2.2L Engine PDF

2003 Saturn L200
2003 ENGINE Engine Mechanical - 2.2L (L61) - Saturn L Series
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
Monday, May 09, 2011 12:52:16
12:51:59 PM
Page 1
2006 Mitchell Repair Information Company, LLC.
2003 Saturn L200

Crankshaft Position Sensor Bolt

Crankshaft Pulley Bolt
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
2003 Saturn L200

Lower Engine-to-Transmission Bell Housing Bolts

Oil Drain Plug
Oil Filter Cap
Oil Gallery Plug
Oil Gallery Plug (Rear)
Oil Level Indicator Tube-to-Intake Manifold Bolt
Oil Pan-to-Block Bolts
Oil Pressure Switch
Oil pump Gerotor Cover Bolts
Oil Pump Pressure Relief Valve Plug
Oxygen Sensor Bolts
Power Steering Pump Bolts
Shift Control Rod Pinch Bolt
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
2003 Saturn L200

ENGINE MECHANICAL SPECIFICATIONS

Engine Mechanical Specifications
Specification
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
Bearing Diameter - Inside - Carrier
20.050-20.063 mm
0.7894-0.7899 in
Bearing Diameter - Outside - Carrier
41.975-41.995 mm
1.6526-1.6534 in
Bearing Journal Diameter
20.000-20.020 mm
0.7874-0.7882 in
Bushing Clearance
0.033-0.102 mm
0.0013-0.0040 in
Bushing Diameter - Inside
36.776-36.825 mm
1.4479-1.4498 in
Bushing Journal Diameter
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
Balance Shaft Bearing Bore Diameter - Carrier
42.000-42.016 mm
1.6535-1.6542 in
Balance Shaft Bushing Bore Diameter
40.763-40.776 mm
1.6048-1.6054 in
Crankshaft Main Bearing Bore Diameter
64.068-64.082 mm
2.5224-2.5229 in
Cylinder Bore Diameter
85.992-86.008 mm
3.3855-3.3861 in
Cylinder Bore Out-of-Round - Maximum
0.010 mm
0.0004 in
Cylinder Bore Taper - Maximum
0.010 mm
0.0004 in
Cylinder Head Deck Surface Flatness - Transverse
0.030 mm
0.0012 in
Cylinder Head Deck Surface Flatness - Longitude
0.050 mm
0.002 in
0.08 mm
0.0031 in
0.040-0.144 mm
0.0016-0.0057 in
Cylinder Head Deck Surface Flatness - Overall

Camshaft
Camshaft End Play
Camshaft Journal Diameter
26.935-26.960 mm
1.0604-1.0614 in
Camshaft Thrust Surface
21.000-21.052 mm
0.8268-0.8252 in
steve
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Page 4
2003 Saturn L200

Connecting Rod
0.029-0.069 mm
0.0011-0.0027 in
Connecting Rod Bore Diameter - Bearing End
52.118-52.134 mm
2.0519-2.05252 in
Connecting Rod Bore Diameter - Pin End
20.007-20.021 mm
0.7877-0.7882 in
Connecting Rod Side Clearance
0.070-0.370 mm
0.0028-0.0146 in
Connecting Rod Straightness - Bend - Maximum
0.021 mm
0.0083 in
Connecting Rod Straightness - Twist - Maximum

Crankshaft
0.04 mm
0.0157 in
49.000-49.014 mm
1.9291-1.9297 in
Connecting Rod Bearing Clearance
Connecting Rod Journal Diameter
Crankshaft End Play
0.050-0.380 mm
0.0012-0.0150 in
Crankshaft Main Bearing Clearance
0.031-0.067 mm
0.0012-0.0026 in
55.994-56.008 mm
2.2045-2.2050 in
Crankshaft Main Journal Diameter

Cylinder Head
Surface Flatness - Block Deck - Transverse
0.030 mm
0.0012 in
Surface Flatness - Block Deck - Longitude
0.050 mm
0.002 in
Surface Flatness - Block Deck - Overall
0.1 mm
0.004 in
Valve Guide Bore - Exhaust
6.000-6.012 mm
0.2362-0.2367 in
Valve Guide Bore - Intake
6.000-6.012 mm
0.2362-0.2367 in
Valve Lifter Bore Diameter - Stationary Lash

Adjusters
Lubrication System
12.013-12.037 mm
0.4730-0.4739 in
Oil Pressure - Minimum - @1000 RPM

Piston Rings
344.75-551.60 kPa
50-80 psi
Piston Ring End Gap - First Compression Ring
0.20-0.40 mm
0.008-0.016 in
Piston Ring End Gap - Second Compression Ring
0.35-0.55 mm
0.014-0.022 in
Piston Ring End Gap - Oil Control Ring - Rails
0.25-0.76 mm
0.010-0.030 in
Piston Ring to Groove Clearance - First Compression

Ring
0.04-0.08 mm
0.0015-0.0031 in
Piston Ring to Groove Clearance - Second

Compression Ring
0.030-0.069 mm
0.0012-0.0027 in
Piston Ring to Groove Clearance - Oil Control Ring
0.090-0.106 mm
0.0035-0.0042 in
Piston Ring Thickness - First Compression Ring
1.170-1.190 mm
0.0461-0.0469 in
Piston Ring Thickness - Second Compression Ring
1.471-1.490 mm
0.0579-0.0587 in
Piston Ring Thickness - Oil Control Ring - Rail Maximum
0.43 mm
0.0169 in
steve
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Page 5
2003 Saturn L200

Piston Ring Thickness - Oil Control Ring - Spacer

Pistons and Pins
1.574-1.651 mm
0.0620-0.0650 in
Piston - Piston Diameter - @14.5 mm up
85.967-85.982 mm
3.3845-3.3851 in
Piston - Piston Pin Bore Diameter
20.002-20.007 mm
0.07875-0.7877 in
Piston - Piston Ring Grove Width - Top
1.23-1.25 mm
0.0484-0.0492 in
Piston - Piston Ring Grove Width - Second
1.52-1.54 mm
0.0598-0.0606 in
Piston - Piston Ring Grove Width - Oil Control
2.52-2.54 mm
0.0992-0.1000 in
Piston - Piston To Bore Clearance
0.010-0.041 mm
0.0004-0.0016 in
Pin - Piston Pin Clearance to Connecting Rod Bore
0.007-0.026 mm
0.0003-0.0010 in
Pin - Piston Pin Clearance to Piston Pin Bore
0.002-0.012 mm
0.0001-0.0005 in
Pin - Piston Pin Diameter
19.995-20.000 mm
0.7872-0.7874 in
0.19-1.16 mm
0.0075-0.0461 in
Pin - Piston Pin End Play

Valve System
Valves - Valve Face Runout - Maximum
0.04 mm
0.0016 in
Valves - Valve Seat Runout - Maximum
0.05 mm
0.0020 in
Valves - Valve Stem Diameter - Intake
5.955-5.970 mm
0.2344-0.2355 in
Valves - Valve Stem Diameter - Exhaust
5.935-5.950 mm
0.2337-0.2343 in
Valves - Valve Stem to Guide Clearance - Intake
0.030-0.057 mm
0.0012-0.0022 in
Valves - Valve Stem to Guide Clearance - Exhaust
0.050-0.077 mm
0.0020-0.0026 in
Valve Lifters - Valve Lifter Diameter - Stationary

Lash Adjuster
11.986-12.000 mm
0.0005-0.0020 in
Valve Lifters - Valve Lifter-to-Bore Clearance Stationary Lash Adjuster
0.013-0.051 mm
3.2210-3.2299 in
Valve Springs - Valve Spring Load - Closed - @32.5

mm
245.0-271.0 N. - Eng Spec.
Valve Springs - Valve Spring Load - Open - @32.5

mm
525.0-575.0 N. - Eng Spec.
SEALERS, ADHESIVES, AND LUBRICANTS

Sealers, Adhesives, and Lubricants
Application
# 6 Intake Rear Camshaft Cap
Balance Shaft Lobes
Cam Lobes
Connecting Rod Bearings
Type of Material
Sealant
Lubricant
Lubricant
Lubricant
Part Number
Permatex Anaerobic Gasket
Maker 51813
5 W 30 or equivalent
Engine Oil Supplement
steve
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Page 6
2003 Saturn L200

Crank Sensor O-ring

Crankshaft Main Bearings
Cylinder Bore
Cylinder Head Plugs
Dipstick Tube O-rings
Engine Block Threaded Plugs
Engine Block To Bed Plate
Engine Oil
Engine Oil Level Indicator Tube O-ring
Fuel Injector O-rings
Fuel Injector Tip Insulators
Intake and Exhaust Valve Stems
Oil Filter Cap (Threads and O-ring Lead-in
Chamfers)
Oil Pan to Bedplate Joint
Oil Pump - Pump Elements
Oxygen Sensor Threads
Piston Pins
Stationary Hydraulic Lash Adjusters
Timing Chain Guide Bolt Access Hole Plug
Valve Rocker Arm / Valve Tip
Water Feed Tube O-rings
Water Pump Drain Plug
Engine Oil
Lubricant
Lubricant
Threadlocker
Lubricant
Sealant
Sealant
5 quarts
Lubricant
Engine Oil
Engine Oil
Lubricant
21485277
21485278
21019581
Engine Oil
Sealant
Engine Oil
Antiseize
Lubricant
Lubricant
Threadlocker
Lubricant
Lubricant
Sealant
21019581
12397953
21485277
Silicone Gel Lubricant
21485278
THREAD REPAIR SPECIFICATIONS

Engine Block - Front View
steve
Monday, May 09, 2011 12:51:59 PM
Page 7
2003 Saturn L200

Fig. 1: Engine Block - Front View

Courtesy of GENERAL MOTORS CORP.
Engine Block - Front View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 423851
M10 x 1.5 215
211
212
2
M8 x 1.25 210
206
207
M12 x
3
855
856
857
1.75
4
M8 x 1.25 210
206
207
5
M6 x 1
205
201
202
6
M6 x 1
205
201
202
7
M6 x 1
205
201
202
8
M6 x 1
205
201
202
9
M8 x 1.25 210
206
207
10
M6 x 1
205
201
202
11
M6 x 1
205
201
202
12
M6 x 1
205
201
202
13
M6 x 1
205
201
202
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
33.5 1.32 26.5 1.04
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
0.93 18.5 0.73

0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
1.00
THRU
0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
0.787 16 0.63
steve
Monday, May 09, 2011 12:51:59 PM
Page 8
2003 Saturn L200

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
33.5 1.32 26.5 1.04
116
855
856
857
858
859
33.5 1.32 26.5 1.04
115
Engine Block - Back View
Fig. 2: Engine Block - Back View

Engine Block - Back View
Service
Engineering
Call
Thread
Counterbore
Drill Depth Tap Depth
Hole
Out
Size
Tool
Insert Drill
Tap Driver (Maximum) (Maximum) Number
J 42385MM (IN) MM (IN)
M12 x
steve
Monday, May 09, 2011 12:51:59 PM
Page 9
2003 Saturn L200

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
1.535 33.5 1.32

0.827 15 0.59
1.161
THRU
0.709
THRU
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
1.535 33.5 1.32
203
THRU
15
Engine Block - Left Side View
Fig. 3: Engine Block - Left Side View

Engine Block - Left Side View
Service
Call
Thread
Counterbore
Drill Depth
Out
Size
Insert Drill
Tool
J 42385MM (IN)
M12 x
1
865
856
857
858
859 19.50 0.768
1.75
Tap Depth
(Maximum)
MM (IN)
Engineering
Hole
Number
-
12.5 0.49
515
steve
Monday, May 09, 2011 12:51:59 PM
Page 10
2003 Saturn L200

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
19.50 0.768 12.5 0.49
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
19.50 0.768 12.5 0.49
516
0.925
0.925
0.807
0.807
0.807
-
18.5
18.5
16.0
16.0
16.0
-
Engine Block - Bottom View
Fig. 4: Engine Block - Bottom View

Engine Block - Bottom View
steve
Monday, May 09, 2011 12:51:59 PM
Page 11
2003 Saturn L200

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
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
Engine Block - Right Side View
steve
Monday, May 09, 2011 12:51:59 PM
Page 12
2003 Saturn L200

Fig. 5: Engine Block - Right Side View

Engine Block - Right Side View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 42385M12 x
1
865
856
857
1.75
M12 x
2
865
856
857
1.75
3
M6 x 1.0 205
201
202
M12 x
4
865
856
857
1.75
5
M8 x 1.25 210
206
207
6
M8 x 1.25 210
206
207
7
M8 x 1.25 210
206
207
M12 x
8
855
856
857
1.75
9
M8 x 1.25 210
206
207
10 M8 x 1.25 210
206
207
11 M8 x 1.25 210
206
207
12 M8 x 1.25 210
206
207

Tap Driver (Maximum) (Maximum)
MM (IN) MM (IN)
Engineering
Hole
Number
-
858
859
19.50 0.778 12.5 0.49
613
858
859
19.50 0.778 12.5 0.49
612
203
204
20.50 0.807 16.5 .065
610
858
859
15.50 0.610 12.5 0.49
606
208
208
208
209
209
209
23.50 0.925 18.0 0.71

23.50 0.925 18.0 0.71
23.50 0.925 18.0 0.71
609
608
607
858
859
33.50 1.319 26.5 1.04
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
steve
Monday, May 09, 2011 12:51:59 PM
Page 13
2003 Saturn L200

13
14
15
M8 x 1.25
M12 x
1.75
M12 x
1.75
210
206
207
208
209
30.50 1.201 22.5 0.89
602
855
856
857
858
859
33.50 1.319 26.5 1.04
616
865
856
857
858
859
19.50 0.778 12.5 0.49
614
Engine Block - Top View
Fig. 6: Engine Block - Top View

Engine Block - Top View
Service
Call
Thread
Counterbore
Drill Depth
Out
Size
Insert Drill
Tool
J 42385MM (IN)
1
M11 x 1.5 507
504
N/A
505
506 113.30 4.461
Tap Depth
(Maximum)
MM (IN)
107.3 4.22
Engineering
Hole
Number
308
steve
Monday, May 09, 2011 12:51:59 PM
Page 14
2003 Saturn L200

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
13.50 0.531 12.5 0.49
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
13.50 0.531 12.5 0.49
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
Lower Crankcase - Front View
Fig. 7: Identifying Front Lower Crankcase Thread Sizes

Lower Crankcase - Front View
Service
Engineering
Thread
Counterbore
Call
Hole
Size
Tool
Out
Insert Drill
1
M8 x 1.25 210
206
207
208
209 23.50 0.925 18.5 0.73
138
2
M8 x 1.25 210
206
207
208
209 30.50 1.201 25.5 1.00
139
steve
Monday, May 09, 2011 12:51:59 PM
Page 15
2003 Saturn L200

3
4
M8 x 1.25
M8 x 1.25
210
210
206
206
207
207
208
208
209
209
30.50 1.201 25.5 1.00

23.50 0.925 18.5 0.73
140
141
Lower Crankcase - Back View
Fig. 8: Identifying Rear Lower Crankcase Thread Sizes

Lower Crankcase - Back View
Service
Engineering
Call
Thread
Counterbore
Hole
Out
Size
Tool
Insert Drill
1
M10 x 1.5 215
211
212
213
214 29.50 1.161
THRU
207
Lower Crankcase - Bottom View
steve
Monday, May 09, 2011 12:51:59 PM
Page 16
2003 Saturn L200

Fig. 9: Identifying Lower Bottom Crankcase Thread Sizes

Lower Crankcase - Bottom View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 423851
M8 x 1.25 210
206
207
2
M8 x 1.25 210
206
207
3
M8 x 1.25 210
206
207
4
M8 x 1.25 210
206
207
5
M8 x 1.25 210
206
207
6
M8 x 1.25 210
206
207
7
M8 x 1.25 210
206
207
8
M8 x 1.25 210
206
207
9
M8 x 1.25 210
206
207
10 M8 x 1.25 210
206
207
11 M8 x 1.25 210
206
207
Drill Depth
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
steve
Monday, May 09, 2011 12:52:00 PM
Page 17
2003 Saturn L200

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
Lower Crankcase - Left View
Fig. 10: Identifying Lower Left Crankcase Thread Sizes

Lower Crankcase - Left View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 423851
M10 x 1.5 215
211
212
2
M10 x 1.5 215
211
212
3
M10 x 1.5 215
211
212
Drill Depth
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
Lower Crankcase - Right View
steve
Monday, May 09, 2011 12:52:00 PM
Page 18
2003 Saturn L200

Fig. 11: Identifying Lower Right Crankcase Thread Sizes

Lower Crankcase - Right View
Service Thread
Counterbore
Drill Depth
Call Out Size Insert Drill
Tool
J 42385MM (IN)
M8 x
1
210
211
212
213
214 30.50 1.201
1.25
Tap Depth
(Maximum)
MM (IN)
Engineering
Hole
Number
-
22.5 0.886
615
Cylinder Head - Top View
steve
Monday, May 09, 2011 12:52:00 PM
Page 19
2003 Saturn L200

Fig. 12: Cylinder Head - Top View

Cylinder Head - Top View
Service
Call
Thread
Counterbore
Out
Size
Tool
Insert Drill
J 423851
M6 x 1.0 205
852
N/A
2
M6 x 1.0 205
852
N/A
3
M6 x 1.0 205
201
202
4
M6 x 1.0 205
201
202
5
M6 x 1.0 205
201
202
6
M6 x 1.0 205
852
N/A
7
M6 x 1.0 205
852
N/A
854
8
M8 x 1.25 No
206
207
Flange
9
M6 x 1.0 205
201
202
10
M6 x 1.0 205
201
202
11
M6 x 1.0 205
852
N/A
12
M6 x 1.0 205
852
N/A
13
M6 x 1.0 205
201
202
14
M6 x 1.0 205
201
202
Drill Depth
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
steve
Monday, May 09, 2011 12:52:00 PM
Page 20
2003 Saturn L200

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
Cylinder Head - Intake Manifold Deck View
steve
Monday, May 09, 2011 12:52:00 PM
Page 21
2003 Saturn L200

Fig. 13: Cylinder Head - Intake Manifold Deck View

Cylinder Head - Intake Manifold Deck View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 423851
M6 x 1.0 205
201
202
2
M6 x 1.0 205
201
202
3
M6 x 1.0 205
201
202
4
M6 x 1.0 205
201
202
5
M6 x 1.0 205
201
202
6
M6 x 1.0 205
201
202
7
M6 x 1.0 205
201
202
8
M6 x 1.0 205
201
202
9
M6 x 1.0 205
201
202
Drill Depth
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
Cylinder Head - Exhaust Manifold Deck View
steve
Monday, May 09, 2011 12:52:00 PM
Page 22
2003 Saturn L200

Fig. 14: Cylinder Head - Exhaust Manifold Deck View

Cylinder Head - Exhaust Manifold Deck View
Service
Thread
Counterbore
Call
Size
Insert Drill
Tool
Out
J 423851
M8 x 1.25 210
206
207
2
M8 x 1.25 210
206
207
3
M8 x 1.25 210
206
207
4
M27 x 2.0 N/A N/A
N/A
5
M8 x 1.25 210
206
207
6
M8 x 1.25 210
206
207
7
M8 x 1.25 210
206
207
8
M8 x 1.25 210
206
207
9
M8 x 1.25 210
206
207
10 M8 x 1.25 210
206
207
11
M6 x 1.0 205
201
202
12 M8 x 1.25 210
206
207
13 M8 x 1.25 210
206
207
14 M8 x 1.25 210
206
207
Drill Depth
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
Cylinder Head - Front View
steve
Monday, May 09, 2011 12:52:00 PM
Page 23
2003 Saturn L200

Fig. 15: Cylinder Head - Front View

Cylinder Head - Front View
Service
Call
Thread
Counterbore
Drill Depth
Out
Insert Drill
Size
Tool
J 42385MM (IN)
1
M8 x 1.25 210
206
207
208
209
25 0.984
2
M6 x 1.0 205
201
202
203
204
20 0.787
Tap Depth
(Maximum)
MM (IN)
20 0.787
16 0.630
Engineering
Hole
Number
6310
6210
Cylinder Head - Back View
steve
Monday, May 09, 2011 12:52:00 PM
Page 24
2003 Saturn L200

Fig. 16: Cylinder Head - Back View

Cylinder Head - Back View
Service
Call
Thread
Counterbore
Out
Size
Insert Drill
Tool
J 42385M12 x
1
865
856
857
1.75
M12 x
2
865
856
857
1.75
3
M8 x 1.25 210
206
207
4
M8 x 1.25 210
206
207
M12 x
5
865
856
857
1.75
M12 x
6
865
856
857
1.75
7
M8 x 1.25 210
206
207
854
8
M8 x 1.25 No
206
207
Flange

Tap Driver (Maximum) (Maximum)
MM (IN) MM (IN)
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
steve
Monday, May 09, 2011 12:52:00 PM
Page 25
2003 Saturn L200

Note: 1, 2, 5, 6 holes are oil passages.

