2006 Suzuki Swift + S

2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

2006 ENGINE

Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

Specification
Application Metric English
A/C Compressor Mounting Bolts 27 N.m 20 lb ft
A/C Compressor Mounting Bracket Bolts 50 N.m 37 lb ft
Air Filter Housing Bolts 12 N.m 106 lb in
Alternator Adjusting Bolt 20 N.m 15 lb ft
Alternator Adjusting Bracket Retaining Bolt 20 N.m 15 lb ft
Auxiliary Catalytic Converter-to-Exhaust Manifold Nuts
40 N.m 30 lb ft
and Bracket Bolts
Camshaft Cap Bolts 16 N.m 12 lb ft
Camshaft Gear Bolt 67.5 N.m 49 lb ft
Camshaft Pressure Plate Bolts 10 N.m 89 lb in
Connecting Rod Bearing Cap Bolts 25 N.m+30°+15° 18 lb ft+30°+15°
Coolant Pump Retaining Bolts 10 N.m 89 lb in
Coolant Temperature Sensor 20 N.m 15 lb ft
Crankshaft Bearing Cap Bolts 50 N.m+45°+15° 37 lb ft+45°+15°
Crankshaft Position Sensor Retaining Bolt 10 N.m 89 lb in
Crankshaft Pulley Bolt 95 N.m+30°+15° 70 lb ft+30°+15°
Cylinder Head Bolts - Camshaft Support Housing and 25 N.m+60°+60° 18 lb ft+60°+60°+60°
Cylinder Head Mounting Bolts +60°+15° +10°
Electronic Ignition System Ignition Coil Mounting Bolts 10 N.m 89 lb in
Electronic Ignition System Ignition Coil Mounting Plate
10 N.m 89 lb in
Bolts
Engine Mount Bracket Retaining Bolt 65 N.m 48 lb ft
Engine Mount Bracket-to-Engine Mount Retaining Bolts 60 N.m 44 lb ft
Engine Mount Retaining Nuts 40 N.m 30 lb ft
Exhaust Flexible Pipe Bracket Bolts 40 N.m 30 lb ft
Exhaust Gas Recirculation Valve Adapter Bolts 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Bolts 15 N.m 11 lb ft
Exhaust Manifold Nuts 25 N.m 18 lb ft
Flexible Plate Bolts 60 N.m 44 lb ft
Flexible Plate Inspection Cover Bolts 10 N.m 89 lb in
Flywheel Bolts 35 N.m+30°+15° 26 lb ft+30°+15°

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Flywheel Inspection Cover Bolts 12 N.m 106 lb in

Front Muffler-to-Main Catalytic Converter Nuts 30 N.m 22 lb ft
Fuel Rail Retaining Bolts 25 N.m 18 lb ft
Intake Manifold Retaining Nuts 25 N.m 18 lb ft
Intake Manifold Support Bracket Lower Bolt-to-Engine
40 N.m 30 lb ft
Block
Intake Manifold Support Bracket Upper Bolts 25 N.m 18 lb ft
Lower Timing Belt Cover Bolts 10 N.m 89 lb in
Oil Pan Retaining Bolts 10 N.m 89 lb in
Oil Pressure Switch 40 N.m 30 lb ft
Oil Pump Retaining Bolts 10 N.m 89 lb in
Oil Pump/Pickup Tube and Support Bracket Bolts 10 N.m 89 lb in
Oil Pump Safety Relief Valve Bolt 36 N.m 22 lb ft
Oil Pump Rear Cover Bolts 6 N.m 53 lb in
Power Steering Pump Mounting Bolts 25 N.m 18 lb ft
Power Steering Pump Pulley Bolts 25 N.m 18 lb ft
Rear Timing Belt Cover Bolts 10 N.m 89 lb in
Spark Plug Cover Bolts 3 N.m 27 lb in
Spark Plugs 25 N.m 18 lb ft
Thermostat Housing Mounting Bolts 20 N.m 15 lb ft
Throttle Cable Bracket Bolts 8 N.m 71 lb in
Timing Belt Automatic Tensioner Bolt 25 N.m 18 lb ft
Timing Belt Idler Pulley Bolt 40 N.m 30 lb ft
Transaxle Bell Housing Bolts 75 N.m 55 lb ft
Transaxle Brace Bolts 40 N.m 30 lb ft
Transaxle Torque Converter Bolts 65 N.m 48 lb ft
Upper Timing Belt Cover Bolts 10 N.m 89 lb in
Valve Cover Bolts 10 N.m 89 lb in

ENGINE MECHANICAL SPECIFICATIONS

Engine Mechanical Specifications

Specification
Application Metric English
General Data
l Engine Type 4 Cylinder - In-Line
l Displacement 1598 cm3 97.51 in3
l Bore Stroke 79.0x81.5 mm 3.1x3.21 in
l Compression Ratio 9.5:1
l Firing Order 1-3-4-2

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

l Maximum Power - At 6200 RPM 77 kw/103.3 hp

l Maximum Torque - At 3400 RPM 145 N.m 106.9 lb ft
Cylinder Bore
l Diameter 79 mm 3.1 in
l Out of Round - Maximum 0.0065 mm 0.00025 in
l Taper - Maximum 0.0065 mm 0.00025 in
Piston
l Diameter 78.970 mm 3.07 in
l Clearance to Bore 0.02-0.04 mm 0.0008-0.0016 in
Piston Rings
l Ring, End Gap - Top Compression 0.15-0.3 mm 0.006-0.012 in
l Ring, End Gap - Second Compression 0.3-0.5 mm 0.012-0.019 in
l Groove Clearance - Top Impression 0.05-0.08 mm 0.0019-0.0031 in
l Groove Clearance - Second Compression 0.05-0.082 mm 0.002-0.003 in
Piston Pin
l Diameter 18 mm 0.708 in
lPin Off-Set 0.5-0.7 mm 0.019-0.027 in
Camshaft
l Lift Intake 7.2 mm 0.283 in
l Lift Exhaust 7.2 mm 0.283 in
l End Play 0.1-0.25 mm 0.0039-0.0079 in
l Journal OD - No. 1 29.935-29.95 mm 1.1785-1.1791 in
l Journal OD - No. 2 26.935-26.95 mm 1.0604-1.0610 in
l Journal OD - No. 3 26.935-26.95 mm 1.0604-1.0610 in
l Journal OD - No. 4 26.935-26.95 mm 1.0604-1.0610 in
l Journal OD - No. 5 26.935-26.95 mm 1.0604-1.0610 in
l Bearing OD - No. 1 30.01 mm 1.181 in
l Bearing OD - No. 2 27.01 mm 1.063 in
l Bearing OD - No. 3 27.01 mm 1.063 in
l Bearing OD - No. 4 27.01 mm 1.063 in
l Bearing OD - No. 5 27.01 mm 1.063 in
Crankshaft
l Main Journal - Diameter - All 54.982-54.994 mm 2.164-2.165 in
l Taper - Maximum 0.005 mm 0.0001 in

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

l Out of Round - Maximum 0.004 mm 0.0001 in

l Main Bearing Clearance - All 0.026-0.042 mm 0.001-0.00165 in
l Crankshaft End Play 0.05-0.28 mm 0.002-0.011 in
l Connecting Rod Journal - Diameter - All 43 mm 1.69 in
l Taper - Maximum 0.005 mm 0.00019 in
l Out of Round - Maximum 0.004 mm 0.00015 in
l Rod Bearing Clearance - All 0.019-0.07 mm 0.0007-0.0027 in
l Rod Side Clearance 0.07-0.242 mm 0.0027-0.009 in
Valve Stem
l Valve Lash Compensators Hydraulic
l Face Angle - All 45-45, 25 degrees
l Seat Angle - All 44.5-45 degrees
l Seat Runout - Maximum, All 0.05 mm 0.0197 in
l Face Runout - Maximum, All 0.03 mm 0.0012 in
l Seat Width - Intake 1.17-1.57 mm 0.0461-0.0618 in
l Seat Width - Exhaust 1.4-1.8 mm 0.055-0.071 in
l Valve Guide Inside Diameter - All 6-6.02 mm 0.236-0.237 in
l Valve Stem Diameter - Intake 5.955-5.97 mm 0.234-0.235 in
l Valve Stem Diameter - Exhaust 5.935-5.95 mm 0.2336-0.2342 in
l Valve Diameter - All - Intake 28.45-28.69 mm 1.120-1.129 in
l Valve Diameter - Exhaust 27.10-27.38 mm 1.067-1.078in
l Valve Spring Loads - Valve Open 554-608 N.m 408-447 lb ft
l Valve Spring Loads - Valve Closed 247-273 N.m 181-200 lb ft
Lubricating Type Forced Feed
Oil Filter Type Cartridge (Full Flow)
Oil Pan Capacity Including Oil Filter 3.75 liter 4 quarts
Oil Pump
l Gap Between Oil Pump Body and Out Rotor 0.4-0.484 mm 0.0157-0.0191 in
l Out Rotor Side Clearance 0.045-0.1 mm 0.0018-0.0039 in
l Inner Rotor Side Clearance 0.035-0.085 mm 0.0014-0.0033 in
l Relief Valve Spring Free Length 81 mm 3.2 in
Oil Pump Type Rotary (Trochoid)

Valve Guide Reaming Table

Size Reamer Production Code Service Code

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Normal - - K
0.075 KM-805 1 K1
0.150 - 2 K2

COMPONENT LOCATOR
DISASSEMBLED VIEWS

Fig. 1: Upper End Components

Courtesy of GENERAL MOTORS CORP.

Callout Component Name

1 Engine Cover
2 Oil Cap
3 Valve Cover
4 Valve Cover Bolt

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

5 Valve Cover Washer

6 Valve Cover Gasket
7 Hydraulic Valve Lash Adjuster
8 Valve Key
9 Valve Spring Retainer
10 Valve Spring
11 Valve Stem Oil Seal
12 Freeze Plug
13 Exhaust manifold
14 Nut
15 Exhaust Manifold Heat Shield
16 Oxygen Sensor
17 Bolt
18 Bolt
19 Thermostat Housing Assembly
20 Thermostat Housing Seal
21 Cylinder Head Gasket
22 Exhaust Valve
23 Intake Valve
24 Camshaft Seal
25 Camshaft Position Sensor
26 Washer
27 Camshaft Gear Bolt
28 Camshaft
29 Plug
30 Stud
31 Engine Coolant Temperature Sensor
32 Coolant Temperature Sensor
33 Bolt
34 Front Camshaft Cap
35 Plug
36 Valve Guide
37 Intermediate Camshaft Cap
38 Washer
39 Head Bolt
40 Exhaust Gas Recirculation Pipe
41 Intake Manifold
42 Throttle Body
43 Intake Manifold Gasket
44 Exhaust Manifold Gasket
45 Cylinder Head

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Fig. 2: Lower End Components

Courtesy of GENERAL MOTORS CORP.

Callout Component Name

1 Piston Ring Set
2 Piston
3 Piston Pin
4 Connection Rod
5 Connecting Rod Bearing Set
6 Connecting Rod Bolt
7 Oil Level Gage Stick
8 Gage Stick Tube
9 Connection Piece
10 Oil Filter
11 Hose Clamp
12 Engine Ventilation Hose

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

13 Engine Ventilation Pipe

14 Bolt
15 Oil Separator Gasket
16 Crankshaft Pulley Bolt
17 Washer
18 Crankshaft Pulley
19 Crankshaft Gear
20 Rear Timing Belt Cover
21 Bolt
22 Coolant Pump
23 Oil Pump
24 Engine Block Seal Ring
25 Oil Pump Body Gasket
26 Engine Block
27 Pressure Relief Valve Plunger
28 Spring
29 Oil Pump Seal Ring
30 Bolt Plug
31 Crankshaft Bearing Set
32 Crankshaft
33 Shaft Seal Ring
34 Flywheel - Manual Transaxle
35 Bolt - Manual Transaxle
36 Bolt
37 Crankshaft Position Sensor
38 Flexible Plate - Automatic Transaxle
39 Bolt - Automatic Transaxle
40 Crankshaft Main Bearing Cap
41 Bolt
42 Bolt
43 Knock Sensor
44 Oil Pan
45 Threaded Ring
46 Bolt
47 Bolt
48 Oil Pickup Tube
49 Bolt
50 Seal
51 Timing Belt
52 Cover Seal
53 Cover
54
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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Bolt
55 Idler Pulley
56 Rear Cover Bolt
57 Bolt
58 Auto Tensioner
59 Seal
60 Bolt
61 Gear
62 Gear
63 Cover
64 Bolt
65 Intake Manifold Support Bracket

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL

Begin the system diagnosis by reviewing Symptoms - Engine Mechanical. 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 Engine Component Description 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 System Check - Vehicle in Engine Controls 1.6 L before using the symptom
tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
Disassembled Views and Engine Component Description.

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

l Inspect for aftermarket devices which could affect the operation of the engine.
l Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
l Check for the correct oil level, proper oil viscosity, and correct filter application.
l 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.

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

l 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:

l Oil Pressure Diagnosis and Testing

l Oil Leak Diagnosis
l Engine Noise Diagnosis
l Engine Knocks Cold and Continues for Two-Three Minutes and/or Knock Increases with Engine
Torque
l Engine Noise Under Load
l Light Knock Hot
l Engine Noise on Start-Up, but Only Lasting a Few Seconds
l Knocks at Idle Hot
l Main Bearing Noise
l Connecting Rod Bearing Noise Symptom
l Piston Noises
l Base Engine Misfire with Abnormal Valve Train Noise
l Engine Compression Test

OIL PRESSURE DIAGNOSIS AND TESTING

Tools Required

l J 36648-A (KM 135) Adapter

l J 21867 (KM-498-B) Pressure Gage

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Fig. 3: View Of Oil Pressure Switch

Courtesy of GENERAL MOTORS CORP.

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-
3 minutes, and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full
on the oil level indicator.
3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following:
l Foamy oil

l Slow idle speed

l Plugged oil filter

l Oil diluted by the following:

¡ Water

¡ Engine Coolant

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Unburned fuel mixtures

¡

l Malfunctioning oil filter bypass valve

l Incorrect or faulty oil pressure gage

l Incorrect or faulty oil pressure gage sensor

l Improper engine oil viscosity for the expected temperature

6. Remove the oil pressure gage sensor.

Fig. 4: J 36648-A In Place Of Oil Pressure Sensor

Courtesy of GENERAL MOTORS CORP.

7. Install the J 36648-A (1) in place of the oil pressure sensor.

8. Connect the J 21867 to the J 36648-A .
9. Start the engine and check the oil pressure at idle speed and engine temperature at 80°C (176°F).

IMPORTANT: The minimum oil pressure should be 30 kPa (8.88 psi).

10. Measure the engine oil pressure.

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

11. If the engine oil pressure is below specifications, inspect the engine for one or more of the following:
l Loose oil filter adapter bolts

l Missing or damaged oil filter adapter O-ring seal or seals

l Worn or dirty oil pump

l Loose oil pump-to-engine block bolts

l Loose, plugged or damaged oil pump screen

l Missing or damaged oil pump screen O-ring seal

l Damage or leak in the oil pump screen suction tube

l Malfunctioning oil pump pressure regulator valve

l Missing or incorrectly installed oil gallery plugs

l Loose camshaft intermediate drive shaft bolts

l Excessive bearing clearance for the following:

¡ Connecting rod or rods

¡ Crankshaft

¡ Camshaft or camshafts

¡ Camshaft intermediate drive shaft sprocket

l Cracked, porous or restricted oil galleries

l Broken valve lifters

12. Repair or replace components as necessary.

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the
necessary parts. On some occasions, a fluid leak may be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.

Finding the Leak:

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
1. After running, the vehicle at normal operating temperature, park the vehicle over a large sheet of
paper.
2. Wait a few minutes.
3. Find the approximate location of the leak by the drippings of the paper.
3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that are hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam,
or spray solvent.
1. Thoroughly clean the area.

