You are on page 1of 216

<- Back

Forward ->

Document ID# 589176
2000 Oldsmobile Alero

Engine Overhaul
In order to overhaul, follow the sequence below.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Draining Fluids and Oil Filter Removal
Engine Flywheel Removal
Oil Level Indicator and Tube Removal
Exhaust Manifold Removal
Intake Manifold Removal
Crankshaft Balancer Removal
Engine Front Cover Removal
Timing Chain, Sprockets, and Tensioner Removal
Water Pump Removal
Timing Chain Housing Removal
Intake Camshaft, Housing and Lifter Removal
Exhaust Camshaft, Housing and Lifter Removal
Cylinder Head Removal
Oil Filter Adapter Removal
Oil Pan Removal
Oil Pump Removal
Balance Shaft Housing Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft Rear Oil Seal and Housing Removal
Crankshaft and Bearings Removal
Engine Block Plug Removal
Engine Block Cleaning and Inspection
Crankshaft Balancer Cleaning and Inspection
Engine Flywheel Cleaning and Inspection
Cylinder Boring and Honing
Crankshaft and Bearings Cleaning and Inspection
Piston and Connecting Rod Disassemble
Piston, Connecting Rod, and Bearings Cleaning and Inspection
Piston Selection
Piston and Connecting Rod Assemble
Camshaft and Housing Cleaning and Inspection
Timing Chain and Sprockets Cleaning and Inspection

Print

33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.

Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Valve Guide Reaming/Valve and Seat Grinding
Cylinder Head Assemble
Oil Pump Disassemble
Oil Pump Cleaning and Inspection
Oil Pump Assemble
Engine Front Cover Cleaning and Inspection
Intake Manifold Cleaning and Inspection
Exhaust Manifold Cleaning and Inspection
Oil Pan Cleaning and Inspection
Balance Shaft Cleaning and Inspection
Service Prior to Assembly
Engine Block Plug Installation
Crankshaft and Bearings Installation
Crankshaft Rear Oil Seal and Housing Installation
Piston, Connecting Rod, and Bearing Installation
Balance Shaft Housing Installation
Oil Pump Installation
Timing Balance Shafts to Engine
Cylinder Head Installation
Intake Camshaft, Housing and Lifter Installation
Exhaust Camshaft, Housing and Lifter Installation
Timing Chain Housing Installation
Water Pump Installation
Timing Chain, Sprockets, Tensioner Installation
Crankshaft Front Cover Oil Seal Installation
Engine Front Cover Installation
Oil Pan Installation
Oil Filter Adapter Installation
Intake Manifold Installation
Crankshaft Balancer Installation
Exhaust Manifold Installation
Oil Level Indicator and Tube Installation
Engine Flywheel Installation
Engine Set-Up and Testing

<- Back

Forward ->

Document ID# 589176
2000 Oldsmobile Alero

Print

<- Back

Forward ->

Document ID# 222185
2000 Oldsmobile Alero

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain bolt and allow the oil to drain from the oil pan.
2. Remove the oil filter.

Print

3. Remove the coolant jacket drain plug and allow the coolant to drain from the water jacket.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not
use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque
and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
4. Install the oil pan drain bolt and the coolant jacket plug.
Tighten
1. Tighten the oil pan drain bolt to 26 N·m (19 lb ft).
2. Tighten the water jacket plug to 30 N·m (22 lb ft).
5. If cleaning or repairing the engine block it is not necessary to reinstall the plugs.

<- Back

Forward ->

Document ID# 222185
2000 Oldsmobile Alero

Print

<. .Back Forward -> Document ID# 62060 2000 Oldsmobile Alero Print Engine Flywheel Removal Tools Required J 38122-A Crankshaft Balancer Holder Important It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full socket engagement on the thin headed flywheel bolts. The flywheel is balanced separately from the engine. Do not orientate the flywheel to the crankshaft.

Clean the thread adhesive from the flywheel bolt holes. Remove the flywheel. 4. 2. if the vehicle has a manual transmission. 3. <.1. 5.Back Forward -> Document ID# 62060 2000 Oldsmobile Alero Print . Remove the flywheel attaching bolt. Remove the flywheel. if the vehicle has an automatic transmission. Remove the flywheel retainer for vehicles with automatic transmission. Use a nylon bristle brush to clean the holes in the crankshaft. Use the J 38122-A to prevent crankshaft rotation.

Remove the tube from the block. Remove the tube bracket to the rear cam carrier lift bracket bolt. <.<.Back Forward -> Document ID# 62156 2000 Oldsmobile Alero Print .Back Forward -> Document ID# 62156 2000 Oldsmobile Alero Print Oil Level Indicator and Tube Removal 1. 2.

Remove the exhaust manifold brace to the manifold bolt.<. Print .Back Forward -> Document ID# 62302 2000 Oldsmobile Alero Exhaust Manifold Removal 1.

. Remove the exhaust manifold heat shield.2. if the exhaust manifold is being replaced.

3. 4. The exhaust manifold heat shield <. transfer the following parts: 1. 6. Remove the exhaust manifold to the cylinder head retaining nuts. The exhaust manifold nuts 2. If the exhaust manifold is being replaced. Remove the exhaust manifold. Clean all of the sealing surfaces. 5.Back Forward -> Document ID# 62302 2000 Oldsmobile Alero Print .

Back Forward -> Document ID# 361116 2000 Oldsmobile Alero Print Intake Manifold Removal Notice Never attempt to remove the intake manifold from a hot engine. . The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot. allow the engine to cool to ambient temperature. Remove the throttle body. 1.<. Disconnect the fuel pressure regulator hose. 2.

