Engine

2014 GMC Acadia Denali
2014 ENGINE Maintenance and Lubrication - Acadia, Enclave And Traverse
2014 ENGINE
Maintenance and Lubrication - Acadia, Enclave And Traverse
SPECIFICATIONS
APPROXIMATE FLUID CAPACITIES
The following approximate capacities are given in US English and metric conversions. See Fluid and
Lubricant Recommendations for more information.
Approximate Fluid Capacities

Specification
Application Metric US English
Cooling System 10.8 liters 11.4 quarts
Engine Oil With Filter 5.7 liters 6.0 quarts
Fuel Tank 83.3 liters 22.0 gallons

Transfer Case 1.0 liters 1.06 quarts
Transmission Fluid
Fluid Change- Drain Plug- Approximate Capacity 4.0-6.0 liters 4.2-6.3 quarts
Overhaul- Approximate Capacity 7.0-9.0 liters 7.4-9.5 quarts
Valve Body Cover Removal- Approximate Capacity 5.0-7.0 liters 5.3-7.4 quarts
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in
this manual. Recheck the fluid level after filling.
FLUID AND LUBRICANT RECOMMENDATIONS
Fluid and Lubricant Recommendations

Usage Fluid/Lubricant
Use only engine oil licensed to the dexos1 specification or equivalent, of
Engine Oil the proper SAE viscosity grade. ACDelco dexos1 Synthetic Blend is
recommended.
50/50 mixture of clean, drinkable water and use only DEX-COOL
Engine Coolant
Coolant.
DOT 3 Hydraulic Brake Fluid (GM Part No. 88862806, in Canada
Hydraulic Brake System
88863462).
Automotive windshield washer fluid that meets regional freeze protection
Windshield Washer
requirements.
Hydraulic Power Steering
DEXRON®-VI Automatic Transmission Fluid.
System
Automatic Transmission DEXRON®-VI Automatic Transmission Fluid.
Carrier Assembly -
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Differential (Rear Drive

SAE 75W-90 Synthetic Axle Lubricant (GM Part No. 88900401, in
Module) and Transfer Case
Canada 89021678).
(Power Transfer Unit)
Multi-Purpose Lubricant, Superlube GM P/N 12346241 (Canadian P/N
Key Lock Cylinders
10953474)
Hood Latch Assembly,
Lubriplate Lubricant Aerosol GM P/N 89021668 (Canadian P/N
Secondary Latch, Pivots,
89021674) or lubricant meeting requirements of NLGI #2, Category LB or
Spring Anchor and Release
GC-LB
Pawl
Hood, Door Hinges and Rear Multi-Purpose Lubricant, Superlube GM P/N 12346241 (Canadian P/N
Folding Seat 10953474)
Weatherstrip Lubricant GM P/N 3634770 (Canadian P/N 10953518) or
Weatherstrip Conditioning
Dielectric Silicone Grease GM P/N 12345579 (Canadian P/N 10953481)
MAINTENANCE ITEMS

The Normal Maintenance Replacement Parts information will only be found in the Owner's Manual. Refer to
the Maintenance Schedule subsection of the Owner's Manual.
You may be able to use the Search information function using the words Replacement Parts.
MAINTENANCE
MAINTENANCE SCHEDULE (NORTH AMERICAN EMISSIONS)
The Maintenance Schedule information will only be found in the Owner's Manual.
Refer to the Maintenance Schedule subsection of the Owner's Manual or you may be able to use the Search
information function using the words Scheduled Maintenance.
GM OIL LIFE SYSTEM RESETTING
When to Change Engine Oil
This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on
engine revolutions and engine temperature and not on mileage. Based on driving conditions, the mileage at
which an oil change is indicated can vary considerably. For the oil life system to work properly, the system
must be reset every time the oil is changed.
On some vehicles, when the system has calculated that oil life has been diminished, a CHANGE ENGINE OIL
SOON message comes on to indicate that an oil change is necessary. Change the oil as soon as possible within
the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system might
not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed
at least once a year and at this time the system must be reset. For vehicles without the CHANGE ENGINE OIL
SOON message, an oil change is needed when the OIL LIFE REMAINING percentage is near 0 percent. Your
dealer has trained service people who will perform this work using genuine parts and reset the system. It is also
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important to check the oil regularly and keep it at the proper level.
If the system is ever reset accidentally, the oil must be changed at 5 000 km (3, 000 miles) since the last oil
change. Remember to reset the oil life system whenever the oil is changed.
How to Reset the Engine Oil Life System
The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever
the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs
where the oil is changed prior to a CHANGE ENGINE OIL SOON message coming on, reset the system.
If the vehicle does not have Driver Information Center (DIC) buttons:
1. Turn the ignition to ON/RUN, with the engine off. The vehicle must be in P (Park) to access this display.
Press the trip odometer reset stem until OIL LIFE REMAINING displays.
2. Press and hold the trip odometer reset stem until OIL LIFE REMAINING shows "100%". Three chimes

sound and the CHANGE ENGINE OIL SOON message goes off.
3. Turn the key to LOCK/OFF.
If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the engine oil life
system has not reset. Repeat the procedure.
If the vehicle has Driver Information Center (DIC) buttons:
1. Turn the ignition to ON/RUN, with the engine off.

2. Press the vehicle information button until OIL LIFE REMAINING displays.
3. Press and hold the set/reset button until "100%" is displayed. Three chimes sound and the CHANGE
ENGINE OIL SOON message goes off.
4. Turn the key to LOCK/OFF.
If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the Engine Oil Life
System has not reset. Repeat the procedure.

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2014 ENGINE Engine Exhaust - Acadia, Enclave And Traverse
2014 ENGINE
Engine Exhaust - Acadia, Enclave And Traverse
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Catalytic Converter Brace Bolt 50 N.m 37 lb ft
Catalytic Converter Hanger Clamp Nut 18 N.m 13 lb ft
Catalytic Converter to Exhaust Flexible Pipe Nut 28 N.m 21 lb ft
Catalytic Converter to Exhaust Manifold Nut 50 N.m 37 lb ft

Exhaust Flexible Pipe to Three-Way Converter Nut 50 N.m 37 lb ft
Exhaust Manifold Bolt 20 N.m 15 lb ft
Exhaust Manifold Heat Shield Bolt 10 N.m 89 lb in
Exhaust Manifold Lower Heat Shield Bolt (Small Bolt) 10 N.m 89 lb in
Exhaust Manifold Lower Heat Shield Bolt (Large Bolt) 50 N.m 37 lb ft
Exhaust Muffler Heat Shield Nut 9 N.m 80 lb in
Three-Way Catalytic Converter to Muffler Assembly Nut 50 N.m 37 lb ft
DIAGNOSTIC INFORMATION AND PROCEDURES

SYMPTOMS - ENGINE EXHAUST
Review the exhaust system description in order to familiarize yourself with the exhaust system
components and the intended function of the components. Refer to Exhaust System Description.
All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform
approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary
and may always be used in order to resolve a system problem. For a detailed explanation, refer to
Strategy Based Diagnosis .
Visual/Physical Inspection
Inspect for aftermarket or non-OEM devices such as, but not limited to; tailpipe extensions, headers and
exhaust cutouts. Any aftermarket exhaust system devices could affect the operation and proper
performance of the exhaust system.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
engine temperature, engine load and frequency of concern.
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause any symptom.
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Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
as designed.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
Loss of power
Refer to Restricted Exhaust
Poor acceleration

Poor fuel economy
Excessive smoke diesel
Exhaust hissing noise
Refer to Exhaust Leakage
Exhaust popping noise
Refer to Exhaust Leakage
Exhaust rattle noise
Refer to Exhaust Noise
Loud exhaust noise
Exhaust buzz, groan, hum noise
RESTRICTED EXHAUST

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Special Tools
J-35314-A Exhaust Back Pressure Gauge
Diagnostic Aids
WARNING: Refer to Hot Exhaust System Warning .
For dual exhaust systems a quick check of exhaust flow will help determine which side of the exhaust system is
restricted. The side that has less exhaust flow is the side that will be suspect and diagnosis should begin there.
Test Description
The numbers below refer to the step numbers on the diagnostic table.

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The exhaust system has very low back pressure under normal conditions. If the exhaust system is
restricted, a significant increase in the exhaust pressure is noticed on the J-35314-A gauge.
Removing the HO2S sensor may set a DTC. When finishing this diagnostic table, be sure to clear all
codes.
This step will isolate the catalytic converter from the remainder of the exhaust system.
Confirming that the condition has been fixed is essential. If the symptom still exists and the vehicle has a
dual exhaust system, proceed to step 2 and repeat diagnostic procedure on the opposite exhaust pipe.
Restricted Exhaust
Step Action Value(s) Yes No
1 Did you verify the customers complaint? - Go to Step 2 -
Did you review the exhaust symptoms Go to Symptoms
2 diagnostic information and perform the - - Engine
necessary inspections? Go to Step 3 Exhaust
Is the system equipped with dual exhaust? Go to
3 -
Diagnostic Aids Go to Step 4
1. Remove the heated oxygen sensor
(HO2S) that is in front of the catalytic
converter. Refer to the appropriate
procedure. Refer to Heated Oxygen

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Sensor Replacement - Bank 1 Sensor

1 or Heated Oxygen Sensor
Replacement - Bank 2 Sensor 1 .
2. Install the J-35314-A Exhaust Back
Pressure Gauge in place of the HO2S
sensor.
9 kPa (1.25
4 3. Start the engine.
psi)
4. Increase and monitor the engine speed at
2, 500 RPM.
5. Observe the exhaust system back
pressure reading on the gauge.
Does the reading exceed the specified value? Go to Step 5 Go to Step 8

1. Turn the engine OFF and place the
ignition in the lock position.
2. Remove the J-35314-A gauge.
3. Reinstall the HO2S sensor. Refer to
Heated Oxygen Sensor Replacement -
Bank 1 Sensor 1 or Heated Oxygen
Sensor Replacement - Bank 2 Sensor
1.
4. Remove the post-catalyst HO2S sensor.
Refer to the appropriate procedure.
Refer to Heated Oxygen Sensor
9 kPa (1.25
5 Replacement - Bank 1 Sensor 2 or
psi)
Bank 2 Sensor 2 .
5. Install the J-35314-A gauge in place of
the post HO2S sensor.
6. Start the engine.
7. Increase and monitor the engine speed at
2, 500 RPM.
8. Observe the exhaust system back
pressure reading on the gauge.
Does the reading exceed the specified value? Go to Step 6 Go to Step 7

Inspect the exhaust system for the following
conditions:
6 Damage in the exhaust pipe -

Debris in the exhaust pipe
Muffler or resonator internal failure
Two-layer exhaust pipe separation

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Did you find and correct the condition?

Go to Step 8 -
Replace the catalytic converter. Refer to
Catalytic Converter Replacement - Left
7 Side or Catalytic Converter Replacement - -
Right Side.
Did you find and correct the condition? Go to Step 8 -
1. Remove the J-35314-A gauge.
2. Reinstall the applicable HO2S sensor.
Refer to Heated Oxygen Sensor
Replacement - Bank 1 Sensor 2 or
8 Bank 2 Sensor 2 . -
3. Clear any codes.

4. Road test the vehicle in order to verify
the repair.
Did you correct the condition? System OK Go to Step 2
EXHAUST LEAKAGE
Exhaust Leakage
Condition Action
WARNING:
Refer to Hot Exhaust System Warning .
DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a
hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing
noise.Refer to Symptoms - Engine Exhaust prior to beginning this table.
Misaligned or improperly Align and tighten the exhaust system components to the
installed exhaust system specifications. Refer to Fastener Tightening Specifications.
components
Ensure the exhaust hangers are in the proper locations and not
loose.
Exhaust leaks at the following Tighten the components to the specifications. Refer to Fastener
connections: Tightening Specifications.
Exhaust manifold to pipe

Flanges
Pipe clamps
Seals or gaskets leaking; Replace the leaking seal or gasket. Refer to the affected components
procedure for service.
Exhaust manifold to

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cylinder head
Exhaust pipes to exhaust
manifold
Catalytic converter
connection
Irregularities at the mating Repair as required or replace the affected component. Refer to the
surfaces on the flange affected components procedure for service.
connections
Exhaust manifold cracked or Replace the exhaust manifold. Refer to Exhaust Manifold
broken Replacement - Left Side or Exhaust Manifold Replacement - Right
Side.
Exhaust system component Replace the leaking component. Refer to the affected component's
connection welds leaking procedure for service.
Muffler or resonator, if Replace the affected muffler or resonator, if equipped. Refer to
equipped, damaged or leaking at Exhaust Muffler Replacement (NB5), Exhaust Muffler

the seams Replacement (NEA/NED or N10).
EXHAUST NOISE
Exhaust Noise
Condition Action
WARNING:
Refer to Hot Exhaust System Warning .
DEFINITION: An audible or physical noise due to a faulty component or damaged components causing a
loose or misaligned exhaust system resulting in a rattle or vibration noise, i.e. buzz, groan, hum.Refer to
Symptoms - Engine Exhaust prior to beginning this table.
Popping or hissing noise Exhaust leak-Refer to Exhaust Leakage.
Loud exhaust 1. Compare to a known good vehicle.
2. Inspect for a damaged or failed muffler or resonator, if equipped.
3. Replace the faulty muffler or resonator (if equipped). Refer to
Exhaust Muffler Replacement (NB5), Exhaust Muffler
Replacement (NEA/NED or N10).
External rattle or vibration noise 1. Inspect for a bent or loose hanger, loose heat shield or loose
clamp.
2. Inspect for a exhaust pipe causing interference.
3. Repair or replace the affected component. Refer to the affected
component's service procedure.
Internal rattle
1. Test the components by tapping with a rubber mallet to confirm a
rattle.
2. Replace the faulty catalytic converter, resonator, if equipped or
muffler. Refer to Exhaust Muffler Replacement (NB5) and

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Exhaust Muffler Replacement (NEA/NED or N10).
REPAIR INSTRUCTIONS
EXHAUST MANIFOLD REPLACEMENT - LEFT SIDE
Removal Procedure
WARNING: Refer to Exhaust Service Warning .
WARNING: Refer to Protective Goggles and Glove Warning .

1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left
Side.
Fig. 1: Identifying Left Side Exhaust Manifold Bolts

Courtesy of GENERAL MOTORS COMPANY

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2. Remove the oil level indicator. Refer to Oil Level Indicator Tube Replacement .
3. Remove the catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
4. Remove the exhaust manifold bolts (1).
5. Remove the exhaust manifold and gasket. Discard the gasket.
NOTE: Do not reuse the gasket.
6. Remove the heated oxygen sensor (1) from the exhaust manifold.
Fig. 2: Identifying Heated Oxygen Sensors & Exhaust Manifold

Installation Procedure
NOTE: A special anti-seize compound is used in the HO2S threads. The compound
consists of liquid graphite and glass beads. The graphite tends to burn away,
but the glass beads remain, making the sensor easier to remove. New or
service replacement sensors have the compound applied to the threads. If the
sensor is removed from an exhaust component and if for any reason the sensor
is to be reinstalled, the threads must have anti-seize compound applied before

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the reinstallation.
1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953 or equivalent.
Fig. 3: Identifying Heated Oxygen Sensors & Exhaust Manifold

2. Install the HO2S (1) to the exhaust manifold.
CAUTION: Refer to Fastener Caution .
Tighten
Tighten the sensor to 42 N.m (31 lb ft).
3. Install one exhaust manifold bolt (1) to the exhaust manifold.

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Fig. 4: Identifying Left Side Exhaust Manifold Bolts

4. Install the NEW exhaust manifold gasket onto the exhaust manifold and bolt.
5. Install the exhaust manifold (with gasket) to the cylinder head and the catalytic converter.
6. Install the remaining exhaust manifold bolts.
Tighten
Tighten the bolts to 20 N.m (15 lb ft).
7. Install the catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
8. Install the oil level indicator. Refer to Oil Level Indicator Tube Replacement .
9. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left
Side.
EXHAUST MANIFOLD REPLACEMENT - RIGHT SIDE
Removal Procedure

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1. Remove the catalytic converter. Refer to Catalytic Converter Replacement - Right Side.
Fig. 5: Identifying Exhaust Manifold Bolts

2. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right
Side.
3. Remove the exhaust manifold bolts (1).
4. Remove the exhaust manifold and gasket out from vehicle. Discard the gasket.
NOTE: Do not reuse the gasket.

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1. Install one exhaust manifold bolt (1) to the exhaust manifold.
Fig. 6: Identifying Exhaust Manifold Bolts

2. Install the NEW exhaust manifold gasket onto the cylinder head and bolt.
3. Install the exhaust manifold (with gasket) to the catalytic converter and the cylinder head.
4. Install the exhaust manifold bolts.
Tighten
Tighten the bolts to 20 N.m (15 lb ft).
5. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right
Side.
6. Install the catalytic converter. Refer to Catalytic Converter Replacement - Right Side.

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CATALYTIC CONVERTER REPLACEMENT - LEFT SIDE
Removal Procedure
1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left
Side.
Fig. 7: Identifying Catalytic Converter Bolts

2. Remove the catalytic converter to exhaust manifold nuts (1).

3. Remove the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
4. Remove the catalytic converter brace bolt (2).

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Fig. 8: Identifying Catalytic Converter Brace Bolt

5. Remove the catalytic converter from the exhaust manifold.

6. Remove and discard the catalytic converter to exhaust manifold seal (1).
1. Install a NEW exhaust manifold seal (1) onto the catalytic converter.

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Fig. 9: Identifying Catalytic Converter Brace Bolt

2. Install the catalytic converter to the exhaust manifold.

3. Install the catalytic converter brace bolt (2).
Tighten
Tighten the bolt to 50 N.m (37 lb ft).
4. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.

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Fig. 10: Identifying Catalytic Converter Bolts

5. Install the catalytic converter to exhaust manifold nuts (1).
Tighten
Tighten the nuts to 50 N.m (37 lb ft).
6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left
Side.
CATALYTIC CONVERTER REPLACEMENT - RIGHT SIDE
Removal Procedure

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1. If equipped with all wheel drive (AWD), remove the transfer case. Refer to Transfer Case Assembly
Replacement .
Fig. 11: Identifying Catalytic Converter To Exhaust Manifold Nuts

3. Remove the catalytic converter to exhaust manifold nuts (2).

4. Remove the catalytic converter from the exhaust manifold.
5. Remove and discard the catalytic converter to exhaust manifold seal (1).
1. Install a NEW catalytic converter to exhaust manifold seal (1) onto the catalytic converter.