Cylinder Head - Bottom View
Fig. 17: Cylinder Head - Bottom View

Cylinder Head - Bottom View
Service
Thread
Counterbore
Call
Size
Insert Drill
Tool
Out
J 42385M12 x
1
865
856
857
1.75
2
N/A
N/A N/A
N/A
3
N/A
N/A N/A
N/A
4
N/A
N/A N/A
N/A
5
N/A
N/A N/A
N/A
Engineering
Hole
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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2003 Saturn L200

Fig. 18: Cylinder Head and Components

Callouts For Fig. 18
Callout
Component Name
1
Engine Oil Fill Cap
2
Ignition Module and Coil Housing Assembly Bolt
3
Ignition Module and Coil Housing Assembly
4
Camshaft Cover
5
Camshaft Cover Gasket
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2003 Saturn L200

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
Camshaft Bearing Cap Bolt

Camshaft Bearing Cap
Fuel Rail Assembly Bolt
Fuel Line Assembly
Injector Wiring Harness
Fuel Rail Assembly (with Fuel Injectors)
Cylinder Head
Front Engine Lift Bracket
Engine Lift Bracket Bolt
Cylinder Head Bolt
Oil Flow Check Valve
Exhaust Manifold Stud
Exhaust Valve
Intake Valve
Camshaft Cover Grounding Strap Bolt
Cylinder Head Oil Passage Plug
Cylinder Head Oil Passage Plug
Spark Plug
Valve Stem Seal
Valve Spring
Valve Spring Retainer
Valve Keys
Hydraulic Lash Adjuster
Roller Finger Follower
Rear Engine Lift Bracket Bolt
Rear Engine Lift Bracket
EGR Port Cover Gasket
EGR Port Cover
EGR Port Cover Bolt
Exhaust Camshaft
Intake Camshaft
Camshaft Cover Grounding Strap
Camshaft Cover Grounding Strap Bolt
Camshaft Cover Bolt
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2003 Saturn L200

Fig. 19: Engine Block and Components

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2003 Saturn L200

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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2003 Saturn L200

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
Crankshaft Bearing 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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2003 Saturn L200

Fig. 20: Timing Chain and Components

Callout
Component Name
1
Upper Timing Chain Guide Bolt
2
Upper Timing Chain Guide
3
Timing Chain
4
Intake Camshaft Sprocket
5
Intake Camshaft Sprocket to Camshaft Bolt
6
Fixed Timing Chain Guide Bolt
7
Fixed Timing Chain Guide
8
Fixed Timing Chain Guide Bolt
9
Oil Pump Cover Bolt
10
Oil Pump Cover
11
Oil Pump Inner Gerotor
12
Oil Pump Outer Gerotor
13
Engine Front Cover Gasket
14
Engine Front Cover
15
Engine Front Cover Access Plate Bolt
16
Front Crankshaft Seal
17
Crankshaft Damper
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2003 Saturn L200

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
Crankshaft Damper Bolt

Engine Front Cover Bolt
Oil Pressure Relief Valve Plunger
Oil Pressure Relieve Valve Spring
Oil Pressure Relief Valve Plug
Crankshaft Sprocket Alignment Key
Timing Chain Oil Nozzle
Exhaust Camshaft Sprocket to Camshaft Bolt
Timing Chain Drive Sprocket
Adjustable Timing Chain Guide Bolt
Adjustable Timing Chain Guide
Timing Chain Tensioner Seal
Timing Chain Tensioner
Drive Chain Guide Bolt
Balance Shaft Drive Chain Guide
Balance Shaft Drive Sprocket
Adjustable Balance Shaft Drive Chain Guide Bolt
Adjustable Balance Shaft Drive Chain Guide
Balance Shaft Drive Chain Tensioner Assembly
Water Pump
Water Pump Drive Sprocket Bolt
Balance Shaft Drive Chain Guide
Balance Shaft Drive Chain Guide Bolt
Engine Front Cover Access Plate Seal
Engine Front Cover Access Plate
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2003 Saturn L200

Fig. 21: Intake Manifold and Components

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2003 Saturn L200

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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2003 Saturn L200

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2003 Saturn L200

Fig. 22: Exhaust Manifold and Components

Callout
Component Name
1
Exhaust Manifold Heat Shield
2
Air Pipe Nut
3
Air Pipe
4
Air Pipe Bolt
5
Air Pipe Gasket
6
Exhaust Manifold Heat Shield Stud
7
Exhaust Manifold Gasket
8
Exhaust Manifold
9
Exhaust Flex Decoupler Stud
10
Exhaust Manifold Nut
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2003 Saturn L200

Fig. 23: Accessory and Engine Drive Belt Components

Callout
Component Name
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2003 Saturn L200

1
2
3
4
5
6
7
8
9
10
11
12
13
Power Steering Pump

Power Steering Pressure Line
Generator Bolt
Generator Pulley
Accessory Drive Belt
Air Compressor Bolt
Air Conditioning Compressor
Accessory Drive Belt Tensioner Bolt
Accessory Drive Belt Tensioner
Generator Assembly
Starter Assembly
Power Steering Pump Bolt
Starter Assembly to Engine Block Bolt
DIAGNOSTIC INFORMATION AND PROCEDURES

DRIVE BELT AND TENSIONER COMPLAINT/CONDITION CHART
Drive Belt and Tensioner Complaint/Condition Chart
Complaint/Condition
Possible Cause(s)
Wrong belt. Belt routing and
alignment on pulleys.
Tension too High
Wrong pulley.
Tension too Low
Tensioner inoperative.
Wrong belt.
Worn belt.
Tensioner inoperative or broken
internal spring.
Wrong pulley.
Wrong belt.
Belt misaligned.
Belt Chirp
Belt installed incorrectly.

Tensioner partially seized.
Tensioner/idler pulley bearing.
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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2003 Saturn L200

Tensioner/idler pulley bearing.

Wrong belt.
Intermittent Squeal or Whistle
Noise
Notice: Diagnosis is difficult.
Requires accessory drive belt
removal and engine cold starts to
validate concern. Do not run
engine for more than 3 minutes
with accessory drive belt off.
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.
Accessory Drive Growl with A/C

On During Acceleration and/or
Belt tensioner (internal).
Growl from Belt Tensioner.
Water pump, power steering
pump, generator, A/C
compressor, tensioner, or idler
bearing.
Hoot or Growl Noise
Idler pulley bearing.
Check tensioner/idler pulley

bearings.
Check for proper belt.
Inspect belt for wear and check
tension.
Replace pulley.
Check pulley alignment.
Check all accessories for
bearing/component seizure.
Replace oil pump pressure
regulator valve.
Check belt tensioner movement.
Check belt tension.
Replace faulty component.

Replace idler pulley bearing.
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
1. Perform the DIAGNOSTIC STARTING POINT -- ENGINE CONTROLS in Self-Diagnostics - 2.2L

in Engine Performance before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
Disassembled Views, Engine Component Description, and Lubrication Description in Engine Unit
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2003 Saturn L200

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:
Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Compression Test
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Coolant in Combustion Chamber
Coolant in Engine Oil
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2003 Saturn L200

BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

Base Engine Misfire without Internal Engine Noises
Cause
Correction
Abnormalities, severe cracking, bumps, or missing Replace the drive belt.
areas in the accessory drive belt
Abnormalities in the accessory drive system and/or
components may cause engine RPM variations and
lead to a misfire DTC. A misfire code may be
present without an actual misfire condition.
Worn, damaged, or mis-aligned accessory drive
Inspect the components, and repair or replace as
components or excessive pulley runout may lead to required.
a misfire DTC.
A misfire code may be present without an actual
misfire condition.
A loose or improperly installed engine flywheel or Repair or replace the flywheel and/or balancer as
crankshaft balancer
required.
misfire condition.
Restricted exhaust system
Repair or replace as required.
A severe restriction in the exhaust flow can cause
significant loss of engine performance and may set a
DTC. Possible causes of restrictions include
collapsed or dented pipes or plugged mufflers and/or
catalytic converters.
Improperly installed or damaged vacuum hoses
Improper sealing between the intake manifold and Replace the intake manifold, gaskets, cylinder
cylinder heads or throttle body.
heads, and/or throttle body as required.
Improperly installed or damaged MAP sensor
Repair or replace the MAP sensor as required.
The sealing grommet of the MAP sensor should not
be torn or damaged.
Damage to the MAP sensor housing
Replace the intake manifold.
Worn or loose rocker arms
Replace the valve rocker arms as required.
The rocker arm bearing end caps and/or needle
bearings should be intact and in the proper position.
Stuck valves
Carbon buildup on the valve stem can cause the
valve not to close properly.
Excessively worn or mis-aligned timing chain
Replace the timing chain and sprockets as required.
Worn camshaft lobes
Replace the camshaft and valve lifters.
Excessive oil pressure
Perform an oil pressure test. Refer to Oil
A lubrication system with excessive oil pressure
Pressure Diagnosis and Testing.
may lead to excessive valve lifter pump up and loss
Repair or replace the oil pump as required.
of compression.
Faulty cylinder head gaskets and/or cracking or
Inspect for spark plugs saturated by coolant.
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2003 Saturn L200

other damage to the cylinder heads and engine block

cooling system passages
Coolant consumption may or may not cause the
engine to overheat.
Worn piston rings
Oil consumption may or may not cause the engine to
misfire.
A damaged crankshaft reluctor wheel

A damaged crankshaft reluctor wheel can result in
different symptoms depending on the severity and
location of the damage.
Inspect the cylinder heads, engine block,

and/or head gaskets.
Inspect the spark plugs for oil deposits.

Inspect the cylinders for a loss of
compression. Refer to Engine Compression
Test.
Perform cylinder leak down and compression
testing to identify the cause.
Replace the sensor and/or crankshaft as required.
Systems with electronic communications, DIS

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

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Cause
Correction
Abnormalities, severe cracking, bumps or missing Replace the drive belt.
areas in the accessory drive belt
Abnormalities in the accessory drive system and/or
components may cause engine RPM variations,
noises similar to a faulty lower engine, and also lead
to a misfire condition. A misfire code may be
present without an actual misfire condition.
Worn, damaged, or mis-aligned accessory drive
Inspect the components, repair or replace as
components or excessive pulley runout
required.
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2003 Saturn L200


misfire condition.
Loose or improperly installed engine flywheel or
crankshaft balancer
misfire condition.
Worn piston rings
Oil consumption may or may not cause the engine
to misfire.
Repair or replace the flywheel and/or balancer as

required.

Test.
testing to determine the cause.
Replace the crankshaft and bearings as required.
Worn crankshaft thrust bearings

Severely worn thrust surfaces on the crankshaft
and/or thrust bearing may permit fore and aft
movement of the crankshaft, and create a DTC
without an actual misfire condition.
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE

Base Engine Misfire with Abnormal Valve Train Noise
Cause
Correction
Worn or loose rocker arms
Replace the valve rocker arms as required.
The rocker arm bearing end caps and/or needle
bearings should intact within the rocker arm
assembly.
Stuck valves
Carbon buildup on the valve stem can cause the
valve to not close properly.
Excessively worn or mis-aligned timing chain
Replace the timing chain and sprockets as required.
Worn camshaft lobes
Replace the camshaft and valve lifters.
Sticking lifters
Replace as required.
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Base Engine Misfire with Coolant Consumption
Cause
Faulty cylinder head gaskets and/or cracking, or
other damage to the cylinder heads and engine block
cooling system passages.
Coolant consumption may or may not cause the
engine to overheat.
Correction
Inspect for spark plugs saturated by coolant.

Perform a cylinder leak down test.
Inspect the cylinder heads and engine block
for damage to the coolant passages and/or a
faulty head gasket.
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2003 Saturn L200

BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION

Base Engine Misfire with Excessive Oil Consumption
Cause
Correction
Worn valves, valve guides and/or valve stem oil
seals
Worn piston rings
Oil consumption may or may not cause the engine
to misfire.
Test.
testing to determine the cause.
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Cause
Correction
Incorrect oil filter without anti-drainback feature
Install the correct oil filter.
Incorrect oil viscosity
1. Drain the oil.
High valve lifter leak down rate
Worn crankshaft thrust bearing
2. Install the correct viscosity oil.

Replace the lifters as required.
Damaged or faulty oil filter by-pass valve
Inspect the thrust bearing and crankshaft.

Inspect the oil filter by-pass valve for proper
operation.
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Upper Engine Noise, Regardless of Engine Speed
Cause
Low oil pressure
Correction
Loose and/or worn valve rocker arm attachments

Worn valve rocker arm

Inspect the valve rocker arm stud, nut or bolt.

Replace the valve rocker arm.
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2003 Saturn L200

Improper lubrication to the valve rocker arms
Inspect the following components, and repair or

replace as required:
The valve rocker arm
The valve lifter
The oil filter bypass valve
The oil pump and pump screen
The engine block oil galleries
Replace the valve spring.
Replace the valve lifters.
Replace the timing chain and sprockets.
Broken valve spring

Worn or dirty valve lifters
Stretched or broken timing chain and/or damaged
sprocket teeth
Worn, damaged, or faulty timing chain tensioners
Worn engine camshaft lobes
Worn valve guides or valve stems
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
required:
Stuck valves
Carbon on the valve stem or valve seat may cause
the valve to stay open.
The valves
The valve guides
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Lower Engine Noise, Regardless of Engine Speed
Cause
Low oil pressure
Correction
Worn accessory drive components

Abnormalities, such as severe cracking, bumps, or
missing areas in the accessory drive belt and/or
misalignment of system components
Loose or damaged crankshaft balancer
Detonation or spark knock

Repair or replace damaged components as
required.
Inspect the accessory drive system.
Inspect the crankshaft balancer.

Verify the correct operation of the ignition system.
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2003 Saturn L200

Refer to DETONATION/SPARK KNOCK in

Troubleshooting No Codes - 2.2L in Engine
Performance.
Loose torque converter bolts
Loose or damaged flywheel

Damaged oil pan, contacting the oil pump screen
An oil pan that has been damaged, may improperly
position the oil pump screen, preventing proper oil
flow to the oil pump.
Oil pump screen loose, damaged or restricted
Inspect the torque converter bolts and

flywheel.
Repair or replace the flywheel.
Worn or damaged balance shafts or bushings
Excessive piston-to-cylinder bore clearance
Excessive piston pin-to-bore clearance
Excessive connecting rod bearing clearance
Inspect the oil pan.

Inspect the oil pump screen.
Inspect the oil pump screen.
Inspect the balance shaft and bushings.
Replace as required.
Inspect the piston and cylinder bore.
Repair as required.
Inspect the piston, piston pin, and the

connecting rod.
required:
The connecting rod bearings

The connecting rods
The crankshaft
The crankshaft journals
required:
Excessive crankshaft bearing clearance
Incorrect piston, piston pin, and connecting rod

installation
Pistons must be installed with the mark or dimple
on the top of the piston, facing the front of the
engine. Piston pins must be centered in the
connecting rod pin bore.
The crankshaft bearings

Verify the pistons, piston pins and connecting
rods are installed correctly.
Repair as required.
ENGINE NOISE UNDER LOAD

Engine Noise Under Load
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2003 Saturn L200

Cause
Low oil pressure
Detonation or spark knock
Loose torque converter bolts
Correction
Verify the correct operation of the ignition. Refer to
DETONATION/SPARK KNOCK in
Troubleshooting No Codes - 2.2L in Engine
Performance.
Cracked flywheel, automatic transmission

Excessive connecting rod bearing clearance
Inspect the torque converter bolts and

flywheel.
Repair as required.
Inspect the flywheel bolts and flywheel.

Repair as required.
required:
The connecting rod bearings

The connecting rods
The crankshaft
required:
Excessive crankshaft bearing clearance
The crankshaft bearings

The cylinder block crankshaft bearing bore
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE

Engine Will Not Crank - Crankshaft Will Not Rotate
Cause
Correction
Seized accessory drive system component
1. Remove accessory drive belts.
2. Rotate crankshaft by hand at the balancer or
flywheel location.
Hydraulically locked cylinder
1. Remove spark plugs and check for fluid.
Coolant/antifreeze in cylinder
Oil in cylinder
Fuel in cylinder
Seized automatic transmission torque converter
2. Inspect for broken head gasket.

3. Inspect for cracked engine block or cylinder
head.
4. Inspect for a sticking fuel injector.
5. Inspect for cracked cylinder wall.
1. Remove the torque converter bolts.
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2003 Saturn L200


flywheel location.
Seized manual transmission
1. Disengage the clutch.

flywheel location.
Refer to Unit Repair Manual - Manual
Transmission.
Broken timing chain and/or gears
Seized balance shaft
Material in cylinder
Broken valve
Piston material
Foreign material
Cracked cylinder wall
Seized crankshaft or connecting rod bearings
Bent or broken connecting rod
Broken crankshaft
Inspect timing chain and gears.

Repair as required.
Inspect balance shaft.
Repair as required.
Inspect cylinder for damaged components
and/or foreign materials.
Inspect for fallen cylinder wall.
Inspect crankshaft and connecting rod

bearings.
Inspect for fallen cylinder wall.
Repair as required.
Inspect connecting rods.
Repair as required.
Inspect crankshaft.
Repair as required.
COOLANT IN COMBUSTION CHAMBER

Coolant in Combustion Chamber
Cause
Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an "overtemperature" condition which may cause engine component damage.
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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2003 Saturn L200

coolant may indicate a faulty gasket or damaged component.

4. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block, with low compression, may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Faulty cylinder head gasket
Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement.
Warped cylinder head
Replace the cylinder head and gasket. Refer to
Cylinder Head Cleaning and Inspection.
Cracked cylinder head
Replace the cylinder head and gasket.
Cracked cylinder sleeve
Replace the components as required.
Cylinder head or block porosity
COOLANT IN ENGINE OIL
Coolant in Engine Oil
Cause
Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant
entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may
lead to an "overtemperature" condition which may cause engine component damage. Contaminated
engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not
properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower
Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
cooling system may indicate a faulty gasket or damaged component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block with low compression may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Faulty cylinder head gasket
Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement.
Warped cylinder head
Replace the cylinder head and gasket. Refer to
Cylinder Head Cleaning and Inspection.
Cracked cylinder head
Replace the cylinder head and gasket.
Cracked cylinder sleeve
Cylinder head or block porosity
ENGINE COMPRESSION TEST
Perform the following steps in order to conduct a compression test for the L61.
1. Conduct the following steps in order to check cylinder compression.
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1. Engine should be at room temperature.

2. Disconnect wiring from the ignition module.
3. Remove the spark plugs.
4. Throttle body valve should be wide open.
5. Battery should be at or near full charge.
2. For each cylinder, crank engine through four compression strokes.
3. The lowest reading cylinder should not be less than 70% of the highest.
4. No cylinder reading should be less than 689 kPa (100 psi).
IMPORTANT: The results of a compression test will fall into the following categories:
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.
CYLINDER LEAKAGE TEST

Tools Required
J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools and Equipment.
IMPORTANT: A leakage test may be performed in order to measure cylinder/combustion
chamber leakage. High leakage may indicate one or more of the following:
Worn or burnt valves

Broken valve springs
Stuck valve lifters
Incorrect valve lash/adjustment
Damaged piston
Worn piston rings
Worn or scored cylinder bore
Damaged cylinder head gasket
Cracked or damaged cylinder head
Cracked or damaged engine block
CAUTION: Refer to BATTERY DISCONNECT CAUTION in Cautions and Notices.
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1. Disconnect the battery ground negative cable.

2. Remove the spark plugs. Refer to SPARK PLUGS - 2.2L in Removal and Installation in Engine
Performance.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the
compression stroke.
4. Install the J 35667-A or equivalent. See Special Tools and Equipment.
IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to prevent the
engine from rotating.
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. See
Special Tools and Equipment.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and
may require component service. In excessive leakage situations, inspect for the following conditions:
Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake
valve or a broken valve spring.
Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve
or a broken valve spring.
Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate
worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a
damaged cylinder head.
Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder
head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.
OIL CONSUMPTION DIAGNOSIS
Excessive oil consumption (not due to leaks) is the use of 0.9L (1 qt) or more of engine oil within 3
200kilometers (2,000 miles). The causes of excessive oil consumption include the following conditions:
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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Oil Consumption Test Procedure
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:
Low oil pressure

Broken valve springs
Sticking valves
Lifters worn, dirty or failed
Worn valve guides
Excessive valve stem to guide clearance
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Failed oil drain back valve
Vehicle Speed Sensitive Vibration Diagnosis
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.
Oil pump-to-engine front cover bolts loose

Refer to Engine Front Cover and Oil Pump Installation.
Oil pump screen loose, plugged, or damaged
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Oil pump screen O-ring seal missing or damaged

Malfunctioning oil pump pressure regulator valve
Excessive bearing clearance
Refer to Crankshaft and Bearings Cleaning and Inspection.
Cracked, porous or restricted oil galleries

Oil gallery plugs missing or incorrectly installed
Refer to Engine Block Assemble.
Broken lash adjusters
OIL LEAK DIAGNOSIS

DEFINITION: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the
component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak.
Repair the cause of the leak as well as the leak itself.
Oil Leak Diagnosis
Step
Action
Value(s)
1. Operate the vehicle until it reaches normal

operating temperature.
2. Refer to Engine Mechanical Specifications in this
service manual.
3. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
4. Wait 15 minutes.
5. Check for drippings.
Are drippings present?
Can you identify the type of fluid and the approximate
location of the leak?
1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Yes
No
Go to Step 2
System OK
Go to Step 10 Go to Step 3

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1. Completely clean the entire engine and

surrounding components.
2. Operate the vehicle for several miles at normal
operating temperature and at varying speeds.
3. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
4. Wait (15 minutes).
5. Identify the type of fluid, and the approximate
location of the leak.
Sealing surfaces
Fittings
1. Completely clean the entire engine and
surrounding components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
3. Operate the vehicle for several miles at normal
operating temperature and at varying speeds.
4. Identify the type of fluid, and the approximate
location of the leak, from the discolorations in the
powder surface.
Sealing surfaces
Fittings
Use J28428E Dye and Light Kit in order to identify the
type of fluid, and the approximate location of the leak.
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10
11
Refer to the manufacturer's instructions when using the

tool.