3. 5. Remove the intake manifold gasket. The gasket is reusable if the gasket is not damaged. Remove the intake manifold. 4. . Remove the intake manifold retaining nuts and bolts.

transfer the following parts: 1. The throttle body gasket. <. The throttle body 2.Back Forward -> Document ID# 361116 2000 Oldsmobile Alero Print . If the intake manifold needs to be replaced.6. The manifold to the throttle body gasket is reusable if the gasket is not damaged.

Remove the balancer assembly.Back Forward -> Document ID# 206122 2000 Oldsmobile Alero Print .<. <. using the J 24420-C . Use the J 38122-A in order to prevent the crankshaft from rotating when loosening the bolt. J 24420-C Harmonic Balancer Puller 1.Back Forward -> Document ID# 206122 2000 Oldsmobile Alero Print Crankshaft Balancer Removal Tools Required 1. J 38122-A Harmonic Balancer Holder 2. 2. Remove the balancer retaining bolt and washer.

Back Forward -> Document ID# 639592 2000 Oldsmobile Alero Engine Front Cover Removal 1.<. Print . Remove the front cover bolts and nuts. 2. 3. The gasket is reusable. Remove the front cover gasket. Remove the front cover.

Back Forward -> Document ID# 639592 2000 Oldsmobile Alero Print . <. Remove the front cover oil seal.4.

Sprockets. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of reassembly. Important . and Tensioner Removal Notice The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year.<. Engine damage may result if the wrong timing chain is used.Back Forward -> Document ID# 206142 2000 Oldsmobile Alero Print Timing Chain. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets.

Remove the timing chain guides. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. 3.Read the entire procedure before removing the timing chain. Remove the tensioner assembly retaining bolts. 4. Remove the tensioner shoe. . 2. Ensure that this is done in order to prevent noise and increased wear on the chain. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. 1.

Replace the timing chain shoe or guides if the scoring exceeds 1. 6. Remove the timing chain. Replace the parts as required. <.045 in). 7.12 mm (0. Inspect the parts for wear.5.Back Forward -> Document ID# 206142 2000 Oldsmobile Alero Print .

<- Back

Forward ->

Document ID# 205836
2000 Oldsmobile Alero

Print

Water Pump Removal
Tools Required
J 36008-A Camshaft Timing Pins

Important
The timing chain tensioner must be removed to unload chain tension before the water pump is removed. If the tension is not unloaded, the
water pump will become cocked in the timing chain housing and the water pump will be difficult to remove.
1. Rotate the timing chain sprockets to line up the holes. Install the J 36008-A .

2. Remove the bolts holding the tensioner in place.

3.
4.
5.
6.
7.
8.
9.

Remove the water pump cover to the cylinder block bolts.
Remove the water pump assembly to the timing chain housing nuts.
Remove the water pump cover assembly.
Remove the water pump.
Remove the water pump cover to the water pump assembly bolts.
Clean and inspect all sealing surfaces.
Inspect the water pump for cracking.

<- Back

Forward ->

Document ID# 205836
2000 Oldsmobile Alero

Print

<- Back

Forward ->

Document ID# 223018
2000 Oldsmobile Alero

Timing Chain Housing Removal
Tools Required
J 39579 Camshaft Gear Holder

1. Remove the camshaft sprocket retaining bolts and washers. Use the J 39579 to hold the sprockets when removing the bolts.
2. Remove the camshaft sprockets. The sprockets are interchangeable. No marking is required.
3. Remove the 4 oil pan bolts.

Print

4.
5.
6.
7.

Remove the timing chain housing to camshaft housing bolts.
Remove the timing chain housing to block bolts.
Remove the timing chain housing.
Remove the timing chain housing gaskets.

<- Back

Forward ->

Document ID# 223018
2000 Oldsmobile Alero

Print

Use this procedure only if the camshaft or lifters are going to be removed. Replace the camshaft housing to cylinder head gasket any time the camshaft housing to cylinder head bolts are loosened or removed. Read the entire procedure before removing the camshaft housing.<. Housing and Lifter Removal Important 1. 4. Ensure that the valve lifters are kept together and identified during disassembly. 3. Do this in order to ensure that the valve lifters are installed in the original location.Back Forward -> Document ID# 257298 2000 Oldsmobile Alero Print Intake Camshaft. Important . 2.

5. Coat the lifter with Camshaft and Lifter Prelube GM P/N United States 12345501. Keep the camshaft contact surface down. Tighten the bolts evenly in order to prevent the cover from binding on the dowel pins. GM P/N Canada 992704 or the equivalent before installation. 3. GM P/N Canada 992869 or an equivalent to the engine oil. 1. 2. Store the lifters upside down on a level surface. 7. 2. 10. Discard the seals. Remove the cover by threading four of the housing to head retaining bolts into the tapped holes in the camshaft housing cover. 6. Remove the camshaft housing cover. The valve lifters are not repairable. Remove the remaining camshaft housing to the cylinder head retaining bolts. The lifters can also be submerged in clean engine oil. Replace the lifters if the lifters are faulty. 11. add Engine Oil Supplement GM P/N United States 1052367. Important 1. 8. Leave the bolts loosely in place to hold the camshaft housing while separating the camshaft cover from the housing. Important Push the cover off of the housing. 9. Be careful not to damage the camshaft or journals. Remove the camshaft housing cover to the camshaft housing retaining bolts. Remove the valve lifters. . Important Keep the valve lifters in order so they can be reinstalled in the same location. Do not get prelube on the camshaft cover seals because the seals will swell. Remove the loosely installed camshaft housing to head bolts. Remove the camshaft sensor bolt. If new lifters are installed. 2.Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. Loosely reinstall one camshaft housing to the cylinder head bolt in order to retain the housing during camshaft and lifter removal. Remove the camshaft. Remove the camshaft sensor. Follow the below guidelines in order to minimize lifter bleed down: 1. 4.