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Fig. 12: Identifying Catalytic Converter To Exhaust Manifold Nuts

2. Install the catalytic converter to the exhaust manifold.

3. Install the catalytic converter to exhaust manifold nuts (2).
Tighten
Tighten the nuts to 50 N.m (37 lb ft).
4. If equipped with all wheel drive (AWD), install the transfer case. Refer to Transfer Case Assembly
Replacement .
THREE-WAY CATALYTIC CONVERTER REPLACEMENT (LLT)

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Fig. 13: View Of Three-Way Catalytic Converter (With LLT)

Three-Way Catalytic Converter Replacement (LLT)

Callout Component Name
Preliminary Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Nut (Qty: 4)
CAUTION:
Refer to Fastener Caution .
1
Tighten
50 N.m (37 lb ft)
Three-Way Catalytic Converter
Procedure
2
1. Disengage the hanger.
2. Remove and discard the gaskets.
EXHAUST MUFFLER REPLACEMENT (NB5)

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Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the three way catalytic converter to muffler pipe nuts (1).
Fig. 14: Identifying Three Way Catalytic Converter-To-Muffler Pipe Nuts

3. With the aid of an assistant, separate the rubber insulators from the exhaust underbody hangers (1).

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Fig. 15: Identifying Exhaust Underbody Hangers

4. With the aid of an assistant, remove the muffler assembly from exhaust flexible pipe and the vehicle.
1. With the aid of an assistant, install the muffler assembly to the vehicle and the exhaust flexible pipe.

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2. With the aid of an assistant, install the rubber insulators to the exhaust underbody hangers (1).
3. Install the three way catalytic converter to muffler piper nuts (1) and tighten to 50 N.m (37 lb ft).

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4. Lower the vehicle.
EXHAUST MUFFLER REPLACEMENT (NEA/NED OR N10)
Removal Procedure
2. Remove the three way catalytic converter to muffler pipe nuts (1).

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3. With the aid of an assistant, separate the rubber insulators from the exhaust underbody hangers (1, 2 and
3).

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4. With the aid of an assistant, remove the muffler assembly from exhaust flexible pipe and the vehicle.
1. With the aid of an assistant, install the muffler assembly to the vehicle and the exhaust flexible pipe.

25

2. With the aid of an assistant, install the rubber insulators to the exhaust underbody hangers (1, 2 and 3).
3. Install the three way catalytic converter to muffler pipe nuts (1) and tighten to 50 N.m (37 lb ft).

26

EXHAUST FLEXIBLE PIPE REPLACEMENT

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Fig. 22: Identifying Exhaust Flexible Pipe

Exhaust Flexible Pipe Replacement

2. Remove the frame brace. Refer to Frame Brace Replacement .
3. Remove the heated oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Bank 1
Sensor 2 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
Nut (Qty: 4)
CAUTION:
1
Tighten
28 N.m (21 lb ft)
Nut (Qty: 2)
2 Tighten
50 N.m (37 lb ft)
3 Exhaust Flex Pipe Assembly
Procedure

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Remove and discard the gaskets.
EXHAUST MANIFOLD LOWER HEAT SHIELD REPLACEMENT
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
Fig. 23: Identifying Exhaust Manifold Lower Heat Shield Bolts

2. Remove the exhaust manifold lower heat shield bolts (1, 2).
3. Remove the exhaust manifold lower heat shield.
1. Position the exhaust manifold lower heat shield to the engine.

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Fig. 24: Identifying Exhaust Manifold Lower Heat Shield Bolts

2. Install the exhaust manifold lower heat shield bolts (1, 2). Tighten bolt (1) to 10 N.m (89 lb in) and
tighten bolt (2) to 50 N.m (37 lb ft).
EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT - RIGHT SIDE
Removal Procedure

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1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1
Sensor 1 .
Fig. 25: Identifying Exhaust Manifold Heat Shield Bolts - Right Side
3. Remove the exhaust manifold heat shield bolts (1).
4. Remove the exhaust manifold heat shield.
1. Install the exhaust manifold heat shield.

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Fig. 26: Identifying Exhaust Manifold Heat Shield Bolts - Right Side
2. Install the exhaust manifold heat shield bolts (1) and tighten to 10 N.m (89 lb in).
4. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .
EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT - LEFT SIDE
Removal Procedure

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1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
Fig. 27: Identifying Engine Wiring Harness Electrical Connector

2. Disconnect the engine wiring harness electrical connector (2) from the heated oxygen sensor (HO2S)
electrical connector (3).
3. Remove the HO2S electrical connector retainer from the engine wiring harness clip (1).
4. Remove the exhaust manifold heat shield bolts (1).

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Fig. 28: Identifying Exhaust Manifold Heat Shield Bolts - Left Side
5. Remove the exhaust manifold heat shield, sliding the shield up over the HO2S pigtail.
1. Install the exhaust manifold heat shield, sliding the shield down over the HO2S pigtail.

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Fig. 29: Identifying Exhaust Manifold Heat Shield Bolts - Left Side
2. Install the exhaust manifold heat shield bolts (1) and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (3).

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Fig. 30: Identifying Engine Wiring Harness Electrical Connector

4. Install the HO2S electrical connector retainer to the wiring harness clip (1).
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
EXHAUST MUFFLER HEAT SHIELD REPLACEMENT
Removal Procedure
1. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (NB5) and Exhaust Muffler

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Fig. 31: Identifying Exhaust Muffler Heat Shield

2. Remove the exhaust muffler front heat shield nuts (3).

3. Remove the exhaust muffler front heat shield (4).
4. Remove the exhaust muffler heat shield nuts (1).
5. Remove the exhaust muffler heat shield (2).
1. Position the exhaust muffler heat shield (2) to the floor panel.

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Fig. 32: Identifying Exhaust Muffler Heat Shield

2. Install the exhaust muffler heat shield nuts (1).
Tighten
Tighten the nuts to 9 N.m (80 lb in).
3. Position the exhaust muffler front heat shield (4) to the floor panel.
4. Install the exhaust muffler front heat shield nuts (3).
Tighten
Tighten the nuts to 9 N.m (80 lb in).
5. Install the muffler assembly. Refer to Exhaust Muffler Replacement (NB5) and Exhaust Muffler

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DESCRIPTION AND OPERATION

EXHAUST SYSTEM DESCRIPTION
IMPORTANT: Use of non-OEM parts may cause driveability concerns.
The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable
and into the exhaust muffler where exhaust noise is lessened.
In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized. The
exhaust system may utilize a slip-joint coupling design with a clamp and a U-bolt or a flange connection with a
gasket.
Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with insulating any
exhaust system vibration, rattle or noise.
Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the exhaust
system to expand as the exhaust system warms up.
Exhaust heat shields are used to protect the body and other components from damage due to the heat from the
exhaust system.
The exhaust system may be comprised of the following components:
Exhaust manifold
Exhaust pipes
Catalytic converters
Exhaust muffler
Exhaust resonator, if equipped
Exhaust tail pipe, if equipped
Exhaust hangers
Exhaust heat shields
Resonator
Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler,
allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require
specific exhaust tuning.
Catalytic Converter
The catalytic converter is an emission control device used to reduce hydrocarbons (HC), carbon monoxide (CO)

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and oxides of nitrogen (NOx) pollutants from the exhaust gas.
The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed within
a sheet metal shell. The substrate may be washcoated with 3 noble metals:
Platium (Pt)
Palladium (Pd)
Rhodium (Rh)
The catalyst in the catalytic converter is not serviceable.
Muffler
The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes
create channels inside the exhaust muffler that lower the sound levels created by the combustion of the engine.

SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS
Illustration Tool Number/Description
EN 35314-A
J 35314-A
Exhaust Back Pressure Gauge
J 35555
Vacuum Pump

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2014 ENGINE Engine Heating and Cooling - Acadia, Enclave And Traverse
2014 ENGINE
Engine Heating and Cooling - Acadia, Enclave And Traverse
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Coolant Recovery Reservoir Bolt 5 N.m 44 lb in
Drain Plug 22 N.m 16 lb ft
Engine Oil Cooler Fitting 24 N.m 18 lb ft
Fan Shroud Mounting Bolt 10 N.m 89 lb in

Radiator Mounting Bolt 10 N.m 89 lb in
Thermostat Housing Bolt 10 N.m 89 lb in
Thermostat Housing Retainer Bolt 50 N.m 37 lb ft
Water Outlet Housing Bolt 10 N.m 89 lb in
Water Pump Bolt*
First Pass 10 N.m 89 lb in
Second Pass 10 N.m 89 lb in
Final Pass Plus 45°
Water Pump Pulley Bolt 10 N.m 89 lb in
*Use NEW fastener.
SCHEMATIC WIRING DIAGRAMS

ENGINE HEATING/COOLING WIRING SCHEMATICS
Engine Cooling
Sunday, April 10, 2016 1:08:45

1:08:41 PM Page 1
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Fig. 1: Engine Cooling Wiring Schematics

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC CODE INDEX
DIAGNOSTIC CODE INDEX

DTC Description
DTC P0480, P0481, DTC P0480 Cooling Fan Relay 1 Control Circuit
P0691, P0692, P0693 or DTC P0481 Cooling Fan Relays 2 and 3 Control Circuit
P0694 DTC P0691 Cooling Fan Relay 1 Control Circuit Low Voltage
DTC P0692 Cooling Fan Relay 1 Control Circuit High Voltage
DTC P0693 Cooling Fan Relays 2 and 3 Control Circuit Low Voltage
DTC P0694 Cooling Fan Relays 2 and 3 Control Circuit High Voltage
DTC P1258 DTC P1258 Engine Coolant Overtemperature - Protection Mode Active
DTC P0480, P0481, P0691, P0692, P0693 OR P0694: COOLING FAN RELAY
Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

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Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic Procedure Instructions provides an overview of each diagnostic category.
DTC Descriptors
DTC P0480
Cooling Fan Relay 1 Control Circuit
DTC P0481
Cooling Fan Relays 2 and 3 Control Circuit
DTC P0691
Cooling Fan Relay 1 Control Circuit Low Voltage
DTC P0692
Cooling Fan Relay 1 Control Circuit High Voltage
DTC P0693
Cooling Fan Relays 2 and 3 Control Circuit Low Voltage
DTC P0694
Cooling Fan Relays 2 and 3 Control Circuit High Voltage
Diagnostic Fault Information
Short to Open/High Short to Signal

Circuit Ground Resistance Voltage Performance
Relay Coil Ignition P0480 P0480, P0481 - -
Relay Switch B+ 1 1 - -
Low Speed Cooling Fan Relay
P0691 P0480, P0691 P0692 -
Control
High Speed Cooling Fan Relay
P0693 P0481 or 1 P0694 -
Control
Cooling Fan Speed Control
P0693 P0481 or 1 P0694 -
Relay Control
Relay Controlled Output 1 1 2 -
1. Fan(s) inoperative without a DTC
2. Fan(s) always ON without a DTC

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Circuit/System Description
The engine cooling fan system consists of a cooling fan assembly containing two electric cooling fans. The
engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans ON
in either high speed or low speed, depending on cooling requirements. The ECM activates the applicable relay
by grounding the control circuit with a solid state device called a driver. Each driver is equipped with a
feedback circuit that is pulled-up to a voltage. The ECM can determine if the control circuit is open, shorted to
ground or shorted to a voltage by monitoring the feedback voltage. In low speed, both fans are turned ON at a
reduced speed. High speed has both fans turned ON at full speed.
Conditions for Running the DTC
The ignition voltage is greater than 11 volts.

The ECM driver transitions from ON to OFF or from OFF to ON.
DTCs P0480, P0481, P0691, P0692, P0693 and P0694 run continuously when the conditions above are
met.

Conditions for Setting the DTC
The commanded state of the ECM driver and the actual state of the control circuit do not match for greater than
5 seconds.
Action Taken When the DTC Sets
DTCs P0480, P0481, P0691, P0692, P0693 and P0694 are Type B DTCs.
Conditions for Clearing the MIL/DTC
DTCs P0480, P0481, P0691, P0692, P0693 and P0694 are Type B DTCs.
Diagnostic Aids
The ECM has the capability of providing command to the fan relays even when a scan tool output control
is being used. Always refer to the fan control command parameters on the scan tool to know which fans
are being commanded ON by the ECM.
The scan tool cooling fan output control operates as follows:
Cooling Fan Relay 1 operates both fans at a low speed
Cooling Fan Relays 2 and 3 operates one fan at a high speed
Cooling Fan Relays 1, 2 and 3 operates both fans at a high speed
Reference Information
Schematic Reference
Engine Heating/Cooling Schematics

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Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX

Electrical Center Identification Views
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
Circuit Testing
Connector Repairs
Testing for Intermittent Conditions and Poor Connections
Wiring Repairs

DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
1. Ignition ON.
2. Verify an audible click is heard or felt from cooling fan relays 1, 2 and 3 when commanding the cooling
fans ON and OFF with a scan tool.
If a click is not heard or felt at one or more of the relays
Refer to Circuit/System Testing
If a click is heard or felt at each of the relays

3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within
the conditions that you observed from the Freeze Frame/Failure Records data.
4. Verify the DTC does not set.
If the DTC sets
If the DTC does not set

5. All OK.

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Circuit/System Testing
1. Ignition OFF, disconnect all of the cooling fan relays. Ignition ON.
2. Verify that a test lamp illuminates between ground and a relay coil ignition circuit terminal listed below:
NOTE: The following tests must be performed on all three fan relay circuits.
KR20C Cooling Fan Low Speed Relay terminal 85/2

KR20D Cooling Fan High Speed Relay terminal 86/1
KR20E Cooling Fan Speed Control Relay terminal 86/1
If the test lamp does not illuminate
1. Ignition OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to
power down. Remove the test lamp.
2. Test for less than 2 ohms in the ignition circuit of the appropriate cooling fan relay, end to end.

If 2 ohms or greater, repair the open/high resistance in the circuit.
If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.
If the test lamp does not illuminate and the circuit fuse is open
power down. Remove the test lamp.
2. Test for infinite resistance between the appropriate cooling fan relay ignition circuit and ground.
If less than infinite resistance, repair the short to ground on the circuit.
If infinite resistance test or replace the appropriate cooling fan relay.
If the test lamp illuminates
3. Connect a DMM, set on the diode setting, between ground and a relay control circuit terminal listed
below:
NOTE: The following tests must be performed on all three fan relay circuits.
KR20C cooling fan low speed relay terminal 86/1

KR20D cooling fan high speed relay terminal 85/2
KR20E cooling fan speed control relay terminal 85/2
4. Verify the DMM reading is greater than 2.5 V or displays O.L with the cooling fan relays commanded
OFF with a scan tool.
If 2.5 V or less
1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module.
2. Test for infinite resistance between the appropriate relay coil control circuit and ground.
If infinite resistance, replace the K20 Engine Control Module.
If greater than 2.5 V or displays O.L.
5. Verify the DMM reading is less than 1 V when commanding the cooling fan relays ON with a scan tool.

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If greater than 1 V or displays OL.

1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, ignition
ON.
2. Test for less than 1 V between the appropriate cooling fan relay control circuit and ground.
If 1 V or greater, repair the short to voltage on the circuit.
If less than 1 V.
power down.
4. Test for less than 2 ohms in the appropriate cooling fan relay control circuit end to end.
If less than 2 ohms, replace the K20 Engine Control Module.
If less than 1 V
6. Test or replace the appropriate cooling fan relay.

Component Testing
1. Ignition OFF.
2. Disconnect a cooling fan relay.
3. Test for 70-110 ohms between terminals 85/2 and 86/1.
If less than 70 ohms or greater than 110 ohms
Replace the cooling fan relay.
If between 70-110 ohms

4. Test for infinite resistance between the following terminals:
30 and 86
30 and 87
30 and 85
85 and 87
OR
3 and 2
3 and 5
3 and 1
1 and 5
If less than infinite resistance
If infinite resistance

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5. Test for less than 2 ohms between KR20E Cooling Fan Speed Control Relay terminals 30/3 and 87A/4.
NOTE: This test only applies to the speed control relay.
If 2 ohms or greater
Replace the KR20E Cooling Fan Speed Control Relay.
If less than 2 ohms

6. Install a 10 A fused jumper wire between relay terminal 85 or 2 and 12 V.
7. Install a jumper wire between relay terminal 86 or 1 and ground.
8. Test for less than 2 ohms between terminals 3/30 and 5/87.
If less than 2 ohms

9. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)
Control Module References for ECM replacement, setup and programming
DTC P1258: ENGINE COOLANT OVERTEMPERATURE - PROTECTION MODE ACTIVE
DTC Descriptors
DTC P1258
Engine Coolant Overtemperature - Protection Mode Active
The engine control module (ECM) uses the engine coolant temperature sensor to monitor the engine for an
over-temperature condition. This condition occurs when the coolant temperature is above a calibrated value.

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The ECM will alternately disable 2 groups of cylinders by turning OFF the fuel injectors. By switching between
the 2 groups of cylinders, the ECM is able to reduce the temperature of the coolant.
Conditions for Running the DTC
The engine is operating for greater than 30 seconds.

DTC P1258 runs continuously once the conditions above have been met.
Conditions for Setting the DTC
The ECM detects that engine coolant temperature is warmer than 132°C (270°F) for 2 seconds or greater.
Action Taken When the DTC Sets
DTC P1258 is a Type A DTC.

The engine will operate in the Overheated Engine Protection Operating Mode.