Sealing surfaces
Fittings
1. Inspect the engine for mechanical damage. Special

interest should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or
pressure bypass valves
Plugged or malfunctioning engine
ventilation system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications
to the engine?
Repair or replace all damaged or modified components.
Go to Step 10 System OK
Go to Step 11 System OK
Go to Step 1
-
CRANKCASE VENTILATION SYSTEM FUNCTIONAL TEST

Functional Check of the Positive Crankcase Ventilation (PCV) System
1.
2.
3.
4.
Disconnect the PCV hose.

Start the engine.
Check for vacuum at the hose. If there is no vacuum, check for a plugged hose or manifold port.
Check for a hose that collapses when blocked (vacuum applied). Replace the plugged or deteriorated
hoses.
5. Allow the engine to idle at the normal operating temperature.
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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 plugged PCV hose may cause the following conditions:
A rough idle
Stalling or a slow idle speed
Oil leaks
Sludge in the engine
A leaking hose would cause the following conditions:
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. 24: Minor Cracks DO NOT Warrant Drive Belt Replacement

Minor cracks in the belt rib are normal. They are the result of reverse bending around a backside pulley. Do not
replace belts for minor cracks.
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Fig. 25: Chunking, Cord Breakage Or Separation DO Warrant Drive Belt Replacement
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
1. Use a torque wrench in order to measure the torque

required to move the tensioner off of the stop.
2. Use a torque wrench on a known good tensioner in
order to measure the torque required to move the
tensioner off of the stop.
Is the first torque reading within 10 percent of the second
torque reading?
Replace the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement.
Is the repair complete?
System OK
REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
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Fig. 26: Loosening Belt Tensioner To Remove/Install Drive Belt

1. Depress the tensioner arm using a 3/8 in. drive breaker bar.
2. Remove the belt assembly off the idler or the A/C compressor pulley.
3. Remove the accessory drive belt.
Installation Procedure
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1. Route the belt around all of the pulleys, except for the idler pulley.
2. Depress the tensioner arm using a 3/8 in. drive breaker bar.
IMPORTANT: Make sure that the belt is properly aligned on the pulleys.
3. Slip the belt over the idler pulley.
DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure
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CAUTION: The tensioner assembly's internal parts are not serviceable. To avoid
injury, do not disassemble the tensioner.
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Fig. 29: Removing & Installing Belt Tensioner Bolt

2. Remove the belt tensioner bolt.
3. Remove the belt tensioner.
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NOTE:
Refer to FASTENER NOTICE in Cautions and Notices.
1. Install the belt tensioner attachment bolt.

Tighten: Tighten the drive belt tensioner bolt 45 N.m (33 lb ft).
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2. Install the accessory drive belt.
ENGINE OIL PRESSURE SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure
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Fig. 32: Disconnecting Engine Oil Pressure Switch

1. Turn the ignition OFF.
2. Disconnect the engine oil pressure (EOP) switch harness connector.
3. Remove the EOP switch using a 1 1/6 inch deep well socket.
1. Apply the RTV sealant, or equivalent, to the EOP switch threads.

NOTE:
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2. Install the EOP switch.

Tighten: Tighten the engine oil pressure switch to 10 N.m (89 lb in).
3. Connect the EOP switch harness connector. Push in the connector until a click is heard, then pull back to
confirm a positive engagement.
4. Check the oil level and fill if low.
5. Start the engine and check the engine for leaks.
ENGINE MOUNT INSPECTION
IMPORTANT: Before replacing any engine mount due to suspected fluid loss, verify that
the source of the fluid is the engine mount, not the engine or accessories.
1. Support the engine.
2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the
engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions:
The hard rubber is covered with heat check cracks.
The rubber is separated from the metal plate of the engine mount.
The rubber is split through the center of the engine mount.
The engine mount itself is leaking fluid.
4. For engine mount replacement. Refer to Engine Mount Replacement.
POWERTRAIN MOUNT BALANCE PROCEDURE - TOTAL MOUNT (W/AUTOMATIC
TRANSAXLE)
IMPORTANT: Follow the balance procedure in the order listed in the following steps.
Powertrain mounts must be tightened in sequence.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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Fig. 33: Removing/Installing Front Transaxle Mount Through Bolt

2. Loosen the front transmission mount through bolt. Do not remove.
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Fig. 34: Removing & Installing Rear Exhaust Manifold Heat Shield
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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Fig. 35: Locating Transmission Mount-To-Transmission Bolts

5. From the engine compartment, loosen the transmission mount to transmission bolts.
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Fig. 36: Locating Engine Mount-To-Intermediate Bracket Bolts

6. Loosen the engine mount to intermediate bracket bolts.
7. Reposition the floor jacks to allow a 1/8 inch gap between the mount and mount bracket.
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NOTE:
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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9. Tighten the engine mount to intermediate bracket bolts starting with the center bolt.
10. Remove the floor jacks.
11. Shake the powertrain vigorously from front to rear and allow the powertrain to settle.
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Fig. 39: Locating Rear Transmission Mount Through-Bolt - Automatic Transaxle

12. Tighten the rear transmission mount through bolt.
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13. Tighten the front transmission mount through bolt.
14. Lower the vehicle.
POWERTRAIN MOUNT BALANCE PROCEDURE - TOTAL MOUNT (W/MANUAL TRANSAXLE)
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Fig. 41: Locating Front Transmission Mount Through-Bolt - Manual Transaxle

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Fig. 42: Locating Rear Transmission Mount Through-Bolt - Manual Transaxle

4. Position two floor jacks with wood blocks under the engine and transmission to support the powertrain
assembly.
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5. From the engine compartment, loosen the transmission mount to transmission bolts.
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6. Loosen the engine mount to intermediate bracket bolts.
7. Reposition the floor jacks to allow a 1/8 inch gap between the mount and mount bracket.
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NOTE:
8. Tighten the transmission mount to transmission bolts using the following sequence:
1. Rear bolt
2. Middle bolt
3. Front bolt
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9. Tighten the engine mount to intermediate bracket bolts starting with the center bolt.
10. Remove the floor jacks.
11. Shake the powertrain vigorously from front to rear and allow the powertrain to settle.
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POWERTRAIN MOUNT BALANCE PROCEDURE - LOWER MOUNT (W/AUTOMATIC
TRANSAXLE)
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Fig. 50: Locating Rear Transmission Mount Through-Bolt - Automatic Transaxle

4. Shake the powertrain vigorously from front to rear and allow powertrain to settle.
NOTE:

Tighten: Tighten the bolt to 90 N.m (66 lb ft).
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POWERTRAIN MOUNT BALANCE PROCEDURE - LOWER MOUNT (W/MANUAL TRANSAXLE)
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4. Shake the powertrain vigorously from front to rear and allow powertrain to settle.
NOTE:

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ENGINE MOUNT BRACKET REPLACEMENT
Removal Procedure
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Fig. 55: Exploded View Of Engine Mount Assembly

1. Remove the engine mount. Refer to Engine Mount Replacement.
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Fig. 56: Removing & Installing Engine Mount Bracket

2. Remove the engine mount bracket to engine bolts.
3. Remove the engine mount bracket from the engine.
NOTE:
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1. Install the engine mount bracket to the engine.
Tighten: Tighten the engine mount bracket to engine bolts to 90 N.m (66 lb ft).
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2. Install the engine mount. Refer to Engine Mount Replacement.
ENGINE MOUNT REPLACEMENT
Removal Procedure
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Fig. 59: Removing & Installing Air Cleaner Assembly

1. Remove the air cleaner assembly.
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Fig. 60: Identifying Properly Installed Engine Support Fixture

2. Support the engine.
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3. Remove the engine mount to bracket bolts.
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Fig. 62: Removing & Installing Engine Mount Assembly

4. Remove the engine mount to body bolts.
5. Remove the engine mount from the vehicle.
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6. Remove the bolt the retains the mount to the engine mount body bracket.
IMPORTANT: Retain the isolation pad for assembly.
7. Remove the mount from the mount bracket and isolation pad.
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NOTE:
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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2. Install the engine mount to the vehicle. Hand tighten the bolts at this time.
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3. Install the engine mount to engine bracket bolts.
Tighten:
Tighten the engine mount to bracket bolts to 55 N.m (41 lb ft).
Tighten the engine mount to vehicle bolts to 55 N.m (41 lb ft).
4. Remove the engine support fixture.
5. Balance the engine mounts. Refer to Powertrain Mount Balance Procedure - Total Mount
(W/Automatic Transaxle) or Powertrain Mount Balance Procedure - Total Mount (W/Manual
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Transaxle).

6. Install the air cleaner assembly.
OIL LEVEL INDICATOR AND TUBE REPLACEMENT
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Fig. 68: Removing & Installing Oil Level Indicator & Tube
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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Fig. 69: Connecting Crankcase Ventilation Hose To Camshaft Cover

1. Disconnect the crankcase ventilation hose from the camshaft cover.
2. Disconnect the crankcase ventilation hose from the intake manifold.
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Fig. 70: Connecting Crankcase Ventilation Hose To Camshaft Cover

1. Connect the crankcase ventilation hose to the camshaft cover.
2. Connect the crankcase ventilation hose to the intake manifold.
INTAKE MANIFOLD REPLACEMENT
Removal Procedure
1. Remove the air cleaner outlet resonator.

2. Remove the throttle body. Refer to THROTTLE BODY in Removal and Installation in Engine
Performance.
3. Disconnect the PCV hose.
4. Disconnect the purge solenoid tube.
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5. Disconnect the brake booster hose.

6. Remove the oil level indicator tube bolt.
7. Remove the fuel rail. Refer to FUEL RAIL & INJECTORS in Removal and Installation in Engine
Performance.
8. Disconnect the knock sensor electrical connector.
Fig. 71: View Of Knock Sensor Connector

9. Remove the knock sensor harness connector from the intake manifold.
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Fig. 72: View Of Intake Manifold

10. Remove the intake manifold nuts and bolts.
11. Remove the intake manifold.
IMPORTANT: The intake manifold gasket is reusable, only replace the gasket if damage
has accrued.
12. If applicable, remove the intake manifold gasket.
1. If applicable, install the intake manifold gasket.

2. Install the intake manifold.
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NOTE:
Fig. 73: View Of Intake Manifold

3. Install the intake manifold nuts and bolts.
Tighten: Tighten the intake manifold nuts and bolts to 10 N.m (89 lb in).
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Fig. 74: View Of Knock Sensor Connector

4. Install the knock sensor harness connector to the intake manifold.
5. Connect the knock sensor electrical connector.
6. Install the fuel rail. Refer to FUEL RAIL & INJECTORS in Removal and Installation in Engine
Performance.
7. Install the throttle body.
8. Install the oil level indicator tube bolt.
Tighten: Tighten the oil level indicator tube bolt to 10 N.m (89 lb in).
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9.
10.
11.
12.
Connect the brake booster hose.

Connect the purge solenoid tube.
Connect the PCV hose.
Install the throttle body. Refer to THROTTLE BODY in Removal and Installation in Engine
Performance.
13. Install the air cleaner outlet resonator.
CRANKSHAFT BALANCER REPLACEMENT
Tools Required
J 38122-A Harmonic Balancer Holder

Removal Procedure
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Fig. 75: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
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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2003 Saturn L200

Fig. 76: Removing & Installing Damper Assembly

3. Remove the damper assembly.
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1. Lubricate the front oil seal and seal surface of the crankshaft balancer with an engine oil supplement.
NOTE:
Misalignment of the keyway may cause damage to the oil pump.
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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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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J 38122-A Crankshaft Pulley Holder

SA9105E Engine Support Fixture (3-Bar). See Special Tools and Equipment.
J 43405 Engine Support Fixture Adapter
Removal Procedure

1. Disconnect the negative battery cable.
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Fig. 80: Removing/Installing Right Front Lower Splash Shield

CAUTION: Refer to VEHICLE LIFTING CAUTION in Cautions and Notices.
3. Jack the vehicle or raise on a hoist.

4. Drain the engine oil.
5. Remove the right wheel and splash shield.
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6. Remove the engine accessory drive belt.
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7. Install the J 38122-A .
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IMPORTANT: The crankshaft damper pulley bolt head and washer assembly prevents
oil leakage at the center of the pulley. Do not damage the sealing
surfaces. If the pulley cannot be removed by pulling with your hand, use a
three jaw puller.
IMPORTANT: Do not pry against the cover.
8. Remove the crankshaft damper pulley and discard the bolt.
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9. Remove the belt tensioner.
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10. Install the SA9105E and the J43405 respectively. See Special Tools and Equipment.
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11. Remove the right engine mount. Refer to Engine Mount and Bracket Replacement - Right.
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Fig. 87: Removing Front Cover Assembly and Gasket

12. Remove the front cover assembly and gasket.
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Fig. 88: Installing Engine Front Cover

1. Install the new front cover gasket and cover the assembly.
NOTE:
2. Install the front cover bolts.

Tighten: Tighten the front cover-to-block bolts to 25 N.m (18 lb ft).
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3. Install the right side engine mount. Refer to Engine Mount and Bracket Replacement - Right.
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4. Remove the SA9105E and the J43405 respectively. See Special Tools and Equipment.
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5. Install the drive belt tensioner.
Tighten: Tighten the drive belt tensioner bolt to 45 N.m (33 lb ft).
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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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8. Install the new damper pulley bolt and washer.
Tighten: Tighten the crankshaft damper pulley bolt to 100 N.m (74 lb ft) plus 75 degrees.
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9. Install the engine accessory drive belt.
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10. Install the right wheel and splash shield.
11. Add the engine oil.
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13. Connect the negative battery cable.
Tighten: Tighten the battery terminal bolts to 17 N.m (13 lb ft).
TIMING CHAIN, SPROCKETS, AND/OR TENSIONER REPLACEMENT
Removal Procedure
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Fig. 97: Pulling Camshafts Straight Up To Avoid Damaging The Cylinder Head Thrust Surfaces
2. Remove the front cover. Refer to Engine Front Cover Replacement (With Oil Pump Assembly).
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Fig. 98: Removing & Installing Camshaft Cover Assembly

3. Remove the camshaft cover assembly. Refer to Camshaft Cover Replacement.
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Fig. 99: Removing Timing Chain Tensioner

IMPORTANT: The timing chain tensioner must be removed to unload the chain tension
before the timing chain is removed. If it is not removed, the timing chain
may become cocked and difficult to remove.
4. Remove timing chain tensioner.
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Fig. 100: Removing Upper Timing Chain Guide

5. Remove the upper timing chain guide.
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Fig. 101: Removing Exhaust Camshaft Sprocket

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. Remove the exhaust camshaft sprocket and discard the bolt.
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Fig. 102: Removing Adjustable Timing Chain Guide

7. Remove the adjustable timing chain guide.
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Fig. 103: Fixed Timing Chain Guide Access Plug

8. Remove the fixed timing chain guide access plug.
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Fig. 104: Fixed Timing Chain Guide & Bolts

9. Remove the fixed timing chain guide.
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Fig. 105: Holding Camshaft Assembly Using 24 mm Wrench

10. Remove the intake camshaft sprocket and discard the bolt.
11. Remove the timing chain through the top of the cylinder head.
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2003 Saturn L200

Fig. 106: Installing Timing Chain Drive Sprocket

12. Remove the timing chain drive sprocket from the crankshaft.
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2003 Saturn L200

Fig. 107: Removing & Installing Timing Chain Oiling Nozzle

13. Remove the timing chain oiling nozzle.
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Fig. 108: Exploded View Of Timing Chain & Components

IMPORTANT: Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in).
14. Inspect the timing chain guides for cracking or wear.
IMPORTANT: Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045
in).
15. Inspect the timing chain tensioner shoe for wear.
16. Inspect the timing chain and sprockets for wear.
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17. Inspect the camshaft sprocket faces for signs of movement.

18. Inspect the camshaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of timing
chain links.

1. Install the timing chain drive sprocket to the crankshaft.
2. Rotate the crank so that the mark on the sprocket is at the 5 o'clock position.
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Fig. 110: Positioning Intake Camshaft

3. Assemble the chain to the intake camshaft sprocket alignment copper link to the INT diamond timing
mark on the camshaft sprocket.
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Fig. 111: Rotating Assembly 90 Degrees To Allow The Chain To Fall Between The Cylinder Block
Bosses
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
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.
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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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
2nd design tensioner.
7. Install the adjustable timing chain guide through the opening on top of the cylinder head and install the
chain guide bolt.
Tighten: Tighten the timing chain guide (adjustable) bolt to 10 N.m (89 lb in).
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8. Install the exhaust camshaft sprocket loosely onto the exhaust camshaft with the timing mark on the
sprocket aligned with the silver link 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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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.
10. Ensure the sprocket timing mark is at the 5 o'clock position.

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Fig. 116: Using 24 mm Wrench To Support The Camshaft

11. Rotate the intake camshaft using a 24 mm wrench on the flats of the camshaft until the sprocket-tocamshaft alignment notch seats.
12. When the sprocket seats on the camshaft, tighten the sprocket bolt finger tight.
13. Rotate the exhaust camshaft using a 24 mm wrench on the flats of the camshaft until the sprocket-tocamshaft alignment notch seats.
14. When the sprocket seats on the camshaft, tighten the sprocket bolt finger tight.
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15. Verify that all colored links are aligned with the appropriate marks on the camshaft and crankshaft
sprockets. If they are not, repeat steps 8-10.
Install the fixed timing chain guide and bolts.
Tighten: Tighten the timing chain guide (fixed) bolts to 10 N.m (89 lb in).
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16. Install the fixed timing chain guide bolt access hole plug.
Tighten: Tighten the timing chain guide bolt access hole plug to 40 N.m (30 lb ft).
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17. Install the upper timing chain guide and bolts.
Tighten: Tighten the timing chain guide (upper) bolts to 10 N.m (89 lb in).
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NOTE:
Use a 24 mm wrench to support the camshaft while applying torque to

camshaft sprocket bolt. Do not torque camshaft bolts against timing chain,
as it may damage the timing chain.
18. Tighten the intake and exhaust camshaft sprocket bolts.

Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) +30 degrees.
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IMPORTANT: There is a 2nd design tensioner with a notch at the plunger end of the
tensioner. This tensioner should be used only with the 2nd design
adjustable guide.
19. Install the sealing ring and tensioner assembly.
Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
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20. Install the timing chain oil nozzle and bolt.
Tighten: Tighten the timing chain oil nozzle bolt to 10 N.m (89 lb in).
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21. Install the camshaft cover assembly. Refer to Camshaft Cover Replacement.
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22. Install the engine front cover. Refer to Engine Front Cover Replacement (With Oil Pump Assembly).
BALANCE SHAFT DRIVE TRAIN REPLACEMENT
Removal Procedure
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2. Remove the front cover. Refer to Engine Front Cover Replacement (With Oil Pump Assembly).
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3. Remove the camshaft cover assembly. Refer to Camshaft Cover Replacement.
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4. Remove the timing chain. Refer to Timing Chain, Sprockets, and/or Tensioner Replacement.
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Fig. 128: Removing Balance Shaft Drive Chain Tensioner

5. Remove the balance shaft drive chain tensioner.
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Fig. 129: Removing Adjustable Balance Shaft Chain Guise

6. Remove the adjustable balance shaft chain guide.
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Fig. 130: Removing Small Balance Shaft Chain Guide

7. Remove the small balance shaft chain guide.
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Fig. 131: Removing Upper Balance Shaft Chain Guide

8. Remove the upper balance shaft chain guide.
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Fig. 132: Removing Balance Shaft Drive Chain

IMPORTANT: Push on the chain between the water pump and the camshaft sprockets
so that all of the slack is between these 2 points. This will allow easier
removal of the chain.
9. Remove the balance shaft drive chain.
10. Remove the crankshaft drive sprocket.
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Fig. 133: View of Balance Shaft Drive Chain Guides

IMPORTANT: Replace the balance shaft drive chain guide if wear exceeds 1.12 mm
(0.045 in).
11. Inspect the balance shaft drive chain guides for cracking or wear.
IMPORTANT: Replace the balance shaft drive chain tensioner shoe if wear exceeds 1.12
mm (0.045 in).
12. Inspect the balance shaft drive chain tensioner shoe for excessive wear.
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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.
Fig. 134: Identifying Balance Shaft Timing Marks

IMPORTANT: If the balance shafts are not correctly timed to the crankshaft the engine
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may vibrate or make excessive noise.