Back Forward -> Document ID# 257298 2000 Oldsmobile Alero Print . <.12. Remove the camshaft housing. 13. Remove the camshaft housing gasket.

The camshaft housing to the cylinder head gasket must be replaced any time the camshaft housing to the cylinder head bolts are loosened or removed. 1. .<.Back Forward -> Document ID# 240457 2000 Oldsmobile Alero Print Exhaust Camshaft. 2. Remove the exhaust camshaft rear cover. During disassembly. be sure that the valve lifters are kept together and identified in order so that the valve lifters may be reinstalled in their original locations. Remove the exhaust camshaft rear cover gasket. Housing and Lifter Removal Important 1. Read the entire procedure before removing the camshaft housing. 3. 2.

Important
Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts.
3. Remove the exhaust camshaft housing to the cylinder head bolts.
Important
Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from the housing.
4. Push the cover off the camshaft housing by threading four of the housing to the head retaining bolts into the tapped holes in the camshaft
cover.
Important
Tighten the bolts evenly to prevent the cover from binding on the dowel pins.

5.
6.
7.
8.
9.

Remove the two loosely installed camshaft housing to the head bolts.
Remove the camshaft cover. Discard the seals.
Loosely install one camshaft housing to the cylinder head bolt to retain the housing during the camshaft and lifter removal.
Remove the camshaft. Be careful not to damage the camshaft or journals.
Remove the valve lifters. Keep the valve lifters in order so that the valve lifters may be reinstalled in the same location from which they
were removed.
10. Do one of the following to minimize lifter bleed down:
1. Store the lifters upside down on a level surface. Keep the camshaft contact surface down.
2. Store the lifters submerged in clean engine oil.
Important
1. The valve lifters are not repairable. Replace the lifters if the lifters are faulty. Do not get prelube on the camshaft cover seals because
the seals will swell.
2. Coat the lifter with Camshaft and Lifter Prelube GM P/N United States 12345501, GM P/N Canada 992704 or an equivalent before
installation.
11. If new lifters are installed, add Engine Oil Supplement GM P/N United States 1052367, GM P/N Canada 992869 or an equivalent to the
engine oil.

12. Remove the camshaft housing.
13. Remove the camshaft housing gasket.

<- Back

Forward ->

Document ID# 240457
2000 Oldsmobile Alero

Print

<- Back

Forward ->

Document ID# 62228
2000 Oldsmobile Alero

Cylinder Head Removal
Tools Required
J 38188 Cylinder Head Broken Bolt Extractor Kit

1. Remove the cylinder head to the block bolts. Follow the reverse of the tightening sequence.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.

Print

or wire brush/wheel will damage the sealing surfaces and produce fine grit residue that will contaminate the engine and engine oil. Clean all of the gasket surfaces. The components exposed to the chemical agents must be rinsed with cleaning solvent in order to neutralize the chemical agent. 5. Failure to use proper cleaning methods may lead to engine damage. or wire brush/wheel in order to clean sealing surfaces. pads. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: 1. Do not use abrasive paper. Proper gasket and sealant removal is crucial and requires that the component sealing surfaces are not damaged during cleaning. Important Do not use any other method or technique to clean these gasket surfaces.Notice Gasket and sealant material must be removed from the component's sealing surfaces before reassembly. pads. Use a new razor blade for each cylinder head and cylinder block. 2. 4. Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. . Do not scratch or gouge any surface. Abrasive paper. Use only a plastic or wood gasket scraper such as J 28410. Appropriate chemical agents can be used to dissolve gasket and/or sealant materials when working on an individual unassembled component.

8.Back Forward -> Document ID# 62228 2000 Oldsmobile Alero Print . and the bolt holes. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals. 6. Clean the old sealer/lube and dirt from the bolt.3. Important Do not use a tap to clean the cylinder head bolt holes. Remove any broken long cylinder head bolts using the J 38188 . 7. Hold the razor blade as parallel to the gasket surface as possible. Clean the bolt holes using a nylon bristle brush. the studs. 9. When cleaning the cylinder head bolt holes 1-8 use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes. Caution Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. <.

<. Remove the oil filter. 2. Ensure that the gasket is removed with the filter. Print .Back Forward -> Document ID# 205864 2000 Oldsmobile Alero Oil Filter Adapter Removal 1.

. Remove the oil filter adapter.3.

Remove the oil filter bypass valve using a screwdriver or punch to pry the valve out. 5.4.Back Forward -> Document ID# 205864 2000 Oldsmobile Alero Print . Clean the oil filter mounting surface. <.

Reuse the oil pan gasket if the pan is not damaged. Inspect the oil pan gasket for damage before reusing the gasket.Back Forward -> Document ID# 62234 2000 Oldsmobile Alero Print . Replace the gasket if necessary. Remove the oil pan.<. 3. 2. Remove the oil pan bolts. <.Back Forward -> Document ID# 62234 2000 Oldsmobile Alero Print Oil Pan Removal 1.

<. Remove the oil pump bolts. Document ID# 223021 2000 Oldsmobile Alero Print . 2. Remove the balance shaft chain guide.Back Forward -> Oil Pump Removal 1. Remove the balance shaft chain cover. 3.

. Remove the oil pump cover.4.

Remove the oil pump from the balance shaft assembly. <.Back Forward -> Document ID# 223021 2000 Oldsmobile Alero Print .5.