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

2. Dry the area.

3. Operate the vehicle for several miles at normal operating temperature and varying speeds.
4. After operating the vehicle, visually check the suspected component.
5. If you still cannot locate the leak, try using the powder or black light and dye method.

Powder Method

1. Clean the suspected area.

2. Apply an aerosol-type powder, such as foot powder, to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the
source.

Black Light and Dye Method

A dye and light kit is available for finding leaks. Refer to the manufacturer's directions when using the kit.

1. Pour the specified amount of dye into the engine oil fill tube.
2. Operate the vehicle under normal operating conditions as directions in the kit.
3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the
source.

Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check
for the following conditions and correct them as they may cause a leak.

Gaskets

l The fluid level/pressure is too high.

l The crankcase ventilation system is malfunctioning.
l The fasteners are improperly tightened.
l The threads are dirty or damaged.
l The flanges or the sealing surface is warped.
l There are scratches, burrs or other damage to the sealing surface.
l The gasket is damaged or worn.
l There is cracking or porosity of the component.
l An improper seal was used, if applicable.

Seals

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

l The fluid level/pressure is too high.

l The crankcase ventilation system is malfunctioning.
l The seal bore is damaged, scratched, burred or nicked.
l The seal is damaged or worn.
l Improper installation is evident.
l There are cracks in the component.
l The shaft surface is scratched, nicked or damaged.
l A loose or worn bearing is causing excess seal wear.

OIL CONSUMPTION DIAGNOSIS

Excessive oil consumption, not due to leaks, is the use of 1.9L (2 qts) or more of engine oil within 3 200
kilometers (2,000 mi). The causes of excessive oil consumption include the following conditions:

l External oil leaks. Tighten bolts and/or replace gaskets and oil seals as necessary.
l 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.
l Improper oil viscosity. Use recommended SAE viscosity for the prevailing temperatures.
l Continuous high speed driving and/or severe usage.
l Crankcase ventilation system restrictions or malfunctioning components.
l 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.
l Piston rings broken, improperly installed, worn, or not seated properly. Allow adequate time for rings to
seat. Replace broken or worn rings as necessary.
l Piston improperly installed or miss-fitted.

ENGINE NOISE DIAGNOSIS

Definition for Knock

Engine knock refers to various types of engine noise. Heavy knock is usually very loud and the result of broken
or excessively worn internal engine components. Light knock is a noticeable noise, but not as loud. Light knock
can be caused by worn internal engine components. Loose or broken external engine components can also cause
heavy or light knock.

ENGINE KNOCKS COLD AND CONTINUES FOR TWO-THREE MINUTES AND/OR KNOCK
INCREASES WITH ENGINE TORQUE

Engine Knocks Cold and Continues for Two-Three Minutes and/or Knock Increases with Engine Torque
Step Action Values Yes No
Does the engine knock when it is cold and
1 continue for 2-3 minutes or does the knock -
increase with torque? Go to Step 2 System OK

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Inspect the flywheel.

2 -
Is the flywheel contacting the splash shield? Go to Step 3 Go to Step 4
Reposition the splash shield.
3 -
Is the repair complete? Go to Step 1 -
Inspect the balancer and the drive pulleys.
4 Is either the balancer or the drive pulleys loose or -
broken? Go to Step 5 Go to Step 6
Tighten or replace the balancer or the drive
5 pulleys. -
Is the repair complete? Go to Step 1 -
Inspect the piston-to-bore clearance. 0.040 mm
6
Is the clearance greater than the specified value? (0.0016 in) Go to Step 7 Go to Step 8
1. Bore the cylinder and hone to size.

IMPORTANT:
Cold engine piston knock usually
disappears when the cylinder is
7 grounded out. Cold engine piston knock, -
which disappears in about 1.5 minutes,
is considered acceptable.

2. Replace the piston.

Is the repair complete? Go to Step 1 -

Inspect the connecting rod.
8 -
Is the connecting rod bent? Go to Step 9 System OK
Replace the connecting rod.
9 -
Is the repair complete? Go to Step 1 -

ENGINE NOISE UNDER LOAD

Engine Noise Under Load

Step Action Values Yes No
Is there a heavy knock when the engine is hot
1 -
and torque is applied? Go to Step 2 System OK
Inspect the balancer and the pulley hub.
2 -
Is the balancer or the pulley hub broken? Go to Step 3 Go to Step 4
Replace the broken balancer or the pulley hub.
3 -
Is the repair complete? Go to Step 1 -
Inspect the torque converter bolts. 45 N.m (33 lb
4
Are the bolts tightened to specified value? ft) Go to Step 5 Go to Step 6
Tighten the torque converter bolts.
5 -
Is the repair complete? Go to Step 1 -
Inspect the accessory belts.
6 -
Are the belts too tight or nicked? Go to Step 7 Go to Step 8

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Replace and/or tension the belts to specifications,

7 as necessary. -
Is the repair complete? Go to Step 1 -
Inspect the exhaust system.
8 -
Is the system grounded? Go to Step 9 Go to Step 10
Reposition the system, as necessary.
9 -
Is the repair complete? Go to Step 1 -
Inspect the flywheel.
10 -
Is the flywheel cracked? Go to Step 11 Go to Step 12
Replace the flywheel.
11 -
Is the repair complete? Go to Step 1 -
0.026-0.046
Inspect the main bearing clearance.
12 mm (0.001-
Is the clearance more than the specified value?
0.0018 in) Go to Step 13 Go to Step 14
Replace the main bearings, as necessary.
13 -
Is the repair complete? Go to Step 1 -
0.019-0.07
Inspect the rod bearing clearance.
14 mm (0.0007-
Is the clearance more than the specified value?
0.0028 in) Go to Step 15 System OK
Replace the rod bearings, as necessary.
15 -
Is the repair complete? Go to Step 1 -

LIGHT KNOCK HOT

Light Knock Hot

Step Action Values Yes No
1 Is there a light knock when the engine is hot? - Go to Step 2 System OK
2 Is detonation or spark knock evident? - Go to Step 3 Go to Step 4
Inspect the engine timing and the fuel quality.
3 -
Was the problem found? Go to Step 1 -
Inspect the torque converter bolts. 45 N.m (33 lb
4
Are the bolts tightened to the specified value? ft) Go to Step 5 Go to Step 6
Tighten the torque converter bolts.
5 -
Is the repair complete? Go to Step 1 -
Inspect the manifold.
6 -
Is there an exhaust leak at the manifold? Go to Step 7 Go to Step 8
Tighten the bolts or replace the gasket.
7 -
Is the repair complete? Go to Step 1 -
Inspect the rod bearing clearance. 0.019-0.07
8 Is the clearance within the specified value? mm (0.0007-
0.0028 in) Go to Step 9 System OK
Replace the rod bearings, as necessary.
9 -
Is the repair complete? Go to Step 1 -

ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS

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 2006 Suzuki Swift + S
2006 ENGINE Engine Mechanical - 1.6L (L91) - Aveo, Swift+ (Canadian) & Wave (Canadian)

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Step Action Values Yes No
IMPORTANT:
An engine that is only operated for short periods between start-ups may have lifter noise that lasts
for a few minutes. This is a normal condition.
Does the engine knock during initial start-up but
1 -
last only a few seconds? Go to Step 2 System OK
Inspect the engine oil.
2 -
Is the proper viscosity oil used in the crankcase? Go to Step 4 Go to Step 3
Install oil of the proper viscosity for the expected
3 seasonal temperatures. -
Is the repair complete? Go to Step 1 -
Inspect the hydraulic lifters.
4 -
Is there evidence of hydraulic lifter bleed-down? Go to Step 5 Go to Step 6
IMPORTANT:
When the engine is stopped, some valves will
be open. Spring pressure against the lifters
will tend to bleed lifter down. Attempts to
5 repair this should be made only if the problem -
is consistent.

Clean, test, and replace the lifters, as necessary.Is

the repair complete? Go to Step 1 -
Inspect the crankshaft end clearance. 0.28 mm
6
Is the clearance greater than specified value? (0.0011 in) Go to Step 7 Go to Step 8
Replace the crankshaft thrust bearing.
7 -
Is the repair complete? Go to Step 1 -
Inspect the front main bearing clearance. 0.026-0.046
8 Is the clearance more than the specified value? mm (0.001-
0.0018 in) Go to Step 9 System OK
Replace the worn parts of the front main bearing.
9 -
Is the repair complete? Go to Step 1 -

KNOCKS AT IDLE HOT

Knocks at Idle Hot

Step Action Values Yes No
1 Does the engine knock at idle when hot? - Go to Step 2 System OK
Inspect the drive belts.
2 -
Are the belts loose or worn? Go to Step 3 Go to Step 4
Tension or replace the belts, as necessary.
3 -
Is the repair complete? Go to Step 1 -
Inspect the A/C compressor and the generator.
4 -
Is either the compressor or the generator faulty? Go to Step 5 Go to Step 6
Replace the faulty A/C compressor or the

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generator.
5 -
Is the repair complete? Go to Step 1 -
Inspect the valve train.
6 -
Are valve train components faulty? Go to Step 7 Go to Step 8
Replace the faulty valve train components.
7 -
Is the repair complete? Go to Step 1 -
Inspect the engine oil.
8 -
Is the proper viscosity oil used in the crankcase? Go to Step 10 Go to Step 9
Install oil of the proper viscosity for the expected
9 seasonal temperatures. -
Is the repair complete? Go to Step 1 -
Inspect the piston pin clearance. 0.02 mm
10
Is the clearance more than the specified value? (0.0008 in) Go to Step 11 Go to Step 12
Replace the piston and the pin.
11 -
Is the repair complete? Go to Step 1 -
Inspect the connecting rod alignment.
12 -
Is the alignment faulty? Go to Step 13 Go to Step 14
Inspect and replace rods, as necessary.
13 -
Is the repair complete? Go to Step 1 -
0.020-0.040
Inspect the piston-to-bore clearance.
14 mm (0.0008-
Is the clearance within the specified range?
0.0016 in) Go to Step 16 Go to Step 15
Hone the bore and fit a new piston.
15 -
Is the repair complete? Go to Step 1 -
Inspect the crankshaft balancer.
16 -
Is the balancer loose? Go to Step 17 Go to Step 18
Torque or replace worn parts.
17 -
Is the repair complete? Go to Step 1 -
Inspect the piston pin offset.
0.9 mm (0.036
18 Is the offset toward the thrust side greater than
in)
the specified value? Go to Step 19 System OK
Install the correct piston.
19 -
Is the repair complete? Go to Step 1 -

MAIN BEARING NOISE

Main Bearing Noise

Step Action Values Yes No
Are dull thuds or knocks heard with every
1 -
engine revolution? Go to Step 2 System OK
Measure the oil pump pressure. Go to Oil
Is the oil pump pressure low? Pressure
2 -
Diagnosis and
Testing Go to Step 3
Inspect the crankshaft end play. Go to

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Is the crankshaft end play greater than the given 0.28 mm Crankshaft
3
value? (0.011 in) Replacement Go to Step 4
Inspect the crankshaft journals. Go to
4 Are the crankshaft journals out-of-round? - Crankshaft
Replacement Go to Step 5
Inspect the belt tension. Go to
5 Is there excessive belt tension? - Crankshaft
Replacement Go to Step 6
Inspect the crankshaft pulley. Go to
6 Is the crankshaft pulley loose? - Crankshaft
Replacement System OK

CONNECTING ROD BEARING NOISE SYMPTOM

Connecting Rod Bearing Noise Symptom

Step Action Yes No
1 Is a knock noise heard under all engine speeds? Go to Step 2 System OK
Inspect the crankshaft connecting rod journal. Go to Oil Pressure
2 Is the crankshaft connecting rod journal worn? Diagnosis and
Testing Go to Step 3
Measure the oil pump pressure. Go to Crankshaft
3
Is the oil pump pressure low? Replacement Go to Step 4
Inspect the crankshaft connecting rod journals. Go to Piston,
Are the journals out-of round? Connecting Rod,
4
and Bearing
Replacement Go to Step 5
Inspect the connecting rods. Go to Piston,
Is there a misaligned connecting rod? Connecting Rod,
5
and Bearing
Replacement Go to Step 6
Inspect the connecting rod bolts. Go to Piston,
Are the connecting rod bolts torqued properly? Connecting Rod,
6
and Bearing
System OK Replacement

PISTON NOISES

Piston Noises
Step Action Yes No
Listen for the following noises:

l A sharp double knock when the engine is idling

1 l A light ticking with no load on the engine
l A slapping noise when the engine is cold?

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Are any of these noises heard? Go to Step 2 System OK

Inspect the piston pin and the bushing. Go to Piston,
Is the piston pin or the bushing worn or loose? Connecting Rod,
2
and Bearing
Replacement Go to Step 3
Inspect the piston. Go to Piston,
Is the piston broken or cracked? Connecting Rod,
3
and Bearing
Replacement Go to Step 4
Inspect the connecting rods. Go to Piston,
Is there a misaligned connecting rod? Connecting Rod,
4
and Bearing
Replacement Go to Step 5
Inspect the piston position. Go to Piston,
Is the piston 180 degrees out of position? Connecting Rod,
5
and Bearing
Replacement System OK

BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE

Base Engine Misfire with Abnormal Valve Train Noise

Step Action Yes No
1 Is a light tapping sound heard from the engine? Go to Step 2 System OK
Inspect the valve springs. Go to Cylinder
2
Are the springs weak or broken? Head Disassemble Go to Step 3
Inspect the valves. Go to Cylinder
3
Are the valves sticking or warped? Head Disassemble Go to Step 4
Inspect the valve lifters. Go to Cylinder
4
Are the valve lifters dirty, stuck, or worn? Head Disassemble Go to Step 5
Inspect the camshaft lobes.
5 Are the camshaft lobes damaged or improperly Go to Camshaft
machined? Replacement Go to Step 6
Inspect the oil supply to the valve train. Go to Cylinder
6
Is the oil supply insufficient or poor? Head Disassemble Go to Step 7
Inspect the valve guides. Go to Cylinder
7
Are the valve guides worn? Head Disassemble Go to Step 8
Inspect the valve spring seat. Go to Cylinder
8
Is the valve spring seat incorrect? Head Disassemble System OK

ENGINE COMPRESSION TEST

IMPORTANT: Disconnect the crankshaft position (CKP) sensor connector to disable the fuel
and the ignition systems.

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Test the compression pressure for each cylinder. Low compression pressure for each cylinder. Low compression
pressure may be the fault of the valves or the pistons. The following conditions should be considered when you
check the cylinder compression:

l The engine should be at normal operating temperature.

l The throttle must be wide open.
l All the spark plugs should be removed.
l The battery must be at or near full charge.

1. Place approximately 3 squirts of oil from a plunger-type oiler into each spark plug port.
2. Insert the engine compression gage into each spark plug port.
3. Crank test each cylinder with 4-5 compression strokes using the starter motor.
4. The lowest reading should not be less than 70 percent of the highest reading. The compression gage
reading should not be less than 689 kPa (100 psi) for any of the cylinders.
5. Examine the gage readings obtained after the 4 "puffs" per cylinder are obtained from cranking the starter
motor. The readings are explained in the following descriptions:
l Normal condition-Compression builds up quickly and evenly to the specified compression on each
cylinder.
l Piston rings faulty-Compression is low on the first stroke and tends to build up on the following
strokes, but the compression pressure does not reach normal. The compression pressure improves
considerably with the addition of oil into the cylinder.
l Valves faulty-Low compression pressure on the first stroke. The compression pressure does not
tend to build up on the following strokes. The compression pressure does not improve much with
the addition of oil into the cylinder.

REPAIR INSTRUCTIONS
ENGINE MOUNT REPLACEMENT

Tools Required

J 28467-B (DW-117) Universal Engine Support Fixture

Removal Procedure

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Fig. 5: Supporting Engine Assembly Using J 28467-B

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Remove the upper radiator cover.
3. Remove the right front splash shield.
4. Support the engine assembly using the J 28467-B (1).

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Fig. 6: View Of Crossmember, Nuts, And Bolts

Courtesy of GENERAL MOTORS CORP.