1. Orient the timing marks on the balance shafts.
1. The intake side balance shaft timing mark should be pointing up.
2. The exhaust side balance shaft timing mark should be pointing down.
2. With the balance shafts oriented, install the balance shaft crankcase sprocket onto the crankshaft.
IMPORTANT: The crankshaft keyway slot will be pointing up (12 o'clock position) when
set at TDC.
3. Place the number 1 piston at top dead center (TDC).
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Fig. 135: Identifying Balance Shaft Chain Colored Links

4. Install the balance shaft chain with the colored links lined up with the marks on the balance shaft
sprockets with the mark on the crankshaft sprocket.
IMPORTANT: There is 1 copper link (1) and 2 chrome links (2) on the balance shaft
chain.
1. Orient the chain so that the copper (1) and chrome (2) links are visible.
2. Place the copper colored link (1) onto the timing mark on the intake side balance shaft sprocket.
3. Working clockwise along the chain, place the first chrome link in line with the timing mark on the
crankshaft sprocket.
4. Align the last chrome link with the timing mark on the exhaust side balance shaft sprocket.
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Fig. 136: Installing Upper Chain Guide & Bolt

5. Install the upper chain guide and bolt.
Tighten: Tighten the balance shaft chain guide (upper) bolts to 10 N.m (89 lb in).
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Fig. 137: Installing Small Chain Guide & Bolts

6. Install the small chain guide and bolt.
7. Tighten the chain guide bolt.
Tighten: Tighten the balance shaft chain guide (fixed) bolts to 10 N.m (89 lb in).
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Fig. 138: Installing Adjustable Chain Guide & Bolts

8. Install the adjustable chain guide and bolts.
Tighten: Tighten the balance shaft chain guide (adjustable) bolt to 10 N.m (89 lb in).
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Fig. 139: Installing Balance Shaft Drive Chain Tensioner

9. Rotate the plunger on the chain tensioner 90. Compress the plunger and lock in place by inserting a thin
wire, or paper clip, into the hole on the side of the plunger body.
10. Install the balance shaft drive chain tensioner and bolts.
11. Tighten the balance shaft drive chain tensioner bolts.
Tighten: Tighten the balance shaft chain tensioner bolts to 10 N.m (89 lb in).
12. Remove the thin wire or paper clip from the chain tensioner to release the plunger.
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13. Install the timing chain. Refer to Timing Chain, Sprockets, and/or Tensioner Replacement.
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14. Install the camshaft cover. Refer to Camshaft Cover Replacement.
Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
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15. Install the front cover. Refer to Engine Front Cover Replacement (With Oil Pump Assembly).
CAMSHAFT COVER REPLACEMENT
Tools Required
J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment.
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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

2. Remove the ignition coil, PCV fresh air hose, ground strap, fuel line, harness bracket, and cam cover
assembly.
3. Remove the power steering pump if removing the intake camshaft.
NOTE:
To avoid valve piston contact, No. 1 cylinder piston must be positioned at
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approximately 60 degrees before-top dead center (BTDC). Pistons are

properly positioned when the diamond shaped hole on the intake camshaft
sprocket is located at 12 o'clock.
IMPORTANT: To rotate the camshafts, use a 24 mm open-end wrench on the camshaft
flats. Camshafts should be rotated in a clockwise direction only, facing
the camshaft sprockets from the passenger side of the vehicle.
4. Locate the No. 1 piston to approximately 60 before top dead center. The diamond shaped hole on the
intake camshaft sprocket is at the 12 o'clock position. Spark plugs can be removed to ease the rotation
effort.
6. Remove the front camshaft caps.
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Fig. 144: Installing Camshaft Sprocket Holding Tool

IMPORTANT: Lubricate the sprocket pins with clean motor oil. This will allow the
sprockets to easily slide on the sprocket pins. Align the diamond shaped
hole straight up on the intake camshaft.
7. Install the J 43655 through the sprocket holes from the timing chain side of the sprocket towards the rear
of the engine. See Special Tools and Equipment.
8. With the guide pins installed in the sprocket, align the guide pins into the slot on the support head.
Tighten: Tighten the support plate-to-engine block to 10 N.m (89 lb in).
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9. Install the wing nuts and tighten.
Fig. 145: Holding Camshaft In Place Using A 24 mm Open End Wrench

10. Hold each camshaft in place using a 24 mm open end wrench and carefully remove the camshaft timing
sprocket retaining bolts and washers. Discard the torque-to-yield (TTY) bolt.
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Fig. 146: Removing Camshaft Bearing Cap Bolts

IMPORTANT: When sliding the timing chain and sprockets onto the guide pins, be sure
the timing chain is positioned properly on the adjustable and fixed guide
or guide damage will occur. Care should be taken when removing the
camshaft sprockets from the camshafts.
11. Slide the camshaft sprockets away from the camshaft.
12. To release the spring tension, rotate the camshaft being serviced.
13. Uniformly loosen and remove the remaining camshaft bearing cap bolts.
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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.
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Fig. 148: Aligning Camshaft Slot In Line With The Notch On The Sprockets
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).
Fig. 149: Holding Camshaft In Place Using A 24 mm Open End Wrench

4. Slide the camshaft sprockets and the timing chain on the guide pins toward the camshafts. Rotate the
camshafts with a 24 mm open-end wrench to properly align the camshafts and sprockets.
5. Install the new camshaft sprocket bolt and tighten. This will pull the camshaft sprockets into the cams.
Hold the camshaft with a 24 mm open end wrench during tightening.
Tighten: Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) plus 30 degrees.
6. Remove the J 43655 . See Special Tools and Equipment.
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7. Install the front camshaft caps.

Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
Fig. 150: Applying LOCTITE 242 & Installing Upper Timing Chain Guide Bolts
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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9. Install the rear intake camshaft bearing cap.

Tighten: Tighten the intake camshaft rear bearing cap bolts to 25 N.m (18 lb ft).
10. Install the power steering pump.
Tighten: Tighten the power steering pump bolts to 25 N.m (18 lb ft).
11. Install the ignition coil, PCV fresh air hose, ground strap, fuel line, harness bracket, and cam cover
assembly.
VALVE ROCKER ARM AND VALVE LASH ADJUSTER REPLACEMENT
Tools Required
J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment.
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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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Fig. 152: Installing Rocker Arms

1. Remove the camshafts. Refer to Camshaft Cover Replacement.
2. Remove the rocker arms.
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Fig. 153: Removing/Installing Lash Adjusters

3. Remove the valve lash adjusters.
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Fig. 154: Installing Valve Lash Adjusters

1. Install the valve lash adjusters.
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2. Install the rocker arms.
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NOTE:
After cylinder block, head, or lifter replacement, it will be necessary to

allow the engine to idle for 3-5 minutes. If the lifters are noisy, warm the
engine up at less than 200 RPM. After the coolant temperature has reached
approximately 85C (185F), cycle the engine RPM from idle to 300 RPM for
approximately 10 minutes or drive the vehicle 8 kilometers (5 miles) to
purge the air. If the air cannot be purged, the faulty lifters will have to be
replaced.
3. Install the camshafts. Refer to Camshaft Cover Replacement.

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CYLINDER HEAD REPLACEMENT

Tools Required

SA9805E Fuel Line Disconnect Set. See Special Tools and Equipment.
Removal Procedure
Fig. 157: Removing Intake Manifold

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2. Remove the intake manifold. Refer to Intake Manifold Replacement.
Fig. 158: Removing Exhaust Manifold Pipe

3.
4.
5.
6.
7.
Remove the exhaust manifold flange bolts.

Remove the coolant reservoir cap.
Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the exhaust manifold down pipe to catalytic convertor bolts.
Disconnect the exhaust down pipe from the exhaust manifold flange studs and secure the exhaust pipe to
the under-carriage.
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Fig. 159: Installing Hose Over Radiator Drain Tube & Loosening Radiator Drain Valve
8. Drain the coolant at the radiator and at the water pump drain plug.
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Fig. 160: Proper Connection Of Pressure Adapter & Gage Bar Set To Fuel Rail
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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Fig. 161: Removing/Installing Upper Radiator Hose From Radiator

14.
15.
16.
17.
Disconnect the A/C pressure switch electrical connection.

Remove the crankcase vent hose from the camshaft cover.
Remove the coolant air bleed hose at the coolant reservoir and remove from the bracket.
Disconnect the upper radiator hose at the cylinder head.
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Fig. 162: Connecting KS Harness Connector (2.2L)

18. Disconnect the electrical connections.
1. Ignition coil
2. Knock sensor (connector only)
3. Coolant temperature sensor
4. Fuel injector harness
5. Front O2 sensor
19. Remove all of the engine harness bracket fasteners and secure the harness away from the engine.
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Fig. 163: Installing Ignition Module Assembly

20. Remove the ignition coil.
21. Remove the power steering pump and secure away from the engine. Do not remove the hydraulic lines.
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22. Remove the camshaft cover ground strap.
23. Remove the camshaft cover bolts and remove the cover.
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before the timing chain is removed. If it is not, the timing chain may
become misaligned and difficult to remove.
25. Remove the upper timing chain tensioner.
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Fig. 167: Removing Camshaft Sprockets

IMPORTANT: Do not allow any load onto the timing chain upon loosening the camshaft
sprocket bolts.
26. Remove the camshaft sprocket bolts using a 24 mm open-end wrench to counter-hold the camshaft while
loosening the bolts. Discard the bolts.
27. Attach a medium size cable tie to the timing chain to prevent the chain from falling into the oil pan.
28. Remove the camshaft sprockets.
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29. Remove the plug to gain access to the fixed timing chain guide bolt.
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30. Remove the fixed timing chain guide upper bolt only.
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Fig. 170: Removing Cylinder Head Bolts Using Loosening Sequence

31. Remove the cylinder head to block bolts using the loosening sequence.
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Fig. 171: Inspecting Timing Chain Guide

NOTE:
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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33. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
34. Remove the right front wheel.
35. Remove the lower splash shield.
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37. Remove the accessory drive belt tensioner.
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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).
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IMPORTANT: The crankshaft damper pulley bolt head and washer assembly prevents
oil leakage at the center of the pulley. Do not damage the sealing
surfaces. If the pulley cannot be removed by hand, use a three jaw puller.
IMPORTANT: Do not pry against the cover.
41. Remove and discard the crankshaft damper pulley bolt.
42. Remove the crankshaft pulley.
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Fig. 177: Removing Front Cover Bolts

43. Remove all front cover bolts except for the bolt that is blocked by the engine mount bracket.
44. Loosen the water pump bolt. Do not remove at this time.
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Fig. 178: Supporting Engine Weight With Floor Jack

46. Support the engine weight with the floor jack under the oil pan.
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47. Remove the right-hand engine mount to bracket bolts.
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48. Remove the engine mount to body bolts.
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50. Remove the engine mount bracket to engine bolts.
51. Remove the bracket from the vehicle.
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Fig. 182: Removing Front Cover

52.
53.
54.
55.
56.
Lower the engine.

Remove the crankshaft damper pulley and discard the bolt.
Remove the upper front cover bolt, behind the engine mount.
Raise the engine just enough to remove the water pump bolt.
Remove the front cover.
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58. Remove the fixed timing chain guide, lower bolt.
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NOTE:
Set crankshaft to 60 degrees before top-dead center or after TDC to

prevent valve to piston contact.
1. Set the crankshaft to 60 degrees before or after top dead center (TDC).
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Fig. 186: Inspecting Timing Chain Guide

2. Install the head gasket placing OBEN facing the top.
IMPORTANT: Always use new cylinder head bolts.
3. Install the cylinder head, aligning it on the dowels.
4. Lightly apply clean engine oil to the threads and to the bottom side of the flange of the head bolts and
allow the oil to drain before installing.
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Fig. 187: Cylinder Head Bolt Tightening Sequence

5. Install and tighten the cylinder head bolts in sequence.
Tighten: Tighten the cylinder head bolts to 30 N.m (22 lb ft) plus 155 degrees.
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Fig. 188: View Of Front Cylinder Head Crankcase Bolts

6. Coat the front cylinder head bolts with LOCTITE 242.
7. Install the front cylinder head bolts.
Tighten: Tighten the cylinder head front chain case bolts to 20 N.m (15 lb ft).
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Fig. 189: Aligning Camshaft Slot In Line With The Notch On The Sprockets
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. 190: Positioning Intake Camshaft

10. Pull up the timing chain and install around the intake camshaft sprocket with the copper link lined up with
the INT diamond timing mark.
11. Install the sprocket onto the camshaft and align with the offset slot.
NOTE:
The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY)

12. Install the new camshaft sprocket bolt. Do not tighten.
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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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14. Install the adjustable timing chain guide through the opening on the top of the cylinder head and install
the chain guide bolt.
Tighten: Tighten the timing chain adjustable guide bolt to 10 N.m (89 lb in).
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Fig. 193: Positioning Exhaust Camshaft

15. Route the timing chain around the exhaust camshaft sprocket with the silver link lined up with the offset
slot.
16. Install the sprocket onto the camshaft and align with the offset slot.
NOTE:
The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY)

17. Install the new camshaft sprocket bolt. Do not tighten.
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NOTE:
Use a 24 mm wrench to support the camshaft while applying torque to

camshaft sprocket bolt. Do not torque camshaft bolts against timing chain,
as it may damage the timing chain.
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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19. Install the fixed guide and install the bolt.
Tighten: Tighten the timing chain fixed guide bolts to 10 N.m (89 lb in).
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20. Apply LOCTITE PST565 to plug the threads.
21. Install the fixed timing chain guide bolt access hole plug.
Tighten: Tighten the timing chain guide bolt access hole plug to 40 N.m (30 lb ft).
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IMPORTANT: There is a 2nd design tensioner with a notch at the plunger end of the
tensioner. This tensioner should be used only with the 2nd design
adjustable guide.
22. Reset the timing chain tensioner by depressing the plunger.
23. Install the sealing ring onto the tensioner and install.
Tighten: Tighten the timing chain tensioner bolts to 75 N.m (55 lb ft).
24. Gently tap the top of the chain, between the camshaft sprockets, with your hand. This will engage the
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tensioner onto the adjustable chain guide.

25. Install the upper timing chain guide and bolts.
Tighten: Tighten the timing chain upper guide bolts to 10 N.m (89 lb in).
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IMPORTANT: Ensure that all of the timing marks and colored links are aligned properly
before proceeding to the next step.
26. Install the front cover gasket and the front cover.
27. Install the front cover bolts.
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Fig. 200: Installing Water Pump Bolt

28. Install the water pump bolt.
Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
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29. Install the drive belt tensioner and belt.
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30. Install the engine mount bracket onto the engine and install the bolts.
Tighten: Tighten the engine mount bracket-to-engine bolts 90 N.m (66 lb ft).
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31. Install the engine mount assembly-to-side rail and install the fasteners.
Tighten: Tighten the engine mount-to-body bolts to 55 N.m (41 lb ft).
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32. Lower the engine and align the engine mount bolts.
33. Install the engine mount bolts-to-bracket bolts.
Tighten: Tighten the engine mount-to-engine mount bracket bolts to 55 N.m (41 lb ft).
34. Remove the floor jack.
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35. Raise the vehicle.
NOTE:
36. Install the crankshaft damper.

37. Lubricate the front oil seal and the seal surface of the crankshaft balancer with an engine oil supplement.
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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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40. Install the drive belt.
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41. Install the A/C line clamps.
42. Install the right wheel splash shield.
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Fig. 209: Removing & Installing Tire & Wheel Assembly

43. Install the tire/wheel.
1. Hand tighten all 5 wheel bolts.
2. Use a torque wrench to initial tighten wheel bolts using a crisscross pattern.
Tighten: Tighten the wheel bolts (initial torque) to 63 N.m (46 lb ft).
3. Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
Tighten: Tighten the wheel bolts (final torque) to 125 N.m (92 lb ft).
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44. Install the wheel cover.

46. Install the camshaft cover. Ensure that the camshaft cover seals are properly seated in the cover.
47. Install the cover bolts and ground strap nut.
Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
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Fig. 211: Removing & Installing Power Steering Pump - L61

48. Install the power steering pump.
Tighten: Tighten the power steering pump bolts to 25 N.m (18 lb ft).
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Fig. 212: Installing Spark Plugs

49. Install the spark plugs.
Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
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50. Install the ignition coil and module assembly to the camshaft cover.
Tighten: Tighten the ignition coil-to-camshaft cover bolts to 8 N.m (71 lb in).
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Fig. 214: Installing Intake Manifold

51. Install the intake manifold onto the intake manifold. The gasket may be reused if not damaged.
53. Install the intake manifold bolts and nuts. Tighten by starting from the center bolt and working outward.
Tighten:
Tighten the intake manifold-to-cylinder head bolts to 10 N.m (89 lb in).
Tighten the manifold-to-cylinder head nuts to 10 N.m (89 lb in).
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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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Fig. 216: Removing & Installing Throttle Body Assembly

56. Install the throttle body. The gasket may be reused if not damaged.
57. Install the throttle body mounting bolts and nuts. Install the throttle cable.
Tighten:
Tighten the throttle body bolts to 10 N.m (89 lb in).
Tighten the throttle body nuts to 10 N.m (89 lb in).
58. Position the engine harness and install the fasteners.
Tighten: Tighten the engine harness bracket bolts to 10 N.m (89 lb in).
59. Connect the electrical connections.
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60. Install the camshaft cover ground strap.

Tighten: Tighten the camshaft cover ground strap fastener to 10 N.m (89 lb in).
Fig. 217: Removing & Installing Surge Tank Coolant Air Bleed Hose
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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2.
3.
4.
5.
Crankcase ventilation hose

Fuel pressure regulator hose
Brake booster hose
EVAP purge hose
NOTE:
Replace plastic fuel retainer whenever the fuel supply is disconnected at

the fuel rail. Install the new retainer into the female cavity of the
connection. Care must be taken to assure that the locking tab is centered
in the window of the female cavity. Firmly press the female connection
onto the male end until a click is heard, then pull back to confirm
engagement. Pinched, kinked, or damaged fuel lines must be replaced.
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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Fig. 218: Removing Exhaust Manifold Pipe

65.
66.
67.
68.
Install the exhaust flange onto the exhaust flange.

Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Position the manifold down pipe onto the flange studs.
Install the flange nuts.
Tighten: Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 lb ft).
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Fig. 219: Removing & Installing Exhaust Manifold Pipe-To-Exhaust/Resonator Fasteners

69. Install the exhaust down pipe to the resonator bolts.
Tighten: Tighten the exhaust manifold pipe-to-resonator bolts to 20 N.m (15 lb ft).
70. Drain the oil.
Tighten: Tighten the oil drain plug to 25 N.m (18 lb ft).
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Fig. 220: Removing & Installing Exhaust Manifold Heat Shield

72. Install the exhaust manifold heat shield and install the bolts.
Tighten: Tighten the exhaust manifold heat shield bolts to 25 N.m (18 lb ft).
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73. Install the air cleaner and inlet tube assembly.
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Fig. 222: View of Oil Cap

74. Add engine oil.
75. Check the level and install the oil cap.
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Fig. 223: Removing Surge Tank Cap

76. Fill the coolant tank.
1. Add 50/50 DEX-COOL and water.
Specifications:
The auto trans volume equals 6.9 quarts.
The manual trans volume equals 7 quarts.
2. Install the coolant surge cap.
77. Connect the battery cable.
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NOTE:
After cylinder block, head, or lifter replacement, it will be necessary to

allow the engine to idle for 3-5 minutes. If the lifters are noisy, warm the
engine up at less than 200 RPM. After the coolant temperature has reached
approximately 85C (185F), cycle the engine RPM from idle to 300 RPM for
approximately 10 minutes or drive the vehicle 8 kilometers (5 miles) to
purge the air. If the air cannot be purged, the faulty lifters will have to be
replaced.
78. Start the vehicle and inspect for leaks.

ENGINE FLYWHEEL REPLACEMENT
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45E.
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Fig. 224: View Of Flywheel

2. Remove the flywheel bolts, and note the position of the flywheel to the crankshaft.
3. Remove the flywheel.
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Fig. 225: View Of Flywheel

1. Position the flywheel on the crankshaft as previously noted.
NOTE:
2. Install the flywheel bolts.

Tighten: Tighten the flywheel bolts to 53 N.m (39 lb ft) plus 25 degrees.
3. Install the transmission. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
ENGINE REPLACEMENT (MANUAL TRANSMISSION)
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Tools Required
J 43628 Frame Alignment Fixture

J 44015 Steering Linkage Installer
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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23.
24.
25.
26.
27.
Remove the heater hoses from the front of the dash.