Press against the shafts and note their movement. check the thrust plate for wear. replace the balance shafts. but do not remove the balance shaft chain guide. 3. 7. Remove the balance shaft chain cover. Check the balance shaft end play prior to disassembling the balance shaft housing. 4. 2. If the shafts do not meet specifications. Compare the shafts against specifications. Print . 6.<. Replace the thrust plate if the plate is worn. Loosen. Set up the indicator to read off the back of the shafts.Back Forward -> Document ID# 62283 2000 Oldsmobile Alero Balance Shaft Housing Removal Tools Required J 39579 Camshaft Gear Holder 1. 5. 8. If the end play does not meet specifications and the thrust plate is not worn.

12. 11.9. Clean all of the balance shaft housing parts in cleaning solvent. Remove the balance shaft driven sprocket bolt. it may break. Important Mark the surface of the driven sprocket if the sprocket is going to be reused. Use the J 39579 to hold the crankshaft. If the bolt is not loosened in a clockwise direction. if a new driven sprocket is installed. 13. This will insure that the chain continues to ride on the same tooth surface. sludge and dirt. 14. Remove the balance shaft assembly fasteners and remove the assembly to the bench. Inspect the housings for the following conditions: . Either surface can be placed against the shaft. Remove the varnish. 10. Remove the driven sprocket from the shaft. Notice The balance shaft driven sprocket bolt is left hand threaded and must be loosened by rotating it in a clockwise direction.

Inspect the cover for the following conditions: 1. Cracks 2. sludge and dirt.Back Forward -> Document ID# 62283 2000 Oldsmobile Alero Print . 16.1. Broken guides 3. Scored bearing bores 3. Cracks 2. Remove the varnish. Clean all of the balance shaft chain cover parts in cleaning solvent. 15. Damaged threaded holes Important Replace the entire assembly if the housings are damaged in any way. Worn guides <.

Connecting Rod. Remove the connecting rod cap.<. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands. 7. and Bearing Removal 1. Install thread protectors (3 in length of 3/8 inch ID hose) on the connecting rod bolts before removing the piston and connecting rod assembly. 3. Also mark the orientation. This will ensure the caps and connecting rods are re-assembled properly. Mark the connecting rod and cap with the cylinder position. Rotate the crankshaft to a position where the connecting rod nuts are the most accessible. 5. 6. . 2. Remove the connecting rod nuts. Remove the piston and connecting rod assembly.Back Forward -> Document ID# 63287 2000 Oldsmobile Alero Print Piston. 4.

<.Back Forward -> Document ID# 63287 2000 Oldsmobile Alero Print .

Back Forward -> Document ID# 62241 2000 Oldsmobile Alero Print Crankshaft Rear Oil Seal and Housing Removal 1. Remove the seal housing to the block bolts. Remove the gasket. Use the following procedure in order to remove the oil seal: A. With the wood blocks on a flat surface. position the seal housing and the blocks. Support the oil seal housing for oil seal removal using 2 wood blocks of equal thickness. Damage to the seal will result in an oil leak. 3. 4. 2. Remove the oil seal housing. This will allow for the transmission side of the oil .<. Notice Properly support the seal housing to prevent damage to the seal during removal. B.

Drive the crankshaft seal evenly out of the transmission side of the oil seal housing. C.seal housing to be supported across the dowel pin and the center bolt holes on both sides of the oil seal opening. <.Back Forward -> Document ID# 62241 2000 Oldsmobile Alero Print . Use a small chisel in the relief grooves on the crankshaft side of the oil seal housing.

Remove the bearing inserts from the block. Remove the crankshaft from the block. or the connecting rods. Remove the crankshaft position sensor. 4. 3. Remove the main bearing bolts. Notice Remove the crankshaft carefully in order to avoid damaging the crankshaft journals.Back Forward -> Document ID# 62281 2000 Oldsmobile Alero Print Crankshaft and Bearings Removal 1. Inspect the position sensor for damage.<. . the main bearing inserts. 5. the rod. Remove the bearing caps. 2. Replace the sensor if necessary.

Note the location of the main bearing high spots. Slight roughness may be removed with a fine polishing cloth soaked in clean engine oil. Grooves 6. Use a micrometer or dial indicator to measure the taper and runout. Inspect the threads. Measure the crankshaft journals.6. Roughness 5. Important Replace the crankshaft if cracks. 10. Chips 3. Clean the oil. 12. Note the result for the later selection of bearing inserts. Burrs may be removed with a fine oil stone. or burned spots are found. 8. <. Inspect the keyway. Cracks 2. If they are not in line. Overheating (discoloration) 11. 7.Back Forward -> Document ID# 62281 2000 Oldsmobile Alero Print . and carbon. find the cause and repair the cause. severe gouges. Inspect the corresponding bearing inserts for imbedded foreign material. Inspect the oil passages for obstructions. Gouges 4. If not within limits the crankshaft must be replaced. Inspect the bearing journals and the thrust surfaces for the following conditions: 1. 9. If foreign material exists. sludge. the crankshaft is bent and must be replaced.

Back Forward -> Document ID# 206108 2000 Oldsmobile Alero Engine Block Plug Removal 1.<. Print . Remove the water jacket drain plug.

.2. Remove the oil flow check valve.

3. . Remove the oil passage plug from the front of the engine block. 4. Remove the oil passage plug from the timing chain tensioner gallery.

Remove the rear oil passage plug.5. .

Remove the timing chain housing alignment pins. Remove the oil passage plug from the right side of the engine block.6. 7. .

Remove the oil pan alignment pins.Back Forward -> Document ID# 206108 2000 Oldsmobile Alero Print . <.8.

