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

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Step 1. Wait for the engine to cool down and gather listed materials. Working on a hot engine is incred- ibly dumb. Step 2. Open the hood and remove the front panel and airbox. (Fig. 1.) Step 3. Protect the air intake with a cover (I used aluminum foil. (Fig. 2.) Fig. 1. Engine all assembled Step 4. Locate the spark plugs. This engine has six-cylindars and twelve spark plugs (six on each side). Select one side to do at a time. Step 5. Starting with the spark plug furthest from the firewall, remove the electrical plug and unscrew unit from the engine using the T-25 Torx bit. Use the magnet to ensure the screw is not dropped into the engine. (Fig. 3.) Step 6. Spray the spark plug boots with WD-40 to loosen them for removal. Wait a few minutes to allow solvent to penetrate. Step 7. Use the 17 mm wrench to pry the boot off from the spark plug. This is the biggest pain in the ass. Try to loosen the boot by turning the boot using your hand. Be careful not to damage or crimp the boot if using the pliers. Fig. 2. Protect your engine! Cover the air intake from accidental beer spilling! Fig. 3. Spark plugs on driver’s side with wires and harnesses intact. Step 8. engine. position labeled, engine. Do this for the entire side of the This part took the longest. Label the of the modules. The boots are both on the module and on the (Fig. 4 and 5.) Fig. 5. The engine has embossed lettering to show which boot goes where. Fig. 6. Old and new spark plugs. I used OEM spark plugs, as seen in Fig. 7. Fig. 4. Engine without spark plug modules. Step 9. Remove the spark plug. This is a pain in the ass as well. Remember, lefty- loosy, righty-tighty. Use the appropriate-sized extension to remove the spark plug. You may have to change extensions mid way. Step 10. Insert new spark plug. Spray with WD-40 before screwing in to allow for easier removal the next time you change spark plugs. Tighten to 28 N m. Step 11. Re-attach boots to the spark plugs, making sure you place them in the right order. You will feel or hear a pop when they connect. Also re-attach modules to the engine block. Step 12. Repeat on other side of engine, noting the number of new and used spark plugs as you go along. Step 13. Once complete, remove cover that was placed on the air intake and replace air box. You are done! There will be some smoke and smell as the WD-40 burns off the engine and plugs.

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a. Remove the ignition coils (with igniter). b. Using a 16 mm plug wrench, remove the spark plugs. c. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. d. Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. e. Adjust the spark plug electrode gap. Electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) g. Reinstall the ignition coils (with igniter).

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Remove DANGER: Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries. No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers. 1 Disconnect ground cable of battery CAUTION: Do not connect quiescent current retention device otherwise this may cause damage to the control module. 2 Remove spark plugs NOTE: To ensure that the engine can be easily cranked when drawing in the timing chain, and to avoid the timing chain jumping across. Remove only once spark plug of each cylinder. 3 Remove cylinder head covers Air cleaner mounted on vehicle Air cleaner positioned at engine side 4.1 Remove fan shroud NOTE: Not Model 211.061/065/070, 230.475 4.2 Remove electric fan 5 Position engine to 40 degrees after TDC of first cylinder. NOTE: Engine must not be cranked backwards. The notches of the camshafts must point toward the inner V. It must be possible to easily insert the two locking plates. If this is not possible, Set the basic position of camshafts. The copper plates of the timing chain must be aligned with the scribe marks on the camshaft sprockets. Owing to the unevenly long paths of the timing chain it may be necessary to crank the engine as many as 14 times till the copper plates get aligned with the scribe marks on the camshaft sprockets. On vehicles equipped with an air pump, the combination valve must be unbolted before the right locking plate is inserted. Installation: Replace Gasket of combination valve. 6 Remove chain tensioner 7 Remove camshaft position sensor 8 Crank engine in direction of rotation until the link for separating the timing chain is easily accessible

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Models: 2008-2009 Chevrolet Colorado, TrailBlazer 2008-2009 GMC Canyon, Envoy 2008-2009 HUMMER H3, H3T 2008-2009 Saab 9-7X All Equipped With Engine RPOs LLR, LLV, LL8 Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated. Some customers may also comment that the engine runs rough. The technician may find DTCs P0300, P0301, P0302, P0303, P0304, P0305, or P0306 set as current or in history, depending on which engine the vehicle is equipped with. Upon further examination, the technician may observe evidence of water intrusion into the spark plug recess area. Cause This condition may be caused by an engine being exposed to a large quantity of water, which may result in some of the water seeping down past the vented threads of an ignition coil bolt, then flowing through the vent opening that is located in the bottom of the related ignition coil bolt hole, and collecting in the spark plug recess area. Correction Important: DO NOT reprogram or replace the engine control module (ECM) for this condition. If evidence of water intrusion in the spark plug recess area/s is not observed, then refer to the appropriate DTC procedures in SI.

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.