balance shaft drive chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide
surface.
3. Inspect the balance shaft drive chain tensioner guide shoe for wear.
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Page 410
Replace the balance shaft drive chain tensioner guide shoe if wear exceeds 1.12 mm (0.045 in) depth on
the chain guide surface.
4.
5.
6.
7.
Inspect the balance shaft drive chain and sprockets for wear.
Inspect the crankshaft sprocket faces for signs of movement.
Inspect the alignment notch in the balance shaft for cracking or damage.
Inspect the water pump, crankshaft, and balance shaft sprocket teeth and chain for signs of excessive
wear, chipping, or seizure of the balance shaft drive chain links.
8. Inspect the timing chain tensioner for damage or wear.
CYLINDER HEAD DISASSEMBLE
Tools Required
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Page 411
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Page 412
Page 413
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Page 414
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.
7. Remove the valve seal. Use the J 36017 . See Special Tools and Equipment. Do not reuse.
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Page 415
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Page 416
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Page 417
Page 418
4. Inspect the valve keeper 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 and the valve head for bending or distortion (3) 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. The valves may be lightly lapped to the valve seats.
Cylinder Head and Gasket Surface Cleaning and Inspection
Page 419
Page 420
Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each
combustion chamber (1).
Replace the cylinder head if the area between the valve seats is cracked (2).
Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each
combustion chamber (3).
4. Clean the cylinder head bolts.
Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
Clean the valve guides.
Clean the threaded holes. Use a nylon bristle brush.
Clean the remains of the sealer from the plug holes.
Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper
use of tools.
10. Replace all suspect bolts.
11. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
IMPORTANT: Do not attempt to weld the cylinder head, replace it.
12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
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Page 421
Inspect the cylinder head deck surface for flatness. Refer to Engine Mechanical Specifications.
Inspect the cylinder head intake and exhaust manifold mating surface for flatness.
Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
Inspect the sealing surfaces.
Page 422
Page 423
In order to avoid damage, install the spark plugs after the cylinder head
has been installed on the engine.
1. Install NEW cylinder head plugs. Coat the plugs with threadlocker P/N 21485277, or equivalent.
Page 424
Page 425
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Page 426
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Page 427
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Page 428
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Page 429
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Page 430
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Page 431
Page 432
Page 433
(0.011 in).
2. If the clearance is greater than the service limit, replace the oil pump assembly.
Page 434
2. If the clearance is greater than the service limit, replace the oil pump assembly.
Fig. 377: Measuring Driven Rotors & Oil Pump Cover Plate Clearance
Courtesy of GENERAL MOTORS CORP.
3. Inspect the end-to-end clearance:
1. Using a SA91101NE , Plastigae, or equivalent, measure the clearance between the side of the
drive and the driven rotors and the oil pump cover plate. See Special Tools and Equipment.
Specification:
The standard rotor to cover side clearance is 0.040-0.125 mm (0.0016-0.0049 in).
The service limit rotor to cover side clearance maximum is 0.08 mm (0.003 in).
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Page 435
2. If the clearance is greater than the service limit, replace the oil pump assembly.
OIL PUMP ASSEMBLE
Front cover damage and engine damage will result if the gerotor gears are
not properly installed into the front cover.
1. Install the gear with the groove in the gear aligning with the race in the front cover.
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Page 436
NOTE:
Page 437
Tighten: Tighten the oil pump pressure relief valve plug to 40 N.m (30 lb ft).
INTAKE MANIFOLD CLEANING AND INSPECTION
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Page 438
Page 439
IMPORTANT:
Fig. 382: Measuring Exhaust Manifold To Cylinder Head Surface For Warpage
Courtesy of GENERAL MOTORS CORP.
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Page 440
5. Use a straight edge and a feeler gage and measure the exhaust manifold mounting face for warpage.
An exhaust manifold face with warpage in excess of 0.25 mm (0.010 in) may cause an exhaust leak and
may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
OIL PAN CLEANING AND INSPECTION
Page 441
1.
2.
3.
4.
5.