3. .<. Spray the cylinder bores and the machined surfaces with engine oil. Flush the engine block with clean water or steam. Inspect the threaded holes. 2. Clean the sealing material from the gasket mating surfaces. 5. Boil the engine block in caustic solution. Refer to Thread Repair . Clean the oil passages. J 8087 Cylinder Bore Gauge 2. 4. Clean the blind holes. 7. J 7872 Magnetic Base Dial Indicator Set 1.Back Forward -> Document ID# 206528 2000 Oldsmobile Alero Print Engine Block Cleaning and Inspection Tools Required 1. drill out the holes and install thread inserts. Clean the threaded holes with a rifle brush. If necessary. 6.

Place the dial indicator stem on the transmission mounting bolt hole boss.203 mm (0. .008 in).008 in). Use a flat mill file to remove any nicks. Record the readings obtained from all of the bolt hole bosses. Measure the crankshaft flange runout using the J 7872 . Set the indicator to 0. Inspect the front cover attaching area for nicks. Hold the gauge plate flat against the crankshaft flange. Temporarily install the crankshaft.8. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses: A. Inspect the oil pan rail for nicks.203 mm (0. C.010 in) must be removed. The measurements should not vary more than 0. Use a straight edge and a feeler gage to check the deck surface for flatness. 11. 10. D. 9. Recheck the crankshaft flange runout if the readings vary more than 0. Inspect the mating surfaces of the transmission case. E. Notice A broken flywheel may result if the transmission case mating surface is not flat.254 mm (0. B. Replace the block if more than 0. Carefully machine minor irregularities.

13. 14. Ensure that the crankshaft bearing caps are installed correctly. The arrows should point toward the front of the engine. The crankshaft Important Recondition the engine block with the crankshaft bearing cap bolts installed and tightened to specification. Inspect the crankshaft main bearing bores.12. Replace the engine block if the crankshaft bearing bores are out of specification. . The camshaft 2. Use the J 8087 to measure the bearing bore concentricity and alignment at the following locations: 1.

Ridging Important If the bore is worn beyond the limits. <. refit the bore with oversized pistons.15. Wear 2. Leave sufficient material to allow honing when fitting the piston. Inspect for the following items: 1. Runout 4. Taper 3.Back Forward -> Document ID# 206528 2000 Oldsmobile Alero Print . Use the J 8087 to inspect the cylinder bores. Select the smallest available oversize piston. 16.

Caution Wear safety glasses in order to avoid eye damage. Inspect the crankshaft balancer for the following: 1.Back Forward -> Document ID# 206239 2000 Oldsmobile Alero Print Crankshaft Balancer Cleaning and Inspection 1. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade . Dry the crankshaft balancer with compressed air. 4. Clean the belt grooves of all dirt or debris with a wire brush. rust or other damage must be replaced. Worn. Clean the crankshaft balancer in solvent.<. 3. grooved. 2. grooves. or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring.

2. gouges. the belt grooves should be free of all dirt or debris. Important In order for the belt to track properly. or deteriorated rubber between the hub and pulley <. Worn.Back Forward -> Document ID# 206239 2000 Oldsmobile Alero Print . or other damage that may not allow the belt to track properly. chunking. Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks. 3.emery cloth. Minor imperfections may be removed with a fine file.

<. Damaged ring gear teeth 2. Clean the flywheel in solvent. Print . 3. Inspect the manual transmission flywheel for the following conditions: 1. Caution Wear safety glasses in order to avoid eye damage. Dry the flywheel with compressed air.Back Forward -> Document ID# 206205 2000 Oldsmobile Alero Engine Flywheel Cleaning and Inspection 1. Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel. 2.

Stress cracks around the flywheel-to-crankshaft bolt hole locations 3.3. Inspect the automatic transmission flywheel for the following conditions: 1. or damaged friction surface 4. Damaged ring gear teeth 2.Back Forward -> Document ID# 206205 2000 Oldsmobile Alero Print . Important Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate. Install a new flywheel. grooved. A scored. Welded areas that retain the ring gear onto the flywheel for cracking <.

Back Forward -> Document ID# 42574 2000 Oldsmobile Alero Print Cylinder Boring and Honing Tools Required J 8087 Cylinder Bore Gauge 1. 2. Measure dimension (2) at 100 mm (4 in) below the head gasket surface. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure the cylinder bore for out-of-round and taper.<. .

Lock the dial indicator at zero before removing the dial from the cylinder. . Measure the cylinder bores by setting the J 8087 at zero in the cylinder at the point of the desired measurement.3. with the gauge at the same zero setting as when the gauge was removed from the cylinder. Measure across the gauge contact points with an outside micrometer.

If honing is not required. cause excessive oil consumption. Refer to Piston and Connecting Rod Installation. 5. by themselves. 6. clean the cylinder bores with hot water and detergent. bore the cylinder for oversize piston and rings.005 in). If dimension (1) is larger than dimension (2) by 0.4. Dry the bore. Clean the bore thoroughly with soap and water. All oversize service pistons are held to the same weights as the standard size pistons.Back Forward -> Document ID# 42574 2000 Oldsmobile Alero Print . lightly break the glaze with a hone. 6. 2. The honing stones must be clean.13 mm (0. Apply clean engine oil to the bore after washing and drying the bore. Replace the piston rings. 1. 3. <. Rub clean engine oil in the bore. do not rebore all the cylinders to the same oversize in order to maintain engine balance. Remeasure the bore. 7. Move the hone slowly up and down to produce a 45 degree cross hatch pattern. 1. and straight. sharp. 2. If relatively few bores require correction. Fine vertical scratches made by the ring ends do not. Do not hone the cylinder in order to remove these scratches. 5. 4. If the bore is glazed but otherwise serviceable.