Remove the upper and lower radiator hoses from the radiator.
Relieve the fuel pressure.
Disconnect the fuel lines.
Secure the radiator to the upper radiator support.
CAUTION: Ensure that the vehicle is properly supported and squarely
positioned. To help avoid personal injury when a vehicle is on a
hoist, provide additional support for the vehicle on the opposite end
from which the components are being removed.
28.
29.
30.
31.
32.
33.
34.
35.
Raise the vehicle on a hoist.

Remove both of the front wheels.
Remove the right front splash shield.
Remove the left front wheel liner push pin from the frame.
Install wood blocks between the transaxle case and frame.
Install wood blocks between the crank pulley and frame.
Lower the vehicle.
Disconnect the right engine and left transaxle mounts by removing the mount assembly-toengine/transaxle bolts. The mount brackets will remain on the engine and transaxle.
36. Disconnect the rear oxygen sensor harness from the frame at the 2 attachment points.
37. Remove the exhaust manifold pipe from the catalytic converter forward.
38. Remove the A/C line to frame attachment clip at the front of the frame.
IMPORTANT: It is not necessary to disconnect the A/C lines.
39. Remove the A/C compressor from the engine and secure to the cooling module.
40. Remove the tie rod-to-steering knuckle bolts and separate the tie rod from the steering knuckle assembly.
Discard the tie rod bolts.
41. Remove the stabilizer bar links from the strut assembly.
NOTE:
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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48. Remove the remaining 4 cage nuts and discard.

Fig. 226: Identifying Engine Frame Alignment Fixture

1. Install the new cage nuts into the body as torque retention of the old nuts may not be sufficient.
IMPORTANT: Ensure that the J 43628 fully engages into all alignment holes.
2. Carefully raise the powertrain into the vehicle.
IMPORTANT: Do not tighten the fasteners at this time.
3. Install the 4 new frame-to-body bolts.
4. Install the suspension supports using the new bolt and tighten all of the frame bolts.
Tighten: Tighten the suspension support bolts to 100 N.m (74 lb ft).
5. Install the ball stud into the steering knuckle. Use the new ball stud nut.
Tighten: Tighten the ball stud-to-steering knuckle nuts to 100 N.m (74 lb ft).
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6. Install the stabilizer link-to-strut assembly.

Tighten: Tighten the stabilizer link-to-strut assembly to 65 N.m (50 lb ft).
IMPORTANT: Use a new tie rod nut. The torque retention of the old nut may not be
sufficient.
7. Install the tie rod into the steering knuckle.
8. Using the J 44015 , or equivalent, seat the tie rod end into the knuckle and tighten again.
Tighten: Tighten the tie rod end linkage installer to 45 N.m (35 lb ft).
9. Remove the linkage installer and install the new tie rod nut and tighten.
Tighten: Tighten the tie rod nut to 60 N.m (45 lb ft).
10. Install the exhaust manifold pipe.
11. Install the A/C compressor-to-engine mounting bolts.
Tighten: Tighten the A/C compressor-to-block bolt to 25 N.m (18 lb ft).
12. Install the A/C line-to-frame attachment clip at the front of the frame.
13. Route the rear oxygen sensor harness and attach to the attachment points.
14. Install the right engine mount bolts and install the left transaxle mount bolts.
Tighten:
Tighten the engine mount-to-engine mount bracket bolts to 55 N.m (41 lb ft).
Tighten the transaxle mount bolts to 55 N.m (41 lb ft).
15.
16.
17.
18.
19.
20.
21.
22.
Raise the vehicle.

Remove the wood blocks from the crank pulley and transaxle case.
Install the left front wheel liner push pin from the frame.
Install the right front splash shield.
Install both of the front wheels.
Lower the vehicle.
Remove the radiator from the upper radiator support.
Connect the fuel lines. Use new fuel line retainer clips.
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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.
Attach the cruise control and throttle cables.

Install the battery tray and fuse block tray.
Connect the engine harness main connector on the bottom of the fuse block.
Install the fuse block.
Connect the PCM electrical connectors.
Install the PCM boot under the front-of-dash cover.
Install the front-of-dash cover.
Connect the following connections:
The purge solenoid
The rear oxygen sensor
The main harness connector by the master cylinder
The transaxle back-up switch
Connect the purge hose to the throttle body.
Install the air cleaner box.
Install the air cleaner lid and the inlet duct.
Connect the intake air temperature (IAT) electrical connection.
Connect the main ground on the left fender well.
Connect the main wire feed to the fuse block.
Install the battery.
Connect the steering gear-to-intermediate shaft pinch bolt and tighten.
Tighten: Tighten the steering gear-to-intermediate shaft pinch bolt to 30 N.m (22 lb ft).
43. Refill the coolant tank.

44. Add power steering fluid.
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ENGINE REPLACEMENT (AUTOMATIC TRANSMISSION)

Removal Procedure
Fig. 227: Removing & Installing Engine - Automatic Transmission

1.
2.
3.
4.
5.
6.
7.
Remove the battery.

Disconnect the main wire feed to the fuse block.
Disconnect the main ground on the left fender well.
Remove the intake air temperature (IAT) electrical connection.
Remove the air cleaner lid and the inlet duct.
Remove the air box.
Disconnect the purge hose from the throttle body and route away from the engine.
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8. Disconnect the following electrical connections:

The purge solenoid electrical
The rear HO2S sensor
The main harness connector near the master cylinder
The generator
The A/C pressure switch
The transmission (3 connectors)
The right front speed sensor (disconnect and pull through the fender well)
9. Remove the cowl cover.
10. Remove the PCM boot from the cowl.
11. Disconnect the PCM electrical connectors and secure to the engine.
12. Remove the fuse block lid.
13. Disconnect the engine harness connectors from the fuse block.
14. Remove the battery tray and fuse block tray.
15. Disconnect the cruise control and throttle cables.
16. Remove the coolant reservoir cap.
17. Disconnect the brake assist vacuum line from the throttle body and route away from the engine.
18. Relieve the fuel pressure.
19. Disconnect the fuel lines and secure away from the engine.
20. Disconnect the EVAP purge hose at the EVAP purge solenoid.
21.
22.
23.
24.
25.
26.
27.
Raise the vehicle.

Drain the engine coolant.
Remove the starter.
Remove the torque converter bolts.
Remove the exhaust system from the catalytic converter forward.
Disconnect the transmission nose bracket.
Remove the A/C compressor mounting bolts and secure to the frame rail.
IMPORTANT: It is not necessary to disconnect the A/C lines.
28. Disconnect the lower engine to transmission bell housing bolts. Do not remove the upper bolts at this
time.
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30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Disconnect the heater hoses at the lower cowl.

Remove the main hose to the coolant reservoir from the engine inlet adapter.
Remove the lower radiator hose from the engine.
Remove the upper radiator hose from the engine.
Drain the power steering fluid by removing the smaller hose from under the reservoir.
Disconnect the metal power steering line.
Attach the engine lift hoist to the lift hooks on the engine and support the engine weight.
Support the weight of the transaxle with the floor jack or jack stand.
Remove the right front engine mount from the wheel housing.
Remove the engine mount bracket from the engine.
Remove the upper bell housing bolts.
Lift the engine out of the vehicle.
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Fig. 228: Removing & Installing Engine - Automatic Transmission

1. Support the transaxle with the floor jack or jack stand.
2. Lower the engine into the vehicle and guide to mate with the dowel pins on the transmission.
3. When the engine and transmission are aligned on the shuffle pins, install the upper bell housing bolts. Do
not torque at this time.
NOTE:
Refer FASTENER NOTICE in Cautions and Notices.
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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6. Install the transmission nose bracket bolts.
Tighten: Tighten the transmission nose bracket bolts to 35 N.m (26 lb ft).
7.
8.
9.
10.
11.
12.
Remove the engine lift hoist.

Attach the metal power steering line.
Attach the lower power steering hose to the bottom of the power steering reservoir.
Install the upper radiator hose.
Install the lower radiator hose.
Attach the main coolant reservoir hose to the engine.
13. Raise the vehicle.

14. Install the lower engine to transmission bell housing bolts and tighten.
Tighten: Tighten the lower engine-to-transmission bell housing bolts to 65 N.m (48 lb ft).
15. Install the torque convertor bolts.
Tighten: Tighten the torque convertor bolts to 45 N.m (33 lb ft).
16. Install the starter.
17. Connect the heater hoses at the lower cowl.
18. Install the A/C compressor to engine mounting bolts.
Tighten: Tighten the A/C compressor-to-block bolts to 25 N.m (18 lb ft).
19.
20.
21.
22.
Install the accessory drive belt.

Install the exhaust down pipes to the catalytic convertor.
Lower the vehicle.
Tighten the upper bell housing bolts.
Tighten: Tighten the upper bell housing bolts to 65 N.m (48 lb ft).
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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26. Install the cruise control and throttle cables.

27. Install the battery tray and fuse block tray.
28. Install the fuse block.
1. Install the fuse block mounting bolts.
2. Route the engine harness into the fuse block.
3. Connect the lower weather pack connector.
4. Connect the main engine harness under the fuse block panel.
5. Assemble the fuse block and install the fuse block cover.
29. Connect the PCM electrical connector.
30. Install the PCM boot to the cowl.
31. Install the cowl cover.
32. Connect the following electrical connections:
1. The main harness connector by the master cylinder
2. The rear HO2S sensor
3. The purge solenoid electrical
33. Connect the purge hose to the throttle body.
34. Install the air box.
35. Install the air cleaner lid and the inlet duct.
36. Install the intake air temperature (IAT) electrical connection.
37. Connect the main ground on the left fender wall.
38. Connect the main wire feed to the fuse block.
39. Install the battery.
40. Add coolant.
41. Add power steering fluid.
42. Start the engine and check for leaks.
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
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Fig. 229: View of Oil Cap

NOTE:
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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1. Remove the engine oil filler cap.
Fig. 230: View Of Engine & Oil Filter

IMPORTANT: Make sure the oil filter gasket is removed from the cylinder block. Do not
tighten the oil filter.
2. Using a 14-flat 68 mm (2.68 in) oil filter wrench or 32 mm (1.26 in) socket, fully unscrew the oil filter
housing cap to allow the drain back of the oil contained in the housing.
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Fig. 231: Removing/Installing Oil Pan Drain Plug

3. Remove the engine oil drain plug and drain the oil into an approved container.
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Fig. 232: Removing/Installing Oil Filter Cap

4. Remove the oil filter assembly from the oil filter housing.
5. Grasp the filter housing cap with the filter element attached and gently tap the filter element on the
recycling container to release the filter element into the container.
6. Install the new oil filter element into the filter housing cap.
7. Inspect the filter housing cap O-ring and replace if worn, cut, or damaged.
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Fig. 233: View Of Engine & Oil Filter

8. Using a 14-flat 68 mm (2.68 in) oil filter wrench or 32 mm (1.26 in) socket, install the oil filter assembly
into the oil filter housing.
Tighten: Tighten the oil filter cap to 25 N.m (18 lb ft).
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Fig. 234: Removing/Installing Oil Pan Drain Plug

9. Clean and install the engine oil drain plug. Replace the drain plug sealing ring if worn or damaged.
Tighten: Tighten the oil drain plug to 25 N.m (18 lb ft).
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Fig. 235: View of Engine Oil Cap

10. Fill the engine with 4.73 L (5 quarts) of new 5W-30 engine oil.
11. Install the engine oil filler cap.
12. Start the engine and check for leaks.
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Fig. 236: Installing Oil Level Indicator Tube

13. Check the engine oil level after the engine is OFF for 5 minutes. Add oil as necessary.
14. Reset the CHANGE OIL SOON telltale lamp.
ENGINE MOUNT AND BRACKET REPLACEMENT - RIGHT
Removal Procedure
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Fig. 237: Removing & Installing Air Cleaner Element

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Fig. 238: Removing/Installing Intake Hose Assembly

2. Remove the air cleaner lid:
1. Loosen the hose clamp at the throttle body.
2. Slide off the flexible inlet hose to the throttle body hose.
3. Unclamp the air cleaner lid.
4. Remove the air cleaner lid, and hose as an assembly.
3. Remove the air cleaner from the air box.
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4. Remove the air box mount bolt.
5. Remove the air box.
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Fig. 240: Supporting Engine With Floor Jack

6. Support the engine weight with the floor jack under the oil pan.
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7. Remove the engine mount to bracket fasteners.
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8. Remove the engine mount to body attachment fasteners.
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10. Remove the engine mount bracket to the engine fasteners.
11. Remove the bracket from the vehicle.
NOTE:
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1. Install the engine mount bracket into the vehicle and tighten the fasteners.
Tighten: Tighten the engine mount bracket-to-engine bolts to 90 N.m (66 lb ft).
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2. Install the engine mount into the vehicle.
3. Install the engine mount to body fasteners.
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4. Install the engine mount to bracket bolts.
Tighten: Tighten the engine mount-to-engine mount bracket bolts to 55 N.m (41 lb ft).
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Fig. 247: Proper Installation Of Air Cleaner Assembly

1. Install the air box. Ensure that the lower pin engages into the rubber mount grommet and that the
lower duct fits into the resonator outlet.
2. Install the air box mount bolt.
3. Install the air cleaner.
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Fig. 248: Removing & Installing Air Cleaner Element

6. Install the air cleaner lid. Ensure that the lid hinge is fully engaged in the air box slots or the lid may not
properly seal.
7. Slide the flexible hose and hose clamp onto the throttle body.
8. Tighten the hose clamp.
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Tools Required
J 43649 Valve Spring Compressor. See Special Tools and Equipment.

J 43655 Camshaft Support Holding Tool. See Special Tools and Equipment.
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SA9102E-A Valve Seal Remover/Replacer. See Special Tools and Equipment.

SA9127E Gage Bar Set. See Special Tools and Equipment.
Removal Procedure
Fig. 249: Properly Installed Camshaft Support Holding Tool & Valve Spring Compressor
1. Remove the spark plugs, cam cover, and camshaft. Refer to Camshaft Cover Replacement.
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Fig. 250: Installing Spark Plug Adapter

IMPORTANT: During the camshaft removal procedure, the pistons are locked by the J
43655 and should not be rotated.
2. Install the J 43649 . Use 4 cam cover bolts to mount the supports to the cam cover threaded holes. See
Tighten: Tighten the cam cover bolts-to-hold valve spring compressor to 10 N.m (89 lb in).
3. Install the spark plug adapter from the SA9127E in the respective cylinder. See Special Tools and
Equipment.
NOTE:
Care should be used when servicing the valve spring, the retainer and the
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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.
Fig. 251: Removing Valve Seal

6. Remove the valve spring cap, retainers, and release spring tension.
7. Remove the cap and spring.
8. Remove the valve stem seal using the SA9102E-A . See Special Tools and Equipment.
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Fig. 252: Inspecting Valve Seal Contact Area

NOTE:
If a valve seal is removed after it has been installed, it must be discarded.

The valve stem lock groove will cut the seal's lip during removal. Use
extreme care when installing valve retainers and do not damage the valve
stems.
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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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.
Fig. 253: Installing Valve Stem Oil Seal

2. Oil the valve guide and valve stem. Install the valve stem oil seal with the SA9102E-A . See Special
Tools and Equipment.
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Fig. 254: Installing Valve Spring & Cap

3. Install the valve spring and cap.
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Fig. 255: Compressing Valve Spring & Installing Retainers

4.
5.
6.
7.
Compress the valve spring and install the retainers.

Install the hydraulic lash adjusters in their correct locations.
Remove the J 43649 and the spark plug adapter. See Special Tools and Equipment.
Install the camshafts, cam cover, and spark plugs. Refer to Camshaft Cover Replacement.
DRAINING FLUIDS AND OIL FILTER REMOVAL
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Fig. 256: Identifying Oil Filter Housing

1. Remove the oil filter cap. Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
NOTE:
4. Install the oil pan drain plug.

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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
J 43653 Flywheel Holding Tool. See Special Tools and Equipment.

Removal Procedure
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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Fig. 257: Removing/Installing Flywheel/Flexplate

2. Remove the flywheel, if the vehicle is equipped with a manual transmission.
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Fig. 258: Removing/Installing Flexplate/Flywheel Bolts

3. Remove the flywheel retainer and flywheel for vehicles equipped with an automatic transmission.
4. Clean the thread adhesive from the flywheel bolts. Use a nylon bristle brush to clean the bolt holes in the
crankshaft.
EXHAUST MANIFOLD REMOVAL
Removal Procedure
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Fig. 259: Identifying Air Pipe, Gasket, Bolts, & Nut

1.
2.
3.
4.
Remove the air pipe nut, if equipped.

Remove the air pipe bolts, if equipped.
Remove the air pipe, if equipped.
Remove the air pipe gasket, if equipped.
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Fig. 260: Removing & Installing Exhaust Manifold & Gasket

5. Remove the exhaust manifold heat shield.
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Fig. 261: Removing Engine Block Heater

6.
7.
8.
9.
10.
11.
Remove the engine block heater, if equipped.

Remove the heated oxygen sensor.
Remove the exhaust manifold to the cylinder head retaining nuts.
Remove the exhaust manifold.
Clean all sealing surfaces.
If the exhaust manifold is being replaced, transfer the following parts:
The exhaust manifold heat shield
The heated oxygen sensor
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12. Replace the exhaust manifold nuts.

INTAKE MANIFOLD REMOVAL
Removal Procedure
Fig. 262: Disconnecting Fuel Pressure Regulator Hose

1. Disconnect the fuel pressure regulator hose from the throttle body and fuel rail.
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2. Remove the throttle body.
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Fig. 264: Removing & Installing Fuel Rail Assembly

3. Remove the fuel pipes and clip.
4. Remove the fuel rail assembly.
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Fig. 265: Removing Knock Sensor

5. Remove the knock sensor connector from the intake manifold.
6. Remove the knock sensor.
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Fig. 266: Removing Intake Manifold

7.
8.
9.
10.
Remove the intake manifold retaining nuts and bolts.

Remove the intake manifold.
Remove the intake manifold gasket. The gasket is reusable if it is not damaged.
If the intake manifold needs to be replaced, transfer the following parts:
The throttle body
The body gasket. The manifold to throttle body gasket is reusable if it is not damaged.
CRANKSHAFT DAMPER REMOVAL

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Tools Required

Removal Procedure
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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3. Remove the damper assembly.
CAMSHAFT COVER REMOVAL
Removal Procedure
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Fig. 269: Removing Power Steering Pump

1. Remove the power steering pump, if equipped.
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Fig. 270: Disconnecting/Connecting Ground Strap On The Camshaft Cover Assembly

2. Remove the camshaft cover grounding strap.
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Fig. 271: Removing Front Lift Bracket

3. Remove the front lift bracket.
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Fig. 272: Removing Rear Lift Bracket

4. Remove the rear lift bracket.
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5. Remove the ignition module and coil assembly.
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6. Remove the camshaft cover assembly.
ENGINE FRONT COVER AND OIL PUMP REMOVAL
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1. Remove the accessory drive belt tensioner.
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2. Remove the engine front cover bolts.
3. Remove the water pump bolt.
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Fig. 277: Removing Engine Front Cover & Gaskets

4. Remove the engine front cover and gaskets.
5. Remove the crankshaft front cover oil seal using an oil seal removal tool.
TIMING CHAIN AND TENSIONER REMOVAL
Removal Procedure
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before the timing chain is removed. If it is not, the timing chain will
become misaligned and it will be difficult to remove.
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2. Remove the timing chain tensioner plunger.
3. Locate the hex on the exhaust camshaft and hold with a 24 mm open-end wrench.
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4. Remove the exhaust cam bolt and exhaust cam sprocket. Discard the bolt.
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6. Remove the plug to gain access to the fixed timing chain guide bolt.
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7. Remove the fixed timing chain guide.
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Fig. 284: Holding Camshaft Assembly Using 24 mm Wrench

8. Locate the hex on the intake camshaft and hold with a 24 mm open-end wrench.
9. Remove the intake cam sprocket bolt, the intake cam sprocket, and the timing chain through the top of the
cylinder head. Discard the bolt.
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Fig. 285: Installing Timing Chain Drive Sprocket

10. Remove the crankshaft sprocket.
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11. Remove the oil nozzle and bolt.
INTAKE CAMSHAFT, FOLLOWER, AND ADJUSTER REMOVAL
Removal Procedure
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Fig. 287: Removing Camshaft Bearing Caps

IMPORTANT: Remove each bolt on each cap 1 turn at a time until there is no spring
tension on the camshaft.
1.
2.
3.
4.
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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IMPORTANT: Keep all of the roller finger followers and valve lash adjusters in order so
that they can be reinstalled in their respective locations.
5. Remove the intake camshaft roller finger followers.
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Fig. 289: Removing Hydraulic Element Adjusters

6. Remove the hydraulic element adjusters.
EXHAUST CAMSHAFT, FOLLOWER, AND ADJUSTER REMOVAL
Removal Procedure
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Fig. 290: Removing Exhaust Camshaft

IMPORTANT: Remove each bolt on each cap one turn at a time until there is no spring
tension on the camshaft.
1. Remove the exhaust camshaft bearing cap bolts.
2. Remove the camshaft bearing caps ensuring they are marked and refitted in the same position on the
assembly.
3. Remove the exhaust camshaft.
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Fig. 291: Removing Exhaust Camshaft Roller Finger Followers

IMPORTANT: Keep all of the roller finger followers and valve lash adjusters in order so
that they can be reinstalled in their respective locations.
4. Remove the exhaust camshaft roller finger followers.
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Fig. 292: Removing Hydraulic Element Adjusters

5. Remove the hydraulic element adjusters.
BALANCE SHAFT DRIVE CHAIN AND TENSIONER REMOVAL
Removal Procedure
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Fig. 293: Removing Balance Shaft Drive Chain Tensioner

1. Remove the balance shaft drive chain tensioner.
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Fig. 294: Removing Adjustable Balance Shaft Chain Guide

2. Remove the adjustable balance shaft chain guide.
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Fig. 295: Removing Small Balance Shaft Drive Chain Guide

3. Remove the small balance shaft drive chain guide.
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Fig. 296: Removing Upper Balance Shaft Drive Chain Guide

4. Remove the upper balance shaft drive chain guide.
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Fig. 297: Removing Balance Shaft Drive Chain

IMPORTANT: It may ease the removal of the balance shaft drive chain to get all of the
slack in the chain between the crankshaft and water pump sprockets.
5. Remove the balance shaft drive chain.
6. Remove the crankshaft drive sprocket.
BALANCE SHAFT REMOVAL
Tools Required
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J 43650 Balance Shaft Bearing Remover/Installer. See Special Tools and Equipment.
Removal Procedure
Fig. 298: Removing Balance Shaft Bearing Carrier Bolts

1. Remove the balance shaft bearing carrier bolts.
IMPORTANT: It is possible to install the intake side balance shaft into the exhaust side
and vice versa. Use care not to install the balance shafts into the wrong
bores. Engine vibration will result.
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IMPORTANT: Do not remove the front balance shaft bearing bolt.