5. Remove the engine mount bracket retaining bolts.

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Fig. 7: View Of Engine Mount

Courtesy of GENERAL MOTORS CORP.

6. Remove the engine mount retaining nuts.

7. Lower the engine.
8. Remove the engine mount.

Installation Procedure

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Fig. 8: View Of Engine Mount

Courtesy of GENERAL MOTORS CORP.

1. Install the engine mount.

2. Raise the engine.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the engine mount retaining nuts.

Tighten: Tighten the engine mount retaining nuts to 40 N.m (30 lb ft).

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Fig. 9: View Of Crossmember, Nuts, And Bolts

Courtesy of GENERAL MOTORS CORP.

4. Install the engine mount bracket retaining bolts.

Tighten: Tighten the engine mount bracket retaining bolts to 55 N.m(41 lb ft).

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Fig. 10: Supporting Engine Assembly Using J 28467-B

Courtesy of GENERAL MOTORS CORP.

5. Remove J 28467-B (1).

6. Install the right front splash shield.
7. Install the upper radiator cover.
8. Connect the negative battery cable.

ENGINE COVER REPLACEMENT

Removal Procedure

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Fig. 11: View Of Engine Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

1. Remove the bolts and nuts from the engine cover.

2. Remove the engine cover.

Installation Procedure

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Fig. 12: View Of Engine Cover

Courtesy of GENERAL MOTORS CORP.

1. Position the engine cover on the engine.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the engine cover bolts and nuts.

Tighten: Tighten the engine cover bolts and nuts to 10 N.m (89 lb ft).

INTAKE MANIFOLD REPLACEMENT

Removal Procedure

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Fig. 13: Locating Fuel Pump Fuse

Courtesy of GENERAL MOTORS CORP.

1. Remove the fuel pump fuse.

2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

3. Disconnect the negative battery cable.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

4. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.

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Fig. 14: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

5. Disconnect the intake air temperature (IAT) sensor connector.

6. Disconnect the air intake tube from the throttle body.

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Fig. 15: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

7. Disconnect the idle air control (IAC) valve connector.

8. Disconnect the throttle position sensor (TPS) connector.
9. Remove the alternator adjusting bolt and the alternator drive belt.
10. Disconnect the engine coolant temperature (ECT) sensor connector.
11. Disconnect the heater inlet hose from the cylinder head.
12. Disconnect the surge tank coolant hose at the throttle body.

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Fig. 16: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

13. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator
and the brake boaster vacuum hose at the intake manifold.
14. Disconnect the throttle body cable from the throttle body and the intake manifold.

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Fig. 17: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

15. Remove the fuel injector rail and fuel injectors as an assembly.
16. Remove the alternator adjusting bracket bolt from the intake manifold.
17. Remove the alternator adjusting bracket.
18. Remove the intake manifold support bracket bolts and the intake manifold.
19. Remove the intake manifold support bracket.

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Fig. 18: Intake Manifold Retaining Nuts/Bolts Removal Sequence

Courtesy of GENERAL MOTORS CORP.

20. Remove the intake manifold retaining nuts/bolts in the sequence shown.
21. Remove the intake manifold.
22. Remove the intake manifold gasket.
23. Clean the sealing surfaces of the intake manifold and the cylinder head.

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Fig. 19: View Of Alternator

Courtesy of GENERAL MOTORS CORP.

24. Remove the alternator. Refer to Generator Replacement (1.4L/1.5L SOHC and 1.4L/1.6L DOHC) in
Engine Electrical.
25. Remove the intake manifold support bracket.

Installation Procedure

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Fig. 20: Intake Manifold Retaining Nuts/Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

1. Install the intake manifold gasket.

2. Install the intake manifold.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the intake manifold retaining nuts/bolts in the sequence shown.

Tighten: Tighten the intake manifold retaining nuts/bolts to 25 N.m (18 lb ft).

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Fig. 21: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

4. Install the intake manifold support bracket.

5. Install the intake manifold support bracket upper bolts to the intake manifold.

Tighten: Tighten the intake manifold support bracket upper bolts to 25 N.m (18 lb ft).

6. Install the intake manifold support bracket lower bolt-to-engine block.

Tighten: Tighten the intake manifold support bracket lower bolt-to-engine block to 40 N.m (30 lb ft).

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Fig. 22: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

7. Install the fuel rail and fuel injectors as an assembly.

8. Connect the throttle cable to the intake manifold and the throttle body.
9. Connect all of the necessary vacuum lines that were previously disconnected.
10. Connect the heater inlet hose to the cylinder head.
11. Connect the surge tank coolant hose to the throttle body.
12. Install the alternator adjusting bracket at the intake manifold.

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Fig. 23: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

13. Install the alternator adjusting bracket bold.

Tighten: Tighten the alternator adjusting bracket bolts to 15 N.m (11 lb ft).

14. Install the alternator adjusting bolt and the alternator drive belt.

Tighten: Tighten the alternator adjusting bolts to 15 N.m (11 lb ft).

15. Connect the ECT sensor connector.

16. Connect the IAC valve connector.
17. Connect the TPS connector.

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Fig. 24: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

18. Connect the air intake tube to the throttle body.

19. Connect the IAT sensor connector.
20. Connect the PCM/ECM ground terminal to the intake manifold.
21. Install the fuel pump fuse.
22. Connect the negative battery cable.
23. Refill the engine cooling system. Refer to Draining and Filling Cooling System .

TIMING BELT INSPECTION

Tools Required

l J 42492-A Timing Belt Adjuster

l J 45059 Angle Meter

Adjustment Procedure

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Fig. 25: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution

1. Disconnect the negative battery cable.

2. Disconnect the intake air temperature (IAT) sensor connector.

3. Remove the air intake tube from the throttle body.
4. Remove the breather tube from the valve cover.

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Fig. 26: Location Of Air Cleaner

Courtesy of GENERAL MOTORS CORP.

5. Remove the air filter housing bolts.

6. Remove the air filter housing.
7. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation .
8. Remove the right front splash shield.

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Fig. 27: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

9. Remove the accessory drive belt.

10. Remove the crankshaft pulley bolt.
11. Remove the crankshaft pulley.

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Fig. 28: View Of Timing Belt Cover Bolts

Courtesy of GENERAL MOTORS CORP.

12. Remove the upper front timing belt cover bolts.

13. Remove the upper front timing belt cover.
14. Remove the lower front timing belt cover bolts.
15. Remove the lower front timing belt cover.
16. Remove the power steering pump mounting bolts, if equipped.
17. Install the crankshaft pulley bolt.

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Fig. 29: View Of Crankshaft Gear And Rear Timing Belt Cover
Courtesy of GENERAL MOTORS CORP.

18. Rotate the crankshaft at least one full turn clockwise using the crankshaft pulley bolt.
19. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.

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Fig. 30: View Of Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

20. Align the camshaft gear timing marks.

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Fig. 31: Using J42492-A Rotating Coolant Pump

Courtesy of GENERAL MOTORS CORP.

21. Slightly loosen the coolant pump retaining bolts.

22. Rotate the coolant pump clockwise using the J 42492-A (1).

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Fig. 32: Aligning Timing Belt Automatic Tensioner Pointer With Bracket Notch
Courtesy of GENERAL MOTORS CORP.

23. Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is
aligned to the notch in the timing belt automatic tensioner bracket.

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Fig. 33: View Of Coolant Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

24. Tighten the coolant pump retaining bolts.

25. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley.
26. Loosen the coolant pump retaining bolts.

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Fig. 34: Aligning Timing Belt Automatic Tensioner Pointer With Bracket Pointer
Courtesy of GENERAL MOTORS CORP.

27. Use the J 42492-A , rotate the coolant pump until the adjust arm pointer of the timing belt automatic
tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.

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Fig. 35: View Of Timing Belt Cover Bolts

Courtesy of GENERAL MOTORS CORP.

28. Tighten the coolant pump retaining bolts.

Tighten: Tighten the coolant pump retaining bolts to 10 N.m (89 lb in).

29. Remove the crankshaft pulley bolt.

30. Install the upper and lower front timing belt cover.
31. Install the upper and lower front timing belt cover bolts.

Tighten: Tighten the upper and lower front timing belt cover bolts to 10 N.m (89 lb in).

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Fig. 36: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

32. Install the crankshaft pulley.

33. Install the crankshaft pulley bolt.

Tighten: Tighten the crankshaft pulley bolt to 95 N.m (70 lb ft) using a torque wrench. Using the J
45059 or KM-470-B , tighten the crankshaft pulley bolt 30 degrees plus 15 degrees.

34. Install the accessory drive belt.

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Fig. 37: Location Of Air Cleaner

Courtesy of GENERAL MOTORS CORP.

35. Install the right front wheel. Refer to Tire and Wheel Removal and Installation .
36. Install the air filter housing.
37. Install the air filter housing bolts.

Tighten: Tighten the air filter housing bolts to 8 N.m (71 lb in).

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Fig. 38: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

38. Connect the air intake tube to the throttle body.

39. Connect the breather tube to the valve cover.
40. Connect the IAT sensor connector.
41. Connect the negative battery cable.

TIMING BELT REPLACEMENT

Tools Required

l J 42492-A (KM-421-A) Timing Belt Adjuster

l J 45059 Angle Meter
l KM-470-B Angular Torque Gage

Removal Procedure

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Fig. 39: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Disconnect the intake air temperature (IAT) sensor connector.
3. Disconnect the air intake tube from the throttle body.
4. Disconnect the breather tube from the valve cover.

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C:\Users\starkes\AppData\Local\Temp\mric_tmp\~od7B6.png (1355 x 1221) @ 564.48px

Fig. 40: Location Of Air Cleaner

Courtesy of GENERAL MOTORS CORP.

5. Remove the air filter housing bolts.

6. Remove the air filter housing.
7. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Remove the right front splash shield.

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Fig. 41: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

9. Remove the accessory drive belt.

10. Remove the crankshaft pulley bolt.
11. Remove the crankshaft pulley.

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Fig. 42: View Of Timing Belt Cover Bolts

Courtesy of GENERAL MOTORS CORP.

12. Remove the upper front timing belt cover bolts.

13. Remove the upper front timing belt cover.
14. Remove the lower front timing belt cover bolts.
15. Remove the lower front timing belt cover.
16. Remove the power steering pump mounting bolts, if equipped.
17. Install the crankshaft pulley bolt.

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Fig. 43: View Of Crankshaft Gear And Rear Timing Belt Cover
Courtesy of GENERAL MOTORS CORP.

18. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft
gear is aligned with the notch at the bottom of the rear timing belt cover.

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Fig. 44: Using J42492-A Rotating Coolant Pump

Courtesy of GENERAL MOTORS CORP.

19. Slightly loosen the coolant pump retaining bolts.

20. Using the J 42492-A (1), rotate the coolant pump counterclockwise to release the tension on the timing
belt.

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Fig. 45: View Of Timing Belt

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Remove the timing belt behind the power steering pump.

21. Remove the timing belt.

Installation Procedure

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Fig. 46: View Of Crankshaft Gear And Rear Timing Belt Cover
Courtesy of GENERAL MOTORS CORP.

1. Align the timing mark on the crankshaft gear to the notch on the bottom of the rear timing belt cover.

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Fig. 47: Aligning The Timing Marks On The Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

2. Align the timing marks on the camshaft gears.

3. Install the timing belt.

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Fig. 48: Using J42492-A Rotating Coolant Pump

Courtesy of GENERAL MOTORS CORP.

4. Rotate the coolant pump clockwise using the J 42492-A (1).

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Fig. 49: Aligning Timing Belt Automatic Tensioner Pointer With Bracket Notch
Courtesy of GENERAL MOTORS CORP.

5. Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is
aligned to the notch in the timing belt automatic tensioner bracket.

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Fig. 50: Aligning Timing Belt Automatic Tensioner Pointer With Bracket Pointer
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

6. Tighten the coolant pump retaining bolts.

7. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt.
8. Loosen the coolant pump retaining bolts.
9. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with
the pointer on the timing belt automatic tensioner bracket.

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Fig. 51: View Of Coolant Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

10. Tighten the coolant pump retaining bolts.

Tighten: Tighten the coolant pump retaining bolts to 10 N.m (89 lb in).

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Fig. 52: View Of Timing Belt Cover Bolts

Courtesy of GENERAL MOTORS CORP.

11. Remove the crankshaft pulley bolt.

12. Install the upper and lower front timing belt cover.
13. Install the upper and lower front timing belt cover bolts.

Tighten: Tighten the upper and lower front timing belt cover bolts to 10 N.m (89 lb in).

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Fig. 53: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

14. Install the crankshaft pulley.

15. Install the crankshaft pulley bolt.

Tighten: Tighten the crankshaft pulley bolt to 95 N.m (70 lb ft) using a torque wrench. Using the J
45059 or the KM-470-B , tighten the crankshaft pulley bolt 30 degrees plus 15 degrees.

16. Install the accessory drive belt, if equipped.

17. Install the right front splash shield.
18. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

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C:\Users\starkes\AppData\Local\Temp\mric_tmp\~od7C4.png (1355 x 1221) @ 564.48px

Fig. 54: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

19. Install the air filter housing.

20. Install the air filter housing bolts.

Tighten: Tighten the air filter housing bolts to 8 N.m (71 lb in).

21. Connect the air intake tube to the throttle body.

22. Connect the breather tube to the throttle body.
23. Connect the IAT sensor connector.
24. Connect the negative battery cable.

TIMING BELT COVER REPLACEMENT

Removal Procedure

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Fig. 55: View Of Timing Belt Automatic Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

1. Remove the timing belt. Refer to Timing Belt Replacement.

2. Remove the camshaft gears. Refer to Camshaft Gear Replacement.
3. Remove the crankshaft gear.
4. Remove the timing belt automatic tensioner bolts.
5. Remove the timing belt automatic tensioner.

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Fig. 56: View Of Timing Belt Idler Pulley

Courtesy of GENERAL MOTORS CORP.

6. Remove the timing belt idler pulley bolt.

7. Remove the timing belt idler pulley

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Fig. 57: View Of Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

8. Remove the rear timing belt cover bolts.

9. Remove the rear timing belt cover.

Installation Procedure

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Fig. 58: View Of Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

1. Install the rear timing belt cover.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the rear timing belt cover bolts.

Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 lb in).

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Fig. 59: View Of Timing Belt Idler Pulley

Courtesy of GENERAL MOTORS CORP.

3. Install the timing belt idler pulley.

4. Install the timing belt idler pulley bolt.

Tighten: Tighten the timing belt idler pulley bolt to 40 N.m(30 lb ft).

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Fig. 60: View Of Timing Belt Automatic Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

5. Install the timing belt automatic tensioner.

6. Install the timing belt automatic tensioner bolts.

Tighten: Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb ft).

7. Install the crankshaft gear.

IMPORTANT: Take extreme care to prevent any scratches, nicks or damage to the
camshafts.

8. Install the camshaft gears. Refer to Camshaft Gear Replacement.

9. Install the timing belt. Refer to Timing Belt Replacement.

VALVE ROCKER ARM COVER REPLACEMENT

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Removal Procedure

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Fig. 61: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Remove the engine cover bolts and cover.

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Fig. 62: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

3. Disconnect the breather tube from the valve cover.

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Fig. 63: View Of Crankcase Ventilation Tube

Courtesy of GENERAL MOTORS CORP.

4. Disconnect the crankcase ventilation tube from the valve cover.

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Fig. 64: View Of Camshaft Position (CMP) Sensor Connector

Courtesy of GENERAL MOTORS CORP.

5. Disconnect the camshaft position (CMP) sensor connect.

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Fig. 65: View Of Ignition Wires And Spark Plugs

Courtesy of GENERAL MOTORS CORP.

6. Disconnect all of the necessary vacuum lines.

7. Disconnect the ignition wires from the spark plugs.

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Fig. 66: Valve Cover Bolts Location

Courtesy of GENERAL MOTORS CORP.