Damage to the teeth of the crankshaft position reluctor ring may effect OBD II system performance. Clean the crankshaft of the following elements: . J 8087 Cylinder Bore Gauge Important Use care when handling the crankshaft. 1. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring.Back Forward -> Document ID# 649407 2000 Oldsmobile Alero Print Crankshaft and Bearings Cleaning and Inspection Tool Required 1.<. J 7872 Magnetic Base Dial Indicator Set 2.

Sludge 3. Carbon 2.1. Dry the crankshaft with compressed air. Thoroughly clean all oil passages and inspect for restrictions or burrs. . Oil 2. 3. Important Reluctor ring teeth should not have imperfections on the rising or falling edges. Imperfections of the reluctor ring teeth may effect OBD II system performance. Perform a visual inspection of the crankshaft for damage. 4. Caution Wear safety glasses in order to avoid eye damage.

wear. 7. 9. Inspect the crankshaft journals for wear (1). Inspect the crankshaft journals for grooves or scoring (2). Inspect the crankshaft journals for pitting or imbedded bearing material (4). 6. Inspect the woodruff keys (crankshaft balancer) (1). Inspect the crankshaft journals for scratches or wear (3).5. the keyway (2). 8. Journals should be smooth with no signs of scoring. and the threaded hole (3) for damage. or damage. .

11. Measure the crankshaft journals for out-of-round.10. Measure the crankshaft journals for taper. Refer to Engine Mechanical Specifications . . Refer to Engine Mechanical Specifications .

Refer to Engine Mechanical Specifications. 14. 13. Use the J 7872 in order to measure the runout of the crankshaft rear flange. . Refer to Engine Mechanical Specifications .12. Using wooden V blocks. Replace or repair the crankshaft if the measurements are not within specifications. support the crankshaft on the front and rear journals. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals.

until the tight crankshaft bearing is located. Inspect the crankshaft for binding. In order to properly measure the crankshaft end play. insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance. A. foreign matter between the crankshaft bearing and the engine block or the crankshaft bearing cap. Turn the crankshaft to check for binding. or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing. the crankshaft bearing caps. the crankshaft bearings. D.15. one crankshaft bearing cap at a time. loosen the crankshaft bearing bolts and studs. B. verify that the correct size crankshaft bearing has been installed. and the fasteners must be installed into the engine block and the bolts and studs tightened to specifications. Firmly thrust the end of the crankshaft first rearward then forward. This will line up the rear crankshaft bearing and the crankshaft thrust surfaces. With the crankshaft pushed forward. C. . the crankshaft. Refer to Engine Mechanical Specifications . If the correct end play cannot be obtained. If the crankshaft does not turn freely. Burrs on the crankshaft bearing cap.

Inspect the crankshaft bearings for craters or pockets.16. . Flattened sections on the crankshaft bearing halves also indicate fatigue.

. both the upper and lower halves of the crankshaft bearing should be replaced. If the lower half of the bearing is worn or damaged. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material. Inspect the crankshaft bearings for excessive scoring or discoloration. Inspect the crankshaft bearings for improper seating indicated by bright.17. the upper half of the crankshaft bearing should also be suitable for use. 18. Generally. 19. polished sections of the bearing. if the lower half of the crankshaft bearing is suitable for use.

If they are not in line. the crankshaft is bent and must be replaced. Burrs may be removed with a fine oil stone. Grooves 6. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions: 1. 20. Roughness 5.Important If cracks. Slight roughness may be removed with a fine polishing cloth soaked in clean engine oil. Inspect the corresponding crankshaft bearings for embedded foreign material and determine the source. Chips 3. Important Note the location of the crankshaft main bearing high spots. Cracks 2. Gouges 4. the crankshaft must be replaced. . Overheating (discoloration) 21. severe gouges or burned spots are found.

22. Inspect the outer surfaces of the crankshaft bearings for the following conditions: 1. This may indicate a bent crankshaft or a tapered bearing journal. 23. Important The crankshaft bearings are of the precision insert type. or file bearing inserts. If the bearing surface of the insert is touched with bare fingers. Looseness or rotation indicated by flattened tangs and wear grooves 24.) . Grooving (Grooves are caused by irregularities of the crankshaft thrust surface. The crankshaft bearings are available in standard and various undersizes. shim. Wear . Inspect the thrust surfaces of the main thrust bearing for the following conditions: 1.surface wear indicates either movement of the insert or high spots in the surrounding material (spot wear). 2. Notice Do not scrape. Inspect the crankshaft bearings for uneven side-to-side wear. the skin oil and acids will etch the bearing surface. Overheating or discoloration 3. Wear 2.

B. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure: A. Tighten the bearing cap to specification. 25. There are two methods to measure bearing clearance. Measuring Crankshaft Bearing Clearances (Micrometer Method) Measure the bearing clearance to determine the correct replacement bearing insert size. Micrometer method yields measurement from which the bearing clearance can be computed. No taper or out-of-round should exist. Measure the bearing bore for taper and out-of-round using the J 8087 .Important If crankshaft bearing failure is due to other than normal wear. Inspect the crankshaft or connecting rod bearing bores. Important . investigate the cause. Micrometer method gives more reliable results and is preferred.

Measuring Crankshaft Bearing Clearances (Plastic Gauge Method) Plastic gauge method yields the bearing clearance directly. Tighten the bearing cap bolts to specification. 90 degrees apart. Measure the crankshaft bearing journal diameter with a micrometer in several places. Average the measurements. Measure the crankshaft bearing journal taper and runout. 5. 2. If the specified clearances cannot be met. 7.Do not mix inserts of different nominal size in the same bearing bore. the crankshaft journals must be reconditioned and undersized bearing inserts installed. Important . 6. Install the crankshaft bearing inserts. 4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer. 3. Select a set of bearing inserts that will produce the desired clearance. Plastic gauge method does not give any indication of bearing run-out. 1.