2. Remove the balance shaft assemblies.
Fig. 299: Installing J 43650

NOTE:
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
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Fig. 300: Tightening Nut

4. When the J 43650 is inserted into the block turn bearing tool so that the foot becomes perpendicular to
the shaft. See Special Tools and Equipment.
5. Center the foot of the bearing tool on the balance shaft bushing.
6. Once the tool is centered on the balance shaft bushing, then insert the centering guide into the front
balance shaft bore and tighten the nut snugly with an appropriate wrench.
NOTE:
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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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.
Fig. 301: Tightening Nut on Bearing Tool

8. Tighten the nut on the bearing tool until the tension releases. When the tension releases, remove the
bearing tool and the balance shaft bushings.
WATER PUMP REMOVAL
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Removal Procedure
Fig. 302: Installing ECT Sensor

1. Remove the engine coolant temperature sensor.
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Fig. 303: Removing Thermostat Housing & Thermostat Element

2. Remove the thermostat and water feed pipe retaining bolts.
IMPORTANT: Twist the water feed pipe while pulling to remove it from the water pump.
3. Remove the thermostat housing and water feed pipe from the water pump.
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Fig. 304: Removing Water Pump Assembly

IMPORTANT: Be sure to remove the bolt that goes through the front of the engine
block.
4. Remove the water pump retaining bolts.
5. Remove the water pump assembly.
CYLINDER HEAD REMOVAL
Tools Required
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J 38188 Cylinder Head Broken Bolt Extractor Kit. See Special Tools and Equipment.
Removal Procedure
Fig. 305: Removing EGR Cover, Gasket, & Bolts

1. Remove the EGR cover, bolts, and EGR cover gasket.
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Fig. 306: Removing Cylinder Head Bolts Using Loosening Sequence

2. Remove the cylinder head to block bolts using the loosening sequence. Discard the used bolts.
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Fig. 307: Removing Cylinder Head Gasket

3.
4.
5.
6.
Remove the cylinder head.

Remove the cylinder head gasket.
Clean all gasket surfaces.
Use the following procedures when cleaning the cylinder head and cylinder block surfaces:
Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do
not scratch or gouge any surface.
IMPORTANT: Do not use any other method or technique to clean these gasket
surfaces.
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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.
Hold the razor blade as parallel to the gasket surface as possible.
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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Fig. 308: Removing Engine Oil Pan Bolts

1. Remove the oil pan bolts.
2. Remove the oil pan at the pry points.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
Tools Required
J 41742 Connecting Rod Guide. See Special Tools and Equipment.

Removal Procedure
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Fig. 309: Removing Connecting Rod Bolts

1. Rotate the crankshaft to a position where the connecting rod bolts are most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure
that caps and connecting rods are reassembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
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Fig. 310: Removing Connecting Rod Cap

5. Remove the connecting rod cap.
6. Install the J 41742 in the connecting rod bolt holes before removing the piston and connecting rod
assembly. See Special Tools and Equipment.
7. Remove the piston and connecting rod assembly.
8. Complete steps 2-7 for the remaining pistons and connecting rods.
LOWER CRANKCASE REMOVAL
Removal Procedure
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Fig. 311: Removing Crankshaft Position Sensor

1.
2.
3.
4.
5.
Remove the crankshaft position sensor.

Inspect the position sensor for damage. Replace if necessary.
Remove the bedplate perimeter bolts.
Remove the crankshaft bearing bolts and discard.
Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase.
ENGINE BLOCK DISASSEMBLE
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Fig. 312: View Of Oil Passage Plug, Oil Flow Check Valve & Water Jacket Drain Plug
1.
2.
3.
4.
5.
6.
Remove the water jacket drain plug.

Remove the oil flow check valve.
Remove the rear oil passage plug.
Remove the six oil passage plugs on the sides of the block.
Remove the two water passage plugs on the top of the block.
Remove the two front oil passage plugs.
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Fig. 313: View of Knock Sensor

7. Remove the knock sensor and bolt.
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Fig. 314: View Of Engine Oil Pressure Sensor

8. Remove the oil pressure switch.
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Fig. 315: View Of Crankshaft Position Sensor

9. Remove the crankshaft position sensor and bolt.
ENGINE BLOCK CLEANING AND INSPECTION
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Fig. 316: Cleaning Engine Block & Lower Crankcase

1.
2.
3.
4.
5.
6.
7.
Clean the sealing material from the gasket mating surfaces.

Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
Flush the engine block with clean water or steam.
Clean the oil passages.
Clean the blind holes.
Spray the cylinder bores and the machined surfaces with engine oil.
Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and
install thread inserts. Refer to Thread Repair.
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Fig. 317: Checking Deck Surface For Flatness

IMPORTANT: Do not attempt to machine the lower crankcase to engine block surfaces.
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor
irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to
remove any nicks.
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Fig. 318: Checking Lower Crankcase Engine Block Side

10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.
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Fig. 319: Checking Lower Crankcase Oil Pan Side

11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.
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Fig. 320: Checking Crankshaft Flange Runout

12. Inspect the mating surfaces of the transmission face.
NOTE:
A broken flywheel may result if the transmission case mating surface is

not flat.
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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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).
Fig. 321: Inspecting Crankshaft Main Bearing Bores

14. Inspect the crankshaft main bearing bores. Use a bore gage to measure the bearing bore concentricity and
alignment.
15. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
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Fig. 322: Inspecting Cylinder Bores Using J 8087

16. Inspect the cylinder bores. Inspect for the following items:
Wear
Taper
Runout
Ridging
CRANKSHAFT BALANCER CLEANING AND INSPECTION
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Fig. 323: View of Crankshaft Balancer

1. Clean the crankshaft balancer.
2. Clean the belt grooves of all dirt or debris with a wire brush.
CAUTION: Refer to SAFETY GLASSES & COMPRESSED AIR CAUTION in
Cautions and Notices.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following:
Worn, grooved, or damaged hub seal surface
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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.
Dirty or damaged belt grooves

The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow
the belt to track properly.
Minor imperfections may be removed with a fine file.
ENGINE FLYWHEEL CLEANING AND INSPECTION
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Fig. 324: View of Flywheel

CAUTION: Standard shop practices, particularly eye protection, should be
followed during these operations to avoid personal injury.
1. Clean the flywheel.
2. Dry the flywheel with compressed air.
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3. Inspect the manual transmission flywheel for the following:
Damaged ring gear teeth
Loose or improperly positioned ring gear
The ring gear has an interference fit onto the flywheel and should be positioned completely against
the flange of the flywheel.
A scored, grooved, or damaged friction surface
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Fig. 326: Removing/Installing Flexplate/Flywheel Bolts

4. Inspect the automatic transmission flywheel for the following:
Damaged ring gear teeth
Stress cracks around the flywheel-to-crankshaft bolt hole locations and weight saving holes
CYLINDER HONING
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Fig. 327: Measuring Cylinder Bore

1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100
mm (4 in) below the head gasket surface.
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Fig. 328: Measuring Bore Gauge With Micrometer

3. Measure the cylinder bores by setting the cylinder gauge dial at zero in the cylinder at the point of the
desired measurement. Lock the dial indicator at zero before removing the dial from the cylinder. Measure
across the gauge contact points with an outside micrometer, with the gauge at the same zero setting as
when the gauge was removed from the cylinder.
4. Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do
not hone the cylinder in order to remove these scratches.
5. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston
rings. Refer to Piston, Connecting Rod, and Bearing Installation.
The honing stones must be clean, sharp, and straight.
Move the hone slowly up and down to produce a 45 degree cross hatch pattern.
Clean the bore thoroughly with soap and water.
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Dry the bore.

Rub clean engine oil in the bore.
Remeasure the bore.
6. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to
the bore after washing and drying the bore.
CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION

Tools Required
J 7872 Magnetic Base Dial Indicator Set. See Special Tools and Equipment.
Fig. 329: View Of Camshaft

IMPORTANT: Use care when handling the crankshaft. Avoid damage to the bearing
surfaces or the lobes of the crankshaft position reluctor ring. Damage to
the teeth of the crankshaft position reluctor ring may effect OBD II system
performance.
1. Clean the crankshaft with solvent.
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2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
CAUTION: Refer to SAFETY GLASSES CAUTION in Cautions and Notices.
3. Dry the crankshaft with compressed air.

IMPORTANT: Reluctor ring teeth should not have imperfections on the rising or falling
edges.
Imperfections of the reluctor ring teeth may effect OBD II system
performance.
4. Perform a visual inspection of the crankshaft for damage.
Fig. 330: Identifying Different Crankshaft Journal Wear Patterns

5. Inspect the crankshaft journals for wear (1).
Journals should be smooth with no signs of scoring, wear, or damage.
6. Inspect the crankshaft journals for grooves or scoring (2).
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7. Inspect the crankshaft journals for scratches or wear (3).

8. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
Fig. 331: Measuring Crankshaft Journals

9. Measure the crankshaft journals for out-of-round.
10. Measure the crankshaft journals for taper.
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Fig. 332: Measuring Crankshaft Runout

11. Measure the crankshaft runout.
Using wooden V blocks, support the crankshaft on the front and rear journals.
12. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. See
13. Use the J 7872 in order to measure the runout of the crankshaft rear flange. See Special Tools and
Equipment.
14. Replace the crankshaft if the measurements are not within specifications.
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Fig. 333: Identifying Crankshaft Bearing Craters Or Pockets

15. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate
fatigue.
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Fig. 334: Identifying Connecting Rod Bearing Scoring Or Discoloration

16. Inspect the crankshaft bearings for excessive scoring or discoloration.
17. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
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Fig. 335: Crankshaft Bearing Polished Sections (Improper Seating)

18. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing.
If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced.
Generally, if the lower half is suitable for use, the upper half should also be suitable for use.
PISTON AND CONNECTING ROD DISASSEMBLE
Tools Required
J 43654 Piston Pin Clip Installer. See Special Tools and Equipment.
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Fig. 336: Piston Rings Disassembled View

CAUTION: Handle the piston carefully. Worn piston rings are sharp and may
cause bodily injury.
1. Disassemble the piston rings. Use a suitable tool in order to expand the rings. Piston rings must not be
reused.
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Fig. 337: Removing Piston Pin Retaining Ring Clips

2. Remove the piston pin retaining clips using the J 43654 . See Special Tools and Equipment.
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Fig. 338: Removing Piston Pin

3. Remove the piston pin.
PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION
Connecting Rod Measurement
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Fig. 339: Cleaning Connecting Rods

1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rods for the following:
Signs of being twisted, bent, nicked, or cracked
Scratches or abrasion on the rod bearing seating surface
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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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Fig. 340: Identifying Piston Damage Inspection Areas

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions:
Cracked ring lands, skirts, or pin bosses
Ring grooves for nicks, burrs that may cause binding
Warped or worn ring lands
Eroded areas at the top of the piston (1)
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Scuffed or damaged skirts (2)

Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure:
1. Piston pin bores and pins must be free of varnish or scuffing.
2. Use an outside micrometer to measure the piston pin in the piston contact areas.
3. Using an inside micrometer, measure the piston pin bore.
4. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be
within 0.002-0.012 mm (0.00007-0.00047 in).
5. If the clearance is excessive, determine which component is out of specification.
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Fig. 341: Measuring Piston Ring End Gap

6. Measure the piston ring end gap using the following procedure:
1. Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm
or 1 inch down from the deck surface). Be sure the ring is square with the cylinder bore by
positioning the ring with the piston head.
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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.
Fig. 342: Measuring Piston Ring Side Clearance

7. Measure the piston ring side clearance using the following procedure:
1. Roll the piston ring entirely around the piston ring groove. If any binding is caused by a distorted
piston ring, replace the ring.
2. With the piston ring on the piston, use feeler gages to check clearance at multiple locations.
3. The clearance between the surface of the top piston ring and the ring land should be no greater than
0.075 mm (0.0030 in).
4. If the clearance is greater than specifications, replace the piston ring.
5. If the new ring does not reduce the top ring side clearance to 0.075 mm (0.0030 in) or less, install a
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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.
Fig. 343: Measuring Piston Diameter

11. Measure piston width using the following procedure:
1. Using an outside micrometer, measure the width of the piston 14.5 mm (0.570 in) above the bottom
of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin.
2. Compare the measurement of the piston to its original cylinder by subtracting the piston width from
the cylinder diameter.
3. The proper clearance specification for the piston is 0.010-0.041 mm (0.0006-0.0016 in).
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12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores
are within specification, replace the piston.
Piston Selection
Fig. 344: Measuring Cylinder Bore

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IMPORTANT: Measurements of all components should be taken with the components at

normal room temperature.
For proper piston fit, the engine block cylinder bores must not have
excessive wear or taper.
A used piston and pin set may be reinstalled if, after cleaning and
inspection, they are within specifications.
1. Inspect the engine block cylinder bore. Refer to Engine Block Cleaning and Inspection.
2. Inspect the piston and the piston pin. Refer to Piston, Connecting Rod, and Bearings Cleaning and
Inspection.
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top
of the cylinder bore.
Fig. 345: Measuring Bore Gauge With Micrometer

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4. Measure the bore gauge with a micrometer and record the reading.
Fig. 346: Measuring Piston Diameter

5. With a micrometer or caliper at a right angle to the piston, measure the piston 14 mm (0.570 in) from the
bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore
clearance.
7. For proper piston-to-bore clearance. Refer to Engine Mechanical Specifications.
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a
permanent marker for installation to the proper cylinder. Refer to Separating Parts.
PISTON AND CONNECTING ROD ASSEMBLE
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Tools Required
J 43654 Piston Pin Clip Installer. See Special Tools and Equipment.
Fig. 347: Assembling Connecting Rod & Piston

IMPORTANT: Install the piston onto the connecting rod with the arrow oriented toward
the front of the engine.
1. Assemble the connecting rod and the piston.
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Fig. 348: Installing Piston Ring Retainers

NOTE:
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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4. Install the second piston pin retainer using an insertion tool.

5. Ensure that the piston moves freely.
Fig. 349: Piston Ring Disassembled View

NOTE:
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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3. Upper control ring

4. Install the lower compression ring (second ring). Place the manufacturer's mark facing up.
5. Install the upper compression ring (top ring).
CAMSHAFT CLEANING AND INSPECTION
Fig. 350: Cleaning & Inspecting Camshaft

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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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.
TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION
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Fig. 351: Exploded View Of Timing Chain & Sprocket Assemblies

1. Inspect the timing chain guides for cracking or wear.
2. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the timing chain tensioner shoe for wear.
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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
Fig. 352: Cleaning Balance Shafts

1.
2.
3.
4.
Clean the balance shafts in solvent.

Remove the balance shaft front bearing carriers from the balance shafts.
Inspect the bearing surfaces on the balance shafts for scoring or unusual wear.
Inspect the balance shaft drive sprockets for wear, damage, or missing teeth. When installing new balance
shaft drive sprockets tighten to 55 N.m (41 lb ft).
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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
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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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

J 36017 Valve Guide Seal Remover. See Special Tools and Equipment.
J 43963 Valve Spring Compressor Adapter. See Special Tools and Equipment.
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Fig. 354: Identifying Cylinder Head Air Bleed Tube

1. Remove the coolant air bleed hose fitting.
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Fig. 355: Identifying Valve Spring Retainers

IMPORTANT: Ensure that the valve train components are kept together and identified in
order for proper re-installation in their original position.
2. Using the J 8062 and the J 43963 , compress the valve spring. See Special Tools and Equipment.
3. Remove the valve keys.
4. Slowly release the J 8062 and the J 43963 from the valve spring assembly. See Special Tools and
Equipment.
5. Remove the retainer.
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Fig. 356: View Of Valve Springs

6. Remove the spring.
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Fig. 357: Identifying Valve Seals

NOTE:
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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Fig. 358: Identifying Engine Valves

8. Remove the valve.
9. Remove the remaining valves.
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Fig. 359: View Of Cylinder Head Plugs

10. Remove the cylinder head plugs.
CYLINDER HEAD CLEANING AND INSPECTION
Valve Cleaning and Inspection
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Fig. 360: Identifying Inspection Points For Valves Damage

IMPORTANT: Do not scratch the valve stem with the wire brush.
1. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush, varnish can be
removed by soaking in Parts Immersion Solvent, or equivalent.
2. Clean the valve guides.
3. Inspect the valve stem for wear (4).
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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
Fig. 361: Identifying Spark Plugs

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1. Remove the spark plugs.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has
failed, use the following faults to determine the cause:
Improper installation
Loose or warped cylinder head
Missing, off location or not fully seated dowel pins
Corrosion in the seal area around the coolant passages
Chips or debris in the cylinder head bolt holes
Bolt holes in the cylinder block not drilled or tapped deep enough
Other
Fig. 362: Inspecting Cylinder Head Gasket Surface

3. Inspect the cylinder head gasket surface.
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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.
IMPORTANT: Do not use a wire brush on any gasket sealing surface.

5.
6.
7.
8.
9.
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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Fig. 363: Checking Cylinder Head Deck Surface

13.
14.
15.
16.
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.

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17. Inspect the cylinder head plugs.

CYLINDER HEAD ASSEMBLE
Tools Required

J 9666 Valve Spring Tester. See Special Tools and Equipment.
J 43963 Valve Spring Compressor Adapter. See Special Tools and Equipment.

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NOTE:
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.
Fig. 366: Inspecting Valve Spring For Squareness

2. Inspect the valve springs. Refer to Engine Mechanical Specifications for the tolerances.
3. Look for the following conditions when inspecting the valve springs:
Expanded height
Unparallel spring ends
Spring tension using J 9666
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Any distorted springs should be replaced
Fig. 367: Applying Prussian Blue

4. Assemble the valves.
5. Use the following steps to measure valve runout:
1. Apply a dab of Prussian blue on the entire valve face. Seat the valve but do not rotate it. The
Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat.
2. Clean all traces of Prussian blue.
3. Apply a dab of Prussian blue on the valve seat and repeat the check. The traces of Prussian blue
transferred to the valve face indicates valve face concentricity.
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4. Replace the valves, if required.
Fig. 368: Identifying Engine Valves

6. Lubricate the valve stems with engine oil supplement.
7. Install the valves.
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Fig. 369: Identifying Valve Seals

8. Install the new valve seals. Fully seat the seals on the valve guides.
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Fig. 370: View Of Valve Springs

9. Install the spring.
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Fig. 371: Identifying Valve Spring Retainers

10.
11.
12.
13.
Install the retainer.

Using the J 8062 and the J 43963 , compress the valve spring. See Special Tools and Equipment.
Install the valve keys.
Slowly release the J 8062 and the J 43963 from the valve/spring assembly. See Special Tools and
Equipment.
14. Inspect for proper valve key seating.
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Fig. 372: Identifying Cylinder Head Air Bleed Tube

NOTE:
15. Install the cylinder head air bleed tube.

OIL PUMP DISASSEMBLE
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Fig. 373: Identifying Pressure Relief Valve

1. Disassemble the pressure relief valve.
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Fig. 374: Removing Gerotor Cover & Bolts

2.
3.
4.
5.
Remove the gerotor cover and bolts.