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Page 442
Page 443
Page 444
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Page 445
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Page 446
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Page 447
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Page 448
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Page 449
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Page 450
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Page 451
Page 452
Bushing (8)
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Page 453
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Page 454
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Page 455
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Page 456
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Page 457
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Page 458
Page 459
15. Remove the driver, bushing (2), fixture plate (1) and bolts.
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Page 460
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Page 461
Drill (1)
Tap (2)
Installer (3)
Alignment Pin (4)
Bushing (5)
Bolts (6)
Fixture Plate (7)
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Page 462
Page 463
The tool kits are designed for use with either a suitable tap wrench or drill motor.
1. Install fixture plate, bolts, and bushing onto engine block deck.
2. Position fixture plate and bushing over hole that is to be repaired.
Page 464
Page 465
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Page 466
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Page 467
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Page 468
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Page 469
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Page 471
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.
ENGINE BLOCK ASSEMBLE
Fig. 412: View Of Oil Passage Plug, Oil Flow Check Valve & Water Jacket Drain Plug
Courtesy of GENERAL MOTORS CORP.
1. Install the drain plug in the water pump.
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Page 473
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Page 474
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Page 475
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Page 476
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Page 477
Bearing Selection
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Page 478
IMPORTANT: Do not mix inserts of different nominal size in the same bearing bore.
2. To measure the bearing clearance using Method A, use the following procedure:
1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 apart.
Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the inserts and lower crankcase. Tighten the bearing cap bolts to specification.
4. Measure the bearing ID in several places 90 apart. Average the measurements.
5. Subtract the journal measurement from the bearing ID measurement to determine the clearance.
6. Determine whether the clearance is within specifications. If out of specifications, choose different
inserts.
7. Measure the connecting rod inside the diameter in the same direction as the length of rod with an
inside micrometer.
8. Measure the crankshaft main bearing inside diameter with an inside micrometer.
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Page 480
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.
IMPORTANT: Do not rotate the crankshaft.
6. Remove the bearing cap, leaving the bearing gaging plastic in place. It does not matter whether the
bearing gaging plastic adheres to the journal or to the bearing cap.
7. Measure the bearing gaging plastic at its widest point with the scale printed on the gaging plastic
package.
8. Remove the gaging plastic.
LOWER CRANKCASE INSTALLATION
Tolls Required
J 36660-A (SA9140E) Torque Angle Meter. See Special Tools and Equipment.
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Page 481
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Page 482
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Page 483
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Page 484
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Page 485
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Page 486
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Page 487
J 42067 Rear Crankshaft Seal Installer. See Special Tools and Equipment.
Installation Procedure
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Page 488
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Page 489
Installation Procedure
Page 490
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Page 491
Page 492
Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft) plus 100 degrees.
6. Install the remaining connecting piston and rod assemblies.
Page 493
J 36660-A (SA9140E) Torque Angle Meter. See Special Tools and Equipment.
Page 494
3. Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow
the oil to drain before installing.
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Page 495
Page 496
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Page 497
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Page 498
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Page 499
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Page 500
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Page 501
7. The timing chain sprocket alignment notch should be oriented to the eleven o'clock position.
8. Tighten the camshaft bearing cap bolts in increments of three turns until they are seated.
Tighten: Tighten the camshaft bearing caps to 10 N.m (89 lb in).
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Page 502
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Page 503
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Page 504
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Page 505
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Page 506
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Page 507
7. The timing chain sprocket alignment notch should be oriented to the two o' clock position.
8. Tighten the camshaft bearing cap bolts in increments of three turns until they are seated, lubricate.
Tighten: Tighten the camshaft bearing caps to 10 N.m (89 lb in).
BALANCE SHAFT INSTALLATION
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Page 508
Tools Required
J 43650 Balance Shaft Bearing Remover/Installer. See Special Tools and Equipment.
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Page 509
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Page 510
Page 511
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Page 512
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Page 513
Page 514
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Page 515
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Page 516
Page 517
the crankshaft drive sprocket, approximately the 6 o'clock position on the crank sprocket.
4. Place the chain around the water pump drive sprocket.
5. Align the last chrome link (3) with the timing mark on the exhaust side balance shaft drive
sprocket.