Measuring Connecting Rod Bearing Side Clearance . 2. the crankshaft bearing caps are tapped into the cylinder block cavity using a brass. Install the bearing caps. Measure the gauging plastic at the widest point with the scale printed on the gaging plastic package. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Select a set of bearing inserts that will produce the desired clearance. Install the bearing cap bolts to specification. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap. Remove the bearing cap. Notice In order to prevent the possibility of cylinder block or crankshaft bearing cap damage. 4. leaving the gauging plastic in place. lead. Remove the gauging plastic. Important Do not rotate the crankshaft. 1. Clean the used bearing inserts. 3. 8. or a leather mallet before the attaching bolts are installed. Place a piece of gauging plastic across the entire bearing width.Do not mix inserts of different nominal size in the same bearing bore. 9. 5. 6. Install the used bearing inserts. 7.

<.1. Refer to Engine Mechanical Specifications . 2. The connecting rod side clearances may also be measured with a dial indicator set.Back Forward -> Document ID# 649407 2000 Oldsmobile Alero Print . Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance.

<. Disassemble the piston rings.Back Forward -> Document ID# 206368 2000 Oldsmobile Alero Piston and Connecting Rod Disassemble Caution Handle the piston carefully. Use a suitable tool in order to expand the rings. The piston rings must not be reused. 1. Worn piston rings are sharp and may cause bodily injury. Print .

2. No special tools are required to remove or install the retainers or the piston pins. Remove the piston pin retaining clips. 3. If the retainers are not damaged. reuse the retainers. Ensure that the piston pin is not damaged. <.Important Two retainers hold the piston pins in place. Remove the piston pin.Back Forward -> Document ID# 206368 2000 Oldsmobile Alero Print .

2. Measure the piston pin to connecting rod bore using the following procedure: A. Scratches or abrasion on the rod bearing seating surface 3.Back Forward -> Document ID# 689460 2000 Oldsmobile Alero Print Piston. Using an inside micrometer. Connecting Rod. Using an outside micrometer. 4. or cracked 2. take two measurements of the piston pin in the area of the connecting rod contact. and Bearings Cleaning and Inspection Connecting Rod Measurement 1. Signs of being twisted. Clean the connecting rods in solvent and dry with compressed air. B. . nicked.<. measure the connecting rod piston pin bore. clean the bores in a circular direction with a light emery paper. Inspect the connecting rods for the following conditions: 1. bent. DO NOT scrape the rod or rod cap. If the connecting rod bores contain minor scratches or abrasions.

Worn piston pin bores (3) 4. 2. If there is evidence of pin bore or pin scoring. Ring grooves for nicks. skirts. replace the piston pin. Ensure that the oil ring holes and slots are clean. Scuffed or damaged skirts (2) 6. Clean the piston skirts and the pins with a cleaning solvent. Piston Measurement 1. Inspect the pistons for the following conditions: 1.0013 in). D. Replace pistons that show any signs or damage or excessive wear. 7. 5. burrs that may cause binding 3. replace the connecting rod. 3. Subtract the piston pin diameter from the piston pin bore diameter. 5. or pin bosses 2. If there is still excessive clearance. 6. The clearance should not be more than 0. replace the rod and pin assembly. DO NOT wire brush any part of the piston. Measure the piston pin bore to piston pin clearances using the following procedure: . Clean the piston ring grooves. If there is excessive clearance.C.032 mm (0. Warped or worn ring lands 4. Eroded areas at the top of the piston (1) 5. Cracked ring lands.

the piston rings must be replaced.76 mm (0.00008-0.002-0. B. . Compare the measurements with those provided below: 1. Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm or 1 inch down from the deck surface).0299 in). measure the piston pin bore. The clearance should be within 0. D.A.00043 in). Using an inside micrometer.25-0. 6. C. Piston pin bores and pins must be free of varnish or scuffing.011 mm (0. If the clearance exceeds the provided specifications. determine which component is out of specification. Measure the end gap of the piston ring with feeler gages. B. Ensure that the ring is square with the cylinder bore by positioning the ring with the piston head. Use an outside micrometer to measure the piston pin in the piston contact areas. D. The second compression ring end gap should be 0.30 mm (0.15-0.40 mm (0.0157 in). 3.012 in). C.0098-0. Measure the piston ring end gap using the following procedure: A. 2. The oil ring end gap should be 0. If the clearance is excessive.006-0. Repeat the procedure for all the piston rings.0098-0.25-0. E. The top compression ring end gap should be 0. Subtract the measurement of the piston pin bore from the piston pin.

8. If any binding is caused by a burr on the corner of the ring groove. Install the 2nd compression ring with the dimple facing up.070 mm (0. If any binding is caused by a distorted piston ring. C. install a new piston. If the new ring does not reduce the clearance to 0. With the piston ring on the piston. Roll the piston ring entirely around the piston ring groove. carefully dress the groove corner with a fine file.0028 in) or less.070 mm (0. E.0028 in). 10. 9. replace the piston ring. use feeler gages to check clearance at multiple locations. B.080 mm (0. D.0031 in). Measure the piston ring side clearance using the following procedure: A. . The clearance between the surface of the top piston ring and the ring land should be no greater than 0. If the clearance is greater than specifications. replace the ring. The top compression ring may be installed with either side up.080 mm (0. There is a locating dimple on the 2nd compression ring near the end for identification of the top side. The clearance between the surface of the second piston ring and the ring land should be no greater than 0. install a new piston.7.0031 in) or less. If the new ring does not reduce the top ring side clearance to 0.