8. Remove the valve cover bolts.

9. Remove the valve cover.

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Fig. 67: View Of Valve Cover And Gasket

Courtesy of GENERAL MOTORS CORP.

10. Remove the valve cover gasket from the valve cover.

Installation Procedure

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Fig. 68: View Of Valve Cover And Gasket

Courtesy of GENERAL MOTORS CORP.

1. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear
valve cover to cylinder head seal.
2. Install the new valve cover gasket to the valve cover.

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Fig. 69: Valve Cover Bolts Location

Courtesy of GENERAL MOTORS CORP.

3. Install the valve cover.

NOTE: Refer to Fastener Notice in Cautions and Notices.

4. Install the valve cover bolts.

Tighten: Tighten the valve cover bolts to 10 N.m (89 lb in).

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Fig. 70: View Of Ignition Wires And Spark Plugs

Courtesy of GENERAL MOTORS CORP.

5. Connect the ignition wires from the spark plugs.

6. Connect all of the necessary vacuum lines.

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Fig. 71: View Of Camshaft Position (CMP) Sensor Connector

Courtesy of GENERAL MOTORS CORP.

7. Connect the CMP sensor connector.

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Fig. 72: View Of Crankcase Ventilation Tube

Courtesy of GENERAL MOTORS CORP.

8. Connect the crankcase ventilation tube from the valve cover.

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Fig. 73: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

9. Connect the breather tube from the valve cover.

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Fig. 74: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

10. Install the spark plug cover.

11. Install the spark plug cover bolts.

Tighten: Tighten the engine cover bolts to 3 N.m (27 lb in).

12. Connect the negative battery cable.

CYLINDER HEAD REPLACEMENT

Tools Required

l J 45059 Angle Meter

l KM-470-B Angular Torque Gage
l J 42492-A (KM-421-A) Timing Belt Adjuster

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Removal Procedure

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Fig. 75: Locating Fuel Pump Fuse

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Remove the fuel pump fuse.

2. Start the engine. Crank the engine after the engine stalls for 10 seconds to rid the fuel system of fuel
pressure.
3. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.

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Fig. 76: View Of Air Intake Tube And Throttle Body

Courtesy of GENERAL MOTORS CORP.

4. Disconnect the breather tube from the valve cover.

5. Disconnect the intake air temperature (IAT) sensor connector.
6. Disconnect the air intake tube from the throttle body.

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Fig. 77: Location Of Air Cleaner

Courtesy of GENERAL MOTORS CORP.

7. Remove the air filter housing bolts.

8. Remove the air filter housing.

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Fig. 78: View Of A/C Pressure Transducer (ACP) Connector

Courtesy of GENERAL MOTORS CORP.

9. Disconnect the A/C pressure transducer (ACP) connector.

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Fig. 79: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

10. Disconnect the idle air control (IAC) valve connector.

11. Disconnect the throttle position (TP) sensor connector.
12. Disconnect the throttle cable from the throttle body and the intake manifold.
13. Disconnect the engine coolant inlet/outlet hose at the throttle body.

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Fig. 80: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

14. Disconnect the manifold absolute pressure (MAP) sensor connector.

15. Disconnect the brake booster vacuum hose.
16. Disconnect the variable geometry induction solenoid (VGIS) connector.
17. Disconnect the VGIS vacuum tank hose.

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Fig. 81: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

18. Remove the engine cover bolts and the cover.

19. Disconnect the breather tube from the valve cover.
20. Disconnect the crankcase ventilation tube from the valve cover.

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Fig. 82: Identifying Fuel Injector Harness Connectors

Courtesy of GENERAL MOTORS CORP.

21. Disconnect the camshaft position (CMP) sensor connector.

22. Disconnect the ignition wires from the spark plugs.
23. Disconnect the fuel injector harness connectors.

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Fig. 83: View Of Fuel Rail

Courtesy of GENERAL MOTORS CORP.

24. Disconnect the fuel line.

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Fig. 84: View Of Alternator Adjusting Nut

Courtesy of GENERAL MOTORS CORP.

25. Remove the bracket nut from the power steering pressure pipe.
26. Remove the power steering pressure pipe.
27. Remove the alternator adjusting nut.

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Fig. 85: Locating EGR Valve

Courtesy of GENERAL MOTORS CORP.

28. Remove the accessory drive bolt.

29. Disconnect the exhaust gas recirculation (EGR) valve connector.
30. Disconnect the ignition coil connector from the electronic ignition (EI) system.
31. Disconnect the front heated oxygen sensor (HO2S) connector.

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Fig. 86: Identifying Canister Purge Solenoid Valve

Courtesy of GENERAL MOTORS CORP.

32. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
33. Remove the engine under-cover bolt and the nuts.
34. Remove the engine under-cover.
35. Remove the canister purge solenoid valve at the intake manifold support bracket.

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Fig. 87: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

36. Remove the bracket bolts from the upper intake manifold support.
37. Remove the bracket bolts from the lower intake manifold support.
38. Disconnect the connector from the engine coolant temperature (ECT) sensor.

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Fig. 88: View Of Exhaust Manifold Shield

Courtesy of GENERAL MOTORS CORP.

39. Remove the exhaust manifold heat shield bolts.

40. Remove the exhaust manifold heat shield.
41. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.

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Fig. 89: View Of Thermostat Housing Upper Radiator Hose

Courtesy of GENERAL MOTORS CORP.

42. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
43. Disconnect the upper radiator hose from the thermostat housing.

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Fig. 90: View Of Upper Front Timing Belt Cover And Bolts
Courtesy of GENERAL MOTORS CORP.

44. Remove the cover bolts from the upper front timing belt.
45. Remove the cover from the upper front timing belt.

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Fig. 91: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

46. Remove the crankshaft pulley bolt.

47. Remove the crankshaft pulley.

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Fig. 92: View Of Lower Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

48. Remove the cover bolts from the lower front timing belt.
49. Remove the cover from the lower front timing belt.

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Fig. 93: View Of Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

50. Align the camshaft gear timing marks.

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Fig. 94: Using J42492-A Rotating Coolant Pump

Courtesy of GENERAL MOTORS CORP.

51. Slightly loosen the coolant pump retaining bolts.

52. Rotate the coolant pump counterclockwise using J 42492-A (1) to relieve the timing belt tension.
53. Remove the timing belt. Refer to Timing Belt Replacement.

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Fig. 95: View Of Intake And Exhaust Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

54. Remove the valve cover. Refer to Valve Rocker Arm Cover Replacement.

NOTE: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

55. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
56. Remove the intake camshaft gear.
57. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
58. Remove the exhaust camshaft gear.

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Fig. 96: View Of Timing Belt Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

59. Remove the bolts from the timing belt automatic tensioner.
60. Remove the timing belt automatic tensioner.

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Fig. 97: View Of CMP Sensor

Courtesy of GENERAL MOTORS CORP.

61. Remove the camshaft position (CMP) sensor bolts.

62. Remove the CMP sensor.

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Fig. 98: View Of Timing Belt Idler Pulley And Bolt

Courtesy of GENERAL MOTORS CORP.

63. Remove the bolt from the timing belt idler pulley.
64. Remove the timing belt idler pulley.

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Fig. 99: View Of Rear Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

65. Remove the bolts from the rear timing belt cover.
66. Remove the rear timing belt cover.

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Fig. 100: View Of Heater Outlet Hose And Coolant Pipe

Courtesy of GENERAL MOTORS CORP.

67. Disconnect the heater outlet hose from the coolant pipe.

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Fig. 101: Cylinder Head Bolt Removal Sequence

Courtesy of GENERAL MOTORS CORP.

68. Loosen all of the cylinder head bolts gradually and in the sequence shown.
69. Remove the cylinder head bolts.
70. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

NOTE: Use extreme care when removing the cylinder head to prevent any engine
oil, dirt, or coolant from entering the engine. Damage to the engine could
result.

71. Remove the cylinder head gasket.

72. Disassembly the cylinder head, if applicable. Refer to Cylinder Head Disassemble.
73. Clean and inspect the cylinder head as necessary. Refer to Cylinder Head Cleaning and Inspection.

Installation Procedure

1. Assemble the cylinder head, if applicable. Refer to Cylinder Head Assemble.

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Fig. 102: Cylinder Head Bolt Installation Sequence

Courtesy of GENERAL MOTORS CORP.

2. Install the cylinder head gasket.

3. Install the cylinder head with the intake manifold and the exhaust manifold attached.
4. Install the cylinder head bolts.

NOTE: Refer to Fastener Notice in Cautions and Notices.

5. Tighten the cylinder head bolts gradually and in the sequence shown.

Tighten: Tighten the bolts to 25 N.m (18 lb ft). Adjust the bolts to 60 degrees plus 60 degrees plus 60
degrees plus 10 degrees using J 45059 or KM-470-B .

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Fig. 103: View Of Heater Outlet Hose And Coolant Pipe

Courtesy of GENERAL MOTORS CORP.

6. Connect the heater outlet hose to the coolant pipe.

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Fig. 104: View Of Rear Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

7. Install the rear timing belt cover.

8. Install the bolts to the rear timing belt cover.

Tighten: Tighten the bolts to 10 N.m (89 lb in).

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Fig. 105: View Of CMP Sensor

Courtesy of GENERAL MOTORS CORP.

9. Install the CMP sensor. Install the CMP sensor bolts.

Tighten: Tighten the bolts to 12 N.m (106 lb in).

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Fig. 106: View Of Timing Belt Idler Pulley And Bolt

Courtesy of GENERAL MOTORS CORP.

10. Install the timing belt idler pulley. Install the bolt. to the timing belt idler pulley

Tighten: Tighten the bolt to 40 N.m (30 lb ft).

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Fig. 107: View Of Timing Belt Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

11. Install the timing belt automatic tensioner. Install the bolts to the timing belt automatic tensioner.

Tighten: Tighten the bolts to 25 N.m (18 lb ft).

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Fig. 108: View Of Intake And Exhaust Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

NOTE: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

12. Install the intake camshaft gear.

13. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten: Tighten the bolt to 67.5 N.m (49 lb ft).

14. Install the exhaust camshaft gear.

15. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten: Tighten the bolt to 67.5 N.m (49 lb ft).

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Fig. 109: View Of Valve Cover And Gasket

Courtesy of GENERAL MOTORS CORP.

16. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the seal
between the rear valve cover and the cylinder head.
17. Install the valve cover and the valve cover gasket.
18. Install the valve cover bolts.

Tighten: Tighten the bolts to 10 N.m (89 lb in).

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Fig. 110: View Of Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

19. Align the timing marks on the camshaft gear.

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Fig. 111: View Of Crankshaft Gear And Rear Timing Belt Cover
Courtesy of GENERAL MOTORS CORP.

20. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.

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Fig. 112: Using J42492-A Rotating Coolant Pump

Courtesy of GENERAL MOTORS CORP.

NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the
breakdown of the composition of the drive belt. Failure to follow this
recommendation will damage the drive belt.

21. Install the timing belt.

22. Rotate the coolant pump clockwise using J 42492-A (1), to apply tension to the timing belt.

Tighten: Tighten the retaining bolt to 10 N.m (89 lb in).

23. Inspect and adjust the timing belt tension. Refer to Timing Belt Inspection.

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Fig. 113: View Of Lower Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

24. Install the retaining bolts that secure the engine mount to the engine mount bracket.

Tighten: Tighten the retaining bolts to 60 N.m (44 lb ft).

25. Install the lower front timing belt cover.

26. Install the bolts to the lower front timing belt cover.

Tighten: Tighten the bolts to 10 N.m (89 lb in).

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Fig. 114: View Of Balancer

Courtesy of GENERAL MOTORS CORP.

27. Install the crankshaft pulley.

28. Install the crankshaft pulley bolt.

Tighten: Tighten the bolt to 95 N.m (70 lb ft) using a torque wrench. Using J 45059 or KM-470-B ,
tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.

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Fig. 115: View Of Upper Front Timing Belt Cover And Bolts
Courtesy of GENERAL MOTORS CORP.

29. Install the upper front timing belt cover.

30. Install the bolts to the upper front timing belt cover.

Tighten: Tighten the bolts to 10 N.m (89 lb in).

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Fig. 116: View Of Thermostat Housing Upper Radiator Hose

Courtesy of GENERAL MOTORS CORP.

31. Connect the upper radiator hose to the thermostat housing.

32. Connect the throttle body coolant hose to the thermostat housing.
33. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.

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Fig. 117: View Of Exhaust Manifold Shield

Courtesy of GENERAL MOTORS CORP.

34. Install the exhaust manifold heat shield. Install the bolts to the exhaust manifold heat shield.

Tighten: Tighten the bolts to 15 N.m (11 lb ft).

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Fig. 118: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

35. Connect the ECT sensor connector.

36. Install the upper bolts to the intake manifold support bracket.

Tighten: Tighten the bolts to 25 N.m (18 lb ft).

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Fig. 119: Identifying Canister Purge Solenoid Valve

Courtesy of GENERAL MOTORS CORP.

37. Install the canister purge solenoid valve at the intake manifold support bracket.
38. Install the engine under-cover.

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Fig. 120: Locating EGR Valve

Courtesy of GENERAL MOTORS CORP.

39. Connect the front HO2S connector.

40. Connect the EI system ignition coil connector.
41. Connect the EGR valve connector.

NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the
breakdown of the composition of the drive belt. Failure to follow this
recommendation will damage the drive belt.

42. Install the accessory drive belt.

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Fig. 121: View Of Alternator Adjusting Nut

Courtesy of GENERAL MOTORS CORP.

43. Install the alternator bracket retaining nut.

Tighten: Tighten the nut to 25 N.m (18 lb ft).

44. Install the alternator nut. Do NOT tighten.

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Fig. 122: View Of Fuel Rail

Courtesy of GENERAL MOTORS CORP.

45. Connect the fuel line at the fuel rail.

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Fig. 123: Identifying Fuel Injector Harness Connectors

Courtesy of GENERAL MOTORS CORP.

46. Connect the fuel injector harness connectors.

47. Connect the ignition wires from the spark plugs.
48. Connect the CMP sensor connector.

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Fig. 124: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

49. Connect the crankcase ventilation tube to the valve cover.

50. Connect the breather tube to the valve cover.
51. Install the engine cover.
52. Install the engine cover bolts.

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Fig. 125: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

53. Connect the VGIS vacuum tank hose.

54. Connect the VGIS connector.
55. Connect the brake booster vacuum hose.
56. Connect the MAP sensor connector.

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Fig. 126: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

57. Connect the engine coolant inlet/outlet hose to the throttle body.
58. Connect the throttle cable to the throttle body and the intake manifold.
59. Connect the TP sensor connector.
60. Connect the IAC valve connector.

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Fig. 127: View Of A/C Pressure Transducer (ACP) Connector

Courtesy of GENERAL MOTORS CORP.

61. Connect the A/C pressure transducer connector.

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Fig. 128: Location Of Air Cleaner

Courtesy of GENERAL MOTORS CORP.

62. Install the air filter housing. Install the air filter housing bolts.

Tighten: Tighten the bolts to 8 N.m (71 lb in).

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Fig. 129: View Of Air Intake Tube And Throttle Body

Courtesy of GENERAL MOTORS CORP.

63. Connect the air intake tube to the throttle body.

64. Connect the IAT sensor connector.
65. Connect the breather tube to the valve cover.
66. Install the fuel pump fuse.
67. Connect the negative battery cable.
68. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.

OIL PAN REPLACEMENT

Removal Procedure

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Fig. 130: View Of Catalytic Converter Lower Flange Nuts

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the right front splash shield.
4. Drain the engine oil from the engine crankcase.
5. Disconnect the heated oxygen sensor (HO2S).
6. Remove the catalytic lower flange nuts from the exhaust manifold and remover the bolts at the bracket.

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Fig. 131: View Of Muffler Pipe Nuts

Courtesy of GENERAL MOTORS CORP.

7. Remove the nuts that secure the front pipe.

8. Remove the catalytic converter and the exhaust pipe as a unit.

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Fig. 132: View Of Oil Pan And Transaxle Housing

Courtesy of GENERAL MOTORS CORP.