The IP will illuminate the coolant temperature indicator lamp and the driver information center (DIC), if
equipped, may display a message.
If the protection mode is active and an ECT sensor DTC sets, the protection mode will remain active at
the start of the next drive cycle until the ECT sensor DTC runs and passes.
Conditions for Clearing the MIL/DTC
DTC P1258 is a Type A DTC.
Schematic Reference
Engine Controls Schematics

Instrument Cluster Description and Operation
Indicator/Warning Message Description and Operation
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions

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Scan Tool Reference
K20 Engine Control Module: Scan Tool Information (LLT) for scan tool information
1. Ignition ON.
2. Verify DTC P0480, P0481, P0691, P0692, P0693 or P0694 is not set.
If a DTC is set
Refer to DTC P0480, P0481, P0691, P0692, P0693 or P0694.
If no DTCs is set
3. Verify the cooling fan operates at each available speed as commanded with a scan tool.
NOTE: A short delay occurs before the ECM changes the cooling fan speed.
Cooling fan does not operate
Refer to Cooling Fan Inoperative.
Cooling fan operates

4. Verify that the engine does not overheat.
Engine overheats
Refer to Engine Overheating.
Engine does not overheat

5. Operate the vehicle within the Conditions for Running the DTC.
If the DTC sets
Refer to Symptoms - Engine Cooling.
If the DTC does not set

6. All OK
Repair Instructions
SYMPTOMS - ENGINE COOLING
Important Preliminary Inspections Before Starting

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Before using the Symptom diagnosis, perform the following:
Perform Diagnostic System Check - Vehicle and verify all of the following items:
Engine control module (ECM) and malfunction indicator lamp (MIL) are operating correctly.
There are no diagnostic trouble codes (DTCs) stored.
Scan tool data is within a normal operating range.
Verify the customer concern.
Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely
important and can lead to correcting a condition without additional testing. It may also help reveal the
cause of an intermittent condition.
Locate the correct symptom. Perform the tests and inspections associated with the symptom.
Review the entire cooling system operation in order to familiarize yourself with the system functions. Refer to
Cooling Fan Description and Operation and Cooling System Description and Operation.

Visual/Physical Inspection
CAUTION: Use the connector test adapter kit EL-35616-F for any test that requires
probing the following items:
The control module harness connectors

The electrical center fuse/relay cavities
The component terminals
The component harness connector
Using this kit will prevent damage caused by the improper probing of
connector terminals.
Several of the symptom procedures call for a careful visual and physical inspection. This can lead to correcting
a condition without further tests and can save time. This inspection should include the following:
Ensure that the control module grounds are clean, tight and correctly located.
Inspect cooling system hoses and pipes for splits, kinks and improper connections. Inspect thoroughly for
any type of leak or restriction.
Inspect for a dirty or restricted radiator or HVAC condenser.
Inspect for aftermarket devices which could affect the operation of the cooling system.
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Inspect the coolant recovery reservoir for proper coolant level.
Identifying Intermittent Conditions
Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement,

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vibration or physical movement of a component. Refer to the following for a list to help isolate an intermittent
condition:
Water intrusion in connectors, terminals or components

Poor connector mating
Terminal contact
High circuit or component resistance-High resistance can include any resistance, regardless of the
amount, which can interrupt the operation of the component.
Harness' that are routed too tight or chaffed circuits
High or low ambient temperatures
High or low engine coolant temperatures
High underhood temperatures
Heat build up in components or circuits due to circuit resistance, poor terminal contact or high electrical
load

High or low system voltage
High vehicle load conditions
Rough road surface
Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
Incorrect installation of non-factory, aftermarket or after factory add on accessories
If an intermittent fault is detected, refer to Testing for Intermittent Conditions and Poor Connections for
specific strategies in diagnosing intermittent conditions.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
Cooling Fan Always On

Cooling Fan Inoperative
Engine Overheating
Loss of Coolant
Thermostat Diagnosis
Engine Fails To Reach Normal Operating Temperature
COOLING FAN ALWAYS ON

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engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans ON
in either high speed or low speed, depending on cooling requirements. The ECM activates the applicable relay
by grounding the control circuit with a solid state device called a driver. Each driver is equipped with a
feedback circuit that is pulled-up to a voltage. The ECM can determine if the control circuit is open, shorted to
ground or shorted to a voltage by monitoring the feedback voltage. In low speed, both fans are turned ON at a
reduced speed. High speed has both fans turned ON at full speed.
Diagnostic Aids

Certain resistance conditions with IAT or ECT sensors may cause unwarranted cooling fan activation. If
the ECM is commanding the cooling fans ON for no apparent reason and without any component or
system DTCs set, the IAT or ECT sensor may be skewed. If this condition is suspected, refer to the
temperature versus resistance tables in the appropriate Engine Controls subsection.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

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1. Ignition ON.
2. Verify that DTC P0480, P0481, P0691, P0692, P0693 or P0694 is not set.
If a DTC is set
If no DTC is set
3. Verify the scan tool parameters listed below display OFF:
Cooling Fan Relay 1 Command
Cooling Fan Relays 2 and 3 Command
If a scan tool parameter displays ON
Refer to Diagnostic Aids and Symptoms - Engine Cooling for further diagnosis.
If both scan tool parameters display OFF

4. Verify that the fans are not activated.
If a fan is operating
Refer to Circuit/System Testing.
If both fans are OFF

5. All OK
Both Cooling Fans Always ON
1. Ignition OFF, disconnect KR20C Cooling Fan Low Speed Relay, ignition ON.
2. Verify that both cooling fans are OFF.
If the cooling fans are ON
1. Ignition OFF, disconnect the harness connector at the G10R Cooling Fan Motor-Right, ignition
ON.
2. Test for less than 1 V between KR20C Cooling Fan Low Speed Relay terminal 87/5 and ground.
If 1 V or greater, repair the short to voltage in the relay controlled output circuit.
If the cooling fans are OFF
3. Test or replace the KR20C Cooling Fan Low Speed Relay.
One Cooling Fan Always ON

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1. Ignition OFF, disconnect the KR20D Cooling Fan High Speed Relay, ignition ON.
2. Verify the cooling fan is OFF.
If the cooling fan is ON
1. Ignition OFF, disconnect the harness connector at the G10L Cooling Fan Motor-Left, ignition ON.
2. Test for less than 1 V between KR20D Cooling Fan High Speed Relay terminal 30/3 and ground.
If 1 V or greater, repair the short to voltage in the relay controlled output circuit.
If the cooling fan is OFF
3. Test or replace the KR20D Cooling Fan High Speed Relay.
Component Testing
1. Ignition OFF.
2. Disconnect a KR20 Cooling Fan Relay.
Replace the KR20 cooling fan relay.

30/3 and 86/1
30/3 and 87/5
30/3 and 85/2
85/2 and 87/5
Replace the KR20 Cooling Fan Relay.
If less than 2 ohms


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If less than 2 ohms

9. All OK.
Repair Instructions
COOLING FAN INOPERATIVE
engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans O
in either high speed or low speed, depending on cooling requirements. In low speed, both fans are turned ON at
a reduced speed. High speed has both fans turned ON at full speed.
Diagnostic Aids

Schematic Reference


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Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference
1. Ignition ON.
2. Verify that DTC P0480, P0481, P0691, P0692, P0693 or P0694 is not set.
If a DTC is set
If no DTCs is set
3. Verify that both cooling fans turn ON and OFF and operate at low and high speed, when commanding th
appropriate cooling fan relays ON and OFF with a scan tool.
If a cooling fan does not operate
If both cooling fans operate

4. All OK.
1. Ignition OFF, disconnect all of the KR20 Cooling Fan Relays.

2. Ignition ON, verify a test lamp illuminates between ground and the B+ circuit terminals listed below:
KR20C Cooling Fan Low Speed Relay B+ circuit terminal 85/1
KR20C Cooling Fan Low Speed Relay B+ circuit terminal 30/3
KR20D Cooling Fan High Speed Relay B+ circuit terminal 87/5
KR20D Cooling Fan High Speed Relay B+ circuit terminal 86/2
KR20E Cooling Fan Speed Control Relay B+ circuit terminal 86/2
If the test lamp does not illuminate and the circuit fuse is good

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1. Disconnect the appropriate cooling fan fuse or power source.

2. Test for less than 2 ohms between the fuse and the appropriate relay B+ circuit terminal, end to
end.
If 2 ohms or greater, repair the open/high resistance in the B+ circuit.
If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.
If the test lamp does not illuminate and the circuit fuse is open
1. Connect a DMM to the appropriate relay B+ circuit terminal.
2. Test for infinite resistance between the B+ circuit and ground.
If less than infinite resistance, repair the short to ground on the B+ circuit.
3. Disconnect the harness connector at the appropriate G10 Cooling Fan Motor.
4. Test for infinite resistance between the appropriate relay controlled output circuit terminal and
ground.
KR20C Cooling Fan Low Speed Relay output circuit terminal 87/5
KR20D Cooling Fan High Speed Relay output circuit terminal 30/3
KR20E Cooling Fan Speed Control Relay circuit terminal 30/3
If infinite resistance, test or replace the appropriate G10 Cooling Fan Motor.
If the test lamp illuminates
3. Connect a DMM, set on the diode setting, between ground and a relay control circuit terminal listed
below:
NOTE: The following tests must be performed on both fan relay circuits.
KR20D Cooling Fan High Speed Relay terminal 85/2

4. Verify the DMM reading is less than 1 V when commanding the cooling fan relays ON with a scan tool.
If greater than 1 V or displays OL.
1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, ignition
ON.
2. Test for less than 1 V between the appropriate cooling fan relay control circuit and ground.
If 1 V or greater, repair the short to voltage on the circuit.
If less than 1 V.
power down.
4. Test for less than 2 ohms between the KR20E Cooling Fan Speed Control Relay terminal 85 and
KR20D Cooling Fan High Speed Relay terminal 85.
If less than 2 ohms, replace the K20 Engine Control Module.

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If less than 1 V
5. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the G10L Cooling Fan
Motor - Left. It may take up to 2 minutes for all vehicle systems to power down.
6. Test for less than 5 ohms between the circuits listed below and ground:
G10L Cooling Fan Motor - Left terminal A
1. Ignition OFF and all vehicle systems OFF, it may take up to 2 minutes for all vehicle systems to
power down.
2. Test for less than 2 ohms in the appropriate ground circuit end to end.
If less than 2 ohms, repair the open/high resistance in the ground connection.
If less than 5 ohms
7. Connect the harness connector at the G10L Cooling Fan Motor - Left.
8. Connect a 50 A fused jumper between the KR20D Cooling Fan High Speed Relay terminals 30/3 and
87/5.
9. Ignition ON, verify the G10L Cooling Fan Motor - Left is activated at high speed.
If the cooling fan does not activate or jumper fuse opens
1. Disconnect the harness connector at the G10L Cooling Fan Motor - Left.
2. Test for less than 2 ohms in the circuit between KR20D Cooling Fan High Speed Relay terminal
30/3 and the G10L Cooling Fan Motor - Left terminal B.
If less than 2 ohms, replace the G10L Cooling Fan Motor - Left.
If the cooling fan activates
10. Ignition OFF, connect a fused jumper between the KR20E Cooling Fan Speed Control Relay switch
circuit terminal 30/3 and the ground circuit terminal 87/5.
11. Connect a 40 A fused jumper between the KR20C Cooling Fan Low Speed Relay terminals 30/3 and
87/5.
12. Ignition ON, verify the G10R Cooling Fan Motor - Right is activated at high speed.
If the cooling fan does not activate
1. Disconnect the harness connector at the G10R Cooling Fan Motor - Right.
2. Test for less than 2 ohms in the circuit between KR20C Cooling Fan Low Speed Relay terminal
87/5 and the G10R Cooling Fan Motor - Right terminal B.
If less than 2 ohms
3. Test for less than 2 ohms in the circuit between KR20E Cooling Fan Speed Control Relay terminal
30/3 and the G10R Cooling Fan Motor - Right terminal A.
If less than 2 ohms, replace the G10R Cooling Fan Motor - Right.

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If the cooling fan activates

13. Ignition OFF, Install the KR20E Cooling Fan Speed Control Relay.
14. Ignition ON, verify both fan motors activate at low speed.
If both cooling fans do not activate at low speed
1. Disconnect both cooling fan motor harness connectors and the KR20E Cooling Fan Speed Control
Relay.
2. Test for less than 2 ohms in circuit between KR20E Cooling Fan Speed Control Relay terminal
87A/4 and the G10L Cooling Fan Motor - Left terminal B.
If less than 2 ohms
3. Test for infinite resistance between KR20E Cooling Fan Speed Control Relay terminal listed below
and ground.
KR20E Cooling Fan Speed Control Relay terminal 87A/4
If less than infinite, repair the short to ground in the circuit.

If infinite, replace the KR20E cooling fan speed control relay.
If both cooling fans activate
15. Ignition OFF, test or replace the cooling fan relay listed below as appropriate:
KR20C Cooling Fan Low Speed Relay
KR20D Cooling Fan High Speed Relay
Component Testing
1. Ignition OFF.
2. Disconnect a KR20 Cooling Fan Relay.
Replace the KR20 cooling fan relay.

30 and 86
30 and 87
30 and 85
85 and 87
OR
3 and 2

20
3 and 5
3 and 1
1 and 5
If less than 2 ohms

If less than 2 ohms

9. All OK.
Repair Instructions
Cooling Fan and Shroud Replacement
ENGINE OVERHEATING
Engine Overheating
Step Action Yes No
DEFINITION: Either of the following conditions indicate a probable engine overheat condition.
The engine temperature gauge is in the red (overheat) zone and/or the engine temperature indicator
is ON.
Hot engine coolant overflows from the coolant recovery reservoir and/or radiator cap onto the

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ground while the engine is running.

1. Inspect and fill the cooling system, as necessary.
Refer to Cooling System Draining and Filling
(Static Fill), Cooling System Draining and
Filling (Vac N Fill).
1 2. Inspect the cooling system for leaks, as
necessary.
3. Repair the cooling system leaks, as necessary.
Has the inspection/repair been performed? Go to Step 2 -

1. Start the engine and allow the engine to run at
approximately 1, 200 RPM.
2. Use the Scan Tool in order to verify the overheat
2 condition.
Go to Diagnostic
Does the Scan Tool verify the engine overheat System Check -
condition? Go to Step 3 Vehicle
1. Verify that the cooling fans are operating
properly.
3 2. Repair the cooling fan system, as necessary.
Does the engine still overheat? Go to Step 4 System OK

Perform the following inspections:
Inspect the radiator and the A/C condenser

cooling fins for debris or any other obstruction.
Inspect the drive belt system and the drive belt
tensioner for proper operation in order to ensure
that the coolant pump is rotating properly.
4 Inspect for loose, damaged and/or missing air
deflector(s).
Check for a pinched or kinked cooling system
hose.
Repair the systems as necessary.

Inspect the thermostat for proper operation. Refer to
5 Thermostat Diagnosis.
Is the thermostat operating properly? Go to Step 7 Go to Step 6
Replace the thermostat. Refer to Engine Coolant
6 Thermostat Replacement.

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1. Inspect for the proper coolant concentration

(mixture). Correct the coolant concentration as
necessary.
IMPORTANT:
Excessive coolant freeze point protection MAY
cause the coolant to boil at low temperatures.
7
2. Remove the radiator cap.
3. Start the engine and inspect for a constant flow
of air bubbles in the engine coolant.
Is there a constant flow of air bubbles in the engine

coolant? Go to Step 8 Go to Step 9
The probable cause of the engine overheat is
combustion chamber gasses leaking into the cooling
system. This condition is usually caused by the

following:
A worn or damaged cylinder head gasket

A worn or damaged cylinder head
8 A worn and/or damaged engine block
Verify this condition by inspecting the spark plug

electrodes and porcelain surrounding the spark plug
electrode for signs of coolant. Replace and/or repair the
engine internal component(s), as necessary, in order to
repair the engine internal coolant leak.
The engine overheat may be caused by a cooling
system blockage. Flush the cooling system. Refer to
9
Flushing.
IMPORTANT:
It is unlikely that the water pump is the cause of the
overheat condition.
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If NONE of the cooling system passages are restricted,
replace the coolant pump. Refer to Water Pump
Replacement.Does the engine still overheat? Go to Step 1 System OK
LOSS OF COOLANT
Loss of Coolant

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Step Action Yes No

DEFINITION: The cooling system is losing coolant either internally or externally.
Were you sent here from Symptoms or another Go to Symptoms -
1
diagnostic table? Go to Step 2 Engine Cooling
Repair any present DTCs. Refer to Diagnostic
2 Starting Point - Vehicle . -
Is the action complete? Go to Step 3
Inspect the coolant level.
3
Is the coolant at the proper level? Go to Step 5 Go to Step 4
Fill the cooling system to the proper level. Refer to
Cooling System Draining and Filling (Static Fill),
4 -
Cooling System Draining and Filling (Vac N Fill).
If the engine is suspected to have a coolant leak into
the cylinder, the coolant can hydraulically lock the
5
cylinder.
Does the engine crankshaft rotate? Go to Step 6 Go to Step 31
Engine overheating can cause a loss of coolant.
6
Is the engine overheating? Go to Step 32 Go to Step 7
Extended engine operation with a low coolant level
7 can cause engine internal component failure.
Is the engine knocking? Go to Step 34 Go to Step 8
1. Idle the engine at normal operating temperature.
2. Inspect for heavy white smoke coming out of
8 the exhaust pipe.
Is a heavy white smoke present from the exhaust pipe? Go to Step 9 Go to Step 10
Coolant in the exhaust system creates a distinctive,
burning coolant odor in the exhaust.
Condensation in the exhaust system can cause an
9
odorless white smoke during engine warm up.
Does the white smoke have a burning coolant type
odor? Go to Step 33 Go to Step 10
With the engine idling, inspect the coolant recovery
system.
10
Does the coolant recovery system discharge coolant
while the engine is idling? Go to Step 15 Go to Step 11
Visually inspect the hoses, pipes and hose clamps at
the following locations:
The auxiliary heater core

11
The coolant reservoir
The heater core
The radiator

24
Are any of the hoses, clamps or pipes leaking?

Go to Step 24 Go to Step 12
Visually inspect the following components:
The block heater

The coolant pressure cap
The coolant reservoir
The core plugs
The cylinder head gaskets
12 The engine block
The intake manifold
The radiator
The thermostat

The water pump
Are any of the listed components leaking? Go to Step 24 Go to Step 13

1. Pressure test the cooling system. Refer to
Cooling System Leak Testing.
13 2. Visually inspect the components listed in steps
11 and 12 again.
Are any leaks present? Go to Step 24 Go to Step 14

Pressure test the coolant pressure cap. Refer to
14 Pressure Cap Testing.
Does the coolant pressure cap hold pressure? Go to Step 16 Go to Step 25
Pressure test the coolant pressure cap. Refer to
15 Pressure Cap Testing.
Does the coolant pressure cap hold pressure? Go to Step 35 Go to Step 25
Inspect for the following conditions:
A coolant smell inside of the vehicle

Coolant in the HVAC module assembly drain
tube
16
Coolant on the vehicle floor covering under the
HVAC module assembly
Is coolant present? Go to Step 26 Go to Step 17

If equipped with auxiliary heating, inspect for the
following conditions:

25
A coolant smell inside of the vehicle

Coolant in the auxiliary HVAC module
assembly drain tube
17 Coolant on the floor covering near the auxiliary
HVAC module assembly
Is coolant present? Go to Step 27 Go to Step 18

1. Add 30 ml (1 oz) of Extended Life Coolant
Leak Detection Dye GM P/N 89022219
(Canadian P/N 89022220) to the cooling system
for each 15 liters (4 gallons) of coolant. Refer to
Approximate Fluid Capacities .
2. Start the vehicle and allow the engine to reach
18 normal operating temperature.
3. Shut the engine off.
4. Use J 42220 universal 12V leak detection lamp
to visually inspect the components listed in
steps 11 and 12.
Are any leaks present? Go to Step 24 Go to Step 19

Use J 42220 universal 12V leak detection lamp to
inspect for the following conditions:
Coolant dye in the HVAC module drain tube

19 Coolant dye on the vehicle floor covering near
the HVAC module
Is coolant dye present? Go to Step 26 Go to Step 20

Use J 42220 universal 12V leak detection lamp to
inspect for the following conditions:
Coolant dye in the auxiliary HVAC module

drain tube
20
Coolant dye on the vehicle floor covering near
the auxiliary HVAC module
Is coolant dye present? Go to Step 27 Go to Step 21

Inspect the underside of the oil fill cap for a
21 gray/white milky substance.
Is there a milky substance under the oil fill cap? Go to Step 22 Go to Step 23
Inspect the engine oil fluid level indicator for a

26
gray/white milky substance.