2. Install the balance shaft chain guides.
BALANCE SHAFT DRIVE CHAIN AND TENSIONER INSTALL
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Page 518
IMPORTANT: If the balance shafts are not properly timed to the engine, the engine may
vibrate and make noise.
1. Install the upper balance shaft chain guide.
Tighten: Tighten the balance shaft chain guide (upper) bolts to 10 N.m (89 lb in).
Page 519
Tighten: Tighten the balance shaft chain guide (fixed) bolts to 10 N.m (89 lb in).
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Page 520
Page 521
8. Remove the paper clip from the balance shaft drive chain tensioner.
TIMING CHAIN, SPROCKETS, TENSIONER INSTALLATION
Tools Required
J 45027 Tensioner Tool. See Special Tools and Equipment.
Page 522
1. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position.
Fig. 459: Aligning Timing Chain Link & Intake Sprocket Timing Mark
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
There are three colored links on the timing chain. Two links are of
matching color and one link is of a unique color. Use the following
procedure to line up the links with the sprockets. Orient the chain so
that the colored links are visible.
Always use new sprocket bolts.
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Page 523
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the
uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
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Page 524
Fig. 461: Identifying Timing Chain Colored Link & Crankshaft Sprocket Timing Mark
Courtesy of GENERAL MOTORS CORP.
4. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with
the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
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Page 525
5. Install the adjustable timing chain guide through the opening in the cylinder head and install the
adjustable timing chain bolt.
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Page 526
Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
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Page 527
Fig. 464: Aligning Timing Chain Link & Exhaust Timing Mark
Courtesy of GENERAL MOTORS CORP.
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
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Page 528
Page 529
Page 530
Tighten: Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
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Page 531
Fig. 468: Holding Camshaft Stationary With Wrench On Hex Casting On Camshaft
Courtesy of GENERAL MOTORS CORP.
13. Using a 24 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the
camshaft sprocket bolt.
Tighten: Tighten the intake camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using a torque
angle meter.
14. Using a 24 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the
camshaft sprocket bolt.
Tighten: Tighten the exhaust camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using a torque
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Page 532
angle meter.
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Page 533
Page 534
3. Install the notch end of the piston assembly into the J 45027-2 (2).
4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
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Page 536
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Page 537
Page 538
Tools Required
Page 539
Page 540
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Page 541
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Page 542
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Page 543
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Page 544
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Page 545
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Page 546
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Page 547
Page 548
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Page 549
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Page 550
Do not use a universal type oil filter wrench to remove oil filter cap.
Damage to the oil cap and the engine may result.
Page 551
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Page 552
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Page 553
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Page 554
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Page 555
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Page 556
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Page 557
2. Install the damper onto the crankshaft indexing keyway. Use care to properly align the keyway and flats
on the damper with the oil pump drive.
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Page 558
Fig. 495: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
Courtesy of GENERAL MOTORS CORP.
NOTE:
3. Install the new retaining bolt and washer using the J 38122-A and a breaker bar to hold the crankshaft.
Tighten: Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) plus 75 degrees.
EXHAUST MANIFOLD INSTALLATION
Installation Procedure
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Page 559
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Page 560
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Page 561
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Page 562
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Page 563
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Page 564
Page 565
Fig. 502: Removing & Installing Oil Level Indicator & Tube
Courtesy of GENERAL MOTORS CORP.
1. Install the oil level indicator tube into the block.
NOTE:
Page 566
Ensure that the correct bolts are used when installing manual transaxle
flywheel or automatic transaxle flexplate. If the incorrect bolts are used,
powertrain damage may result.
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Page 567
3. Holding the flywheel with the J 43653 , tighten the bolts evenly. See Special Tools and Equipment.
Tighten: Tighten the flywheel bolt to 53 N.m (39 lb ft) plus 25 degrees.
The cylinder block is lost foam cast aluminum with four cylinders arranged in-line. The cylinders have cast in
place iron liners. The block has five crankshaft bearings with the thrust bearing located on the second bearing
from the front 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 cast nodular iron with eight counterweights. The number five counterweight is also the
ignition system reluctor wheel. The main bearing journals are cross-drilled, except # 5, and the upper bearings
are grooved. The crankshaft has a slip fit balance shaft drive sprocket. Number two main bearing is the thrust
bearing. A harmonic damper is used to control torsional vibration.