9. Remove the bolts that secure the oil pan to the transaxle housing.

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Fig. 133: View Of Transaxle Housing

Courtesy of GENERAL MOTORS CORP.

10. Remove the bolt that secures the transaxle housing to the oil pan.

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Fig. 134: View Of Oil Pan

Courtesy of GENERAL MOTORS CORP.

11. Remove the grommet.

12. Remove the oil pan retaining bolts.
13. Remove the oil pan from the engine block.
14. Remove the gasket from the oil pan.

Installation Procedure

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Fig. 135: View Of Oil Pan

Courtesy of GENERAL MOTORS CORP.

1. Install the gasket to the oil pan.

IMPORTANT: Install the oil pan within 5 minutes after applying the liquid gasket to the
oil pan.

2. Install the oil pan to the engine block.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the oil pan retaining bolts.

Tighten: Tighten the bolts to 10 N.m (89 lb in).

4. Discard the used oil pan drain plug washer and replace it with a new one.
5. Install the grommet.

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Fig. 136: View Of Transaxle Housing

Courtesy of GENERAL MOTORS CORP.

6. Install the bolt that secures the transaxle housing to the oil pan.

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

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Fig. 137: View Of Oil Pan And Transaxle Housing

Courtesy of GENERAL MOTORS CORP.

7. Install the bolts that secure the oil pan to the transaxle housing.

Tighten: Tighten the bolts to 25 N.m (18 lb ft).

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Fig. 138: View Of Catalytic Converter Lower Flange Nuts

Courtesy of GENERAL MOTORS CORP.

8. Install the catalytic converters and the exhaust pipe as a unit.

Tighten:
l Tighten the nuts that secure the catalytic converter to the exhaust manifold to 50 N.m (37 lb ft).

l Tighten the exhaust pipe bracket bolts to 50 N.m (37 lb ft).

l Tighten the front muffler nuts to 30 N.m (22 lb ft).

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Fig. 139: View Of Muffler Pipe Nuts

Courtesy of GENERAL MOTORS CORP.

9. Connect the HO2S.

10. Install the right front splash shield.
11. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Connect the negative battery cable.
13. Refill the engine crankcase with engine oil.

OIL PUMP CLEANING AND INSPECTION

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Fig. 140: View Of Crankshaft Seal

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Clean the oil pump and the engine block gasket mating surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.

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Fig. 141: View Of Oil Pump

Courtesy of GENERAL MOTORS CORP.

5. Remove the oil pump rear cover bolts.

6. Remove the rear cover.
7. Clean the oil pump housing and all of the parts.
8. Inspect all of the parts for signs of wear. Refer to Engine Mechanical Specifications.
9. Coat all of the oil pump parts with clean engine oil.
10. Reinstall all of the oil pump parts.

NOTE: Fill oil pump cavities with petroleum jelly prior to installation. This will
ensure that there is oil pressure immediately on start-up and will prevent
engine damage.

NOTE: Refer to Fastener Notice in Cautions and Notices.

11. Install the oil pump rear cover and the bolts.

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Tighten: Tighten the oil pump rear cover bolts to 6 N.m (53 lb in).

12. Install the safety relief valve, the spring, the washer, and the bolt.

Tighten: Tighten the oil pump safety relief valve bolt to 30 N.m (22 lb ft).

OIL PUMP REPLACEMENT

Removal Procedure

Fig. 142: View Of Oil Pressure Switch

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Remove the timing belt. Refer to Timing Belt Replacement.

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3. Remove the rear timing belt cover. Refer to Timing Belt Cover Replacement.
4. Disconnect the oil pressure switch connector.

Fig. 143: View Of Oil Pump/Pickup Tube And Bolts

Courtesy of GENERAL MOTORS CORP.

5. Remove the crankshaft position (CKP) sensor bolt.

6. Remove the CKP sensor.
7. Remove the oil pan. Refer to Oil Pan Replacement.
8. Remove the oil pump pickup tube and the support bracket bolts.
9. Remove the oil pump pickup tube.

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Fig. 144: Identifying Oil Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

10. Remove the oil pump retaining bolts (1).

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

11. Carefully separate the oil pump and the gasket from the engine block and the oil pan.
12. Remove the oil pump.

Installation Procedure

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Fig. 145: Identifying Oil Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

1. Apply a bead of room temperature vulcanizing (RTV) sealer to the oil pump gasket.
2. Install a new oil pump gasket to the oil pump.
3. Coat the threads of the oil pump bolts with LOCTITE® 242.

NOTE: Refer to Fastener Notice in Cautions and Notices.

4. Install the oil pump to the engine block with the bolts (1).

Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb in).

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Fig. 146: View Of Crankshaft Seal

Courtesy of GENERAL MOTORS CORP.

5. Install a new oil pump to the crankshaft shaft seal.

6. Coat the lip of the seal with a thin coat of grease.

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Fig. 147: View Of Oil Pump/Pickup Tube And Bolts

Courtesy of GENERAL MOTORS CORP.

7. Coat the threads of the oil pump pickup tube and the support bracket bolts with LOCTITE ®242.
8. Install the oil pump pickup tube and the bolts.

Tighten: Tighten the oil pump pickup tube and the support bracket bolts to 10 N.m (89 lb in).

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Fig. 148: View Of Oil Pressure Gage Sensor

Courtesy of GENERAL MOTORS CORP.

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

10. Install the CKP sensor and the bolt.

Tighten: Tighten the crankshaft position sensor retaining bolt to 10 N.m (89 lb in).

11. Connect the oil pressure switch connector.

12. Install the timing belt cover. Refer to Timing Belt Cover Replacement.
13. Install the timing belt. Refer to Timing Belt Replacement.
14. Connect the negative battery cable.

ENGINE REPLACEMENT

Removal Procedure

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Fig. 149: Locating Fuel Pump Fuse

Courtesy of GENERAL MOTORS CORP.

1. Remove the fuel pump fuse.

2. Start the engine. Crank the engine for 10 seconds after stalling to rid the fuel system of fuel pressure.
3. Drain the engine oil.
4. Remove the battery and the battery tray. Refer to Battery Tray Replacement in Engine Electrical.

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Fig. 150: View Of Thermostat Housing Upper Radiator Hose

Courtesy of GENERAL MOTORS CORP.

5. Discharge the air conditioning (A/C) system, if equipped. Refer to Refrigerant Recovery and
Recharging in Heating, Ventilation, and Air Conditioning.
6. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
7. Remove the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in
Engine Cooling.
8. Disconnect the upper radiator hose from the thermostat housing.
9. If the vehicle is equipped with a power steering pump, perform the following procedures:
1. Disconnect the power steering return hose from the power steering pump.
2. Remove the union nut from the power steering pressure hose.
3. Disconnect the power steering pressure hose from the power steering pump.

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Fig. 151: View Of Air Intake Tube

Courtesy of GENERAL MOTORS CORP.

10. Disconnect the intake air temperature (IAT) sensor connector.

11. Disconnect the breather tube from the valve cover.
12. Disconnect the air intake tube from the throttle body.
13. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -
1.6L (L91).

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Fig. 152: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

14. Remove the bolts from the spark plug cover.

15. Remove the spark plug cover.

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Fig. 153: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

16. Disconnect the connector from the idle air control (IAC) valve.
17. Disconnect the connector from the throttle position sensor (TPS).
18. Disconnect the connector from the A/C pressure (ACP) transducer, if equipped.
19. Disconnect the camshaft position (CMP) sensor.
20. Disconnect the throttle cable from the throttle body and from the intake manifold bracket.

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Fig. 154: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

21. Disconnect the connector from the manifold absolute pressure (MAP) sensor.

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Fig. 155: Spark Plug Wire Routing

Courtesy of GENERAL MOTORS CORP.

22. Disconnect the ignition wires from the spark plugs.

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Fig. 156: Identifying Fuel Injector Harness Connectors

Courtesy of GENERAL MOTORS CORP.

23. Disconnect the surge tank coolant hose at the throttle body.
24. Disconnect the fuel injector connectors.

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Fig. 157: Locating EGR Valve

Courtesy of GENERAL MOTORS CORP.

25. Disconnect the connector from the exhaust gas recirculation (EGR) valve.
26. Disconnect the electrical connector at the electronic ignition (EI) system ignition coil
27. Disconnect the oxygen sensor connector.
28. Disconnect the connector from the crankshaft position sensor (CPS).

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Fig. 158: View Of Fuel Rail

Courtesy of GENERAL MOTORS CORP.

29. Disconnect all of the necessary vacuum lines. Disconnect the brake booster vacuum hose at the intake
manifold.
30. Disconnect the fuel feed line at the fuel rail.

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Fig. 159: View Of Battery Tray

Courtesy of GENERAL MOTORS CORP.

31. Remove the bolts from the battery tray support.

32. Remove the battery tray support.

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Fig. 160: View Of Lower Radiator Hose

Courtesy of GENERAL MOTORS CORP.

33. Disconnect the lower radiator hose from the coolant pipe.

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Fig. 161: Locating A/C Evaporator Pipes

Courtesy of GENERAL MOTORS CORP.

34. Remove the bolt from the A/C compressor pipe and hose assembly, if equipped.
35. Remove the A/C compressor pipe and hose assembly from the compressor.
36. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
37. Remove the front splash shield and the engine undercover.
38. Disconnect the A/T oil cooler inlet/outlet pipe, if equipped. Refer to Transmission Cooler Pipes and
Hoses Replacement (Inlet) or Transmission Cooler Pipes and Hoses Replacement (Outlet) in
Automatic Transmission - Aisin (81-40LE).
39. Disconnect the A/T shift control cable, if equipped. Refer to Shift Control Cable Replacement - Floor
Shift in Automatic Transmission - Aisin (81-40LE).
40. Disconnect all of the A/T electrical connectors, if equipped.
41. Disconnect the electrical connector at the A/C compressor coil, if equipped.
42. Disconnect the connector from the rear heat oxygen sensor (HO2S).

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Fig. 162: View Of Catalytic Converter Lower Flange Nuts

Courtesy of GENERAL MOTORS CORP.

43. Remove the lower flange nuts from the exhaust manifold studs. Retain the gasket.
44. Remove the bolts at the bracket.

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Fig. 163: View Of Muffler Pipe Nuts

Courtesy of GENERAL MOTORS CORP.

45. Remove the nuts that secure the front muffler pipe. Retain the gasket.
46. Remove the front exhaust pipe as a unit.

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Fig. 164: Rear Mounting Bracket Bolts And Bracket

Courtesy of GENERAL MOTORS CORP.

47. Remove the nut and bolt from the damping block connection.
48. Remove bolts from the rear mounting bracket. Remove the bracket.
49. Remove the A/T drive axle, if equipped. Refer to Inner Shaft and/or Housing Replacement - Front
Drive Axle in Front Drive Axle.

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Fig. 165: View Of Oil Pressure Switch

Courtesy of GENERAL MOTORS CORP.

50. Disconnect the electrical connector at the oil pressure switch.

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Fig. 166: View Of Generator Voltage Regulator

Courtesy of GENERAL MOTORS CORP.

51. Remove the battery harness connector nut from the generator.
52. Disconnect the connector from the generator voltage regulator.

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Fig. 167: Identifying Canister Purge Solenoid Valve

Courtesy of GENERAL MOTORS CORP.

53. Disconnect the electrical connector from the evaporative (EVAP) emission canister purge solenoid.

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Fig. 168: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

54. Remove the bolts from the intake manifold support bracket.
55. Remove the intake manifold support bracket.
56. Disconnect the connector from the engine coolant temperature (ECT) sensor.
57. Remove the lower starter mounting bolt.
58. Remove the starter solenoid nuts in order to disconnect the electrical cable.
59. Remove the lower engine wire harness.

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Fig. 169: View Of Torque Converter Bolts

Courtesy of GENERAL MOTORS CORP.

60. Remove the rubber from the oil pan.

61. Remove the torque converter service cover and the bolts.

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Fig. 170: View Of Engine Assembly With Engine Assembly Support Fixture
Courtesy of GENERAL MOTORS CORP.

62. Install the engine lifting device.

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Fig. 171: View Of Crossmember, Nuts, And Bolts

Courtesy of GENERAL MOTORS CORP.

63. Remove the retaining bolts from the engine mount bracket.
64. Remove the bracket from the engine block.

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Fig. 172: View Of Upper Transaxle Mounting Bracket Bolts

Courtesy of GENERAL MOTORS CORP.

65. Remove the 3 bolts from the upper transaxle mounting bracket.

IMPORTANT: Verify that the engine and transaxle assembly is not attached to the
vehicle.

66. Lift up the vehicle slowly to separate the engine and transaxle assembly from the vehicle. Refer to Lifting
and Jacking the Vehicle in General Information.
67. Separate the engine block from the transaxle.
68. Remove the engine.

Installation Procedure

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Fig. 173: View Of Crossmember, Nuts, And Bolts

Courtesy of GENERAL MOTORS CORP.

1. Install the engine and transaxle assembly into the engine compartment.
2. Install the right engine mount bracket to the engine block.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the mounting bolts to the bracket.

Tighten: Tighten the bolts to 60 N.m (44 lb ft).

4. Install the bracket to the engine mount with 2 retaining bolts.

Tighten: Tighten the bolts to 60 N.m (44 lb ft).

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Fig. 174: View Of Upper Transaxle Mounting Bracket Bolts

Courtesy of GENERAL MOTORS CORP.

5. Install the upper transaxle mounting bracket with 3 bolts.

Tighten: Tighten the bolts to 60 N.m (44 lb ft).

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Fig. 175: View Of Torque Converter Bolts

Courtesy of GENERAL MOTORS CORP.

6. Install the service cover to the transaxle torque converter with bolts.

Tighten: Tighten the bolts to 65 N.m (48 lb ft).

7. Install the rubber to the oil pan.

8. Position the starter electrical wire on the solenoid terminal.
9. Install the starter solenoid nuts.

Tighten: Tighten the nuts to 15 N.m (11 lb ft).

10. Install the lower mounting bolts to the starter.

Tighten: Tighten the bolt to 43 N.m (32 lb ft).

11. Connect the ECT sensor connector.

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Fig. 176: View Of Intake Manifold Support Bracket

Courtesy of GENERAL MOTORS CORP.

12. Install the intake manifold support bracket.

1. Install the upper bracket bolts to the intake manifold.

Tighten: Tighten the bolts to 25 N.m (18 lb ft).

2. Install the lower bracket bolts to the engine block.

Tighten: Tighten the bolts to 40 N.m (30 lb ft).

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Fig. 177: Identifying Canister Purge Solenoid Valve

Courtesy of GENERAL MOTORS CORP.

13. Connect the electrical connector to the EVAP canister purge solenoid.

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Fig. 178: View Of Generator Voltage Regulator

Courtesy of GENERAL MOTORS CORP.

14. Connect the voltage regulator connector to the generator.

15. Install the battery harness connector to the generator using a nut.

Tighten: Tighten the nut to 15 N.m (11 lb ft).

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Fig. 179: View Of Oil Pressure Switch

Courtesy of GENERAL MOTORS CORP.

16. Connect the electrical connector to the oil pressure switch.

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Fig. 180: Identifying Damping Block Connection Nut And Bolt

Courtesy of GENERAL MOTORS CORP.

17. Install the A/T drive axle. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle in
Front Drive Axle.
18. Install the rear mounting bracket and the bracket bolts.

Tighten: Tighten the bolts to 60 N.m (44 lb ft).

19. Install the damping block connection bolt and nut.

Tighten: Tighten the bolt and the nut to 80 N.m (59 lb ft).

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Fig. 181: View Of Muffler Pipe Nuts

Courtesy of GENERAL MOTORS CORP.

20. Install the front exhaust pipe and the gasket.

21. Install the nuts to the front exhaust pipe.

Tighten: Tighten the nuts to 30 N.m (22 lb ft).

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Fig. 182: View Of Catalytic Converter Lower Flange Nuts

Courtesy of GENERAL MOTORS CORP.