22 Is there a milky substance on the engine oil fluid level
indicator? Go to Step 33 Go to Step 23
Inspect the automatic transmission oil fluid level
indicator, if equipped, for a gray/white milky
23 substance.
Is there a milky substance on the automatic
transmission fluid level indicator? Go to Step 28 Go to Step 36
Repair or replace the leaking component. Refer to the
24 appropriate repair. -
Is the repair complete? Go to Step 36
Replace the coolant pressure cap.
25 -
Replace the heater core. Refer to Heater Core
26 Replacement . -
Replace the auxiliary heater core. Refer to Auxiliary
27 Heater Core Replacement . -
1. Remove the transmission oil cooler lines from
the radiator.
2. Pressure test the cooling system. Refer to
28 Cooling System Leak Testing.
3. Inspect the transmission oil cooler for coolant.
Is coolant present in the transmission oil cooler? Go to Step 29 Go to Step 30

1. Replace the radiator. Refer to Radiator
Replacement.
29 2. Service the automatic transmission. Refer to -
Engine Coolant/Water in Transmission .

Install the cooler lines to the radiator.
30 -
Repair the engine no crank condition. Refer to Engine
31 Will Not Crank - Crankshaft Will Not Rotate . -
Repair the engine overheating condition. Refer to
32 Engine Overheating. -
Repair the engine internal coolant leak. Refer to
Coolant in Combustion Chamber or Coolant in
33 -
Engine Oil .

27
Repair the engine knock. Refer to Lower Engine

34 Noise, Regardless of Engine Speed . -
Repair the combustion pressure in the cooling system
problem. Refer to Coolant in Combustion
35 -
Chamber .
Operate the system in order to verify the repair.
36
Did you find and correct the condition? System OK Go to Step 2
THERMOSTAT DIAGNOSIS
Tools Required
J 24731 188 Tempilstick

J 24731 206 Tempilstick
The coolant thermostat can be tested using a temperature (tempil) stick. The temperature stick is a pencil-like
device which has a wax material containing certain chemicals that melt at a given temperature. Temperature
sticks can be used to determine a thermostat's operating range by rubbing 87°C (188°F) and 97°C (206°F) stick
on the outlet coolant pipe.
1. Use a tempilstick in order to find the opening and the closing temperatures of the thermostat.
J 24731 188 Tempilstick melts at 87°C (188°F). The thermostat should begin to open at 90°C
(194°F).
J 24731 206 tempilstick melts at 97°C (206°F). The thermostat should be fully open at 107°C
(225°F).
2. Replace the thermostat if it does not operate properly between this temperature range.
COOLANT HEATER INOPERATIVE
The coolant heater operates using 110 V AC external power and is designed to warm the coolant in the engine
block area for improved starting in very cold weather. The coolant heater also helps reduce fuel consumption
when a cold engine is warming up. The unit is equipped with a detachable AC power cord. There is an internal
thermal switch in the coolant heater cord that prevents operation above -18°C (0°F). A weather shield on the
cord is provided to protect the plug when not in use.

28
Circuit Testing
Connector Repairs
Wiring Repairs
NOTE: The coolant heater cord will read Open due to an internal thermal switch if the
ambient temperature is above -18°C (0°F).
1. Ignition OFF, disconnect the coolant heater cord from the E19 Coolant Heater.

2. Test for 30-40 ohms between the terminals of the E19 Coolant Heater.
If not within 30-40 ohms
Replace the E19 Coolant Heater.
If within 30-40 ohms

3. Test for infinite resistance between each terminal of the E19 Coolant Heater and ground.
Replace the E19 Coolant Heater.
4. Test or replace the coolant heater cord.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic repair.
Coolant Heater Replacement

Coolant Heater Cord Replacement
ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE
Engine Fails To Reach Normal Operating Temperature

Step Action Yes No
1. Ensure that the cooling system is full.
2. Allow the engine to cool.

29
4. Turn the air conditioning system off.

1 5. Inspect the engine cooling fan(s).
Is the electric cooling fan on? Go to Step 2 Go to Step 3

1. Diagnose and repair the cooling fan system. Refer
to Cooling Fan Always On.
2 2. Verify the customer complaint.
Does the engine still fail to reach normal operating

temperature? Go to Step 3 System OK
Install the Scan Tool to the DLC. Compare the Scan
Tool coolant temperature reading to the I/P cluster
3 coolant temperature.
Is the I/P cluster coolant temperature close to the
reading on the Scan Tool? Go to Step 5 Go to Step 4
1. Diagnose and repair the coolant temperature
gauge system.

Inspect the thermostat for proper operation. Refer to
5 Thermostat Diagnosis.
Is the thermostat operating properly? Go to Step 1 Go to Step 6
1. Replace the thermostat. Refer to Engine Coolant
Thermostat Replacement.

PRESSURE CAP TESTING
Special Tools
J 24460-01 Cooling System Pressure Tester

J 42401 Radiator Cap/Surge Tank Test Adapter
Pressure Cap Testing
1. Remove the pressure cap.
CAUTION: To avoid being burned, do not remove the radiator cap or surge tank

30
cap while the engine is hot. The cooling system will release scalding
fluid and steam under pressure if radiator cap or surge tank cap is
removed while the engine and radiator are still hot.
2. Wash the pressure cap sealing surface with water.

3. Use the J 24460-01 cooling system pressure tester (1) with J 42401 radiator cap/surge tank test adapter
(2) in order to test the pressure cap.
Fig. 2: Identifying Pressure Cap Testing Tool J 42401

IMPORTANT: Lubricate J-42401 and pressure cap o-rings with coolant and press cap to
seat o-ring on J-42401 before turning to engage threads.
4. Test the pressure cap for the following conditions:

Pressure release when the J 24460-01 cooling system pressure tester exceeds the pressure rating of
the pressure cap.

31
Maintain the rated pressure for at least 10 seconds.
Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions:

The pressure cap does not release pressure which exceeds the rated pressure of the cap.
The pressure cap does not hold the rated pressure.
COOLING SYSTEM LEAK TESTING
Special Tools
J-24460-01 Cooling System Pressure Tester
1. Remove the pressure cap.

WARNING: Under pressure, the temperature of the solution in the radiator can
be considerably higher, without boiling. Removing the radiator cap
while the engine is hot (pressure is high), will cause the solution to
boil instantaneously, with explosive force. The solution will spew
out over the engine, fenders and the person removing the cap.
Serious bodily injury may result. Flammable antifreeze, such as
alcohol, is not recommended for use at any time. Flammable
antifreeze could cause a serious fire.
WARNING: In order to help avoid being burned, do not remove the radiator cap
while the engine and the radiator are hot. Scalding fluid and steam
can be blown out under pressure if the cap is removed too soon.
2. Test the operation of the pressure cap. Refer to Pressure Cap Testing.
3. Use the J-24460-01 tester in order to apply pressure to the cooling system.

32
Fig. 3: Pressure Testing Cooling System Using J 24460-01

Do not exceed the pressure cap rating.
4. The cooling system should hold the rated pressure for at least 2 minutes.
Observe the gauge for any pressure loss.
5. Repair any leaks as required.
REPAIR INSTRUCTIONS
COOLING SYSTEM DRAINING AND FILLING (STATIC FILL)
Draining Procedure
Special Tools
J 26568 Coolant and Battery Tester

33
WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and
steam under pressure if radiator cap or surge tank cap is removed while
the engine and radiator are still hot.
1. Place a drain pan under the radiator hose.
NOTE: Draining the cooling system with the pressure cap installed will siphon the
coolant from the overflow tank.
2. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement.
3. Move down the end of the radiator hose to drain the radiator.
4. Drain the cooling system.
5. Remove the coolant pressure cap.
6. If a complete engine block drain is required, remove the engine drain plugs.
7. Inspect the coolant.

8. Follow the appropriate procedure based on the condition of the coolant.
Normal in appearance-Follow the filling procedure.
Discolored-Follow the flush procedure. Refer to Flushing.
Filling Procedure
1. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement.
CAUTION: The procedure below must be followed. Improper coolant level could
result in a low or high coolant level condition, causing engine
damage.
2. If the engine block drain plug was removed, perform the following:
1. Apply pipe sealer to the drain plugs.

2. Install the drain plugs.
Tighten
Tighten the drain plug to 22 N.m (16 lb ft).

4. Slowly fill the cooling system with a 50/50 coolant mixture. Refer to Approximate Fluid Capacities .

34
NOTE: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
5. Install the coolant pressure cap.

7. Run the engine at 2, 000-2, 500 RPM until the engine reaches normal operating temperature.
8. Allow the engine to idle for 3 minutes.
9. Shut the engine OFF.
10. Allow the engine to cool.
11. Top off the coolant as necessary.
12. Inspect the concentration of the engine coolant, using the J 26568 coolant and battery tester.
13. Rinse away any excess coolant from the engine and the engine compartment.
COOLING SYSTEM DRAINING AND FILLING (VAC N FILL)

Special Tools
GE-47716 Vac-N-Fill Coolant Refill Tool

J 26568 Coolant and Battery Tester
Draining Procedure
WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and
steam under pressure if radiator cap or surge tank cap is removed while
the engine and radiator are still hot.
1. Remove the radiator cap.

2. Attach the venturi assembly to the vacuum tank.

35
Fig. 4: View Of Venturi Assembly & Vacuum Tank

3. Attach a shop air hose to the venturi assembly.

36
Fig. 5: View Of Shop Air Hose & Venturi Assembly

Ensure the valve on the venturi assembly is closed.
4. Attach the vacuum hose to the vacuum tank.

5. Attach the extraction hose to the vacuum hose.

37
Fig. 6: Attaching Extraction Hose To Vacuum Hose

6. Insert the extraction hose into the radiator cap opening and into the radiator until the extraction hose
contacts the bottom of the radiator end tank.
7. Open the valve on the venturi assembly to start a vacuum draw.

38
Fig. 7: Identifying Valve On Venturi Assembly

8. Use the extraction hose to draw out coolant until the radiator is empty.
9. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the
vacuum tank into a suitable container for disposal.
10. If a complete engine block drain is required, remove the engine block drain plug.
11. Inspect the coolant.
12. Follow the appropriate procedure based on the condition of the coolant.
Normal in appearance-Follow the filling procedure.
Discolored-Follow the flush procedure. Refer to Flushing.
Vac-N-Fill Procedure
NOTE: To prevent boiling of the coolant/water mixture in the vehicles cooling system,
do not apply vacuum to a cooling system above 49°C (120°F). The tool will not
operate properly when the coolant is boiling.
1. Attach the Vac-N-Fill cap to the vehicles coolant fill port.

39
Fig. 8: Identifying Vac-N-Fill Cap

2. Install the extension hose.

3. Attach the vacuum gauge assembly to the Vac-N-Fill cap.

40
Fig. 9: Attaching Vacuum Gauge Assembly To Vac-N-Fill Cap

4. Attach the fill hose to the barb fitting on the vacuum gauge assembly.

41
Fig. 10: Attaching Fill Hose To Barb Fitting On Vacuum Gauge Assembly
Ensure that the valve is closed.
5. Pour the coolant mixture into the graduated reservoir.

42
Fig. 11: View Of Graduated Reservoir & Hose

NOTE: Use a 50/50 mixture of DEX-COOL anti-freeze and clean, drinkable water.
Always use more coolant than necessary. This will eliminate air from
being drawn into the cooling system.
6. Place the fill hose in the graduated reservoir.

7. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the
vacuum tank.
NOTE: Prior to installing the vacuum tank onto the graduated reservoir, ensure
that the drain valve located on the bottom of the tank is closed.
8. Attach the venturi assembly to the vacuum tank.

43
Fig. 12: View Of Venturi Assembly & Vacuum Tank

9. Attach a shop air hose to the venturi assembly.

44
Fig. 13: View Of Shop Air Hose & Venturi Assembly

Ensure the valve on the venturi assembly is closed.
10. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.

45
Fig. 14: Attaching Vacuum Hose To Vacuum Gauge Assembly & Vacuum Tank
11. Clamp off the overflow hose.

12. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be
present.

46

13. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in HG).

47
Fig. 16: View Of Vacuum Gauge

Cooling hoses may start to collapse. This is normal due to vacuum draw.
14. To aid in the fill process, position the graduated reservoir above the coolant fill port.
15. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose,
close the valve. This will eliminate air from the fill hose.

48
Fig. 17: Identifying Valve On Vacuum Gauge Assembly

16. Close the valve on the venturi assembly.

17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monito
for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant.
18. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the
system.
19. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 11-
17.

49
Fig. 18: View Of Vacuum Gauge & Radiator

Remove the extension hose.
20. Remove the J 42401 radiator cap and surge tank test adapter.
21. Detach the Vac-N-Fill cap from the vehicles coolant fill port.
22. Add coolant to the system as necessary.
23. Inspect the concentration of the coolant mixture using J 26568 coolant and battery tester.
24. Detach the vacuum hose form the vacuum gauge assembly.
NOTE: After filling the cooling system, the extraction hose can be used to remove
excess coolant to achieve the proper coolant level.
25. Attach the extraction hose to the vacuum hose.

50
Fig. 19: Attaching Extraction Hose To Vacuum Hose

26. Open the valve on the venturi assembly to start a vacuum draw.

51

27. Use the extraction hose to draw out coolant to the proper level.

52
Fig. 21: Using Extraction Hose To Draw Out Coolant

28. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the
vacuum tank into a suitable container for disposal.
FLUSHING
IMPORTANT: Do not use a chemical flush.
Store used coolant in the proper manner, such as in a used engine coolant holding tank. Do not pour used
coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the
sewer system or ground water. This is illegal and ecologically unsound.
Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a
back flusher, follow the manufacturer's instruction. Always remove the thermostat before flushing the cooling
system.
When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove
the contaminants before the engine is seriously damaged.

53
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
Draining and Filling (Vac N Fill).
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
3. Clean and flush the coolant recovery reservoir with clean, drinkable water.
4. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
5. Follow the drain and fill procedure using only clean, drinkable water. Refer to Cooling System Draining
and Filling (Static Fill), Cooling System Draining and Filling (Vac N Fill).
6. Run the engine for 20 minutes.
7. Stop the engine.
9. Repeat the procedure if necessary, until the fluid is nearly colorless.
10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
RADIATOR CLEANING
WARNING: NEVER spray water on a hot heat exchanger. The resulting steam could
cause personal injury.
CAUTION: The heat exchanger fins are necessary for good heat transfer. Do not
brush the fins. This may cause damage to the fins, reducing heat transfer.
Some conditions may require the use of warm water and a mild detergent.
NOTE: Remove bugs, leaves, dirt and other debris by blowing compressed air
through the engine side of the radiator.
Clean the A/C condenser fins.

Clean between the A/C condenser and radiator.
Clean the radiator cooling fins.
Straighten any damaged cooling fins.
COOLANT RECOVERY RESERVOIR REPLACEMENT

54
Fig. 22: View Of Coolant Recovery Reservoir

Coolant Recovery Reservoir Replacement

Preliminary Procedures
1. Drain the coolant from the recovery reservoir.