Connecting Rod and Piston
The connecting rods are powdered metal. The connecting rod incorporates the floating piston pin. The pistons
are cast aluminum. The piston rings are of a low tension type to reduce friction. The top compression ring is
ductile iron with a molybdenum facing and phosphate coated sides. The second compression ring is gray iron.
The oil ring is a three-piece spring construction with chromium plating.
Oil Pan
The oil pan is die cast aluminum. The oil pan includes an attachment to the transmission to provide additional
structural support.
Balance Shaft Assembly
There are two block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder
bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is
tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the
maximum effectiveness of the balance shaft system and reduces noise and vibration.
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Cylinder Head
The cylinder head is a lost foam aluminum casting. Pressed-in powdered metal valve guides and valve seat
insets are used. The fuel injection nozzle is located in the intake port. The cylinder head incorporates camshaft
bearing journals and camshaft bearing caps.
Valves
There are two intake and two exhaust valves per cylinder. Rotators are used on all of the intake valves. The
rotators are located at the bottom of the valve spring to reduce valve train reciprocating mass. Positive valve
stem seals are used on all valves.
Camshaft
Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron.
The intake camshaft has a pressed-in hex insert. The hex inset is used to drive the direct drive power steering
pump.
Valve Lifters
The valve train uses a roller finger follower acted on by a hydraulic element adjuster. The roller finger follower
reduces friction and noise.
Camshaft Cover
The camshaft cover is cast aluminum with steel crankcase ventilation baffling incorporated. The camshaft cover
has mounting locations for the ignition system.
Camshaft Drive
A single row roller chain is used for camshaft drive. There is a tensioner and active guide used on the slack side
of the chain to control chain motion and noise. The chain drive promotes long valvetrain life and low
maintenance.
Intake and Exhaust Manifold
The intake manifold is made of composite plastic. The exhaust manifold is cast iron. The intake manifold
incorporates a distribution and control system for PCV gases. The exhaust manifold is a dual plane design that
promotes good low end torque and performance.
LUBRICATION DESCRIPTION
Engine Oil
At the refinery, crude oil is separated by heating and distilling it into gases, light fuels, solvents, and lubricatingoil base stocks. After being further processed, the base stocks are selectively blended and fortified with
additives to produce an engine oil with the desired properties.
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Engine oil, then, is a sort of prescription. It contains different ingredients to do different things. Some of these
things are done by the base oil, the rest by the additives.
What is Engine Oil Supposed to Do?
It Should Lubricate
That's its primary job, to provide a separating film between moving parts and thus control friction and wear.
It Should Cool
Engine oil is the principal coolant for the pistons, main bearings, rod bearings, and camshaft. As such, it
removes up to 10 percent of the total heat load generated by the engine.
It Should Seal
The sealing function is to seal combustion pressures. Even though most pistons have 2 compression rings and
an oil ring, high pressure gases, containing unburnt fuel combustion products and water, can still leak into the
crankcase through ring gaps and microscopic valleys in the cylinder walls. This normal leakage is called
"blowby". Oil is used to fill in the valleys and reduce that leakage.
However, oil can not be expected to seal the canyons in a badly worn engine. Nor can it effectively seal a brand
new engine until the parts have seated themselves. That is why oil consumption is occasionally higher for the
first few thousand miles during new vehicle operation.
It Should Keep the Engine Clean
Combustion contaminants and dirt in the oil are unavoidable, but such particles tend to clump. If clumping is
allowed to take place, sludge and varnish may follow.
Good engine oils are designed to prevent the particles from clumping and hold them in suspension. When the
oil is drained, the suspended particles come out with it.
It Should Make Starting Easier
This is strictly a cold weather requirement. When it's freezing outside, the oil should be thin enough to give the
engine a fair chance of starting. Yet as the oil gets hot and thins out, it should not become so thin that it will not
lubricate or seal properly. That is what multigrade oils are for. Some of them, and all those that Saturn
recommends, are designed to work in almost any temperature range.