Clean all parts in cleaning solvent. Remove the varnish, sludge, and dirt.
Inspect the oil pump gears for wear and scoring. Ensure all components are within specifications.
Replace the front cover and oil pump assembly if out of specification or damaged.
OIL PUMP CLEANING AND INSPECTION

Tools Required
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SA91101NE Feeler Gage Set. See Special Tools and Equipment.
Fig. 375: Measuring Driven Rotor & Pump Body Clearance

1. Inspect the body clearance:
1. Using a SA91101NE or equivalent, measure the clearance between the driven rotor and the pump
body. See Special Tools and Equipment.
Specification:
The standard driven rotor to pump body side clearance is 0.150-0.277 mm (0.006-0.0011 in).
The service limit driven rotor to pump body side clearance is a maximum of 0.277 mm
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(0.011 in).
2. If the clearance is greater than the service limit, replace the oil pump assembly.
Fig. 376: Measuring Clearance Between Both Rotor Tips

2. Inspect the tip clearance:
1. Using a SA91101NE or equivalent, measure the clearance between both rotor tips. See Special
Tools and Equipment.
Specification: The service limit rotor tip clearance is a maximum of 0.150 mm (0.006 in).
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Fig. 377: Measuring Driven Rotors & Oil Pump Cover Plate Clearance
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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OIL PUMP ASSEMBLE
Fig. 378: Exploded View of Gerotor Gears

NOTE:
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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NOTE:
2. Install the gerotor cover and bolts.

Tighten: Tighten the oil pump gerotor cover bolts to 6 N.m (53 lb in).
Fig. 379: Identifying Pressure Relief Valve Piston

3. Install the pressure relief valve piston.
4. Install the pressure relief valve spring.
5. Install the pressure relief valve plug.
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Tighten: Tighten the oil pump pressure relief valve plug to 40 N.m (30 lb ft).
INTAKE MANIFOLD CLEANING AND INSPECTION
Fig. 380: Cleaning & Inspecting Intake Manifold

1.
2.
3.
4.
Clean the intake manifold mating surfaces.

Inspect the intake manifold for damage.
Inspect the intake manifold for cracks near the compression limiters.
Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as
necessary.
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5. Replace the intake manifold as necessary.

EXHAUST MANIFOLD CLEANING AND INSPECTION
Fig. 381: Inspecting Exhaust Manifold

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IMPORTANT:
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon

installation of the exhaust manifold, install a NEW gasket. An
improperly installed gasket or leaking exhaust system may effect
On-Board Diagnostics (OBD) II system performance.
Remove the oxygen sensor prior to cleaning the manifold, do not
submerge the oxygen sensor in cleaning solvent.
1. Remove the oxygen sensor from the manifold.

2. Clean the exhaust manifold in solvent.
CAUTION: Refer to SAFETY GLASSES CAUTION in Cautions and Notices.
3. Dry the exhaust manifold with compressed air.

4. Inspect the heat shield for damage.
Fig. 382: Measuring Exhaust Manifold To Cylinder Head Surface For Warpage
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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
Fig. 383: Cleaning & Inspecting Oil Pan

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1.
2.
3.
4.
5.
Clean the oil pan mating surface.

Clean the oil pan. Remove all the sludge and the oil deposits.
Inspect the threads for the engine oil drain plug.
Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
Inspect the oil pan for cracking resulting from impact or flying road debris.
IMPORTANT: The oil pan baffle and pickup screen are not removable from the oil pan.
6. Inspect the oil pan baffle and pickup screen.

7. Repair or replace the oil pan as necessary.
THREAD REPAIR - MAIN CAP BOLT HOLE
Thread Repair Kit
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Fig. 384: View of Self-locking Insert

The Time Sert thread repair process involves a solid bushing type insert. The insert is made of carbon and is
self-locking. During the bushing installation process, the driver tool expands the bottom external threads of the
insert into the base material. This action mechanically locks the insert in place. Also when installed to the
proper depth, the flange of the insert will be seated against the counter-bore of the repaired hole.
CAUTION: Standard shop practices, particularly eye protection, should be followed
during these operations to avoid personal injury.
IMPORTANT: The use of a cutting type fluid GM P/N 1052864, WD 40, or equivalent is
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recommended when performing drilling, counter-boring, and tapping

procedures.
Fig. 385: View of Driver Tool

Driver oil must be used on installer driver tool.
The tool kits are designed for use with either a suitable tap wrench or drill motor.
1. Drill out threads of damaged hole.
M6 inserts require a minimum drill depth of 15 mm (0.59 in).
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M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
2. Using compressed air, clean out any chips.
Fig. 386: Counter-boring Hole

3. Counter-bore hole to full depth permitted by tool.
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Fig. 387: Tapping Threads of Drilled Hole

5. Using a tap wrench, tap threads of drilled hole.
M6 inserts require a minimum tap depth of 15 mm (0.59 in).
M8 inserts require a minimum tap depth of 20 mm (0.79 in).
M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
7. Spray cleaner GM P/N 12346139, P/N 12377981 or equivalent into holes.
8. Using compressed air, clean any cutting oil and chips out of drilled hole.
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Fig. 388: Applying Lubricant to Threads of Installer Tool

IMPORTANT: Do not allow oil or other foreign material to contact outside diameter (OD)
of insert.
9. Lubricate threads of installer tool with drive oil.
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Fig. 389: Installing Insert to Installer Tool

10. Install insert onto installer tool.
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Fig. 390: Applying High Strength Threadlock Red to Insert OD Threads

11. Apply High Strength Threadlock Red, J42385-109 or equivalent to insert OD threads.
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Fig. 391: Installing Insert

IMPORTANT: Installer tool will tighten up before screwing completely through insert.
This is acceptable. You are forming bottom threads of insert and
mechanically locking insert to base material threads.
12. Install insert into hole.
1. Install insert until flange of insert contacts counter-bored surface.
2. Continue to rotate installer tool through insert.
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Fig. 392: View of Properly Installed Insert

IMPORTANT: A properly installed insert will be either flush or slightly below flush with
surface of base material.
13. Inspect insert for proper installation into hole.
Main Cap Bolt Hole Thread
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Fig. 393: View of Main Cap Bolt Thread Repair Kit

1. The main cap bolt thread repair kit consists of the following items:
Drill (1)
Tap (2)
Installer (3)
Fixture Plate (4)
Long Bolts (5)
Short Bolts (6)
Alignment Pin (7)
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Bushing (8)
Fig. 394: Identifying Alignment Doll Pins

2. Remove the alignment doll pins on holes 1-4 if necessary.
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Fig. 395: Installing Fixture Plate

3. Install fixture plate, bolt and bushing onto engine block.
Position the fixture plate and bushing over the hole that is to be replaced.
4. Position alignment pin in desired hole and tighten fixture retaining bolts.
5. Drill out the damaged hole.
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7. Using a tap wrench, tap the threads of the drilled hole.
In order to tap new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap
aligns with the top of the bushing.
9. Spray cleaner GM P/N 12346139 (or equivalent) into the hole.
10. Using compressed air, clean any cutting oil and chips out of the hole.
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Fig. 397: Applying Lubricant to Thread of Installer Tool

IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter
(OD) of the insert.
11. Lubricate the threads of the installer tool (2) with the driver oil (1).
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Fig. 398: Installing Insert to Driver Tool

12. Install the insert (2) onto the driver tool (1).
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Fig. 399: Applying Threadlock To Insert

13. Apply High Strength Threadlocker Red, J42385-109, (or equivalent) to the insert OD threads.
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Fig. 400: Identifying Bushing, Fixture Plate, & Tool

IMPORTANT: The fixture plate and bushing remains installed onto the engine block
during the insert installation procedure.
14. Install the insert and driver through the bushing (2), fixture plate (1) and into the hole.
Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2).
The installer tool will tighten up before screwing completely through the insert. This is acceptable. You
are forming the bottom threads of the insert and mechanically locking the insert to the base material
threads.
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15. Remove the driver, bushing (2), fixture plate (1) and bolts.
Fig. 401: Installing Alignment Doll Pins

16. Install the alignment doll pins in holes 1-4 if necessary.
Cylinder Head Bolt Hole
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Fig. 402: View of Cylinder Head Bolt Thread Repair Kit

The cylinder head bolt thread repair kit consists of the following items:
Drill (1)
Tap (2)
Installer (3)
Alignment Pin (4)
Bushing (5)
Bolts (6)
Fixture Plate (7)
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Fig. 403: Installing Fixture Plate, Bolts, & Bushing

CAUTION: Standard shop practices, particularly eye protection, should be followed
during these operations to avoid personal injury.
IMPORTANT: The use of a cutting type fluid GM P/N 1052864, WD 40 (or equivalent) is
recommended when performing drilling, counter-boring, and tapping
procedures.
Driver oil must be used on installer driver tool.
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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.
Fig. 404: Positioning Alignment Pin

3. Position alignment pin through bushing and into hole.
4. With alignment pin in desired hole, tighten fixture retaining bolts.
5. Remove alignment pin from hole.
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Fig. 405: Drilling Out Threads of Damaged Hole

IMPORTANT: During drilling process, it is necessary to repeatedly remove drill and
clean chips from hole.
6. Install drill sleeve onto the drill if required.
7. Drill out threads of damaged hole.
M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
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9. Using tap wrench, tap threads of drilled hole.
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Fig. 407: Aligning Mark of Tap With Top of Drill Bushing

10. Tap new threads to proper depth by turning tap into hole until mark on tap aligns with top of drill
bushing.
11. Remove fixture plate, bushing, and bolts.
13. Spray cleaner GM P/N 12346139, P/N 12377981 (or equivalent) into hole.
14. Using compressed air, clean any cutting oil and chips out of hole.
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Fig. 408: Applying Lubricant to Threads of Installer Tools

IMPORTANT: Do not allow oil or other foreign material to contact outside diameter (OD)
of insert.
15. Lubricate threads of installer tool with driver oil.
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Fig. 409: Installing Insert to Driver Tool

16. Install the insert (2) onto driver tool (1).
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Fig. 410: Apply High Strength Threadlock Red To Insert Of Threads

17. Apply High Strength Threadlock Red, J42385-109 (or equivalent) to insert OD threads.
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Fig. 411: Installing Insert & Driver into Hole

18. Install insert and driver into hole.
IMPORTANT: Installer tool will tighten up before screwing completely through insert.
This is acceptable. You are forming bottom threads of insert and
mechanically locking insert to base material threads.
19. Rotate driver tool until mark on tool aligns with deck surface of engine block.
SERVICE PRIOR TO ASSEMBLY
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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
1. Install the drain plug in the water pump.
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2. Apply sealant P/N 21485278, to the plug before installation.

NOTE:
3. Install the coolant jacket plugs.

Tighten: Tighten the coolant jacket plug to 35 N.m (26 lb ft).
4. Install the rear oil passage plugs.
5. Apply sealant P/N 21485278, to the plugs before installation.
Tighten: Tighten the oil passage plug to 60 N.m (44 lb ft).
6. Install the other oil passage plugs.
7. Apply sealant P/N 21485278, to the plug before installation.
Tighten: Tighten the oil passage plugs to 35 N.m (26 lb ft).
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Fig. 413: View Of Crankshaft Position Sensor

8. Lubricate the crankshaft position sensor O-ring with engine oil.
9. Install the crankshaft position sensor and bolt.
Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
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Fig. 414: View Of Engine Oil Pressure Sensor

10. Install the oil pressure switch.
Tighten: Tighten the oil pressure switch to 10 N.m (89 lb in).
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Fig. 415: View of Knock Sensor

11. Install the knock sensor and bolt.
Tighten: Tighten the knock sensor bolt to 25 N.m (18 lb ft).
CRANKSHAFT AND BEARINGS INSTALLATION
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Fig. 416: Inspecting Crankshaft & Connecting Rod Bearing Bores

IMPORTANT: If the crankshaft bearing failure is due to other than normal wear, investigate
the cause. Inspect the crankshaft or connecting rod bearing bores.
Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:
Tighten the bearing cap to specification.

Measure the bearing bore for taper and out-of-round.
No taper or out-of-round should exist.
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Bearing Selection
Fig. 417: Measuring Bearing Clearance

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are 2
methods to measure bearing clearance.
Method A gives more reliable results and is preferred. Method A yields measurement from which
the bearing clearance can be computed.
Method B yields the bearing clearance directly. Method B does not give any indication of bearing
run-out.
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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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Fig. 418: Measuring Bearing Clearance: Method B

3. To measure the bearing clearance using Method B, use the following procedure:
1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of bearing gaging plastic across the entire bearing width.
4. Install the bearing caps.
NOTE:
In order to prevent the possibility of cylinder block or crankshaft

bearing cap damage, the crankshaft bearing caps are tapped into the
cylinder block cavity using a brass, lead, or a leather mallet before
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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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Fig. 419: View Of Crankshaft Bearing Inserts

1. Install the crankshaft bearings and lubricate bearing surfaces with engine oil.
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Fig. 420: Identifying Crankshaft

2. Install the crankshaft on the journals.
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Fig. 421: Applying Sealer to Engine Block to Bedplate Mating Surfaces

3. Apply sealer P/N 21019581, to the surfaces of the engine block to bedplate mating surfaces.
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Fig. 422: Identifying Crankshaft Bearing Inserts

4. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
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Fig. 423: View Of Upper & Lower Crankcase W/Bolts

5. Install the lower crankcase. Tap gently into place with a suitable tool if necessary. Ensure it is aligned
properly on the dowels.
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Fig. 424: Identifying Crankshaft Bearing Bolt Tightening Sequence

NOTE:
6. Install the crankshaft bearing bolts in sequence finger tight.

1. Tighten the crankshaft bearing bolts in sequence.
Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft).
2. Tighten the crankshaft bearing bolts in sequence.
Tighten: Tighten the crankshaft bearing bolts 70 degrees using the J 36660-A (SA9140E). See
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Fig. 425: Lower Crankcase Perimeter Bolt Tightening Sequence

7. Tighten the lower crankcase perimeter bolts in sequence.
Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).
CRANKSHAFT REAR OIL SEAL INSTALLATION
Tools Required
J 42067 Rear Crankshaft Seal Installer. See Special Tools and Equipment.
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Fig. 426: Removing Seal Recess

1. Remove the excess sealer from the seal recess.
2. Lubricate the outside diameter of the crankshaft seal with clean engine oil.
3. Press the new crankshaft seal into housing, using the J 42067 . See Special Tools and Equipment. The
installer also establishes the depth of the seal in the crankshaft seal bore.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Tools Required
J 41742 Connecting Rod Guide. See Special Tools and Equipment.
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J 43953 Piston Ring Compressor. See Special Tools and Equipment.
Fig. 427: Installing Connecting Rod Bearings

1. Install the connecting rod bearings. Use the proper size bearings.
1. Install the bearing inserts into the connecting rod and the connecting rod cap.
2. Lubricate the connecting rod bearings with clean engine oil.
2. Install the J 41742 into the connecting rod bolt holes This protects the crankshaft journal during piston
and connecting rod installation. See Special Tools and Equipment.
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3. Install the piston and connecting rod into the cylinder.

1. Stagger each piston ring end gap equally around the piston.
2. Lubricate the piston and piston rings with clean engine oil.
3. Install the J 43953 over the piston. See Special Tools and Equipment. Do not disturb the piston
ring end gap location.
4. The piston must be installed so that the arrow on top of the piston faces the front of the engine.
5. Place the piston in its matching bore.
6. Push the piston into its bore with a hammer handle. Guide the connecting rod to connecting rod
journal while tapping the piston into place.
7. Hold the J 43953 against the engine block until all rings have entered the cylinder bore. See
8. Remove the connecting rod guides from the connecting rod bolt holes.
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Fig. 428: Installing Connecting Rod Cap

IMPORTANT: Ensure that the connecting rod cap is properly oriented on the connecting
rod.
4. Install the connecting rod cap.
IMPORTANT: Always use new bolts.
5. Install the connecting rod bolts.
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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.
Fig. 429: Measuring Connecting Rod Side Clearance

7. Measure the connecting rod side clearance with a feeler gage.
Tighten: Tighten the connecting rod side clearance to 0.07-0.37 mm (0.0027-0.0145 in).
CYLINDER HEAD INSTALLATION
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J 36660-A (SA9140E) Torque Angle Meter. See Special Tools and Equipment.
Fig. 430: View Of Cylinder Head And Gasket

IMPORTANT: Do not use any sealing material.
1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
IMPORTANT: Always use new cylinder head bolts.
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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.
Fig. 431: Identifying Cylinder Head Bolt Tightening Sequence

NOTE:
4. Install and tighten the cylinder head bolts in sequence.

Tighten:
Tighten bolts 30 N.m (22 lb ft).
Then turn all the bolts 155 degrees in sequence. Use the J 36660-A (SA9140E). See Special Tools
and Equipment.
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Fig. 432: Locating Front Cylinder Head Bolts

5. Install the front cylinder head bolts.
Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).
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Fig. 433: Removing & Installing EGR Cover & Gasket

6. Install the EGR cover (2), the bolts (1), and the EGR cover gasket (3).
Tighten: Tighten the EGR cover bolts to 25 N.m (18 lb ft).
Tools Required
INTAKE CAMSHAFT, FOLLOWER, AND ADJUSTER INSTALL
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Fig. 434: View Of Hydraulic Element Lash Adjusters

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with engine oil supplement.
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Fig. 435: Lubricating Valve Tips

3. Lubricate the valve tips with engine oil supplement.
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Fig. 436: View Of Camshaft Roller Followers

IMPORTANT: Used roller followers must be returned to the original position on the
camshaft. If the camshaft is being replaced, the roller followers actuated
by the camshaft must also be replaced.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller
followers with engine oil supplement.
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Fig. 437: View Of Camshaft Bearing Caps

5. Set the intake camshaft on top of the roller followers in the camshaft bearing journals and lobes.
Lubricate with engine oil supplement.
6. Install the camshaft bearing caps and hand start the camshaft cap bolts.
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Fig. 438: View Of Camshaft Alignment Notches

NOTE:
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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Fig. 439: Applying Camshaft Bearing Cap Sealer To Rear Cap

9. Apply Permatex Anaerobic Gasket Maker 51813, 3.5 mm (0.138 in) bead, to rear intake camshaft
bearing cap.
10. Install the rear intake camshaft bearing cap bolts.
EXHAUST CAMSHAFT, FOLLOWER, AND ADJUSTER INSTALL
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Fig. 440: View Of Hydraulic Element Lash Adjusters

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic element lash adjusters with engine oil supplement.
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Fig. 441: Lubricating Valve Tips

3. Lubricate the valve tips with engine oil supplement.
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Fig. 442: Identifying Exhaust Camshaft Roller Followers

IMPORTANT: Used roller followers must be returned to the original position on the
camshaft. If the camshaft is being replaced, the roller followers actuated
by the camshaft must also be replaced.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller
followers with engine oil supplement.
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Fig. 443: View Of Camshaft & Bearing Caps

5. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with
engine oil supplement.
6. Install the camshaft bearing caps and hand start the camshaft cap bolts.
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Fig. 444: Alignment Timing Chain Sprocket Notch

NOTE:
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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Tools Required
J 43650 Balance Shaft Bearing Remover/Installer. See Special Tools and Equipment.
Fig. 445: Installing Balance Shaft

1. Install the balance shaft bushing using the J 43650 . See Special Tools and Equipment.
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Fig. 446: Seating Balance Shaft Bushing

2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See Special Tools and
Equipment.
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See Special Tools and
Equipment.
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Fig. 447: Installing Balance Shaft

IMPORTANT: If the balance shafts are not properly timed to the engine, the engine may
vibrate or make noise.
IMPORTANT: Install the balance shaft assemblies to the engine using the following
steps:
4. Place the number one piston at top dead center (TDC).
5. Install the balance shaft drive chain sprocket on the crankshaft
6. Install the balance shafts into their bores.
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7. Install the balance shaft retaining bolts.

Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).
Fig. 448: Aligning Exhaust Sprocket Arrow with Carrier Notch

8. Align the arrow on the exhaust sprocket with the notch on the carrier. The arrow should point down.
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Fig. 449: Aligning Intake Sprocket Arrow with Carrier Notch

9. Align the arrow on the intake sprocket with the notch on the carrier. The arrow should point up.
WATER PUMP INSTALLATION
Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to
ensure proper sealing.
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Fig. 450: View Of Water Pump Assembly

1. Install the water pump assembly.
2. Install the water pump bolts.
NOTE:
3. Tighten the water pump bolts.

4. Apply sealant P/N 21485278 to the water pump drain plug.
5. Install the water pump drain plug, if necessary.
Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
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Fig. 451: Installing Water Feed Tube & Thermostat Housing

6. Install the water feed tube.
7. Lubricate the feed tube O-Ring with anti-freeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or
damage the O-Ring.
9. Install the thermostat housing to block bolts and stud.
Tighten: Tighten the bolts and stud to 10 N.m (89 lb in).
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Fig. 452: Removing & Installing Engine Coolant Temperature Sensor

10. Install the engine coolant temperature sensor by hand.
11. Tighten the engine coolant temperature sensor.
Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).
TIMING BALANCE SHAFTS TO ENGINE
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Fig. 453: Installing Balance Shaft Drive Chain

vibrate or make noise.
1. Install the balance shaft drive chain with colored links lined up with the marks on the balance shaft drive
sprockets and crankshaft sprocket. Use the following procedure to line up the links with the sprockets:
1. Orient the chain so that the copper colored and chrome links are visible.
2. Place the copper colored link (1) so that it lines up with the timing mark on the intake side balance
shaft sprocket.
3. Working clockwise around the chain, place the first chrome link (2) in line with the timing mark on
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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
Fig. 454: Installing Upper Balance Shaft Guide Chain

NOTE:
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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).
Fig. 455: Installing Small Balance Shaft Chain Guide

2. Install the small balance shaft chain guide.
3. Tighten the balance shaft chain guide bolts.
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Tighten: Tighten the balance shaft chain guide (fixed) bolts to 10 N.m (89 lb in).
Fig. 456: Installing Adjustable Balance Shaft Drive Chain Guide

4. Install the adjustable balance shaft drive chain guide.
Tighten: Tighten the balance shaft chain guide (adjustable) bolt to 10 N.m (89 lb in).
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Fig. 457: Installing Chain Tensioner

5. Set the chain tensioner by performing the following steps:
1. Turn the plunger 90 degrees in its bore and compress the plunger.
2. Turn the tensioner back to the 12 o'clock position and insert a paper clip through the hole on the
plunger body and into the hole on the tensioner plunger.
6. Install the balance shaft drive chain tensioner.
7. Tighten the balance shaft drive chain tensioner bolts.
Tighten: Tighten the balance shaft chain tensioner bolts to 10 N.m (89 lb in).
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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.
Fig. 458: View Of Crankshaft Sprocket Timing Mark

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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
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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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.
Fig. 460: Locating Cylinder Block Bosses

3. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes
around both sides of the cylinder block bosses (1, 2).
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Fig. 461: Identifying Timing Chain Colored Link & Crankshaft Sprocket Timing Mark
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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Fig. 462: View Of Timing Chain Tensioner Guide

NOTE:
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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Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
Fig. 463: Identifying Exhaust Camshaft Sprocket

IMPORTANT: Always install new sprocket bolts.
6. Install the exhaust camshaft sprocket and a new bolt loosely onto the exhaust camshaft.
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Fig. 464: Aligning Timing Chain Link & Exhaust Timing Mark
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
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Fig. 465: Using 24 mm Wrench To Align Camshaft

IMPORTANT: Do not turn the camshaft more than 1/2 turn in either direction. To do so
may cause valve to piston contact. This may damage a valve and/or a
piston. If the camshaft is 180 degrees out of time, use the following
procedure to realign the cam.
8. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the
camshaft sprocket seats in the notch in the front of the intake camshaft.
1. Turn the crankshaft 45 degrees in either direction.
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2. Turn the intake cam to the appropriate location.

3. Turn the crankshaft back to top dead center.
9. When the sprocket seats on the cam, tighten the sprocket bolt hand tight.
10. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not,
repeat the portion of the procedure necessary to align the timing marks.
Fig. 466: View Of Fixed Timing Chain Guide

11. Install the fixed timing chain guide.
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Tighten: Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
Fig. 467: View Of Upper Timing Chain Guide

12. Install the upper timing chain guide.
Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
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Fig. 468: Holding Camshaft Stationary With Wrench On Hex Casting On Camshaft
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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angle meter.
Fig. 469: Measuring Timing Chain Tensioner Assembly

15.
16.
17.
18.
Remove the old oil from the timing chain tensioner.

Inspect the timing chain tensioner for scoring or free movement.
Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
Measure the timing chain tensioner assembly from end to end.
A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the
compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will
measure 85 mm (3.35 in) (a) from end to end.
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Fig. 470: Compressing Timing Chain Tensioner

19. If the timing chain tensioner is not in the compressed state, perform the following steps:
1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
2. Install the J 45027-2 (2) into a vise.
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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.
Fig. 471: Measuring Timing Chain Tensioner Assembly

20. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the
tensioner. Clean dirt or debris out with a lint free cloth.
21. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the
bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston
assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need
to be reset again.
22. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the
tensioner does not read 72 mm (2.83 in) (a) from end to end repeat steps 16.1 and 16.4.
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Fig. 472: Identifying Timing Chain Tensioner

23. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the
cylinder head.
24. Install the timing chain tensioner assembly.
Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
25. The timing chain tensioner is released by compressing it 2 mm (0.079 in) which will release the locking
mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on
the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt
diagonally downwards to release the tensioner.
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Fig. 473: View Of Oil Nozzle & Bolt

26. Inspect to ensure that all dirt and debris is removed from the timing chain oiling nozzle hole in the engine
block.
27. Install the timing chain oiling nozzle.
Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
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Fig. 474: View Of Fixed Timing Chain Guide Access Plug

28. Apply sealant P/N 21485277 compound to the thread, and install the timing chain guide bolt access hole
plug.
Tighten: Tighten the access hole plug to 90 N.m (59 lb ft).
CRANKSHAFT FRONT OIL SEAL INSTALLATION
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Tools Required
SA9107T Converter Seal Replacer

Fig. 475: Installing Crankshaft Front Oil Seal

IMPORTANT: Ensure that the engine front cover is properly supported when installing the
seal.
Install the seal into the front cover by driving it in from the timing chain side using the SA9107T .
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ENGINE FRONT COVER AND OIL PUMP INSTALLATION

Fig. 476: Installing Engine Front Cover & Gasket

1. Install the engine front cover and new gasket.
NOTE:
2. Install the long water pump bolt.

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Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).

3. Install the engine front cover bolts.
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4. Install the accessory drive belt tensioner.
CAMSHAFT COVER INSTALLATION
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1. Assemble the camshaft cover and gasket. Ensure that the gasket is located in the retaining groove on the
camshaft cover.
2. Install the cover on the cylinder head and hand tighten the bolts.
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Fig. 480: Installing Front Lift Bracket

3. Install the front lift bracket and tighten the bolts.
Tighten: Tighten the front lift bracket bolts to 25 N.m (18 lb ft).
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Fig. 481: Installing Rear Lift Bracket

4. Install the rear lift bracket and tighten the bolts.
Tighten: Tighten the rear lift bracket bolts to 25 N.m (18 lb ft).
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Fig. 482: Disconnecting/Connecting Ground Strap On The Camshaft Cover Assembly

5. Install the ground strap.
Tighten:
Tighten the camshaft cover bolts to 10 N.m (89 lb in).
Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
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Fig. 483: Installing Spark Plugs

6. Install the spark plugs.
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7. Install the ignition coil and module assembly to the cam cover.
Tighten: Tighten the ignition coil-to-camshaft cover bolts to 8 N.m (71 lb in).
8. Install the power steering pump, if equipped.
Tighten: Tighten the power steering pump to 25 N.m (18 lb ft).
OIL PAN INSTALLATION
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Fig. 485: Installing Oil Pan

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
IMPORTANT: Ensure that there is not any excessive RTV around the oil pickup gallery
flange area.
2. Apply a 2 mm (0.08 in) bead of RTV P/N 12346286 around the perimeter of the oil pan and suction port
opening. Do not apply more than a 2 mm (0.08 in) bead.
3. Install the oil pan.
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Fig. 486: Oil Pan Bolts Tightening Sequence

4. Install the oil pan bolts finger tight then tighten using the torque sequence.
Tighten: Tighten the oil pan-to-block bolts to 25 N.m (18 lb ft).
OIL FILTER INSTALLATION
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Fig. 487: Removing/Installing Oil Filter Cap

NOTE:
Do not use a universal type oil filter wrench to remove oil filter cap.
Damage to the oil cap and the engine may result.
1. Install the new oil filter on the oil filter cap.

2. Lubricate the O-ring on the oil filter cap with clean 5W-30 engine oil.
3. Install the oil filter cap.
Tighten: Tighten the oil filter cap to 25 N.m (18 lb ft).
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INTAKE MANIFOLD INSTALLATION
Fig. 488: Installing Intake Manifold Studs

NOTE:
1. Install the intake manifold studs in the cylinder head.

Tighten: Tighten the intake manifold-to-cylinder head studs to 6 N.m (60 lb in).
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Fig. 489: Installing Intake Manifold

2. Install a new intake manifold gasket onto the intake manifold.
4. Install the intake manifold bolts and nuts. Tighten by starting from the center bolt and working outward.
Tighten:
Tighten the intake manifold-to-cylinder head bolts to 10 N.m (89 lb in).
Tighten the intake manifold-to-cylinder head nuts to 10 N.m (89 lb in).
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Fig. 490: Removing & Installing Fuel Rail Assembly

5. Install the fuel rail assembly.
6. Install the fuel rail stud.
Tighten: Tighten the fuel rail bracket stud to 10 N.m (89 lb in).
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7. Install the throttle body. The gasket may be reused if not damaged.
Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).
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Fig. 492: Identifying Fuel Pressure Regulator Hose

8. Install the pressure regulator vacuum harness.
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Fig. 493: Installing Knock Sensor Connector

9. Install the knock sensor connector onto the intake manifold.
CRANKSHAFT DAMPER INSTALLATION
Tools Required
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1. Lubricate the front oil seal and seal surface of the crankshaft balancer with an engine oil supplement.
NOTE:
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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
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Fig. 496: Installing Exhaust Manifold Studs

NOTE:
1. Install new exhaust manifold studs.

Tighten: Tighten the exhaust manifold studs-to-cylinder head to 10 N.m (89 lb in).
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Fig. 497: Removing & Installing Exhaust Manifold & Gasket

2. Install the new exhaust manifold gasket.
3. Install the exhaust manifold to the cylinder head.
4. Install the exhaust manifold to cylinder head retaining nuts. Tighten the nuts starting from the center and
working outward.
Tighten: Tighten the exhaust manifold-to-cylinder head nuts to 12 N.m (9 lb ft).
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Fig. 498: Connecting Exhaust Manifold HO2S Electrical Connection

5. Coat the threads of the oxygen sensor with anti-seize compound P/N 12397953.
6. Install the oxygen sensor.
Tighten: Tighten the oxygen sensor bolts to 30 N.m (22 lb ft).
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Fig. 499: Installing Engine Block Heater

7. Install the engine block heater, if equipped.
Tighten: Tighten the engine block heater bolt to 10 N.m (89 lb in).
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Fig. 500: Removing & Installing Exhaust Manifold Heat Shield

8. Install the exhaust manifold heat shield.
9. Install the exhaust manifold heat shield bolts.
Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).
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Fig. 501: Identifying Air Pipe, Gasket, Nut & Bolts

10. Install the air pipe gasket (4).
11. Install the air pipe (2).
12. Install the air pipe bolts (3).
Tighten: Tighten the air pipe bolts to 25 N.m (18 lb ft).
13. Install the air pipe nut (1).
Tighten: Tighten the air pipe nut to 16 N.m (11 lb ft).
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OIL LEVEL INDICATOR AND TUBE INSTALLATION
1. Install the oil level indicator tube into the block.
NOTE:
2. Install the indicator tube bracket to the intake manifold bolt.

Tighten: Tighten the oil level indicator tube-to-intake manifold bolt to 10 N.m (89 lb in).
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ENGINE FLYWHEEL INSTALLATION

Tools Required
J 43653 Flywheel Holding Tool. See Special Tools and Equipment.

NOTE:
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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1. Install the flywheel.

2. Install the new bolts.
NOTE:
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.
DESCRIPTION AND OPERATION

ENGINE COMPONENT DESCRIPTION
Cylinder Block
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
These are additives that allow oil to lubricate when it is hot.

Oxidation is a complex chemical reaction between oil molecules and oxygen. As the operating temperature of
oil goes up, so does the oil's oxidation rate. And unless the oil is heavily enriched with additives to fight
oxidation, all sorts of undesirable things could happen. The worst of these is that the oil gets thicker and thicker
- permanently.
Thus, a driver who waits too long between oil changes or uses low-quality oil and embarks on a cross-country
trip during the summer may find the oil oxidized to a point so thick it will not drain out of the crankcase.
Rust and Corrosion 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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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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Fig. 504: Identifying American Petroleum Institute Logo

Multi-Grade Oils
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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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
Fig. 505: Lubrication System (Oil Flow)

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2003 Saturn L200


Callout
Component Name
1
Hydraulic Lifter
2
Cam Bearing
3
Cylinder Head
4
Timing Chain Tensioner
5
Cam Drive Chain Oil Nozzle
6
Crankshaft Bearing
7
Balance Shaft Chain Tensioner
8
Oil Pump
9
Oil Pick Up
10
Oil Pan
11
Bedplate
12
Balance Shaft Bearings
13
Oil Filter
Oil is applied under pressure to the crankshaft, connecting rods, balance shaft assembly, camshaft bearing
surfaces, valve lifters, and timing chain hydraulic tensioner. All other moving parts are lubricated by gravity
flow or splash. Oil enters the gerotor type oil pump through a fixed inlet screen. The oil pump is driven by the
crankshaft. The oil pump body is within the engine front cover. The pressurized oil from the pump passes
through the oil filter. The oil filter is located on the right front side of the engine block.
The oil filter is housed in a casting that is integrated with the engine block. The oil filter is a disposable
cartridge type. A by-pass valve in the engine block allows continuous oil flow in case the oil filter should
become restricted. Oil then enters the gallery when it is distributed to the balance shafts, crankshaft, and
camshafts. The connecting rod bearings are oiled by constant oil flow passages through the crankshaft
connecting the main journals to the rod journals. A groove around each main bearing furnishes oil to the drilled
crankshaft passages.
An oil cooling hole, which indexes once each revolution with the connecting rod oil feed hole, is drilled in the
connecting bearing surface. The pressurized oil passes through the oil flow check valve into the cylinder head
and then into each camshaft feed gallery. Cast passages feed each hydraulic element adjuster and drilled
passages feed each camshaft bearing surface. An engine oil pressure switch or sensor is installed at the end. Oil
returns to the oil pan through passages cast into the cylinder head. The timing chain lubrication drains directly
into the oil pan.
SEPARATING PARTS
IMPORTANT:
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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2003 Saturn L200

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 installation to their
original location and position.
Separate, mark, or organize the following components:
Piston and the piston pin

Piston to the specific cylinder bore
Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap
A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near
the bearing bore may affect component geometry.
Crankshaft main and connecting rod bearings

Camshaft and valve lifters
Valve lifters, lifter guides, pushrods and rocker arm assemblies
Valve to the valve guide
Valve spring and shim to the cylinder head location
Engine block main bearing cap location and direction
Oil pump drive and driven gears
REPLACING ENGINE GASKETS

Gasket Reuse and Applying Sealants
Do not reuse any gasket unless specified.

Gaskets that can be reused will be identified in the service procedure.
Do not apply sealant to any gasket or sealing surface unless called out in the service information.
Separating Components
Use a rubber mallet to separate components.

Bump the part sideways to loosen the components.
Bumping should be done at bends or reinforced areas to prevent distortion of parts.
Cleaning Gasket Surfaces
Remove all gasket and sealing material from the part using a wood or plastic gasket scraper make from
aluminum surfaces.
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2003 Saturn L200

Care must be used to avoid gouging or scraping the sealing surfaces.

Do not use any other method or technique to remove sealant or gasket material from a part.
Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces.
These methods of cleaning can cause damage to the component sealing surfaces.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil.
This grit is abrasive and has been known to cause internal engine damage.
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.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALER

Pipe Joint Compound
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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2003 Saturn L200

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.
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.

After properly tightening the fasteners, remove the excess sealer from the outside of the joint.
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:
Piston and the piston pin
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2003 Saturn L200

Piston to the specific cylinder bore

Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap
A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near
the bearing bore may affect component geometry.
Crankshaft main and connecting rod bearings

Camshaft and valve lifters
Valve lifters, guides, pushrods, pivot supports and rocker arms
Valve to the valve guide
Valve spring and shim to the cylinder head location
Engine block main bearing cap location and direction
Oil pump drive and driven gears
TOOLS AND EQUIPMENT

Special tools are listed and illustrated throughout this section with a complete listing at the beginning of the
section. These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations
for which they are intended. The use of these special tools will also minimize possible damage to engine
components. Some precision measuring tools are required for inspection of certain critical components. Torque
wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.
To properly service the engine assembly, the following items should be readily available:
Approved eye protection and safety gloves

A clean, well-lit, work area
A suitable parts cleaning tank
A compressed air supply
Trays or storage containers to keep parts and fasteners organized
An adequate set of hand tools
Approved engine repair stand
An approved engine lifting device that will adequately support the weight of the components
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration
Tool Number/ Description
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2003 Saturn L200

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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2003 Saturn L200

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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Page 582
2003 Saturn L200

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
steve
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Page 583
2003 Saturn L200

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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Page 584
2003 Saturn L200

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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Page 585
2003 Saturn L200

J 43628
Frame Alignment Fixture
J 43649
Valve Spring Compressor
J 43650
Balance Shaft Bearing Remover/Installer
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2003 Saturn L200

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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Page 587
2003 Saturn L200

J 43914
Clamp Pliers, Universal
J 43936
Fuel Pressure Adapter Cap
J 43953
Piston Ring Compressor
steve
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Page 588
2003 Saturn L200

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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Page 589
2003 Saturn L200

SA9101E
Piston Pin Retainer/Replacer
SA9102-E
Valve Seal Remover/Replacer
SA9105-E
Engine Support Fixture (3 Bar)
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2003 Saturn L200

SA91101NE
Feeler Gauge Set
SA9123E
Gasket Seal Cutter
SA9124E
Regulator Valve Remover/Replacer
SA9127E
Gauge Bar Set
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Page 591
2003 Saturn L200

SA9127E-7
Fuel Flow/Pressure Adapter
SA9140E
Torque Angle Gauge
SA9156E
Fuel Tank Lock Ring Remover
SA9171E
Flex Hone
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Page 592
2003 Saturn L200

SA9177NE
Straight Edge (24")
SA9179NE
Magnetic Base Dial Indicator Set
SA9213NE
Gas Check Tester
SA9805E
Fuel Line Separator
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Page 593

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2003 Saturn L200

2003 ENGINE Engine Mechanical - 2.2L (L61) - Saturn L Series

2006 Mitchell Repair Information Company, LLC.

2003 Saturn L200

Crankshaft Position Sensor Bolt

2006 Mitchell Repair Information Company, LLC.

2003 Saturn L200

Lower Engine-to-Transmission Bell Housing Bolts

2006 Mitchell Repair Information Company, LLC.

2003 Saturn L200

ENGINE MECHANICAL SPECIFICATIONS

Bearing Diameter - Inside - Carrier

Bearing Diameter - Outside - Carrier

Bearing Journal Diameter

Bushing Diameter - Inside

Bushing Journal Diameter

Balance Shaft Bearing Bore Diameter - Carrier

Balance Shaft Bushing Bore Diameter

Crankshaft Main Bearing Bore Diameter

Cylinder Bore Diameter

Cylinder Bore Out-of-Round - Maximum

Cylinder Bore Taper - Maximum

Cylinder Head Deck Surface Flatness - Transverse

Cylinder Head Deck Surface Flatness - Longitude

Cylinder Head Deck Surface Flatness - Overall

Camshaft End Play

Camshaft Journal Diameter

Camshaft Thrust Surface

2006 Mitchell Repair Information Company, LLC.

2003 Saturn L200

Connecting Rod Bore Diameter - Bearing End

Connecting Rod Bore Diameter - Pin End

Connecting Rod Side Clearance

Connecting Rod Straightness - Bend - Maximum

Connecting Rod Straightness - Twist - Maximum

Connecting Rod Bearing Clearance

Connecting Rod Journal Diameter

Crankshaft End Play

Crankshaft Main Bearing Clearance

Crankshaft Main Journal Diameter

Surface Flatness - Block Deck - Transverse

Surface Flatness - Block Deck - Longitude

Surface Flatness - Block Deck - Overall

Valve Guide Bore - Exhaust

Valve Guide Bore - Intake

Valve Lifter Bore Diameter - Stationary Lash

Oil Pressure - Minimum - @1000 RPM

Piston Ring End Gap - First Compression Ring

Piston Ring End Gap - Second Compression Ring

Piston Ring End Gap - Oil Control Ring - Rails

Piston Ring to Groove Clearance - First Compression

Piston Ring to Groove Clearance - Second

Piston Ring to Groove Clearance - Oil Control Ring

Piston Ring Thickness - First Compression Ring

Piston Ring Thickness - Second Compression Ring

Piston Ring Thickness - Oil Control Ring - Rail Maximum

2006 Mitchell Repair Information Company, LLC.

2003 Saturn L200

Piston Ring Thickness - Oil Control Ring - Spacer

Piston - Piston Diameter - @14.5 mm up

Piston - Piston Pin Bore Diameter

Piston - Piston Ring Grove Width - Top