2. Remove the front compartment sight shield if necessary. Refer to Front Compartment Front
Sight Shield Replacement (Enclave) , Front Compartment Front Sight Shield Replacement
(Traverse) , Front Compartment Front Sight Shield Replacement (Acadia) .
Coolant Recovery Reservoir Bolt (Qty: 2)
CAUTION:
1
Tighten
5 (44 lb in)
Coolant Recovery Reservoir
2 Procedure
Remove the overflow hose from the reservoir.
RADIATOR INLET HOSE REPLACEMENT

55
Fig. 23: Identifying Radiator Inlet Hose

Radiator Inlet Hose Replacement

1. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
2. Remove the front compartment sight shield. Refer to Front Compartment Front Sight Shield
Replacement (Enclave) , Front Compartment Front Sight Shield Replacement (Traverse) ,
Front Compartment Front Sight Shield Replacement (Acadia) .
Radiator Inlet Hose Clamp (Qty: 2)
Procedure
Using J 38185 hose clamp pliers reposition the radiator inlet hose clamps.
1
Special Tools
J 38185 Hose Clamp Pliers
For equivalent regional tools, refer to Special Tools.
2 Radiator Inlet Hose
RADIATOR OUTLET HOSE REPLACEMENT

56
Fig. 24: Identifying Radiator Outlet Hose

Radiator Outlet Hose Replacement

2. Remove the front compartment sight shield. Refer to Front Compartment Front Sight Shield
Replacement (Enclave) , Front Compartment Front Sight Shield Replacement (Traverse) ,
Front Compartment Front Sight Shield Replacement (Acadia) .
Radiator Outlet Hose Clamp (Qty: 2)
Procedure
Using J 38185 hose clamp pliers reposition the radiator outlet hose clamps.
1
Special Tools
J 38185 Hose Clamp Pliers
For equivalent regional tools, refer to Special Tools.
2 Radiator Outlet Hose
ENGINE OIL COOLER CONNECTOR REPLACEMENT

57
Fig. 25: View Of Engine Oil Cooler Connector

Engine Oil Cooler Connector Replacement

1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
System Draining and Filling (Vac N Fill).
2. Remove the engine oil cooler pipe from the oil cooler fittings on the radiator. Refer to Engine Oil
Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection.
Engine Oil Cooler Fitting
CAUTION:
1 Procedure
Remove the plastic caps from the quick connect fittings by pulling the caps back along the
pipe before installation.
Do not remove the upper and lower engine oil cooler fittings from the radiator at the
same time, otherwise the engine oil cooler may fall inside the radiator end tank.
The correct thread engagement is critical. Cross-threaded fittings can achieve proper

58
tightness and still leak.
Tighten
24 N.m (18 lb ft)
ENGINE OIL COOLER HOSE/PIPE QUICK-CONNECT FITTING DISCONNECTION AND

CONNECTION
Special Tools
DT-47731 1/2 in. Cooler Line Quick Release Tool

J 28585 Universal Snap Ring Remover for the 5/8 in. Cooler Line
Removal Procedure

1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before
installation.
2. Install the DT-47731 1/2 in. cooler line quick release tool onto the transmission oil cooler (TOC) pipe or
use the J 28585 universal snap ring remover for the 5/8 in. cooler line.

59
Fig. 26: View Of J 41623-B & Generator Cooling Inlet Pipe

3. Slide the DT-47731 1/2 in. cooler line quick release tool toward the TOC pipe fitting or use the J 28585
universal snap ring remover for the 5/8 in. cooler line.

60
Fig. 27: Sliding J 41623-B Toward Generator Cooling Inlet Pipe Fitting
4. Connect the DT-47731 1/2 in. cooler line quick release tool onto the TOC pipe fitting.

61
Fig. 28: Rotating Quick-Connect On Coolant Pipe

NOTE: Rotate the DT-47731 1/2 in. cooler line quick release tool to engage the
TOC pipe fitting's retainer slots. The DT-47731 1/2 in. cooler line quick
release tool should be nearly flush with the fitting.
5. Rotate the DT-47731 1/2 in. cooler line quick release tool or use the J 28585 universal snap ring remover
for the 5/8 in. cooler line until the retainer clip (1) rises above the fitting retainer seat.

62
Fig. 29: Rotating Quick-Connect Until Retainer Clip Rises Above Fitting Retainer Seat
6. Pull back on the TOC pipe to disengage the pipe from the TOC pipe fitting.

63
Fig. 30: View Of J 41623-B & Generator Cooling Inlet Pipe

7. Remove the DT-47731 1/2 in. cooler line quick release tool or the J 28585 universal snap ring remover
for the 5/8 in. cooler line from the TOC pipe.
1. Install the TOC pipe into the TOC pipe fitting.

64
Fig. 31: View Of Generator Cooling Inlet Pipe & Generator Cooling Inlet Pipe Fitting
NOTE: Discard the TOC retaining clip and install a new retaining clip.
A distinct snap should be heard or felt when assembling the TOC pipe to the fitting.
2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull.
COOLING FAN AND SHROUD REPLACEMENT

65
Fig. 32: View Of Cooling Fan & Shroud

Cooling Fan and Shroud Replacement

1. Remove front bumper impact bar. Refer to Front Bumper Impact Bar Replacement (Acadia) .
2. Remove radiator inlet hose at radiator. Refer to Radiator Inlet Hose Replacement.
3. Disconnect electrical connector at fan shroud harness.
4. Remove front fascia upper support. Refer to Front Bumper Fascia Upper Support Replacement
(Acadia, Enclave, Traverse) .
5. Remove hood latch. Refer to Hood Primary and Secondary Latch Replacement .
6. Remove upper radiator mounting brackets and tip radiator forward for additional clearance.
Fan Shroud Mounting Bolt (Qty: 2)
CAUTION:
1
Procedure
Remove small pushpin retainers.
Tighten

66
10 N.m (89 lb in)

Fan Shroud
Procedure
2
Tilt fan shroud rearward and upward to remove.
TIP: Reposition of radiator hoses my be necessary for removal.
ENGINE COOLANT THERMOSTAT REPLACEMENT
Fig. 33: View Of Thermostat Housing & Components

Engine Coolant Thermostat Replacement

1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill),
Cooling System Draining and Filling (Vac N Fill).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement .
4. Disconnect the radiator outlet hose from the thermostat housing. Refer to Radiator Outlet Hose
Replacement.
5. Remove the heater inlet and outlet hoses. Refer to Heater Inlet Hose Replacement and Heater
Outlet Hose Replacement .

67
Thermostat Housing Bolt (Qty: 3)
CAUTION:
1
Procedure
Remove the thermostat housing bolts.
Tighten
10 N.m (89 lb in)
Thermostat Housing Retainer Bolt
Procedure
2 Remove the thermostat housing retainer bolt.
Tighten
50 N.m (37 lb ft)
3 Thermostat Housing
Thermostat
Procedure
4
1. Remove the thermostat and discard the thermostat gasket.
2. Install a new thermostat gasket.
WATER OUTLET REPLACEMENT

68
Fig. 34: Identifying Water Outlet Housing

Water Outlet Replacement

1. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
2. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket
Replacement - Right Side .
Water Outlet Housing Bolt (Qty: 2)
CAUTION:
1
Procedure
Remove the water outlet housing bolts.
Tighten
10 N.m (89 lb in)
2 Water Outlet Housing
Seal
Procedure

69
1. Remove the water outlet housing seal. Discard the seal.

3
2. Install a new water outlet housing seal.
WATER PUMP REPLACEMENT
Special Tools
EN 46104 Water Pump Pulley Holding Tool
Removal Procedure
2. Remove the drive belt. Refer to Drive Belt Replacement .
3. Remove the right engine strut mount. Refer to Engine Mount Strut Replacement - Right Side .
4. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement -
Right Side .
5. Use the EN 46104 tool in order to retain the water pump pulley.

70
Fig. 35: View Of EN 46104 Installed On Water Pump Pulley

6. Remove the water pump pulley bolts.
Fig. 36: Locating Water Pump Pulley & Bolts

7. Remove the water pump pulley.

8. Remove the water pump bolts and DISCARD the bolts.

71
Fig. 37: Identifying Water Pump Components

9. Remove the water pump.

10. Remove and DISCARD the water pump seal.
11. Carefully clean the water pump sealing surfaces.
1. Install a NEW water pump seal.

72
Fig. 38: Identifying Water Pump Components

2. Install the water pump.

3. Install the NEW water pump bolts and hand tighten the water pump bolts.
CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.

Install a NEW torque-to-yield or single use fastener when installing
this component. Failure to replace the torque-to-yield or single use
fastener could cause damage to the vehicle or component.
4. Tighten the water pump bolts in sequence.

73
Fig. 39: Water Pump Bolts Tightening Sequence

1. On the initial pass, tighten the bolts in sequence to 10 (89 lb in).

2. On the second pass, tighten the bolts in sequence to 10 (89 lb in).
3. On the final pass, tighten the bolts in sequence shown an additional 45°.
5. Install the water pump pulley bolts.

74
Fig. 40: Locating Water Pump Pulley & Bolts

6. Use the EN 46104 tool in order to retain the water pump pulley.

75
Fig. 41: View Of EN 46104 Installed On Water Pump Pulley

7. Install the water pump pulley bolts and tighten to 10 (89 lb in).
8. Install the right engine strut mount. Refer to Engine Mount Strut Replacement - Right Side .
9. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right
Side .
10. Install the drive belt. Refer to Drive Belt Replacement .
11. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
RADIATOR REPLACEMENT

76
Fig. 42: Identifying Radiator

Radiator Replacement
2. Remove radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
3. Remove radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
4. Remove fan shroud top mounting bolts and pushpin from radiator and position fan shroud
rearward. Refer to Cooling Fan and Shroud Replacement.
5. Remove transmission inlet cooling hose from radiator. Refer to Fluid Cooler Inlet Hose
Replacement .
6. Remove transmission outlet cooling hose from radiator. Refer to Fluid Cooler Outlet Hose
Replacement .
7. Remove coolant reservoir hose from radiator filler neck.
8. Remove the front bumper fascia upper support. Refer to Front Bumper Fascia Upper Support
Replacement (Acadia, Enclave, Traverse) .
9. Pinch fastening tabs together at top of condenser to remove from radiator and position forward.
10. Remove side rubber air deflectors from radiator tanks.
Radiator Mounting Bolt (Qty: 2)

77
CAUTION:
1
Tighten
10 N.m (89 lb in)
Radiator
2 NOTE:
Bottom of condenser mounts into holding fixtures at bottom of radiator.
Radiator will slide out between the condenser and fan shroud.
RADIATOR AIR SIDE BAFFLE AND DEFLECTOR REPLACEMENT

Fig. 43: Radiator Air Side Baffle And Deflector

Radiator Air Side Baffle and Deflector Replacement

1. Remove the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement
(Acadia) .

78
2. Reposition the power steering fluid cooler without disconnecting the lines. Refer to Power
Steering Fluid Cooler Replacement .
1 Radiator Air Side Baffle and Deflector Retainer (Qty: 6)
2 Radiator Air Side Baffle and Deflector Retainer (Qty: 4)
Radiator Air Side Baffle and Deflector
Procedure
3
Pull the sides of the radiator air side baffle and deflector away from the radiator and lower
to remove.
COOLANT HEATER REPLACEMENT
Fig. 44: View Of Coolant Heater

Coolant Heater Replacement

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Coolant Heater
1
Procedure
1. Disconnect the coolant heater cord from the coolant heater.

79
2. Remove the coolant heater.
COOLANT HEATER CORD REPLACEMENT
Removal Procedure
Fig. 45: Identifying Coolant Heater Cord Clips & Coolant Heater
2. Disconnect the coolant heater power supply cord from the coolant heater.
4. Disconnect the coolant heater cord clips (3) from the cylinder heads.
5. Disconnect the coolant heater cord clip from the engine wiring harness.

80
Fig. 46: Identifying Coolant Heater Cord

6. Remove the coolant heater cord (1) from the vehicle.
1. Position the coolant heater cord (1) to the engine harness.

81
Fig. 47: Identifying Coolant Heater Cord

2. Connect the coolant heater cord clip to the engine wiring harness.
3. Connect the coolant heater cord clips (3) to the cylinder heads.

82
Fig. 48: Identifying Coolant Heater Cord Clips & Coolant Heater
5. Connect the coolant heater cord to the coolant heater.
DESCRIPTION AND OPERATION

COOLING FAN DESCRIPTION AND OPERATION

83
Fig. 49: Cooling Fan Description and Operation

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in
series/parallel (S/P) configuration that allows the engine control module (ECM) to operate both fans together at
low or high speeds. The cooling fans receive positive voltage from the cooling fan relays which receive battery
positive voltage from the underhood fuse block.
During low speed operation, the ECM supplies the ground path for the low speed fan 1 relay through the fan 1
relay control circuit. This energizes the fan 1 relay coil, closes the relay contacts and supplies battery positive
voltage from the Fan 1 fuse through the cooling fan motor supply voltage circuit to the left engine cooling fan.
The ground path for the left cooling fan is through the S/P fan 2 relay and the right engine cooling fan. The
result is a series circuit with both fans running at low speed.
During high speed operation the ECM continues to supply battery positive voltage for the right cooling fan by
grounding the coil of the fan 1 relay. The ECM also grounds the high speed fan 3 relay and the S/P fan 2 relay
through the fan 3 relay control circuit. This energizes the S/P fan 2 relay coil, closes the relay contacts and
provides a direct ground path for the left engine cooling fan. At the same time the fan 3 relay coil is energized
closing the relay contacts and providing battery positive voltage from the Fan 2 fuse on the cooling fan motor
supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have
their own ground path. The result is a parallel circuit with both fans running at high speed.
COOLING SYSTEM DESCRIPTION AND OPERATION
The cooling systems function is to maintain an efficient engine operating temperature during all engine speeds
and operating conditions. The cooling system is designed to remove approximately one-third of the heat

84
produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the
radiator until the thermostat opens. This allows the engine to warm quickly.
Cooling Cycle
Coolant is drawn from the radiator outlet to the thermostat. The flow of coolant will be stopped at the
thermostat until the engine is warmed; while the thermostat is closed the water pump circulates coolant through
the engine block and heater core. Coolant is returned to the water pump through the engine bypass and the
heater core outlet hose. This provides the passenger compartment with heat and defrost.
After the thermostat opens, the coolant is pumped through the water pump outlet and into the engine block and
heater core. In the engine block, the coolant circulates through the water jackets surrounding the cylinders
where it absorbs heat.
The coolant is then forced through the cylinder head gasket openings and into the cylinder heads. In the cylinder
heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where
it absorbs additional heat.
From the cylinder heads, the coolant is then forced into the radiator where it is cooled and the coolant cycle is
completed.
Operation of the cooling system requires proper functioning of all cooling system components. The cooling
system consists of the following components:
Coolant
The engine coolant is a solution made up of a 50/50 mixture of DEX-COOL® and suitable drinking water. The
coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the
atmosphere.
Radiator
The radiator is a heat exchanger consisting of a core and 2 tanks. The aluminum core is a tube and fin crossflow
design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to
improve heat transfer to the atmosphere.
The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature
rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch
tabs. The tabs are part of the aluminum header at each end of the core.
Heat is removed from the coolant as the coolant passes through the radiator. The fins on the core transfer heat
from the coolant passing through the tubes. Air passing between the fins absorbs the heat and cools the coolant.
Pressure Cap
The pressure cap seals and pressurizes the cooling system. The cap contains a blow off or pressure valve and a
vacuum or an atmospheric valve:

85
The pressure valve is held against the seat by a spring that protects the radiator by relieving pressure that
exceeds 15 psi.
The vacuum valve is held against the seat by a spring that permits opening of the valve to relieve vacuum
created when the cooling system cools. The vacuum, if not relieved, might cause the radiator to collapse.
The pressure cap allows the cooling system pressure to build up when the temperature increases. As the
pressure builds, the boiling point of the coolant increases. Therefore, the engine coolant can be safely run at a
temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant
becomes, the faster the heat transfers from the radiator into the cooler air.
The pressure in the cooling system can get too high. When the pressure exceeds the strength of the spring, the
pressure valve rises, venting the excess pressure.
As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This
vacuum causes the vacuum valve to open. This equalizes the pressure in the cooling system with the
atmospheric pressure, preventing the radiator from collapsing.
Coolant Recovery System
The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery
reservoir is also called a recovery tank or expansion tank. This tank is partially filled with coolant and is
connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator
and the reservoir.
In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure within the
cooling system gets too high, the pressure valve in the pressure cap will open. This allows the coolant, which
has expanded due to heat, to flow through the overflow tube and into the recovery reservoir. As the engine cool
down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens
the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the
radiator. Under normal operating conditions, no coolant is lost. Although the coolant level in the recovery
reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant
recovery reservoir is the elimination of almost all air bubbles from the cooling system. Coolant without bubbles
absorbs heat much better than coolant with bubbles.
Air Baffles and Seals
The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are
installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine
cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals
prevent air from bypassing the radiator and A/C condenser and prevent recirculation of hot air for better hot
weather cooling and A/C condenser performance.
Transmission Oil Cooler
The transmission oil cooler is a heat exchanger that is located inside one of the radiator end tanks. The
transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator. The oil
pump pumps the fluid through the transmission oil cooler feed line to the oil cooler. The fluid flows through the

86
cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the oil cooler
return line back to the transmission.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Illustration Tool Number/Description
GE-47716
Vac N Fill Coolant Refill Tool

EN-24460-A
J-24460-01
Cooling System Pressure Tester
GE-24731
J-24731
Tempilstick

87
GE-26568
J-26568
Coolant and Battery Fluid Tester

DT-28585
J-28585
Universal Snap Ring Remover
EL-35616-F
Connector Test Adapter Kit
BO-38185
J-38185
Hose Clamp Pliers

88

GE-42220
J-42220
Universal 12V Leak Detection Lamp
GE-42401-A
J-42401
Radiator Cap and Surge Tank Test Adapter
EN-46104
J-46104
Water Pump Pulley Holding Tool

89
DT-47731
Cooler Line Quick Release Tool

90
ENGINE PERFORMANCE Firing Order & Cylinder Identification - GM, & Saturn - All Models
ENGINE PERFORMANCE
Firing Order & Cylinder Identification - GM, & Saturn - All Models
FIRING ORDER & CYLINDER IDENTIFICATION
NOTE: This information is intended as a quick reference for firing order and cylinder
identification only. The information provided covers many vehicles and may
include some information that does not apply to the vehicle you have currently
selected.
3 CYLINDER ENGINE
Engine Configuration Firing Order Cylinder Identification
In-Line 3 1-3-2
4 CYLINDER ENGINE
In-Line 4 1-3-4-2
5 CYLINDER ENGINE
Sunday, April 10, 2016 1:40:30

1:40:28 PM Page 1
1
In-Line 5 1-3-5-4-2
IN-LINE 6 ENGINE
In-Line 6 1-5-3-6-2-4
V6 ENGINE
2.5L V6 Engine - Tracker
2.5L Tracker 1-2-3-4-5-6

2
3.5L VIN 4 V6 Engine

3.5L VIN 4 1-4-2-5-3-6
3.8L & 4.3L V6 Engines
3.8L & 4.3L 1-6-5-4-3-2
All Other V6 Engines