22. Install the exhaust front pipe and gasket to the catalytic converter. Secure with the retaining nuts.

Tighten: Tighten the nuts to 40 N.m (30 lb ft).

23. Secure the exhaust front pipe to the bracket with a bolt.

Tighten: Tighten the bolt to 40 N.m (30 lb ft).

24. Connect the rear HO2S connector.

25. Connect the A/C compressor coil connector, if equipped.
26. If the vehicle is equipped with automatic transmission, perform the following procedures:
1. Connect all of the A/T electrical connectors.
2. Connect the A/T shift control cable. Refer to Shift Control Cable Replacement - Floor Shift in
Automatic Transmission - Aisin (81-40LE).
3. Connect the A/T oil cooler inlet/outlet pipe. Refer to Transmission Cooler Pipes and Hoses

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Replacement (Inlet) or Transmission Cooler Pipes and Hoses Replacement (Outlet) in

Automatic Transmission - Aisin (81-40LE).

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Fig. 183: Locating A/C Evaporator Pipes

Courtesy of GENERAL MOTORS CORP.

27. Install the front splash shield and the engine undercover.
28. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
29. Install the pipe and hose assembly to the A/C compressor, if equipped. Secure with a retaining bolt.

Tighten: Tighten the bolt to 33 N.m (24 lb ft).

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Fig. 184: View Of Lower Radiator Hose

Courtesy of GENERAL MOTORS CORP.

30. Connect the lower radiator hose to the coolant pipe.

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Fig. 185: View Of Battery Tray

Courtesy of GENERAL MOTORS CORP.

31. Install the battery tray support. Secure the support with a bolt.

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Fig. 186: View Of Fuel Rail

Courtesy of GENERAL MOTORS CORP.

32. Connect the brake booster vacuum hose at the intake manifold. Connect all of the necessary vacuum
lines.
33. Connect the fuel feed line at the fuel rail.

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Fig. 187: Locating EGR Valve

Courtesy of GENERAL MOTORS CORP.

34. Connect the CPS connector.

35. Connect the oxygen sensor connector.
36. Connect the electrical connector at the EI system ignition coil
37. Connect the EGR valve connector.

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Fig. 188: Identifying Fuel Injector Harness Connectors

Courtesy of GENERAL MOTORS CORP.

38. Connect the fuel injector connectors.

39. Connect the surge tank coolant hose at the throttle body.

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Fig. 189: Spark Plug Wire Routing

Courtesy of GENERAL MOTORS CORP.

40. Connect the ignition wires to the spark plugs.

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Fig. 190: Manifold Absolute Pressure (MAP) Sensor

Courtesy of GENERAL MOTORS CORP.

41. Connect the MAP sensor connector.

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Fig. 191: View Of Throttle Body And Throttle Cable

Courtesy of GENERAL MOTORS CORP.

42. Connect the throttle cable to the throttle body and to the intake manifold bracket.
43. Connect the CMP sensor.
44. Connect the ACP transducer connector, if equipped.
45. Connect the TPS connector.
46. Connect the IAC valve connector.

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Fig. 192: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

47. Install the spark plug cover. Install the bolts to the spark plug cover.

Tighten: Tighten the bolts to 3 N.m (27 lb in).

48. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 1.6L
(L91).

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Fig. 193: View Of Air Intake Tube

Courtesy of GENERAL MOTORS CORP.

49. Connect the air intake tube to the throttle body.

50. Connect the breather tube to the valve cover.
51. Connect the IAT sensor connector.

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Fig. 194: View Of Thermostat Housing Upper Radiator Hose

Courtesy of GENERAL MOTORS CORP.

52. If the vehicle is equipped with a power steering pump, perform the following procedures:
1. Connect the power steering pressure hose to the power steering pump.
2. Install the union nut to the power steering pump.

Tighten: Tighten the nut to 28 N.m (21 lb ft).

3. Connect the power steering return hose to the power steering pump.
53. Connect the upper radiator hose to the thermostat housing.
54. Install the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in
Engine Cooling.
55. Install the battery and the battery tray. Refer to Battery Tray Replacement in Engine Electrical.

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Fig. 195: Locating Fuel Pump Fuse

Courtesy of GENERAL MOTORS CORP.

56. Install the fuel pump fuse.

57. Fill the engine crankcase with engine oil.
58. Fill the engine coolant system. Refer to Draining and Filling Cooling System in Engine Cooling.
59. Bleed the power steering system, if equipped. Refer to Bleeding the Power Steering System in Power
Steering System.
60. Fill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating,
Ventilation, and Air Conditioning.

ENGINE OIL AND OIL FILTER REPLACEMENT

Removal Procedure

1. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Position an appropriate drain pan under the engine.
3. Remove the oil pan drain plug bolt.

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4. Remove the oil filter.

Installation Procedure

NOTE: Refer to Fastener Notice .

1. Install the oil filter.

Tighten: Tighten the oil filter to 14 N.m (10 lb ft).

2. Discard the used oil pan drain plug washer and replace with a new oil pan drain plug washer.
3. Install the oil pan drain plug bolt.

Tighten: Tighten the oil pan drain plug bolt to 55 N.m (40 lb ft).

4. Lower the vehicle.

5. Fill the engine with oil to the appropriate mark.
6. Start engine and inspect for leaks.

EXHAUST MANIFOLD REPLACEMENT

Removal Procedure

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Fig. 196: View Of Exhaust Manifold Shield

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Disconnect the pre-converter oxygen sensor connector.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.

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Fig. 197: View Of Catalytic Converter Retaining Nuts

Courtesy of GENERAL MOTORS CORP.

5. Remove the auxiliary catalytic converter nuts from the exhaust manifold.

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Fig. 198: Exhaust Manifold Retaining Nut Removal Sequence

Courtesy of GENERAL MOTORS CORP.

6. Remove the exhaust manifold retaining nuts in the sequence shown.

7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

9. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

Installation Procedure

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Fig. 199: Exhaust Retaining Nut Installation Sequence

Courtesy of GENERAL MOTORS CORP.

1. Install the exhaust manifold gasket.

2. Install the exhaust manifold.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the exhaust manifold retaining nuts and tighten them in the sequence shown.

Tighten: Tighten the exhaust manifold retaining nuts 25 N.m (18 lb ft).

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Fig. 200: View Of Catalytic Converter Retaining Nuts

Courtesy of GENERAL MOTORS CORP.

4. Install the auxiliary catalytic converter nuts to the exhaust manifold.

Tighten: Tighten the auxiliary catalytic converter-to-exhaust manifold nuts to 40 N.m (30 lb ft).

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Fig. 201: View Of Exhaust Manifold Shield

Courtesy of GENERAL MOTORS CORP.

5. Install the exhaust manifold heat shield.

6. Install the exhaust manifold heat shield bolts.

Tighten: Tighten the exhaust manifold heat shield bolts to 15 N.m (11 lb ft).

7. Connect the pre-converter oxygen sensor connector.

8. Connect the negative battery cable.

EXHAUST MANIFOLD REMOVAL

Exhaust Manifold Removal

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Fig. 202: View Of Exhaust Manifold Heat Shield And Bolts

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

NOTE: Refer to Oxygen Sensor Notice in Cautions and Notices.

2. Disconnect the oxygen sensor connector.

3. Remove the exhaust manifold heat shield.

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Fig. 203: View Of Exhaust Manifold Nuts And Pup Converter

Courtesy of GENERAL MOTORS CORP.

4. Remove the exhaust manifold nuts from the pup converter.

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Fig. 204: Exhaust Manifold Retaining Nut Removal Sequence

Courtesy of GENERAL MOTORS CORP.

5. Remove the exhaust manifold retaining nuts in the sequence shown and remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

Exhaust Manifold Installation

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Fig. 205: Exhaust Manifold Retaining Nut Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

1. Install the exhaust manifold and gasket.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

Tighten: Tighten the exhaust manifold retaining nuts to 25 N.m (18 lb ft).

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Fig. 206: View Of Exhaust Manifold Nuts And Pup Converter

Courtesy of GENERAL MOTORS CORP.

3. Install the exhaust manifold nuts to the catalytic converter.

Tighten: Tighten the exhaust manifold nuts to 40 N.m (30 lb ft).

CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION

l J 45059 Angle Meter

l KM-470-B Angular Torque Gage

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Fig. 207: Inspecting Crankshaft End Play

Courtesy of GENERAL MOTORS CORP.

1. Coat the crankshaft bearings with engine oil.

2. Install the upper crankshaft bearings into the engine block crankshaft journals.
3. Install the lower crankshaft bearings into the crankshaft bearing caps.
4. Install the crankshaft.
5. Inspect the crankshaft end play with the crankshaft bearings installed.
6. Check for permissible crankshaft end play. Refer to Engine Mechanical Specifications.

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Fig. 208: Checking Middle Crankshaft Journal For Out-Of-Round Runout

Courtesy of GENERAL MOTORS CORP.

7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft
journal for permissible out-of-round (runout). Refer to Engine Mechanical Specifications.

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Fig. 209: Inspecting Crankshaft Bearing Clearances

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Grease the crankshaft journals and lubricate the crankshaft bearings
slightly so that the plastic gauging thread does not tear when the
crankshaft bearing caps are removed.

8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile
plastic threads).
9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the
crankshaft journals and the crankshaft bearings.

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Fig. 210: Using J 45059 To Tighten Bearing Caps

Courtesy of GENERAL MOTORS CORP.

10. Install the crankshaft bearing caps.

NOTE: Refer to Fastener Notice in Cautions and Notices.

11. Install the crankshaft bearing cap bolts.

Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb ft). Using the J 45059 or KM-470-B
(1) tighten the crankshaft bearing cap bolts 45 degrees plus 15 degrees.

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Fig. 211: Measuring Plastic Gaging Flattened Plastic Thread Using Scale Printed On Plastic Gaging
Package
Courtesy of GENERAL MOTORS CORP.

12. Remove the crankshaft bearing caps.

13. Measure the width of the flattened plastic thread of the plastic gaging using the scale printed on the
plastic gaging package.
14. Inspect the bearing clearances for permissible tolerance ranges. Refer to Engine Mechanical
Specifications.

PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION

Tools Required

l J 45059 Angle Meter

l KM-470-B Angular Torque Gage

Piston Inspection

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Fig. 212: Inspecting Piston

Courtesy of GENERAL MOTORS CORP.

1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the
connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear. Refer to Engine Mechanical Specifications.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.

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Fig. 213: Inspecting Piston Fit To Connecting Rod

Courtesy of GENERAL MOTORS CORP.

8. Inspect the piston for fit to the connecting rod.

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Fig. 214: Inspecting Engine Block Cylinder Bore

Courtesy of GENERAL MOTORS CORP.

9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gage. Refer to Engine
Mechanical Specifications.
10. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to Engine Mechanical
Specifications. If the bearing bore is beyond specifications, replace the engine block.
11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gage. Refer to
Engine Mechanical Specifications.
12. Inspect the engine block cylinder bore for glazing.

Connecting Rod Bearing Inspection

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Fig. 215: Placement Of Plastigage On Journal

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Coat the connecting rod bearings with engine oil.

IMPORTANT: Grease the connecting rod journals and lubricate the connecting rod
bearings slightly so that the plastic gaging thread does not tear when the
connecting rod bearing caps are removed.

2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod bearing caps.
4. Measure all of the connecting rod bearing clearances using a commercially available plastic gaging,
ductile plastic threads.

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Fig. 216: Using J 45059 Or KM-470-B To Torque Rod Bolts

Courtesy of GENERAL MOTORS CORP.

5. Cut the plastic gaging threads to the length of the bearing width. Lay them axially between the connecting
rod journals and the connecting rod bearings.
6. Install the connecting rod bearing caps.

NOTE: Refer to Fastener Notice in Cautions and Notices.

7. Install the connecting rod bearing cap bolts.

Tighten: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft).

8. Using the J 45059 or the KM-470-B (1), tighten the crankshaft cap bolts another 30 degrees plus 15
degrees.

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Fig. 217: Measuring Plastigage

Courtesy of GENERAL MOTORS CORP.

9. Remove the connecting rod bearing caps.

10. Measure the width of the flattened plastic thread of the plastic gaging (1) using the scale printed on the
plastic gaging package. Plastic gaging is available for different tolerance ranges.
11. Inspect the bearing clearance for permissible tolerance ranges. Refer to Engine Mechanical
Specifications.

PISTON, CONNECTING ROD, AND BEARING REPLACEMENT

Tools Required

l J 24086-B (KM 427) Piston Pin Remover/Installer Set

l J 45059 Angle Meter, KM-470-B Angular Torque Gage

Removal Procedure

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Fig. 218: View Of Oil Suction Pipe And Bolts

Courtesy of GENERAL MOTORS CORP.

1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder
Head Replacement.
2. Remove the oil pan. Refer to Oil Pan Replacement.
3. Remove the oil suction pipe bolts.
4. Remove the oil suction pipe.

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Fig. 219: Removing Cylinder Ridge

Courtesy of GENERAL MOTORS CORP.

5. Move the piston to the bottom of the piston stroke.

6. Mark the connecting rod cap for position.
7. Remove the connecting rod cap bolts.
8. Remove the connecting rod cap and the lower connecting rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.

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Fig. 220: Expanding Piston Rings

Courtesy of GENERAL MOTORS CORP.

CAUTION: Handle the piston carefully. Worn piston rings are sharp and may
cause bodily injury.

11. Remove the piston.

12. Use a piston ring expander tool to expand the piston rings.
13. Remove the piston rings.

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Fig. 221: Pressing Out Piston Pin

Courtesy of GENERAL MOTORS CORP.

14. Remove the piston pin from the piston and connecting rod assembly using J 24086-B (1).
15. Separate the piston from the connecting rod.

Installation Procedure

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Fig. 222: Pressing Out Piston Pin

Courtesy of GENERAL MOTORS CORP.

1. Align the notch on the piston and the connecting rod so that the proper sides will be facing the front of the
engine.
2. Install the piston pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting rod assembly usingJ 24086-B (1).
6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gage. Refer to Engine Mechanical Specifications.
8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below
specifications.

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Fig. 223: Measuring Piston Ring Side Clearance

Courtesy of GENERAL MOTORS CORP.

9. Measure the piston ring side clearance using a feeler gage. Refer to Engine Mechanical Specifications.
10. If the piston ring is too thick, try another piston ring.
11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery
paper placed on a sheet of glass.

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Fig. 224: Identifying Piston Oil Rings, Second Compression Ring, And Top Compression Ring
Courtesy of GENERAL MOTORS CORP.

12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the
piston.
13. Install the second compression ring to the middle ring groove of the piston.
14. Install the top compression ring to the top ring groove of the piston.

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Fig. 225: View Of Piston Oil Rings, Oil Ring Rail Gaps, Second Compression Ring, Top
Compression Ring And Piston Top Notch
Courtesy of GENERAL MOTORS CORP.

15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the
expansion necessary for installation.
16. Stagger the piston oil rings (3), the oil ring rail gaps (1), the second compression ring (4), and the top
compression ring (3) in relation to the notch on the top of the piston (2).

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Fig. 226: Installing Piston Using Ring Compressor And Wood Handle
Courtesy of GENERAL MOTORS CORP.

17. Lubricate the cylinder wall and the piston rings with clean engine oil.
18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to
prevent damaging the crankshaft journal.
19. Install the connecting rod cap and bearings. Refer to Crankshaft and Bearings Cleaning and
Inspection.

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Fig. 227: Tightening Connecting Rod Bearing Cap Bolts

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

20. Install the connecting rod cap bolts.

Tighten: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Using the J 45059 , tighten
the bolts one turn of 30 degrees plus one turn of 15 degrees.

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Fig. 228: View Of Oil Suction Pipe And Bolts

Courtesy of GENERAL MOTORS CORP.

21. Install the oil suction pipe.

22. Install the oil suction pipe bolts.

Tighten: Tighten the oil suction pipe bolts to 10 N.m (89 lb in).