It Should Prevent Rust and Corrosion
Metal can actually rust or corrode in oil, if the oil contains water or acids from the combustion process. A wellformulated oil protects against rusting by putting a chemical film on the metal parts, shielding them from water.
It protects against acid attack by neutralizing the acid.
Additives
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Additives are chemicals that give fresh engine oil its custom-made properties. Although used in small amounts,
they provide a tremendous boost to the performance abilities of the engine oil. They, in fact, represent the major
difference between the oils of the early 1940's and the highly advanced prescription oils of today.
Most Commonly Used Additives
Anti-wear Agents
In highly loaded parts like camshafts and valve lifters, an oil film is usually squeezed so thin it breaks. This
would mean damaging metal-to-metal contact. When the oil film breaks down, these agents react chemically
with the metal surfaces and from a protective coating that reduces wear.
Detergent-Dispersants
Combustion contaminants and dirt particles in the oil tend to clump, which can lead to sludge and varnish
deposits. Detergent-dispersants are the additives that not only keep the engine clean but also stop such particles
from massing. They work by surrounding the particles, most of which are invisible, with a shell of molecules.
This action causes the imprisoned particles to repel one another. It also makes them a part of the oil, like cream
is part of homogenized milk. They can not settle out on engine parts or clog oil passages.
Oxidation Inhibitors
For every gallon of gasoline burned, about a gallon of water forms as steam. Most of the steam goes out the
tailpipe, but some of it leaks as part of the blowby gases into the crankcase, where it becomes acidic. Water
build-up in the oil increases with short-trip driving. If it were not for rust and corrosion inhibitors and regular oil
changes, engines would wear because of that water.
V.I. Improvers
V.I. stands for viscosity index. Oils having a high viscosity index tend to thin out less when heated and thicken
less when cooled. V.I. improvers are used to raise an oil's viscosity index for all-season operation. Without them
there would not be multigrade oils.
Foam Inhibitors
Foam can result from air being whipped into the oil by moving engine parts, which could lead to oil loss,
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Page 571
hydraulic valve lifter noise, and improper cooling and lubrication. Foam inhibitors weaken the surface tension
of oil, which causes the air bubbles to break more readily.
Pour Point Depressants
The pour point of an oil is the lowest temperature at which the oil will flow. Below that temperature, wax
crystals form, grow, and interconnect, then solidify or freeze the oil. Pour point depressants lower this freezing
temperature by coating the wax crystals as they form, thereby checking crystal growth.
Friction Modifiers
These are the newest members of the family of additives in modern oils. They further reduce surface friction
between moving parts. Friction modifiers, along with low viscosity, make "Energy Conserving" and similarly
labeled oils possible. Such oils can increase a vehicle's fuel economy by several percent.
Oil Container Labels
The American Petroleum Institute (API) logo is a circle divided into 3 sections. The top half of the circle is the
"API Service" section, which indicates the oil's degree of fuel efficiency. The center of the circle is the "Energy
Conservation" section, which indicates the oil's degree of fuel efficiency. The center of the circle is the
"Viscosity" section, which is used to indicate the viscosity of the oil. The oil container should have a "Starburst"
label instead of the doughnut shaped symbol.
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Page 572
These oils make seasonal changing unnecessary. They contain viscosity-index improvers that enable each oil to
exhibit suitable flow properties at both ends of the thermometer.
They have labels like SAE 5W-30, 10W-30, or 15W-40. Some may have labels like SAE 5W-10W-20W-30, in
this case, just ignore the middle numbers and read the oil as SAE 5W-30.
Oil Can Save You Gas
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Page 573
Many factors are involved in determining the overall fuel economy obtained when driving a vehicle. One of the
factors is the fuel efficiency of the engine oil being used.
In addition to being rated on the basis of their performance and viscosity, oils are rated on their ability to reduce
the amount of fuel consumed during driving. Oils are rated against a reference oil in a standard engine test much
like the ones described earlier in the Oil Performance Ratings section.