3
All Others 1-2-3-4-5-6

8 CYLINDER ENGINE
4.0L, 4.4L & 4.6L V8 Engines
4.0L, 4.4L, 4.6L 1-2-7-3-4-5-6-8
5.0L, 5.7L (VIN R & VIN K) & 7.4L V8 Engines

4
5.0L, 5.7L (VIN R & K), 7.4L 1-8-4-3-6-5-7-2
6.6L Diesel V8 Engine
6.6L Diesel 1-2-7-8-4-5-6-3
All Other V8 Engines

5
All Others 1-8-7-2-6-5-4-3

6
GENERAL INFORMATION Engine Overhaul Procedures
GENERAL INFORMATION
Engine Overhaul Procedures
* PLEASE READ THIS FIRST *
NOTE: Examples used in this article are general in nature and do not necessarily relate
to a specific engine or system. Illustrations and procedures have been chosen
to guide mechanic through engine overhaul process. Descriptions of processes
of cleaning, inspection, assembly and machine shop practice are included.
Always refer to appropriate engine overhaul article, if available, in the ENGINES

section for complete overhaul procedures and specifications for the vehicle
being repaired.
DESCRIPTION
Examples used in this article are general in nature and do not necessarily relate to a specific engine or system.
Illustrations and procedures have been chosen to guide mechanic through engine overhaul process. Description
of cleaning, inspection, and assembly processes are included.
ENGINE IDENTIFICATION
Engine may be identified from Vehicle Identification Number (VIN) stamped on a metal tab. Metal tab may be
located in different locations depending on manufacturer. Engine identification number or serial number is
located on cylinder block. Location varies with each manufacturer.
INSPECTION PROCEDURES

being repaired.
GENERAL
Sunday, April 10, 2016 1:49:20

1:49:18 PM Page 1
1


being repaired.
Engine components must be inspected to meet manufacturer's specifications and tolerances during overhaul.
Proper dimensions and tolerances must be met to obtain proper performance and maximum engine life.
Micrometers, depth gauges and dial indicator are used for checking tolerances during engine overhaul.
Magnaflux, Magnaglo, dye-check, ultrasonic and x-ray inspection procedures are used for parts inspection.
MAGNETIC PARTICLE INSPECTION

being repaired.
Magnaflux & Magnaglo
Magnaflux is an inspection technique used to locate material flaws and stress cracks. Component is subjected t
a strong magnetic field. Entire component or a localized area can be magnetized. Component is coated with
either a wet or dry material that contains fine magnetic particles.
Cracks which are outlined by the particles cause an interruption of magnetic field. Dry powder method of
Magnaflux can be used in normal lighting and crack appears as a bright line.
Fluorescent liquid is used along with a Black light in the Magnaglo Magnaflux system. Darkened room is
required for this procedure. The crack will appear as a glowing line. Complete demagnetizing of component
upon completion is required on both procedures. Magnetic particle inspection applies to ferrous materials only.
PENETRANT INSPECTION


2
being repaired.
Zyglo
The Zyglo process coats material with a fluorescent dye penetrant. Component is often warmed to expand
cracks that will be penetrated by the dye. Using darkened room and Black light, component is inspected for
cracks. Crack will glow brightly.
Developing solution is often used to enhance results. Parts made of any material, such as aluminum cylinder
heads or plastics, may be tested using this process.
Dye Check
Penetrating dye is sprayed on the previously cleaned component. Dye is left on component for 5-45 minutes,
depending upon material density. Component is then wiped clean and sprayed with a developing solution.
Surface cracks will show up as a bright line.

ULTRASONIC INSPECTION

being repaired.
If an expensive part is suspected of internal cracking, ultrasonic testing is used. Sound waves are used for
component inspection.
X-RAY INSPECTION

being repaired.
This form of inspection is used on highly stressed components. X-ray inspection may be used to detect internal
and external flaws in any material.
PRESSURE TESTING

3

being repaired.
Cylinder heads can be tested for cracks using a pressure tester. Pressure testing is performed by plugging all but
one of the holes of cylinder head and injecting air or water into the open passage.
Leaks are indicated by the appearance of wet or damp areas when using water. When air is used, it is necessary
to spray the head surface with a soap solution. Bubbles will indicate a leak. Cylinder head may also be
submerged in water heated to specified temperature to check for cracks created during heat expansion.

CLEANING PROCEDURES

being repaired.
GENERAL

being repaired.
All components of an engine do not have the same cleaning requirements. Physical methods include bead
blasting and manual removal. Chemical methods include solvent blast, solvent tank, hot tank, cold tank and
steam cleaning of components.
BEAD BLASTING

4

being repaired.
Manual removal of deposits may be required prior to bead blasting, followed by some other cleaning method.
Carbon, paint and rust may be removed using bead blasting method. Components must be free of oil and grease
prior to bead blasting. Beads will stick to grease or oil soaked areas causing area not to be cleaned.
Use air pressure to remove all trapped residual beads from component after cleaning. After cleaning internal
engine parts made of aluminum, wash thoroughly with hot soapy water. Component must be thoroughly cleaned
as glass beads will enter engine oil resulting in bearing damage.

CHEMICAL CLEANING

being repaired.
Solvent tank is used for cleaning oily residue from components. Solvent blasting sprays solvent through a
siphon gun using compressed air.
The hot tank, using heated caustic solvents, is used for cleaning ferrous materials only. DO NOT clean
aluminum parts such as cylinder heads, bearings or other soft metals using the hot tank. After cleaning, flush
parts with hot water.
A non-ferrous part will be ruined and caustic solution will be diluted if placed in the hot tank. Always use eye
protection and gloves when using the hot tank.
Use of a cold tank is for cleaning aluminum cylinder heads, carburetors and other soft metals. A less caustic and
unheated solution is used. Parts may be left in the tank for several hours without damage. After cleaning, flush
parts with hot water.
Steam cleaning, with boiling hot water sprayed at high pressure, is recommended as the final cleaning process
when using either hot or cold tank cleaning.
COMPONENT CLEANING

5

being repaired.
SHEET METAL PARTS

being repaired.
Examples of sheet metal parts are rocker covers, front and side covers, oil pan and bellhousing dust cover. Glas
bead blasting or hot tank may be used for cleaning.
Ensure all mating surfaces are flat. Deformed surfaces should be straightened. Check all sheet metal parts for
cracks and dents.
INTAKE & EXHAUST MANIFOLDS

being repaired.
Using solvent cleaning or bead blasting, clean manifolds for inspection. If intake manifold has an exhaust
crossover, all carbon deposits must be removed. Inspect manifolds for cracks, burned or eroded areas, corrosion
and damage to fasteners.
Exhaust heat and products of combustion cause threads of fasteners to corrode. Replace studs and bolts as
necessary. On "V" type intake manifolds, sheet metal oil shield must be removed for proper cleaning and
inspection. Ensure all manifold parting surfaces are flat and free of burrs.

6
CYLINDER HEAD REPLACEMENT


being repaired.
REMOVAL

being repaired.
Remove intake and exhaust manifolds and valve cover. Cylinder head and camshaft carrier bolts (if equipped)
should be removed only when engine is cold. On many aluminum cylinder heads, removal while hot will cause
cylinder head warpage. Mark rocker arm or overhead cam components for location.
Remove rocker arm components or overhead cam components. Components must be installed in original
location. Individual design rocker arms may utilize shafts, ball-type pedestal mounts or no rocker arms. For all
design types, wire components together and identify according to corresponding valve. Remove cylinder head
bolts. Note length and location. Some applications require cylinder head bolts be removed in proper sequence to
prevent cylinder head damage. See Fig. 1. Remove cylinder head.
INSTALLATION

being repaired.

7
Ensure all surfaces and head bolts are clean. Check that head bolt holes of cylinder block are clean and dry to
prevent block damage when bolts are tightened. Clean threads with tap to ensure accurate bolt torque.
Install head gasket on cylinder block. Some manufacturers may recommend sealant be applied to head gasket
prior to installation. Note that all holes are aligned. Some gasket applications may be marked so that certain area
faces upward. Install cylinder head using care not to damage head gasket. Ensure cylinder head is fully seated
on cylinder block.
Some applications require head bolts be coated with sealant prior to installation. This is done if head bolts are
exposed to coolant passages. Some applications require head bolts be coated with light coat of engine oil.
Install head bolts. Head bolts should be tightened in proper steps and sequence to specification. See Fig. 1.
Install remaining components. Tighten all bolts to specification. Adjust valves if required. See VALVE
ADJUSTMENT.
NOTE: Some manufacturers require that head bolts be retightened after specified

amount of operation. This must be done to prevent head gasket failure.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
VALVE ADJUSTMENT

8
being repaired.
Engine specifications will indicate valve train clearance and temperature at which adjustment is to be made on
most models. In most cases, adjustment will be made with a cold engine. In some cases, both a cold and a hot
clearance will be given for maintenance convenience.
On some models, adjustment is not required. Rocker arms are tightened to specification and valve lash is
automatically set. On some models with push rod actuated valve train, adjustment is made at push rod end of
rocker arm while other models do not require adjustment.
Clearance will be checked between tip of rocker arm and tip of valve stem in proper sequence using a feeler
gauge. Adjustment is made by rotating adjusting screw until proper clearance is obtained. Lock nut is then
tightened. Engine will be rotated to obtain all valve adjustments to manufacturer's specifications.
Some models require hydraulic lifter to be bled down and clearance measured. Push rods of different length ca
be used to obtain proper clearance. Clearance will be checked between tip of rocker arm and tip of valve stem i
proper sequence using a feeler gauge.
Overhead cam engines designed without rocker arms actuate valves directly on a cam follower. A hardened,
removable disc is installed between the cam lobe and lifter. Clearance will be checked between cam heel and
adjusting disc in proper sequence using a feeler gauge. Engine will be rotated to obtain all valve adjustments.
On overhead cam engines designed with rocker arms, adjustment is made at valve end of rocker arm. Ensure
valve to be adjusted is riding on heel of cam on all engines. Clearance will be checked between tip of rocker
arm and tip of valve stem in proper sequence using a feeler gauge. Adjustment is made by rotating adjusting
screw until proper clearance is obtained. Lock nut is then tightened. Engine will be rotated to obtain all valve
adjustments to manufacturer's specifications.
CYLINDER HEAD OVERHAUL


being repaired.
CYLINDER HEAD DISASSEMBLY

9


being repaired.
Mark valves for location. Using valve spring compressor, compress valve springs. Remove valve locks.
Carefully release spring compressor. Remove retainer or rotator, valve spring, spring seat and valve. See Fig. 2.
Fig. 2: Exploded View of Valve Assemblies
CYLINDER HEAD CLEANING & INSPECTION


10
being repaired.
Clean cylinder head and valve components using approved cleaning methods. Inspect cylinder head for cracks,
damage or warped gasket surface. Place straightedge across gasket surface. Determine clearance at center of
straightedge. Measure across both diagonals, longitudinal center line and across cylinder head at several points.
See Fig. 3.
On cast iron cylinder heads, if warpage exceeds .003" (.08 mm) in a 6" span, or .006" (.15 mm) over total
length, cylinder head must be resurfaced. On most aluminum cylinder heads, if warpage exceeds .002" (.05
mm) in any area, cylinder head must be resurfaced. Warpage specification may vary by manufacturer. If
warpage exceeds specification on some cylinder heads, cylinder head must be replaced.
Cylinder head thickness should be measured to determine amount of material which can be removed before
replacement is required. Cylinder head thickness must not be less than the manufacturer's specification.
If cylinder head required resurfacing, it may not align properly with intake manifold. On "V" type engines,
misalignment is corrected by machining intake manifold surface that contacts cylinder head. Cylinder head ma
be machined on surface that contacts intake manifold. Using oil stone, remove burrs or scratches from all
sealing surfaces.
Fig. 3: Checking Cylinder Head for Warpage
VALVE SPRINGS

11

being repaired.
Inspect valve springs for corroded or pitted valve spring surfaces which may lead to breakage. Polished spring
ends caused by a rotating spring indicate that spring surge has occurred. Replace springs showing evidence of
these conditions.
Inspect valve springs for squareness using a 90-degree straightedge. See Fig. 4. Replace valve spring if out-of-
square exceeds manufacturer's specification.

Fig. 4: Checking Valve Spring Squareness
Using vernier caliper, measure free length of all valve springs. Replace springs if not within specification.
Using valve spring tester, test valve spring pressure at installed and compressed heights. See Fig. 5.
Usually compressed height is installed height minus valve lift. Replace valve spring if not within specification.

12
It is recommended to replace all valve springs when overhauling cylinder head. Valve springs may need to be
installed with color coded end or small coils at specified area according to manufacturer.
Fig. 5: Checking Valve Spring Pressure
VALVE GUIDE

being repaired.

13
Measuring Valve Guide Clearance
Check valve stem-to-guide clearance. Ensure valve stem diameter is within specification. Install valve in valve
guide. Install dial indicator assembly on cylinder head with tip resting against valve stem just above valve
guide. See Fig. 6.
Fig. 6: Measuring Valve Stem-to-Guide Clearance
Lower valve approximately 1/16" below valve seat. Push valve stem against valve guide as far as possible.
Adjust dial indicator to zero. Push valve stem in opposite direction and note reading. Clearance must be within
specification.

14
If valve guide clearance exceeds specification, valves with oversize stems may be used and valve guides are
reamed to larger size or valve guide must be replaced. On some applications, a false guide is installed, then
reamed to proper specification. Valve guide reamer set is used to ream valve guide to obtain proper clearance
for new valve.
Reaming Valve Guide
Select proper reamer for size of valve stem. Reamer must be of proper length to provide clean cut through entire
length of valve guide. Install reamer in valve guide and rotate to cut valve guide. See Fig. 7.

15
Fig. 7: Reaming Valve Guides

16
Replacing Valve Guide
Replace valve guide if clearance exceeds specification. Valve guides are either pressed, hammered or shrunk in
place, depending upon cylinder head design and type of metal used.
Remove valve guide from cylinder head by pressing or tapping on a stepped drift. See Fig. 8. Once valve guide
is installed, distance from cylinder head to top of valve guide must be checked. This distance must be within
specification.
Aluminum heads are often heated before installing valve guide. Valve guide is sometimes cooled in dry ice
prior to installation. Combination of a heated cylinder head and cooled valve guide ensures a tight guide fit
upon assembly. The new guide must be reamed to specification.
Fig. 8: Typical Valve Guide Remover & Installer
VALVES & VALVE SEATS

being repaired.
Valve Grinding
Valve stem O.D. should be measured in several areas to indicate amount of wear. Replace valve if not within
specification. Valve margin area should be measured to ensure that valve can be ground. See Fig. 9.
If valve margin is less than specification, the valves will be burned. Valve must be replaced. Due to minimum
margin dimensions during manufacture, some new type valves cannot be reground. Some manufacturers use
stellite coated valves that must NOT be machined. Valves can only be lapped into valve seat.

17
CAUTION: Some valves are sodium filled. Extreme care must be used when
disposing of damaged or worn sodium-filled valves.
Fig. 9: Measuring Valve Head Margin
Resurface valve to proper angle specification using valve grinding machine. Follow manufacturer's instructions
for valve grinding machine. Specifications may indicate a different valve face angle than seat angle. Measure
valve margin after grinding. Replace valve if not within specification. Valve stem tip can be refinished using
valve grinding machine.
Valve Lapping
During valve lapping of recently designed valves, be sure to follow manufacturer's recommendations. Surface
hardening and materials used with some valves do not permit lapping. Lapping process will remove excessive
amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between valve face and seat. Use either a hand drill or lapping
stick with suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem and guide. Apply a thin coat of fine valve
grinding compound between valve and seat. Rotate lapping tool between the palms or with hand drill.
Lift valve upward off the seat and change position often. This is done to prevent grooving of valve seat. Lap
valve until a smooth polished seat is obtained. Thoroughly clean grinding compound from components. Valve-
to-valve seat concentricity should be checked. See VALVE SEAT CONCENTRICITY.

18
CAUTION: Valve guides must be in good condition and free of carbon deposits prior
to valve seat grinding. Some engines contain an induction hardened valve
seat. Excessive material removal will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be ground. Ensure stone is true and has a smooth
surface. Select correct size pilot for valve guide dimension. Install pilot in valve guide. Lightly lubricate pilot
shaft. Install stone on pilot. Move stone off and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Various angle grinding stones are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out the old insert and machining an oversize insert bore.
Replacement oversize insert is usually cooled and the cylinder head is sometimes warmed. Valve seat is pressed

19
into the head. This operation requires specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide. Position gauge arm on the valve seat. Adjust dial indicator
to zero. Rotate arm 360 degrees and note reading. Runout should not exceed specification.
To check valve-to-valve seat concentricity, coat valve face lightly with Prussian Blue dye. Install valve and
rotate it on valve seat. If pattern is even and entire seat is coated at valve contact point, valve is concentric with
the valve seat.
CYLINDER HEAD REASSEMBLY


being repaired.
Valve Stem Installed Height
Valve stem installed height must be checked when new valves are installed or when valves or valve seats have
been ground. Install valve in valve guide. Measure distance from tip of valve stem to spring seat. See Fig. 11.
Distance must be within specification to allow sufficient clearance for valve operation.
Remove valve and grind valve stem tip if height exceeds specification. Valve tips are surface hardened. DO
NOT remove more than .010" (.25 mm) from tip. Chamfer sharp edge of reground valve tip. Recheck valve
stem installed height.