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

24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder
Head Replacement.

CAMSHAFT REPLACEMENT

Removal Procedure

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Fig. 229: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

1. Remove the timing belt. Refer to Timing Belt Replacement.

2. Remove the engine cover bolts.
3. Remove the engine cover.

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Fig. 230: View Of Throttle Cable

Courtesy of GENERAL MOTORS CORP.

4. Disconnect the breather tube form the valve cover.

5. Disconnect the crankcase ventilation tube from the valve cover.

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Fig. 231: View Of Camshaft Position (CMP) Sensor Connector

Courtesy of GENERAL MOTORS CORP.

6. Disconnect the camshaft position (CMP) sensor connector.

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Fig. 232: View Of Ignition Wires And Spark Plugs

Courtesy of GENERAL MOTORS CORP.

7. Disconnect the ignition wires from the spark plugs.

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Fig. 233: Valve Cover Bolts Location

Courtesy of GENERAL MOTORS CORP.

8. Remove the valve cover bolts.

9. Remove the valve cover and gasket.

IMPORTANT: Use extreme care when removing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
11. Remove the intake camshaft gear.
12. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
13. Remove the exhaust camshaft gear.

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Fig. 234: Sequence Of Camshaft Caps And Bolts

Courtesy of GENERAL MOTORS CORP.

14. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

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Fig. 235: Camshaft Mounting

Courtesy of GENERAL MOTORS CORP.

15. Remove the intake camshaft caps. Maintain the correct positions for installation.
16. Remove the intake camshaft.
17. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
18. Remove the exhaust camshaft.

Installation Procedure

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Fig. 236: Camshaft Mounting

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

1. Lubricate the camshaft journals and the camshaft caps with engine oil.
2. Install the intake camshaft.
3. Install the intake camshaft caps in their original positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original positions.

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Fig. 237: Sequence Of Camshaft Caps And Bolts

Courtesy of GENERAL MOTORS CORP.

7. Install the exhaust camshaft cap bolts.

NOTE: Refer to Fastener Notice in Cautions and Notices.

8. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

Tighten: Tighten the camshaft cap bolts to 16 N.m (12 lb ft).

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Fig. 238: View Of Intake And Exhaust Camshaft Gears

Courtesy of GENERAL MOTORS CORP.

9. Measure the intake camshaft end play and the exhaust camshaft end play. Refer to Engine Mechanical
Specifications.
10. Install the intake camshaft gear.
11. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten: Tighten the intake camshaft gear bolt to 67.5 N.m (49 lb ft).

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Fig. 239: View Of Intake And Exhaust Camshaft

Courtesy of GENERAL MOTORS CORP.

12. Install the exhaust camshaft gear.

13. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten: Tighten the exhaust camshaft bolt to 67.5 N.m (49 lb ft).

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Fig. 240: Valve Cover Bolts Location

Courtesy of GENERAL MOTORS CORP.

14. Install the valve cover and the valve cover gasket.
15. Install the valve cover washers.
16. Install the valve cover nuts.

Tighten: Tighten the valve cover nuts to 9 N.m (80 lb in).

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Fig. 241: Identifying Cover Screws

Courtesy of GENERAL MOTORS CORP.

17. Connect the ignition wires to the spark plugs.

18. Connect the CMP sensor.
19. Install the engine cover.
20. Install the engine cover bolts.

Tighten: Tighten the spark plug cover bolts to 3 N.m (27 lb in).

21. Install the oil filler cap.

22. Connect the vacuum line.
23. Connect the air breather tube to the valve cover.
24. Install the timing belt. Refer to Timing Belt Replacement.

CAMSHAFT GEAR REPLACEMENT

Removal Procedure

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Fig. 242: Spark Plug Wire Routing

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Remove the timing belt. Refer to Timing Belt Replacement.
3. Remove the engine cover bolts.
4. Remove the engine cover.
5. Disconnect the ignition wires from the spark plugs.
6. Disconnect the crankcase ventilation tubes from the valve cover.
7. Disconnect the camshaft position (CMP) sensor.

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Fig. 243: Valve Cover Bolts Location

Courtesy of GENERAL MOTORS CORP.

8. Remove the valve cover nuts.

9. Remove the valve cover washers.
10. Remove the valve cover and the valve cover gasket.

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Fig. 244: Holding Camshaft To Tighten Sprocket

Courtesy of GENERAL MOTORS CORP.

NOTE: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

11. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
12. Remove the intake camshaft gear.
13. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
14. Remove the exhaust camshaft gear.

Installation Procedure

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Fig. 245: Holding Camshaft To Tighten Sprocket

Courtesy of GENERAL MOTORS CORP.

NOTE: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

1. Install the intake camshaft gear.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten: Tighten the intake camshaft gear bolt to 67.5 N.m (49 lb ft).

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Fig. 246: View Of Intake And Exhaust Camshaft

Courtesy of GENERAL MOTORS CORP.

3. Install the exhaust camshaft gear.

4. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten: Tighten the exhaust camshaft gear bolt to 67.5 N.m (49 lb ft).

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Fig. 247: Spark Plug Wire Routing

Courtesy of GENERAL MOTORS CORP.

5. Connect the engine ventilation crankcase ventilation tubes to the valve cover.
6. Connect the ignition wires to the spark plugs.
7. Install the timing belt. Refer to Timing Belt Replacement.
8. Install the engine cover.
9. Connect the negative battery cable.

VALVE ROCKER ARMS CLEANING AND INSPECTION

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Fig. 248: View Of Valve Stem

Courtesy of GENERAL MOTORS CORP.

1. Inspect the valve stem tip for wear.

2. Inspect the valve key grooves and the oil seal grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be straight.
6. Inspect the valve face for grooving. If the groove is so deep that refacing the valve would result in a sharp
edge, replace the valve.

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Fig. 249: Measuring Valve spring Height

Courtesy of GENERAL MOTORS CORP.

7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to Engine Mechanical Specifications. If the valve spring height
does not match the specifications, replace the valve spring.

Cleaning Procedure

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Fig. 250: View Of Cylinder Head

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Clean the cylinder head.

2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil, and varnish.

CYLINDER HEAD DISASSEMBLE

Tools Required

l J 8062 (KM 348) Valve Spring Compressor

l KM-653-A Adaptor

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Disassembly Procedure

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Fig. 251: Exhaust Manifold Retaining Nut Sequence

Courtesy of GENERAL MOTORS CORP.

1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to
Camshaft Replacement.
2. Remove the coolant temperature sensor (CTS).
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.

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Fig. 252: View Of Thermostat Housing Assembly, Mounting Bolts, Fuel Rail Assembly, And
Retaining Bolts
Courtesy of GENERAL MOTORS CORP.

9. Remove the thermostat housing mounting bolts.

10. Remove the thermostat housing assembly.
11. Remove the fuel rail retaining bolts and the fuel rail assembly.

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Fig. 253: Intake Manifold Retaining Nuts And Retaining Bolt Removal Sequence
Courtesy of GENERAL MOTORS CORP.

12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold studs.

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Fig. 254: View OF DIS Coil Mounting Bracket

Courtesy of GENERAL MOTORS CORP.

15. Remove the direct ignition system (DIS) coil mounting bolts.
16. Remove the DIS coil with the ignition wires attached.
17. Remove the DIS coil mounting bracket bolts.
18. Remove the electrical exhaust gas recirculation (EEGR) valve adapter bolts.
19. Remove the EEGR valve adapter bolts.
20. Remove the EEGR valve adapter.
21. Remove the EEGR valve adapter gasket.
22. Remove the spark plugs.

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Fig. 255: Camshaft Cap Bolt Sequence

Courtesy of GENERAL MOTORS CORP.

23. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

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Fig. 256: View Of Intake Valve Tappet Adjusters

Courtesy of GENERAL MOTORS CORP.

24. Remove the intake camshaft caps. Maintain the correct positions for installation.
25. Remove the intake camshaft.
26. Remove the intake valve tappet adjusters.
27. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
28. Remove the exhaust camshaft.
29. Remove the exhaust valve tappet adjusters.

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Fig. 257: Compressing Valve Springs

Courtesy of GENERAL MOTORS CORP.

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

30. Compress the valve springs with J 8062 and KM-653-A .

31. Remove the valve keys.
32. Remove the J 8062 and KM-653-A .
33. Remove the valve spring caps.
34. Remove the valve springs. Maintain the original position of the valve springs for installation.

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Fig. 258: Removal Of Valves

Courtesy of GENERAL MOTORS CORP.

35. Remove the valves. Maintain the original position of the valves for installation.
36. Remove the valve stem seals.

VALVE GUIDE REAMING/VALVE AND SEAT GRINDING

Tools Required

l KM-571-B Gage or equivalent

l KM-805 Valve Guide Reamer
l KM-340-1-C Cutter Set

Valve Grind-In

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Fig. 259: Lubricating Valve Stem With Fine-Grained Paste Using Commercially Available
Grinding Tool
Courtesy of GENERAL MOTORS CORP.

1. Lubricate the valve stem using a fine-grained paste.

2. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to
distribute the paste.

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Fig. 260: Cleaning Valves, Valve Guides, And Cylinder Head

Courtesy of GENERAL MOTORS CORP.

3. Check the contact pattern on the valve head and in the cylinder head.
4. Clean the valves, the valve guides, and the cylinder head.

Valve Grind

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Fig. 261: Refacing Valve

Courtesy of GENERAL MOTORS CORP.

1. Ensure there are no crater line burns on the valve cone.

2. The valve may be reground only 2 times. Do not grind the valve stem end.
3. The angle at the valve face is 45 degrees.
4. Inspect the assembly height of the intake valves and the exhaust valves.

Valve Guide - Ream

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Fig. 262: Using KM-571-B Measuring Valve Guide Diameter

Courtesy of GENERAL MOTORS CORP.

1. Measure the diameter of the valve guide using the KM-571-B (1) and a commercially available inside
micrometer.

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Fig. 263: Reaming Valve Guide From Upper Side Of Cylinder Head
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Valve oversizes may already have been fitted in production.

2. An oversize service code is on the valve guide and the valve stem end. The Valve Guide Reaming Table
give the correct size, reamer, and production codes for each service. Refer to Engine Mechanical
Specifications.
3. Ream the valve guide using the KM-805 from the upper side of the cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the valve guide with the new code.

Valve Seat - Cut

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Fig. 264: Identifying Valve Seat Angle, Upper Correction Angle, And Lower Correction Angle
Courtesy of GENERAL MOTORS CORP.

1. Place the cylinder head on wooden blocks.

2. Cut the intake and exhaust valve seats using the KM-340-7 included in the KM-340-1-C as follows:
l Valve seat: A 44.5-45 degree side (b) using the KM-340-13 included in the KM-340-1-C

l Upper correction angle: A 30 degree side (a) using the KM-340-13 included in the KM-340-1-C

l Lower correction angle: A 60 degree side (c) using the KM-340-26 included in the KM-340-1-C

3. Clean the chippings from the cylinder head.

4. Inspect the dimensions to make sure the valve seat width is as follows:
l Intake: 1.17-1.57 mm (0.046-0.062 in)

l Exhaust: 1.4-1.8 mm (0.055-0.071 in)

CYLINDER HEAD CLEANING AND INSPECTION

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Fig. 265: Inspecting Cylinder Head

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Clean the sealing surfaces.

2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head using a feeler gage and a straight edge.
5. Check the sealing surfaces for damage. The cylinder head sealing surfaces must be flat within 0.050 mm
(0.002 in) maximum.

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Fig. 266: Measuring Cylinder Head Height

Courtesy of GENERAL MOTORS CORP.

6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height
should be 134.08-134.23 mm (5.279-5.285 in). If the cylinder head height is less than this value, replace
the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned spots.

CYLINDER HEAD ASSEMBLE

Tools Required

l J 8062 Valve Spring Compressor - Head Off

l KM-653-A Adaptor

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Fig. 267: View Of Valve Springs And Seals

Courtesy of GENERAL MOTORS CORP.

1. Install new valve stem seals.

2. Lubricate the valve stems with engine oil.
3. Carefully install the valves in their original positions. Do not damage the valve stem seals.
4. Install the valve springs in their original positions.
5. Install the valve spring caps.

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Fig. 268: Compressing Valve Springs

Courtesy of GENERAL MOTORS CORP.

6. Compress the valve springs with J 8062 and KM-653-A .

7. Install the valve keys.
8. Remove J 8062 and KM-653-A .

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Fig. 269: View Of Intake Valve Tappet Adjusters

Courtesy of GENERAL MOTORS CORP.

9. Lubricate the valve tappet adjusters with engine oil.

10. Install the valve tappet adjusters.

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Fig. 270: Sequence Of Camshaft Caps And Bolts

Courtesy of GENERAL MOTORS CORP.

11. Install the intake camshaft.

12. Install the intake camshaft caps in their original positions.
13. Install the exhaust camshaft.
14. Install the exhaust camshaft caps in their original positions.
15. Install the camshaft cap bolts.

NOTE: Refer to Fastener Notice in Cautions and Notices.

16. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

Tighten: Tighten the camshaft cap bolts to 16 N.m (12 lb ft).

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Fig. 271: View Of EGR Valve Adapter

Courtesy of GENERAL MOTORS CORP.

17. Install the spark plugs.

Tighten: Tighten the spark plugs to 25 N.m (18 lb ft).

18. Install the exhaust gas recirculation (EGR) valve adapter gasket.
19. Install the EGR valve adapter.
20. Install the EGR valve adapter bolts.

Tighten: Tighten the exhaust gas recirculation valve adapter bolts to 25 N.m (18 lb ft).

21. Install the direct ignition system (DIS) coil mounting bracket.
22. Install the DIS coil mounting bracket bolts.

Tighten: Tighten the direct ignition system coil mounting bracket bolts to 10 N.m (89 lb in).

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23. Install the DIS coil with the ignition wires attached.
24. Install the DIS coil mounting bolts.

Tighten: Tighten the direct ignition system coil mounting bolts to 10 N.m (89 lb in).

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Fig. 272: Intake Manifold Retaining Nuts/Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

25. Install the intake manifold studs.

26. Install the intake manifold gasket.
27. Install the intake manifold.
28. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

Tighten: Tighten the intake manifold retaining nuts and retaining bolts to 25 N.m (18 lb ft).

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Fig. 273: View Of Fuel Rail Assembly

Courtesy of GENERAL MOTORS CORP.

29. Install the fuel rail assembly with the bolts.

Tighten: Tighten the fuel rail assembly retaining bolts to 25 N.m (18 lb ft).

30. Install the thermostat housing assembly.

31. Install the thermostat housing mounting bolts.

Tighten: Tighten the thermostat housing mounting bolts 20 N.m (15 lb ft).

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Fig. 274: Exhaust Retaining Nut Installation Sequence

Courtesy of GENERAL MOTORS CORP.

32. Install the exhaust manifold studs.

33. Install the exhaust manifold gasket.
34. Install the exhaust manifold.
35. Install the exhaust manifold retaining nuts in the sequence shown.

Tighten: Tighten the exhaust manifold retaining nuts to 25 N.m (18 lb ft).

36. Install the exhaust manifold heat shield.

37. Install the exhaust manifold heat shield bolts.

Tighten: Tighten the exhaust manifold heat shield bolts to 15 N.m (11 lb ft).

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Fig. 275: View Of Coolant Temperature Sensor

Courtesy of GENERAL MOTORS CORP.

38. Install the coolant temperature sensor.

Tighten: Tighten the coolant temperature sensor to 20 N.m (15 lb ft).

39. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder
Head Replacement.

CRANKSHAFT REPLACEMENT

Tools Required

l OTC 1726 (KM 412) Engine Overhaul Stand

l J 42492-A (KM 421-A) Timing Belt Adjuster
l J 45059 Angle Meter
l KM-470-B Angular Torque Gage

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l J 36972 (KM 635) Crankshaft Rear Oil Seal Installer

Removal Procedure

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Fig. 276: View Of Flywheel

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the
camshafts.

