Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. If equipped with an automatic transmission, remove the exhaust manifold. 2. Drain the cooling system. 3. Remove the thermostat housing to water pump feed pipe bolts. 4. Remove the thermostat housing to water pump feed pipe. 5. Remove the thermostat. 2004 Pontiac Sunfire L4-2.2L VIN F Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing to water pump feed pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the thermostat housing to water pump feed pipe bolt. ^ Tighten the thermostat housing to water pump feed pipe bolt to 10 Nm (18 inch lbs.). 4. If equipped with an automatic transmission, install the exhaust manifold. 5. Fill the cooling system.

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The front inside door handle bezel has electrical connectors, the rear does not. 1. Insert a flat bladed tool behind the forward upper edge of the door handle bezel. 2. Gently pry the upper portion of the bezel away from the door trim panel. 3. Pull the bezel forward over the inside door handle. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. 2. 3. 4. Connect the electrical connectors, if any, to the inside door handle bezel. Guide the inside door handle through the opening in the door handle bezel. Snap the door handle bezel into place. Work the rubber around and behind both the manual lock knob and the inside door handle.

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Legend (1) Auto Level Control (ALC) Harness (2) Auto Level Control (ALC) Sensor Legend (1) Auto Level Control (ALC) Inflator Solenoid Valve (2) Inflator Air Switch (3) Body Harness (4) Rear Electric Accessory Plug Housing (5) Auto Level Control (ALC) Inflator Relay (6) Auto Level Control Harness Behind Rear Left Wheelhouse Legend (1) Pass Through P403 (2) In-line connector C407 (3) Auto Level Control Harness (4) Auto Level Control (ALC) Sensor Connector (5) Auto Level Control (ALC) Air Compressor (6) Auto Level Control (ALC) Compressor Relay (7) Auto Level Control (ALC) Connector Below Vehicle, Rear Of LR Wheelhouse

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Note: GM does not provide timing chain timing marks, or information to perform timing chain service without the special tools shown in this procedure. Tools Required: – - J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench Important: ^ ^ Before remove the timing chain, read the entire procedure. The timing chain on the engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. ^ Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. Refer to Engine Front Cover Replacement. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the Timed position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. Notice: Do NOT attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket: 10.1. 10.2. 10.3. 10.4. Lower the vehicle. Hold the intake camshaft sprocket with the J 39579 and remove the sprocket bolt and washer. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket.

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Removal Procedure 1. 2. 3. 4. 5. 6. Remove the camshaft cover. Raise and support the vehicle. Remove the #1 cylinder spark plug. Rotate the crankshaft in the engine rotational direction clockwise, until #1 piston is at top dead center (TDC) on the compression stroke. Remove the engine front cover. Lower the vehicle. Important: The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If not removed, the timing chain will become cocked and it will be difficult to remove. 7. Remove the timing chain tensioner. 8. Remove the fixed timing chain guide access plug. 2002 Pontiac Grand AM L4-2.2L VIN F 9. Remove the fixed timing chain guide. 10. Remove the upper timing chain guide. 11. Use a 24 mm wrench to hold the camshafts from turning.