In this particular test, the fuel economy is measured and compared with that of a reference oil. If the tested oil
provides at least 1.5 percent better economy than the reference oil, it is labeled "Energy Conserving II". These
energy conserving designations are indicated on the lower half of the API logo to indicate fuel efficiency.
Energy Conserving II oils should provide the best fuel efficiency, by the lease fuel efficient oils, ones that do
not contain either designation.
Synthetic Oils
Compared with conventional motor oils, the synthetics involve different chemical processes and ingredient
percentages. However, the base stock still comes from crude petroleum, and the additives are virtually the same
as those commonly used.
From a performance standpoint, they work well, especially for engine start-up at very low temperatures. But,
based on all the information, synthetic oils can not be left in an engine any longer than conventional oils.
Extended use is the principal claim of synthetics. They can be used, but must have the right service category,
viscosity grade, and fuel efficiency designation for the vehicle. The oil must be changed as specified in your
owner's manual.
A second category, beginning with the letter C, also exists. These oils, CC, CD, CE, etc., are intended for
diesels, like in trucks and bulldozers, and by themselves are not suitable for gasoline engines.
Viscosity
Viscosity is resistance to flow. Thick oils have a high resistance and, therefore, a high viscosity. Thin oils have
a low resistance and, by the same token, a low viscosity.
A Society of Automotive Engineers (SAE) number that appears in the center of the API logo. The SAE number
defines the viscosity grading of oils, both single-grade and multigrade.
Single-Grade Oils
"Single-grade" refers to oils whose labeled viscosity applies at one temperature only. In general, single-grade
oils indicated their viscosity by a single number, for example SAE 10W or SAE30. The higher the number, the
thicker the oil. The W, for winter, tells you that the labeled viscosity applies at a sub-freezing temperature.
Other wise it applies at 100C (212F).
Most non-W oils thicken when the temperature drops, which makes cold-engine starting very difficult or
downright impossible. Many W oils also thin out too much in warmer weather, which hurts their ability to
lubricate and seal.
Oil Filter
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The oil cap and filter screw directly to the oil filter housing which is casting the block. A bypass valve is
installed in the cap under the oil filter and automatically opens when the filter has become too dirty. The oil
then passes through the filter without the filter being crushed.
Lubrication System
The engine oil pump is located on the front of the engine and is driven by flats on the crankshaft. Oil is pulled
from the oil pan into the gerotor pump. The pump forces oil under pressure to the oil filter. A regulator valve
mounted in the front cover oil outlet regulates oil pressure and vents excess back to the inlet side of the oil
pump.
Oil enters the filter and is routed through the main oil gallery in the engine cylinder block. The engine oil filter
anti-drain back valve prevents oil from draining out of the engine's oil galleries when it is not running and the
by-pass valve allows oil to by-pass or flow around the filter's paper element if it should become plugged.
Engine oil leaving the pump flows through the cylinder block main oil gallery and is pressure fed to the main
and connecting rod bearings. Oil then flows to the cylinder head and lubricates the camshaft, hydraulic lifters,
and rocker arms. Air is bled out when starting.
Mounted on the oil pump housing is the oil pressure sensor. When the oil pressure drops to low, the sensor
grounds the electrical circuit for the warning lamp in the instrument cluster.
Oil Flow
Page 575
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.
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Separating Components
Remove all gasket and sealing material from the part using a wood or plastic gasket scraper make from
aluminum surfaces.
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Page 577
Assembling Components
When assembling components, use only the sealant specified or equivalent in the service procedure.
Sealing surfaces should be clean and free of debris or oil.
Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during
assembly.
Components requiring lubrication will be identified in the service procedure.
When applying sealant to a component, apply the amount specified in the service procedure.
Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping
properly or cause component damage when tightened.
Tighten bolts to specifications. Do not overtighten.
IMPORTANT: Three types of sealer are commonly used in engines. These are RTV sealer,
anaerobic gasket eliminator sealer, and pipe joint compound. The correct
sealer and amount must be used in the proper location to prevent oil leaks. DO
NOT interchange the three types of sealers. Use only the specific sealer or the
equivalent as recommended in the service procedure.
Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where
two non-rigid parts (such as the oil pan and the engine block) are assembled together.
Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include:
exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container.
Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind
threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the
bolt is tightened.
Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed
must be clean and dry.
Tighten the bolts to specifications. Do not overtighten.
RTV Sealer
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Room Temperature Vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used
where two rigid parts (such as the lower crankcase and the engine block) are assembled together.
Do not use Room Temperature Vulcanizing (RTV) sealant in areas where extreme temperatures are
expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator
is specified.
Follow all safety recommendations and directions that are on the container.
Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of
any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from
clamping properly or cause damage when the bolt is tightened.
Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
Tighten bolts to specifications. Do not overtighten.
Anaerobic Sealer
Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts
(such as castings) are assembled together. When two rigid parts are disassembled and no sealer or gasket
is readily noticeable, the parts were probably assembled using a gasket eliminator.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the
gasket material, refer to Replacing Engine Gaskets procedure in this service manual.
Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be clean and
dry.
Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping
properly or cause damage when tightened.
IMPORTANT: Anaerobic sealed joints that are partially torqued and allowed to cure more
than five minutes may result in incorrect shimming and sealing of the joint. Do
not allow the sealer to enter any blind threaded holes, as it may prevent the
bolt from seating properly or cause damage when the bolt is tightened.
Separating Parts
IMPORTANT: Many internal engine components will develop specific wear patterns on their
friction surfaces. When disassembling the engine, internal components MUST
be separated, marked, or organized in a way to ensure reinstallation to their
original location and position.
Separate, mark, or organize the following components:
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J 7872
Magnetic Base Dial Indicator
J 8062
Valve Spring Compressor - Head Off
J 9666
Valve Spring Tester
J 35268-A
Camshaft Front Main Seal Installer
J 35667-A
Cylinder Head Leakdown Tester
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J 35749
Oil Pressure Socket
J 36017
Valve Guide Seal Remover
J 36660-A
Torque Angle Meter
J 37088-A
Fuel Line Disconnect Set
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J 38122
Crankshaft Pulley Holder
J 38188
Cylinder Head Broken Bolt Extractor Kit
J 39194-C
O2 Sensor Wrench
J 41545
Transaxle Range Switch Alignment Tool
J 41742
Connecting Rod Guide Pin
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J 41775
Valve Seal Installer
J 42065
Crank Hub Holding Tool
J 42067
Rear Main Seal Installer
J42069
Timing Belt Alignment Kit
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J 42096
Valve Guide Reamer
J 42098
Crank Hub Torx Socket
J 43290
Fuel Siphoning Hose
J 43405
Engine Support Fixture Adapter
J 43421
Cooling System Pressure Test Adapter
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J 43628
Frame Alignment Fixture
J 43649
Valve Spring Compressor
J 43650
Balance Shaft Bearing Remover/Installer
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J 43651
Water Pump Holding Tool
J 43653
Flywheel Holding Tool
J 43654
Piston Pin Clip Installer
J 43655
Camshaft Sprocket Holding Tool
J 43827
Fuel Sending Unit Wrench
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J 43914
Clamp Pliers, Universal
J 43936
Fuel Pressure Adapter Cap
J 43953
Piston Ring Compressor
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J 43963
Valve Spring Compressor (Off Vehicle)
J 44015
Steering Linkage Installer
J 44628
Bearing Bridge Sleeve Wrench
J 44953
Oil Pressure Fitting
J 45027
Tensioner Tool
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SA9101E
Piston Pin Retainer/Replacer
SA9102-E
Valve Seal Remover/Replacer
SA9105-E
Engine Support Fixture (3 Bar)
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SA91101NE
Feeler Gauge Set
SA9123E
Gasket Seal Cutter
SA9124E
Regulator Valve Remover/Replacer
SA9127E
Gauge Bar Set
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SA9127E-7
Fuel Flow/Pressure Adapter
SA9140E
Torque Angle Gauge
SA9156E
Fuel Tank Lock Ring Remover
SA9171E
Flex Hone
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SA9177NE
Straight Edge (24")
SA9179NE
Magnetic Base Dial Indicator Set
SA9213NE
Gas Check Tester
SA9805E
Fuel Line Separator
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