1. Remove the engine. Refer to Engine Replacement.

2. Remove the flywheel bolts.
3. Remove the flywheel.

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Fig. 277: View Of Crankshaft Rear Oil Seal

Courtesy of GENERAL MOTORS CORP.

4. Remove the crankshaft rear oil seal.

5. Mount the engine assembly on the OTC 1726 .

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Fig. 278: Upper And Lower Front Timing Belt Cover And Bolts
Courtesy of GENERAL MOTORS CORP.

6. Remove the upper and the lower front timing belt cover bolts.
7. Remove the upper and the lower front timing belt cover.

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Fig. 279: View Of Coolant Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

8. Slightly loosen the water pump retaining bolts.

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Fig. 280: Removing Timing Belt Tension Using J 42492-A

Courtesy of GENERAL MOTORS CORP.

9. Rotate the water pump using J 42492-A to remove the tension from the timing belt.
10. Remove the timing belt.

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Fig. 281: Identifying Valve Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

11. Disconnect the crankcase ventilation tubes from the valve cover.
12. Remove the engine cover bolts.
13. Remove the engine cover.
14. Disconnect the ignition wires from the spark plugs.
15. Remove the valve cover nuts.
16. Remove the valve cover washers.
17. Remove the valve cover and the valve cover gasket.

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Fig. 282: Holding Camshaft To Tighten Sprocket

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the
camshafts.

18. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
19. Remove the intake camshaft gear.
20. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
21. Remove the exhaust camshaft gear.

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Fig. 283: View Of Timing Belt Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

22. Remove the timing belt automatic tensioner bolts.

23. Remove the timing belt automatic tensioner.
24. Remove the timing belt idler pulley bolt.
25. Remove the timing belt idler pulley.

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Fig. 284: View Of Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

26. Remove the crankshaft timing belt gear.

27. Remove the rear timing belt cover bolts.
28. Remove the rear timing belt cover.

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Fig. 285: Rotating Engine Using OTC 1726

Courtesy of GENERAL MOTORS CORP.

29. Rotate the engine on the OTC 1726 (1).

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Fig. 286: View Of Oil Pan, Oil Pickup Tube And Bolts
Courtesy of GENERAL MOTORS CORP.

30. Remove the oil pan retaining bolts.

31. Remove the oil pan.
32. Remove the oil pickup tube bolts.
33. Remove the oil pickup tube.

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Fig. 287: Identifying Oil Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

34. Remove the oil pump retaining bolts (1).

35. Remove the oil pump.

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Fig. 288: View Of Connecting Rod Bearing Cap Rod Bolts

Courtesy of GENERAL MOTORS CORP.

36. Mark the order of the connecting rod bearing caps.

37. Remove the connecting rod bearing cap bolts for all of the pistons.
38. Remove the connecting rod bearing caps and the lower connecting rod bearings.
39. Remove the upper connecting rod bearings.

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Fig. 289: View Of Connecting Rod Bearing Cap Rod Bolts

Courtesy of GENERAL MOTORS CORP.

40. Mark the order of the crankshaft bearing caps.

41. Remove the crankshaft bearing cap bolts.
42. Remove the crankshaft bearing caps and the lower crankshaft bearings.
43. Remove the crankshaft.
44. Remove the upper crankshaft bearings.

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

45. Clean the parts, as needed.

Installation Procedure

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Fig. 290: Inspecting Crankshaft End Play

Courtesy of GENERAL MOTORS CORP.

1. With the crankshaft and bearings in place, plastic gage all bearing clearances. Refer to Crankshaft and
Bearings Cleaning and Inspection.
2. Inspect the crankshaft end play with the crankshaft bearings installed.
3. Inspect for permissible crankshaft end play. Refer to Crankshaft and Bearings Cleaning and
Inspection.

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Fig. 291: Checking Crankshaft Journal For Out-Of-Round Runout

Courtesy of GENERAL MOTORS CORP.

4. With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft
bearings and the middle crankshaft journal for permissible out-of-round runout. Refer to Engine
Mechanical Specifications.

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Fig. 292: View Of Engine Block

Courtesy of GENERAL MOTORS CORP.

5. Coat the crankshaft bearings with engine oil.

6. Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
7. Install the crankshaft bearings in he engine block.
8. Install the crankshaft.

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Fig. 293: Using J 45059 To Tighten Bearing Caps

Courtesy of GENERAL MOTORS CORP.

9. Install the crankshaft bearings to the crankshaft bearing caps.

10. Install the crankshaft bearing caps.

NOTE: Refer to Fastener Notice in Cautions and Notices.

NOTE: Do not reuse crankshaft bearing cap bolts. Failure to replace the
crankshaft bearing cap bolts can lead to crankshaft bearing cap bolt
breakage or crankshaft bearing failure. A broken crankshaft bearing bolt
can lead to extensive engine damage.

11. Install the new crankshaft bearing bolt.

Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb ft). Using the J 45059 (1) or the KM-
470-B , tighten the crankshaft bearing cap bolts another 45 degrees.

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12. Install the upper connecting rod bearings to the connecting rods.
13. Install the lower connecting rod bearings to the connecting rod bearing caps.

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Fig. 294: View Of Connecting Rod Bearing Caps

Courtesy of GENERAL MOTORS CORP.

14. Install the connecting rod bearing caps to the connecting rods.
15. Install the new connecting rod bearing cap bolts.

Tighten: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Using the J 45059 or the
KM-470-B , tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees.

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Fig. 295: Identifying Oil Pump Retaining Bolts

Courtesy of GENERAL MOTORS CORP.

16. Install the oil pump.

17. Install the oil pump retaining bolts (1).

Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb in).

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Fig. 296: View Of Oil Pan Pickup Tube

Courtesy of GENERAL MOTORS CORP.

18. Install the oil pump pickup tube.

19. Install the oil pump pickup tube bolts.

Tighten: Tighten the oil pump/pickup tube bolts to 10 N.m (89 lb in).

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Fig. 297: View Of Oil Pan

Courtesy of GENERAL MOTORS CORP.

20. Install the oil pan gasket to the oil pan.

21. Install the oil pan.

IMPORTANT: Install the oil pan within 5 minutes after applying the liquid gasket to the
oil pan.

22. Install the oil pan retaining bolts.

Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 lb in).

23. Rotate the engine on the OTC 1726 .

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Fig. 298: View Of Timing Belt Cover And Bolts

Courtesy of GENERAL MOTORS CORP.

24. Install the rear timing belt cover.

25. Install the rear timing belt cover bolts.

Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 lb in).

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Fig. 299: View Of Timing Belt Tensioner And Bolts

Courtesy of GENERAL MOTORS CORP.

26. Install the crankshaft timing belt gear.

27. Install the timing belt automatic tensioner.
28. Install the timing belt automatic tensioner bolts.

Tighten: Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb ft).

29. Install the timing belt idler pulley.

30. Install the timing belt idler pulley bolt.

Tighten: Tighten the timing belt idler pulley bolt to 40 N.m (30 lb ft).

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Fig. 300: View Of Intake And Exhaust Camshaft

Courtesy of GENERAL MOTORS CORP.

NOTE: Use extreme care when installing the camshaft not to nick, scratch, or
damage the camshaft lobes or bearing surfaces.

31. Install the intake camshaft gear.

32. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.

Tighten: Tighten the intake camshaft gear bolt to 67.5 N.m (49 lb ft).

33. Install the exhaust camshaft gear.

34. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.

Tighten: Tighten the exhaust camshaft bolt to 67.5 N.m (49 lb ft).

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Fig. 301: View Of Ignition Wires And Spark Plugs

Courtesy of GENERAL MOTORS CORP.

35. Install the timing belt. Refer to Timing Belt Replacement.

36. Adjust the timing belt tension. Refer to Timing Belt Inspection.
37. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear
valve cover-to-cylinder head seal.
38. Install the valve cover and the valve cover gasket.
39. Install the valve cover washers.
40. Install the valve cover nuts.

Tighten: Tighten the valve cover nuts to 9 N.m (80 lb in).

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Fig. 302: View Of Timing Belt Cover Bolts

Courtesy of GENERAL MOTORS CORP.

41. Connect the ignition wires to the spark plugs.

42. Install the engine cover.
43. Install the engine cover bolts.

Tighten: Tighten the engine cover bolts to 3 N.m (27 lb in).

44. Connect the crankcase ventilation tube to the valve cover.

45. Install the upper and lower front timing belt cover.
46. Install the upper and lower front timing belt cover bolts.

Tighten: Tighten the upper and lower front timing belt cover bolts to 10 N.m (89 lb in).

47. Install the power steering pump, if equipped.

48. Install the power steering pump mounting bolts.

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Tighten: Tighten the power steering pump mounting bolts to 25 N.m (18 lb in).

49. Install the engine lifting device.

50. Remove the engine from the OTC 1726 .

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Fig. 303: Installing New Crankshaft Rear Oil Seal Using J36972
Courtesy of GENERAL MOTORS CORP.

51. Install a new crankshaft rear oil seal using the J 36972 (1) or KM-635 .

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Fig. 304: View Of Flywheel

Courtesy of GENERAL MOTORS CORP.

52. Install the flywheel.

53. Install the flywheel bolts.

Tighten: Tighten the flywheel bolts to 35 N.m (25 lb ft). Use the J 45059 or KM-470-B to tighten the
flywheel bolts 30 degrees plus 15 degrees. For the manual transaxle, tighten the flexible plate bolts to 60
N.m (44 lb ft).

54. Install the engine. Refer to Engine Replacement.

EXHAUST MANIFOLD INSTALLATION

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Fig. 305: Exhaust Manifold Retaining Nut Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

1. Install the exhaust manifold and gasket.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

Tighten: Tighten the exhaust manifold retaining nuts to 25 N.m (18 lb ft).

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Fig. 306: View Of Exhaust Manifold Nuts And Pup Converter

Courtesy of GENERAL MOTORS CORP.

3. Install the exhaust manifold nuts to the catalytic converter.

Tighten: Tighten the exhaust manifold nuts to 40 N.m (30 lb ft).

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Fig. 307: View Of Exhaust Manifold Heat Shield And Bolts

Courtesy of GENERAL MOTORS CORP.

4. Install the heat shield.

Tighten: Tighten the heat shield bolts to 13 N.m (10 lb ft).

5. Connect the oxygen sensor connector.

6. Connect the negative battery cable.

DESCRIPTION AND OPERATION

ENGINE COMPONENT DESCRIPTION

Cylinder Head and Gasket

The cylinder head is made up of an aluminum alloy. The cylinder head uses crossflow intake and exhaust ports.
A spark plug is located on the exhaust side of each combustion chamber.

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Crankshaft

The crankshaft has 8 integral weights which are cast with it for balancing. Oil holes run through the center of
the crankshaft to supply oil to the connecting rods, the bearings, the pistons, and the other components. The end
thrust load is taken by the thrust washers installed at the center journal.

Timing Belt

IMPORTANT: This engine design is what is commonly referred to as an interference type

engine. Meaning in the event of a timing belt failure, the crankshaft and pistons
would continue to rotate and camshafts and valves would remain stationary.
Under certain circumstances, it would cause damage to the pistons, valves and
the cylinder head itself. Refer to the Maintenance Schedule and perform the
timing belt inspections and replacements at the intervals that are suggested.

The timing belt coordinates the crankshaft and the camshaft and keeps them synchronized. The timing belt also
turns the coolant pump. The timing belt and the pulleys are toothed so that there is no slippage between them.
There is a tension pulley that maintains the correct timing belt tension. The timing belt is made of a tough
reinforced rubber similar to that used on the serpentine accessory drive belt. The timing belt requires no
lubrication.

Oil Pump

The oil pump draws engine oil from the oil pan and feeds it under pressure to the various parts of the engine. An
oil strainer is mounted before the inlet of the oil pump to remove impurities which could clog or damage the oil
pump or the other engine components. When the drive gear rotates, the driven gear rotates. This causes the
space between the gears to open and narrow constantly, pulling oil in from the oil pan when the space opens and
pumping the oil out to the engine as it narrows.

At high engine speeds, the oil pump supplies a much higher amount of oil than required for lubrication of the
engine. The oil pressure regulator prevents too much oil from entering the engine lubrication passages. During
normal oil supply, a coil spring and a valve keep the bypass closed, directing all of the oil pumped to the engine.
When the amount of oil being pumped increases, the pressure becomes high enough to overcome the force of
the spring. This opens the valve of the oil pressure regulator, allowing the excess oil to flow through the valve
and drain back to the oil pan.

Oil Pan

The oil pan is mounted to the bottom of the cylinder block. The oil pan houses the crankcase and is made of
aluminum.

Engine oil is pumped from the oil pan by the oil pump. After the oil passes through the oil filter, the oil is fed
through 2 paths to lubricate the cylinder block and the cylinder head. In one path, the oil is pumped through the
oil passages in the crankshaft to the connecting rods, then to the pistons and the cylinders in the cylinder block.
The oil then drains back into the oil pan. In the 2nd path, the oil is pumped through the oil passages to the
camshaft. The oil passes through the internal passageways in the camshafts to lubricate the valve assemblies in
the cylinder head before draining back into the oil pan.

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Exhaust Manifold

A single 4-port, rear-takedown exhaust manifold is used with this engine. The exhaust manifold is designed to
direct the escaping exhaust gases out of the combustion chambers with a minimum of back pressure. The
oxygen sensor (O2S) is mounted to the exhaust manifold.

Intake Manifold

The intake manifold has 4 independent long ports and uses inertial supercharging to improve engine torque at
low and moderate speeds. The plenum is attached to the intake manifold.

Camshafts

This engine is a dual over head camshaft (DOHC) type, which means there are 2 camshafts. One camshaft
operates the intake valves, and the other camshaft operates the exhaust valves. The camshafts sit in journals in
the cylinder head on the top of the engine. They are held in place by camshaft caps. The camshaft journals of
the cylinder head are drilled for oil passages. Engine oil travels to the camshafts under pressure where it
lubricates each camshaft journal. The oil returns to the oil pan through drain holes in the cylinder head. The
camshaft lobes are machined into the solid camshaft to open and close the intake and exhaust valves precisely
the correct amount at the correct time. The camshaft lobes are oiled by splash action from pressurized oil
escaping from the camshaft journals.

Exhaust Gas Recirculation (EGR) Valve

The exhaust gas recirculation (EGR) system is used to lower oxides of nitrogen (NOx) emission levels caused
by high combustion temperatures. The main element of the system is the EGR valve which is operated
electrically by the engine control module (ECM).

The EGR valve feeds small amounts of exhaust gas into the intake manifold to decrease the combustion
temperature. The amount of exhaust gas recirculated is controlled by variations in electrical signal and exhaust
back pressure. If too much exhaust gas enters, combustion will not take place. For this reason, very little
exhaust gas is allowed to pass through the valve, especially at idle.

The EGR valve is controlled precisely by the ECM according to various operating conditions of the engine.

CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the ten-thousandths of an inch. When any internal engine parts are serviced, care and
cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly, to
protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically
stated.

Whenever valve train components are removed for service, they should be kept in order. They should be
installed in the same locations, and with the same mating surfaces, as when they were removed.

Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect

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cables may result in damage to the wire harness or other electrical parts.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

Special Tools
Illustration Tool Number/ Description

J 8062
(KM-348)
Valve Spring Compressor

J 21867
(KM-498-B)
Pressure Gage

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J 24086-B
(KM-427)
Piston Pin Remover/Installer Set

J 28467-B
(DW-117)
Universal Engine Support Fixture

J 36648-A
(KM-135)
Adapter

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J 36972
Crankshaft Rear Oil Seal Installer

J 42492-A
(KM-421-A)
Timing Belt Adjuster

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J 45059
Angle Meter

KM-340-1-C
Cutter Set

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KM-412
(OTC 1726)
Engine Overhaul Stand

KM-470-B
Angular Torque Gage

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KM-571-B
Gage

KM-635
Crankshaft Rear Oil Seal Installer

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KM-653-A
Adapter

KM-805
Valve Guide Reamer

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