20
Fig. 11: Measuring Valve Stem Installed Height
VALVE STEM OIL SEALS

being repaired.
Valve stem oil seals must be installed on valve stem. See Fig. 2. Seals are needed due to pressure differential at
the ends of valve guides. Atmospheric pressure above intake guide, combined with manifold vacuum below
guide, causes oil to be drawn into the cylinder.
Exhaust guides also have pressure differential created by exhaust gas flowing past the guide, creating a low
pressure area. This low pressure area draws oil into the exhaust system.
Some manufacturers require that special color code or specified height valve stem oil seal be installed in

21
designated area.
Replacement (On-Vehicle)
Mark rocker arm or overhead cam components for location. Remove rocker arm components or overhead cam
components. Components must be installed in original location. Remove spark plugs. Valve stem oil seals may
be replaced by holding valves against seats using air pressure.
Air pressure must be installed in cylinder using an adapter for spark plug hole. An adapter can be constructed by
welding air hose connection to spark plug body with porcelain removed.
Rotate engine until piston is at top of stroke. Install adapter in spark plug hole. Apply a minimum of 140 psi
(9.8 kg/cm2 ) line pressure to adapter. Air pressure should hold valve closed. If air pressure does not hold valve
closed, check for damaged or bent valve. Cylinder head must be removed for service.
Using valve spring compressor, compress valve springs. Remove valve locks. Carefully release spring

compressor. Remove retainer or rotator and valve spring. Remove valve stem oil seal.
If oversize valves have been installed, oversize oil seals must be used. Coat valve stem with engine oil. Install
protective sleeve over end of valve stem. Install new oil seal over valve stem and seat on valve guide. Remove
protective sleeve. Install spring seat, valve spring and retainer or rotator. Compress spring and install valve
locks. Remove spring compressor. Ensure valve locks are fully seated.
Install rocker arms or overhead cam components. Tighten all bolts to specification. Adjust valves if required.
Remove adapter. Install spark plugs, valve cover and gasket.
VALVE SPRING INSTALLED HEIGHT

being repaired.
Valve spring installed height should be checked during reassembly. Measure height from lower edge of valve
spring to the upper edge. DO NOT include valve spring seat or retainer. Distance must be within specification.
If valves and/or seats have been ground, a valve spring shim may be required to correct spring height. See Fig.
12.

22
Fig. 12: Measuring Valve Spring Installed Height
ROCKER ARMS & ASSEMBLIES

being repaired.
Rocker Studs
Rocker studs are either threaded or pressed in place. Threaded studs are removed by locking 2 nuts on the stud.
Unscrew the stud by turning the jam nut. Coat new stud threads with Loctite and install. Tighten to
specification.
Pressed-in stud can be removed using a stud puller. Ream stud bore to proper specification and press in a new
oversize stud. Pressed-in studs are often replaced by cutting threads in the stud bore to accept a threaded stud.
Rocker Arms & Shafts
Mark rocker arms for location. Remove rocker arm retaining bolts. Remove rocker arms. Inspect rocker arms,

23
shafts, bushings and pivot balls (if equipped) for excessive wear. Inspect rocker arms for wear in valve stem
contact area. Measure rocker arm bushing I.D. Replace bushings if excessively worn.
The rocker arm valve stem contact point may be reground, using special fixture for valve grinding machine.
Remove minimum amount of material as possible. Ensure all oil passages are clear. Install rocker arm
components in original location. Ensure rocker arm is properly seated in push rod. Tighten bolts to
specification. Adjust valves if required. See VALVE ADJUSTMENT.
PUSH RODS

being repaired.
Remove rocker arms. Mark push rods for location. Remove push rods. Push rods can be steel or aluminum,
solid or hollow. Hollow push rods must be internally cleaned to ensure oil passage to rocker arms is cleaned.
Check push rods for damage, such as loose ends on steel tipped aluminum types.
Check push rod for straightness. Roll push rod on a flat surface. Using feeler gauge, check clearance at center.
Replace push rod if bent. The push rod can also be supported at each end and rotated. A dial indicator is used to
detect a bent area in the push rod.
Lubricate ends of push rod and install push rod in original location. Ensure push rod is properly seated in lifter.
Install rocker arm. Tighten bolts to specification. Adjust valves if required. See VALVE ADJUSTMENT.
LIFTERS

being repaired.
Hydraulic Lifters
Before replacing a hydraulic lifter for noisy operation, ensure noise is not caused by worn rocker arms or valve
tips. Also ensure sufficient oil pressure exists. Hydraulic lifters must be installed in original location. Remove
rocker arm assembly and push rod. Mark components for location. Some applications require intake manifold,

24
cylinder head or lifter cover removal. Remove lifter retainer plate (if used). To remove lifters, use a hydraulic
lifter remover or magnet. Different type lifters are used. See Fig. 13.
On sticking lifters, disassemble and clean lifter. DO NOT mix lifter components or positions. Parts are select-
fitted and are not interchangeable. Inspect all components for wear. Note amount of wear in lifter body-to-
camshaft contact area. Surface must have smooth and convex contact face. If wear is apparent, carefully inspect
cam lobe.
Inspect push rod contact area and lifter body for scoring or signs of wear. If body is scored, inspect lifter bore
for damage and lack of lubrication. On roller type lifters, inspect roller for flaking, pitting, loss of needle
bearings and roughness during rotation.
Measure lifter body O.D. in several areas. Measure lifter bore I.D. Ensure components or oil clearance is within
specification. Some models offer oversize lifters. Replace lifter if damaged.
If lifter check valve is not operating, obstructions may be preventing it from closing or valve spring may be
broken. Clean or replace components as necessary.
Check plunger operation. Plunger should drop to bottom of the body by its own weight when assembled dry. If
plunger is not free, soak lifter in solvent to dissolve deposits.
Lifter leak-down test can be performed on lifter. Lifter must be filled with special test oil. New lifters contain
special test oil. Using lifter leak-down tester, perform leak-down test following manufacturer's instructions. If
leak-down time is not within specifications, replace lifter assembly.
Lifters should be soaked in clean engine oil several hours prior to installation. Coat lifter base, roller (if
equipped) and lifter body with ample amount of Molykote or camshaft lubricant. See Fig. 13. Install lifter in
original location. Install remaining components. Valve lash adjustment is not required on most hydraulic lifters
Preload of hydraulic lifter is automatic. Some models may require adjustment.
NOTE: Some manufacturers require that a crankcase conditioner be added to engine

oil and engine operated for specified amount of time to aid in lifter break-in
procedure if new lifters or camshaft are installed.

25
Fig. 13: Typical Hydraulic Valve Lifter Assemblies
Mechanical Lifters
Lifter assemblies must be installed in original locations. Remove rocker arm assembly and push rod. Mark
components for location. Some applications require intake manifold or lifter cover removal. Remove lifter
retainer plate (if used). To remove lifters, use lifter remover or magnet.

26
Inspect push rod contact area and lifter body for scoring or signs of wear. If body is scored, inspect lifter bore
for damage and lack of lubrication. Note amount of wear in lifter body-to-camshaft contact area. Surface must
have smooth and convex contact face. If wear is apparent, carefully inspect cam lobe.
Coat lifter base, roller (if equipped) and lifter body with ample amount of Molykote or camshaft lubricant.
Install lifter in original location. Install remaining components. Tighten bolts to specification. Adjust valves.
See VALVE ADJUSTMENT.
PISTONS, CONNECTING RODS & BEARINGS


being repaired.
RIDGE REMOVAL

being repaired.
Ridge in cylinder wall must be removed prior to piston removal. Failure to remove ridge prior to removing
pistons will cause piston damage in piston ring lands or grooves.
With piston at bottom dead center, place rag in bore to trap metal chips. Install ridge reamer in cylinder bore.
Adjust ridge reamer using manufacturer's instructions. Remove ridge using ridge reamer. DO NOT remove an
excessive amount of material. Ensure ridge is completely removed.
PISTON & CONNECTING ROD REMOVAL

27

being repaired.
Note top of piston. Some pistons may contain a notch, arrow or be marked FRONT. Piston must be installed in
proper direction to prevent damage with valve operation.
Check that connecting rod and cap are numbered for cylinder location and which side of cylinder block the
number faces. Proper cap and connecting rod must be installed together. Connecting rod cap must be installed
on connecting rod in proper direction to ensure bearing lock procedure. Mark connecting rod and cap if
necessary. Pistons must be installed in original location.
Remove cap retaining nuts or bolts. Remove bearing cap. Install tubing protectors on connecting rod bolts. This
protects cylinder walls from scoring during removal. Ensure proper removal of ridge. Push piston and
connecting rod from cylinder. Connecting rod boss can be tapped with a wooden dowel or hammer handle to
aid in removal.
PISTON & CONNECTING ROD

being repaired.
Disassembly
Using ring expander, remove piston rings. Remove piston pin retaining rings (if equipped). Note direction of
piston installation on connecting rod. On pressed type piston pins, special fixtures and procedures according to
manufacturer must be used to remove piston pins. Follow manufacturer's recommendations to avoid piston
distortion or breakage.
Cleaning
Remove all carbon and varnish from piston. Pistons and connecting rods may be cleaned in cold type chemical
tank. Using ring groove cleaner, clean all deposits from ring grooves. Ensure all deposits are cleaned from ring
grooves to prevent ring breakage or sticking. DO NOT attempt to clean pistons with wire brush.
Inspection
Inspect pistons for nicks, scoring, cracks or damage in ring areas. Connecting rod should be checked for cracks
using Magnaflux procedure. Piston diameter must be measured in manufacturer's specified area.

28
Using telescopic gauge and micrometer, measure piston pin bore of piston in 2 areas, 90 degrees apart. This is
done to check diameter and out-of-round.
Install proper bearing cap on connecting rod. Ensure bearing cap is installed in proper location. Tighten bolts or
nuts to specification. Using inside micrometer, measure inside diameter in 2 areas, 90 degrees apart.
Connecting rod I.D. and out-of-round must be within specification. Measure piston pin bore I.D. and piston pin
O.D. All components must be within specification. Subtract piston pin diameter from piston pin bore in piston
and connecting rod to determine proper fit.
Connecting rod length must be measured from center of crankshaft journal inside diameter to center of piston
pin bushing using proper caliper. Connecting rods must be the same length. Connecting rods should be checked
on an alignment fixture for bent or twisted condition. Replace all components which are damaged or not within
specification.
PISTON & CYLINDER BORE FIT


being repaired.
Ensure cylinder is checked for taper, out-of-round and properly honed prior to checking piston and cylinder
bore fit. See CYLINDER BLOCK. Using dial bore gauge, measure cylinder bore.
Measure piston skirt diameter at 90 degree angle to piston pin at specified area by manufacturer. Subtract pisto
diameter from cylinder bore diameter to determine piston-to-cylinder clearance. Clearance must be within
specification. Mark piston for proper cylinder location.
ASSEMBLING PISTON & CONNECTING ROD

being repaired.
Install piston on connecting rod for corresponding cylinder. Ensure reference marking on top of piston
corresponds with connecting rod and cap number. See Fig. 14.

29
Lubricate piston pin and install in connecting rod. Ensure piston pin retainers are fully seated (if equipped). On
pressed type piston pins, follow manufacturer's recommended procedure to avoid distortion or breakage.
Fig. 14: Installing Typical Piston Pin
CHECKING PISTON RING CLEARANCES

being repaired.
Piston rings must be checked for side clearance and end gap. To check end gap, install piston ring in cylinder in
which it is to be installed. Using an inverted piston, push ring to bottom of cylinder in smallest cylinder

30
diameter.
Using feeler gauge, check ring end gap. See Fig. 15. Piston ring end gap must be within specification. Ring
breakage will occur if insufficient ring end gap exists.
Some manufacturers permit correcting insufficient ring end gap by using a fine file while other manufacturers
recommend using another ring set. Mark rings for proper cylinder installation after checking end gap.
Fig. 15: Checking Piston Ring End Gap
For checking side clearance, install rings on piston. Using feeler gauge, measure clearance between piston ring
and piston ring land. Check side clearance in several areas around piston. Side clearance must be within
specification.
If side clearance is excessive, piston ring grooves can be machined to accept oversize piston rings (if available).
Normal practice is to replace piston.
PISTON & CONNECTING ROD INSTALLATION

31

being repaired.
Cylinders must be honed prior to piston installation. See CYLINDER HONING under CYLINDER BLOCK.
Install upper connecting rod bearings. Lubricate upper bearings with engine oil. Install lower bearings in rod
caps. Ensure bearing tabs are properly seated. Position piston ring gaps according to manufacturer's
recommendations. See Fig. 16. Lubricate pistons, rings and cylinder walls.

32
Fig. 16: Positioning Typical Piston Ring End Gap
Install ring compressor. Use care not to rotate piston rings. Compress rings with ring compressor. Install plastic
tubing protectors over connecting rod bolts. Install piston and connecting rod assembly. Ensure piston notch,
arrow or FRONT mark is toward front of engine. See Fig. 17.

33
Fig. 17: Installing Piston & Connecting Rod Assembly
Carefully tap piston into cylinder until rod bearing is seated on crankshaft journal. Remove protectors. Install
rod cap and bearing. Lightly tighten connecting rod bolts. Repeat procedure for remaining cylinders. Check
bearing clearance. See MAIN & CONNECTING ROD BEARING CLEARANCE.
Once clearance is checked, lubricate journals and bearings. Install bearing caps. Ensure marks are aligned on
connecting rod and cap. Tighten rod nuts or bolts to specification. Ensure rod moves freely on crankshaft.
Check connecting rod side clearance. See CONNECTING ROD SIDE CLEARANCE.
CONNECTING ROD SIDE CLEARANCE


34
being repaired.
Position connecting rod toward one side of crankshaft as far as possible. Using feeler gauge, measure clearance
between side of connecting rod and crankshaft. See Fig. 18. Clearance must be within specification.
Check for improper bearing installation, wrong bearing cap or insufficient bearing clearance if side clearance is
insufficient. Connecting rod may require machining to obtain proper clearance. Excessive clearance usually
indicates excessive wear at crankshaft. Crankshaft must be repaired or replaced.
Fig. 18: Measuring Connecting Rod Side Clearance
MAIN & CONNECTING ROD BEARING CLEARANCE

being repaired.

35
Plastigage Method
Plastigage method may be used to determine bearing clearance. Plastigage can be used with an engine in service
or during reassembly. Plastigage material is oil soluble.
Ensure journals and bearings are free of oil or solvent. Oil or solvent will dissolve material and false reading
will be obtained. Install small piece of Plastigage along full length of bearing journal. Install bearing cap in
original location. Tighten bolts to specification.
CAUTION: DO NOT rotate crankshaft while Plastigage is installed. Bearing clearance

will not be obtained if crankshaft is rotated.
Remove bearing cap. Compare Plastigage width with scale on Plastigage container to determine bearing
clearance. See Fig. 19. Rotate crankshaft 90 degrees. Repeat procedure. This is done to check journal
eccentricity. This procedure can be used to check oil clearance on both connecting rod and main bearings.

Fig. 19: Measuring Bearing Clearance
Micrometer & Telescopic Gauge Method

36
A micrometer is used to determine journal diameter, taper and out-of-round dimensions of the crankshaft. See
CLEANING & INSPECTION under CRANKSHAFT & MAIN BEARINGS in this article.
With crankshaft removed, install bearings and caps in original location on cylinder block. Tighten bolts to
specification. On connecting rods, install bearings and caps on connecting rods. Install proper connecting rod
cap on corresponding rod. Ensure bearing cap is installed in original location. Tighten bolts to specification.
Using a telescopic gauge and micrometer or inside micrometer, measure inside diameter of connecting rod and
main bearings bores. Subtract each crankshaft journal diameter from the corresponding inside bearing bore
diameter. This is the bearing clearance.
CRANKSHAFT & MAIN BEARINGS


being repaired.
REMOVAL

being repaired.
Ensure all main bearing caps are marked for location on cylinder block. Some main bearing caps have an arrow
stamped on them. The arrow must face timing belt or timing chain end of engine. Remove main bearing cap
bolts. Remove main bearing caps. Carefully remove crankshaft. Use care not to bind crankshaft in cylinder
block during removal.
CLEANING & INSPECTION

37

being repaired.
Thoroughly clean crankshaft using solvent. Dry with compressed air. Ensure all oil passages are clear and free
of sludge, rust, dirt and metal chips.
Inspect crankshaft for scoring and nicks. Inspect crankshaft for cracks using Magnaflux procedure. Inspect rear
seal area for grooving or damage. Inspect bolt hole threads for damage. If pilot bearing or bushing is used,
check pilot bearing or bushing fit in crankshaft. Inspect crankshaft gear for damaged or cracked teeth. Replace
gear if damaged. Ensure oil passage plugs are tight (if equipped).
Using micrometer, measure all journals in 4 areas to determine journal taper, out-of-round and undersize. See
Fig. 20. Some crankshafts can be reground to the next largest undersize, depending on the amount of wear or
damage. Crankshafts with rolled fillet cannot be reground and must be replaced.

38
Fig. 20: Measuring Crankshaft Journals
Crankshaft journal runout should be checked. Install crankshaft in "V" blocks or bench center. Position dial
indicator with tip resting on the main bearing journal area. See Fig. 21. Rotate crankshaft and note reading.
Journal runout must not exceed specification. Repeat procedure on all main bearing journals. Crankshaft must
be replaced if runout exceeds specification.

39

Fig. 21: Measuring Crankshaft Main Bearing Journal Runout
INSTALLATION

being repaired.
Install upper main bearing in cylinder block. Ensure lock tab is properly located in cylinder block. Install
bearings in main bearing caps. Ensure all oil passages are aligned. Install rear seal (if removed).
Ensure crankshaft journals are clean. Lubricate upper main bearings with clean engine oil. Carefully install
crankshaft. Check each main bearing clearance using Plastigage method. See MAIN & CONNECTING ROD
BEARING CLEARANCE.
Once clearance is checked, lubricate lower main bearing and journals. Install main bearing caps in original
location. Install rear seal in rear main bearing cap (if removed). Some rear main bearing caps require sealant to
be applied in corners to prevent oil leakage.
Install and tighten all bolts except thrust bearing cap to specification. Tighten thrust bearing cap bolts finger
tight only. Some models require that thrust bearing be aligned. On most applications, crankshaft must be moved
rearward then forward. Procedure may vary with manufacturer. Thrust bearing cap is then tightened to
specification. Ensure crankshaft rotates freely. Crankshaft end play should be checked. See CRANKSHAFT
END PLAY.

40
CRANKSHAFT END PLAY

being repaired.
Dial Indicator Method
Crankshaft end play can be checked using dial indicator. Mount dial indicator on rear of cylinder block.
Position dial indicator tip against rear of crankshaft. Ensure tip is resting against flat surface.

Pry crankshaft rearward. Adjust dial indicator to zero. Pry crankshaft forward and note reading. Crankshaft end
play must be within specification. If end play is not within specification, check for faulty thrust bearing
installation or worn crankshaft. Some applications offer oversize thrust bearings.
Feeler Gauge Method
Crankshaft end play can be checked using feeler gauge. Pry crankshaft rearward. Pry crankshaft forward. Using
feeler gauge, measure clearance between crankshaft and thrust bearing surface. See Fig. 22.

41
Fig. 22: Checking Crankshaft End Play
Crankshaft end play must be within specification. If end play is not within specification, check for faulty thrust
bearing installation or worn crankshaft. Some applications offer oversize thrust bearings.
CYLINDER BLOCK

being repaired.
Block Cleaning
Only cast cylinder blocks should be hot tank cleaned. Aluminum cylinder blocks should be cleaned using cold

42
tank method. Cylinder block is cleaned in order to remove carbon deposits, gasket residue and water jacket
scale. Remove oil gallery plugs, freeze plugs and cam bearings before cleaning block.
Block Inspection
Visually inspect the block. Check suspected areas for cracks using the Dye Penetrant inspection method. Block
may be checked for cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of cylinders, main bearing saddles, near expansion plugs and
between cylinders and water jackets. Inspect lifter bores for damage. Inspect all head bolt holes for damaged
threads. Threads should be cleaned using tap to ensure proper head bolt torque. Consult machine shop
concerning possible welding and machining (if required).
Cylinder Bore Inspection
Inspect bore for scoring or roughness. Cylinder bore is dimensionally checked for out-of-round and taper using
dial bore gauge. For determining out-of-round, measure cylinder parallel and perpendicular to the block center
line. Difference in the 2 readings is the bore out-of-round. Cylinder bore must be checked at top, middle and
bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and bottom. If wear has exceeded allowable limits, block
must be honed or bored to next available oversize piston dimension.
Cylinder Honing
Cylinder must be properly honed to allow new piston rings to properly seat. Cross-hatching at correct angle and
depth is critical to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used. Drive hone must be lubricated during operation. Mix
equal parts of kerosene and SAE 20W engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone from top to bottom of cylinder using even strokes to
produce 45 degree cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone to extend below
cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder wall with hot soapy water to remove abrasive
particles. Blow dry with compressed air. Coat cleaned cylinder walls with lubricating oil.
Deck Warpage
Check deck for damage or warped gasket surface. Place a straightedge across gasket surface of the deck. Using
feeler gauge, measure clearance at center of straightedge. Measure across width and length of cylinder block at
several points.
If warpage exceeds specifications, deck must be resurfaced. If warpage exceeds manufacturer's maximum
tolerance for material removal, replace block.

43
NOTE: Some manufacturers recommend that a total amount of material (cylinder head
and cylinder block) can only be removed before components must be replaced.
Deck Height
Distance from crankshaft center line to block deck is called the deck height. Measure and record front and rear
main journals of crankshaft. To compute this distance, install crankshaft and retain with center main bearing and
cap only. Measure distance from crankshaft journal to block deck, parallel to cylinder center line.
Add one half of main bearing journal diameter to distance from crankshaft journal to block deck. This
dimension should be checked at front and rear of cylinder block. Both readings should be the same.
If difference exceeds specification, cylinder block must be repaired or replaced. Deck height and warpage
should be corrected at the same time.
Main Bearing Bore & Alignment

For checking main bearing bore, remove all bearings from cylinder block and main bearing caps. Install main
bearing caps in original location. Tighten bolts to specification. Using inside micrometer, measure main bearin
bore in 2 areas 90 degrees apart. Determine bore size and out-of-round. If diameter is not within specification,
block must be align-bored.
For checking alignment, place a straightedge along center line of main bearing saddles. Check for clearance
between straightedge and main bearing saddles. Block must be align-bored if clearance exists.
Expansion Plug Removal
Drill hole in center of expansion plug. Remove with screwdriver or punch. Use care not to damage sealing
surface.
Expansion Plug Installation
Ensure sealing surface is free of burrs. Coat expansion plug with sealer. Using wooden dowel or pipe of slightly
smaller diameter, install expansion plug. Ensure expansion plug is evenly located.
Oil Gallery Plug Removal
Remove threaded oil gallery plugs using appropriate wrench. Soft press-in plugs are removed by drilling into
plug and installing a sheet metal screw. Remove plug with slide hammer or pliers.
Oil Gallery Plug Installation
Ensure threads or sealing surface is clean. Coat threaded oil gallery plugs with sealer and install. Replacement
soft press-in plugs are installed with a hammer and drift.
CAMSHAFT

44

being repaired.
CLEANING & INSPECTION

being repaired.
Clean camshaft with solvent. Ensure all oil passages are clear. Inspect cam lobes and bearing journals for
pitting, flaking or scoring. Using micrometer, measure bearing journal O.D.
Support camshaft at each end with "V" blocks. Position dial indicator with tip resting on center bearing journal.
Rotate camshaft and note camshaft runout reading. If reading exceeds specification, replace camshaft.
Check cam lobe lift by measuring base circle of camshaft using micrometer. Measure again at 90-degree angle
to tip of cam lobe. Cam lift can be determined by subtracting base circle diameter from tip of cam lobe
measurement.
Different lift dimensions are given for intake and exhaust cam lobes. Reading must be within specification.
Replace camshaft if cam lobes or bearing journals are not within specification.
Inspect camshaft gear for chipped, eroded or damaged teeth. Replace gear if damaged. On camshafts using
thrust plate, measure distance between thrust plate and camshaft shoulder. Replace thrust plate if not within
specification.
CAMSHAFT BEARINGS

45

being repaired.
Removal & Installation
Remove camshaft rear plug. Camshaft bearing remover is assembled with shoulder resting against bearing to be
removed according to manufacturer's instructions. Tighten puller nut until bearing is removed. Remove
remaining bearings, leaving front and rear bearings until last. These bearings act as a guide for camshaft bearing
remover.
To install new bearings, puller is rearranged to pull bearings toward the center of block. Ensure all lubrication
passages of bearing are aligned with cylinder block. Coat new camshaft rear plug with sealant. Install camshaft
rear plug. Ensure plug is even in cylinder block.
CAMSHAFT INSTALLATION


being repaired.
Lubricate bearing surfaces and cam lobes with ample amount of Molykote or camshaft lubricant. Carefully
install camshaft. Use care not to damage bearing journals during installation. Install thrust plate retaining bolts
(if equipped). Tighten bolts to specification. On overhead camshafts, install bearing caps in original location.
Tighten bolts to specification. On all applications, check camshaft end play.
CAMSHAFT END PLAY

being repaired.
Using dial indicator, check camshaft end play. Position dial indicator on front of engine block or cylinder head.
Position indicator tip against camshaft. Push camshaft toward rear of cylinder head or engine and adjust
indicator to zero.

46
Move camshaft forward and note reading. Camshaft end play must be within specification. End play may be
adjusted by relocating gear, shimming thrust plate or replacing thrust plate depending on each manufacturer.
TIMING CHAINS & BELTS


being repaired.

TIMING CHAINS

being repaired.
Timing chains will stretch during operation. Limits are placed upon amount of stretch before replacement is
required. Timing chain stretch will alter ignition timing and valve timing.
To check timing chain stretch, rotate crankshaft to eliminate slack from one side of timing chain. Mark
reference point on cylinder block. Rotate crankshaft in opposite direction to eliminate slack from remaining side
of timing chain. Force other side of chain outward and measure distance between reference point and timing
chain. See Fig. 23. Replace timing chain and gears if not within specification.

47
Fig. 23: Measuring Timing Chain Stretch
Timing chains must be installed so timing marks on camshaft gear and crankshaft gear are aligned according to
manufacturer. See Fig. 24.

48
Fig. 24: Typical Gear Timing Mark Alignment
TIMING BELTS

being repaired.
Cogged tooth belts are commonly used on overhead cam engines. Inspect belt teeth for rounded corners or
cracking. Replace belt if it is cracked, damaged, missing teeth or oil soaked.
Used timing belt must be installed in original direction of rotation. Inspect all sprocket teeth for wear. Replace
all worn sprockets. Sprockets are marked for timing purposes. Engine is positioned so that crankshaft sprocket
mark will be upward. Camshaft sprocket is aligned with reference mark on cylinder head or timing belt cover

49
and then timing belt can be installed. See Fig. 25.
Fig. 25: Typical Camshaft Belt Sprocket Alignment
TENSION ADJUSTMENT

50

being repaired.
If guide rails are used with spring loaded tensioners, ensure at least half of original rail thickness remains.
Spring loaded tensioner should be inspected for damage.
Ensure all timing marks are aligned. Adjust belt tension using manufacturer's recommendations. Belt tension
may require checking using tension gauge. See Fig. 26.

51
Fig. 26: Adjusting Typical Timing Belt Tension
TIMING GEARS

being repaired.
TIMING GEAR BACKLASH & RUNOUT

being repaired.
On engines where camshaft gear operates directly on crankshaft gear, gear backlash and runout must be
checked. To check backlash, install dial indicator with tip resting on tooth of camshaft gear. Rotate camshaft
gear as far as possible. Adjust indicator to zero. Rotate camshaft gear in opposite direction as far as possible an
note reading.
To determine timing gear runout, mount dial indicator with tip resting on face edge of camshaft gear. Adjust
indicator to zero. Rotate camshaft gear 360 degrees and note reading. If backlash or runout exceeds
specification, replace camshaft and/or crankshaft gear.
REAR MAIN OIL SEAL INSTALLATION

being repaired.

52
One-Piece Type Seal
For one-piece type oil seal installation, coat block contact surface of seal with sealer if seal is not factory
coated. Ensure seal surface is free of burrs. Lubricate seal lip with engine oil and press seal into place using
proper oil seal installer. See Fig. 27.
Fig. 27: Installing Typical One-Piece Oil Seal
Rope Type Seal
For rope type rear main oil seal installation, press seal lightly into seat area. Using seal installer, fully seat seal
in bearing cap or cylinder block.
Trim seal ends even with cylinder block parting surface. Some applications require sealer to be applied on main
bearing cap before installing. See Fig. 28.

53
Fig. 28: Installing Typical Rope Seal
Split-Rubber Type Seal
Follow manufacturer's procedures when installing split-rubber type rear main oil seals. Installation procedures
vary with manufacturer and engine type. See Fig. 29.

54
Fig. 29: Installing Typical Split-Rubber Seal
OIL PUMP

being repaired.
ROTOR TYPE

55

being repaired.
Mark oil pump rotor locations before removing. See Fig. 30. Remove outer rotor and measure thickness and
diameter. Measure inner rotor thickness. Inspect shaft for scoring or wear. Inspect rotors for pitting or damage.
Inspect cover for grooving or wear. Replace worn or damaged components.
Measure outer rotor-to-body clearance. Replace pump assembly if clearance exceeds specification. Measure
clearance between rotors. See Fig. 31. Replace shaft and both rotors if clearance exceeds specification.
Install rotors in pump body. Position straightedge across pump body. Using feeler gauge, measure clearance
between rotors and straightedge. Pump cover wear is measured using a straightedge and feeler gauge. Replace
pump if clearance exceeds specification.
Fig. 30: Typical Rotor Type Oil Pump

56
Fig. 31: Measuring Rotor Clearance
GEAR TYPE

being repaired.
Mark oil pump gear location before removing. See Fig. 32. Remove gears from pump body. Inspect gears for
pitting or damage. Inspect cover for grooving or wear. Measure gear diameter and length. Measure gear housing
cavity depth and diameter. See Fig. 33. Replace worn or damaged components.
Pump cover wear is measured using a straightedge and feeler gauge. Replace pump or components if warpage
or wear exceeds specification, or mating surface of pump cover is scratched or grooved.

57
Fig. 32: Typical Gear Type Oil Pump

58
Fig. 33: Measuring Oil Pump Gear Cavity
BREAK-IN PROCEDURE

being repaired.
ENGINE PRE-OILING

59

being repaired.
Pre-oil engine prior to operation to prevent engine damage. Lightly oiled oil pump will cavitate unless oil pump
cavities are filled with engine oil or petroleum jelly.
Engine pre-oiling can be done using pressure oiler (if available). Connect pressure oiler to cylinder block oil
passage such as oil pressure sending unit. Operate pressure oiler long enough to ensure correct amount of oil
has filled crankcase. Check oil level while pre-oiling.

If pressure oiler is not available, disconnect ignition system. Remove oil pressure sending unit and replace with
oil pressure test gauge. Using starter motor, rotate engine starter until gauge shows normal oil pressure for
several seconds. DO NOT crank engine for more than 30 seconds to avoid starter motor damage. Ensure oil
pressure has reached the most distant point from the oil pump.
NOTE: If new lifters or camshaft are installed, some manufacturers require that a
crankcase conditioner be added to engine oil. The engine should be operated
for specified amount of time to aid in lifter break-in procedure.
INITIAL START-UP

being repaired.
Start engine and operate engine at low speed while checking for coolant, fuel and oil leaks. Stop engine.
Recheck coolant and oil level. Adjust if necessary.
CAMSHAFT

60

being repaired.
Break-in procedure is required when new or reground camshaft has been installed. Operate and maintain engine
speed between 1500-2500 RPM for approximately 30 minutes. Procedure may vary due to manufacturer's
recommendations.
PISTON RINGS

being repaired.
Piston rings require a break-in procedure to ensure seating of rings to cylinder walls. Serious damage may occu
to rings if correct procedures are not followed.
Extremely high piston ring temperatures are obtained during break-in process. If rings are exposed to
excessively high RPM or high cylinder pressures, ring damage can occur. Follow piston ring manufacturer's
recommended break-in procedure.
FINAL ADJUSTMENTS

being repaired.
Check or adjust ignition timing and dwell (if applicable). Adjust valves (if necessary). Adjust idle speed and
mixture. Retighten cylinder heads (if required). If cylinder head or block is aluminum, retighten bolts when
engine is cold. Follow the engine manufacturer's recommended break-in procedure and maintenance schedule
for new engines.
NOTE: Some manufacturers require that head bolts be retightened after specified
amount of operation. This must be done to prevent head gasket failure.

61
GENERAL INFORMATION Engine Performance Diagnostic Routine Outline
GENERAL INFORMATION
Engine Performance Diagnostic Routine Outline
NOTE: This article is generic in nature and all information does not apply to all
vehicles. For vehicle specific information, see the appropriate articles in the
ENGINE PERFORMANCE category.
WHERE DOES DRIVEABILITY DIAGNOSIS START?

PERFORM BASIC INSPECTION

1. Verify Customer Complaint

2. Check for Relevant Technical Service Bulletins (TSBs)
3. Perform Visual Inspection (See Basic Diagnostic Procedures)
4. Test Engine Sub-Systems (See Basic Diagnostic Procedures)
Mechanical Condition (Compression)
Ignition Output
Fuel Delivery
5. Check Air Induction System For Leaks
6. Check & Adjust Basic Engine Settings(See On-Vehicle Adjustments)
Ignition Timing
Idle Speed
CHECK FOR TROUBLE CODES
1. Check for Diagnostic Trouble Codes (DTCs).(See Self-Diagnostics)

2. Repair cause of DTCs.
3. Clear PCM memory and repeat self-test.
DIAGNOSE SYMPTOM
Sunday, April 10, 2016 1:50:20

1:50:18 PM Page 1
1
GENERAL INFORMATION Engine Performance Diagnostic Routine Outline
1. If no self-diagnostics available, or no trouble codes present, identify symptom.

2. See trouble shooting procedure to identify problem. (See Trouble Shooting - No Codes)
TEST SYSTEM
1. Perform required tests. (See Systems & Component Testing)

2. Verify complaint is repaired.


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2014 GMC Acadia Denali

2014 ENGINE Maintenance and Lubrication - Acadia, Enclave And Traverse

Maintenance and Lubrication - Acadia, Enclave And Traverse

Approximate Fluid Capacities

Fuel Tank 83.3 liters 22.0 gallons

FLUID AND LUBRICANT RECOMMENDATIONS

Fluid and Lubricant Recommendations

Sunday, April 10, 2016 1:55:33

Differential (Rear Drive

GM OIL LIFE SYSTEM RESETTING

When to Change Engine Oil

Sunday, April 10, 2016 1:55:32 PM Page 2

How to Reset the Engine Oil Life System

If the vehicle has Driver Information Center (DIC) buttons:

1. Turn the ignition to ON/RUN, with the engine off.

Sunday, April 10, 2016 1:55:32 PM Page 3

Engine Exhaust - Acadia, Enclave And Traverse

Fastener Tightening Specifications

DIAGNOSTIC INFORMATION AND PROCEDURES

Sunday, April 10, 2016 1:09:11

Refer to Restricted Exhaust

Refer to Restricted Exhaust

Poor fuel economy

Refer to Restricted Exhaust

Excessive smoke diesel

Refer to Restricted Exhaust

Exhaust hissing noise

Refer to Exhaust Leakage

Exhaust popping noise

Refer to Exhaust Leakage

Exhaust rattle noise

Refer to Exhaust Noise

Loud exhaust noise

Refer to Exhaust Noise

Exhaust buzz, groan, hum noise

Refer to Exhaust Noise

Sunday, April 10, 2016 1:09:09 PM Page 2

J-35314-A Exhaust Back Pressure Gauge

WARNING: Refer to Hot Exhaust System Warning .

Sunday, April 10, 2016 1:09:09 PM Page 3

Sensor Replacement - Bank 1 Sensor

Does the reading exceed the specified value? Go to Step 5 Go to Step 8

Does the reading exceed the specified value? Go to Step 6 Go to Step 7

6 Damage in the exhaust pipe -

Sunday, April 10, 2016 1:09:09 PM Page 4

Did you find and correct the condition?

Did you correct the condition? System OK Go to Step 2

Exhaust manifold to pipe

Sunday, April 10, 2016 1:09:09 PM Page 5

Sunday, April 10, 2016 1:09:09 PM Page 6

Exhaust Muffler Replacement (NEA/NED or N10).

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

Fig. 1: Identifying Left Side Exhaust Manifold Bolts

Sunday, April 10, 2016 1:09:09 PM Page 7

NOTE: Do not reuse the gasket.

Fig. 2: Identifying Heated Oxygen Sensors & Exhaust Manifold

Sunday, April 10, 2016 1:09:09 PM Page 8

Fig. 3: Identifying Heated Oxygen Sensors & Exhaust Manifold

2. Install the HO2S (1) to the exhaust manifold.