Measure piston width using the following procedure: A.0031 in). measure the width of the piston 42 mm (1.Back Forward -> Document ID# 689460 2000 Oldsmobile Alero Print . Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter.11.078 mm (0.0010-0. B. replace the piston. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification. <. The proper clearance specification for the piston is 0. 12.026-0. C.65 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. Using an outside micrometer.

the engine block cylinder bores must not have excessive wear or taper.Back Forward -> Document ID# 589169 2000 Oldsmobile Alero Piston Selection Tools Required J 8087 Cylinder Bore Gauge Important Measurements of all components should be taken with the components at normal room temperature.<. For proper piston fit. Print .

1.5 in) from the top of the cylinder bore. 4. Measure at a point 64 mm (2. Measure the J 8087 with a micrometer and record the reading. Inspect the engine block cylinder bore. 2. they are within specifications. Refer to Piston. after cleaning and inspection.A used piston and pin set may be reinstalled if. Connecting Rod. and Bearings Cleaning and Inspection 3. Inspect the piston and the piston pin. Refer to Engine Block Cleaning and Inspection . Use the J 8087 to measure the cylinder bore diameter. .

With a micrometer or caliper at a right angle to the piston. hone the cylinder bore or replace the cylinder block. 10.5. 8. 9. 6. select another piston and measure for the clearances. 7. Refer to Engine Mechanical Specifications . When the piston-to-cylinder bore clearance is within specifications. If the proper clearance cannot be obtained.Back Forward -> Document ID# 589169 2000 Oldsmobile Alero Print . <. mark the top of the piston using a permanent marker for installation to the proper cylinder. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. For proper piston-to-bore clearance. measure the piston 11 mm (0. If the proper fit cannot be obtained. Refer to Separating Parts .437 in) from the bottom of the skirt.

The oil squirt hole at the lower end of the connecting rod must face the exhaust side of the piston. Assemble the connecting rod and the piston. 1. Notice Print .<.Back Forward -> Document ID# 206374 2000 Oldsmobile Alero Piston and Connecting Rod Assemble Important Install the piston onto the connecting rod with the arrow oriented toward the front of the engine.

Install the following components of the oil control ring assembly (bottom ring): A. Install the second piston pin retainer. Notice Use a piston ring expander to install the piston rings. The expander B. The rings may be damaged if expanded more than necessary. D. Ensure that the piston moves freely. Use the following procedure in order to assemble the piston pin and the retainer: A.Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage. Install the connecting rod and the piston pin. C. 3. The upper oil control ring Oil control ring gaps should be oriented 180° apart. E. 2. . The lower oil control ring C. Install one side of one piston pin retainer into the retaining groove. B. Push the piston pin until the pin bottoms in the previously installed retainer. Coat the piston pin with oil. Rotate the retainer until it is fully seated in the groove.

4.Back Forward -> Document ID# 206374 2000 Oldsmobile Alero Print . Install the upper compression ring (top ring). Place the manufacturer's mark facing up. <. Install the lower compression ring (second ring). 5.

3. Inspect the camshaft sprocket bolt holes for damaged threads (3). 2. 4.<. Inspect the camshaft sprocket alignment pin for damage and straightness (4). Inspect the valve lifters for scoring where the valve lifters contact the camshaft. Inspect the camshaft journals and lobes for wear or scoring (1. 2).Back Forward -> Document ID# 208636 2000 Oldsmobile Alero Camshaft and Housing Cleaning and Inspection 1. Print .

Back Forward -> Document ID# 208636 2000 Oldsmobile Alero Print . Inspect the camshaft housing and cover for cracks or other signs of damage. Inspect the camshaft housing and cover for scoring in lifter bores and camshaft journals. Wash the camshaft housing and cover in solvent. 3. Remove all traces of RTV from the power steering pump seal area on the intake camshaft housing and cover. Clean the camshaft housing and cover.5. 2. 6. 1. <.

Replace the timing chain guides if wear exceeds 1. 2. Print .045 in).<. Inspect the timing chain guides for cracking or wear.12 mm (0.Back Forward -> Document ID# 208662 2000 Oldsmobile Alero Timing Chain and Sprockets Cleaning and Inspection 1.

Inspect the retaining tab for wear or damage.3. 5. 4. Replace the timing chain tensioner shoe if wear exceeds 1. Inspect the timing chain tensioner shoe for wear.045 in). Replace components as necessary. .12 mm (0.

chipping. Inspect the camshaft sprocket teeth and chain for signs of excessive wear. Inspect the timing chain and sprockets for wear. or seizure of the timing chain links. 8. Inspect the camshaft sprocket faces for signs of movement. Inspect the alignment pin holes in the camshaft for cracking or damage. 9.Back Forward -> Document ID# 208662 2000 Oldsmobile Alero Print .6. 7. <.

Print .Back Forward -> Document ID# 208725 2000 Oldsmobile Alero Cylinder Head Disassemble Tools Required 1. Remove the O-ring. 2.<. 3. J 8062 Valve Spring Compressor 2. J 36017 Valve Guide Seal Remover 1. Remove valve train components. Remove the coolant outlet.

Important Ensure that the valve train components are kept together and identified in order for proper re-installation in their original position. Compress the valve spring. using the J 8062 . 4. .

6. 8. 7. Remove the valve keys. . Remove the valve spring. 9. Remove the valve spring seat (exhaust only). Slowly release the J 8062 from the valve spring assembly.5. Remove the valve retainer.

Notice Do not damage the valve guide. 13. 12. Remove the valve.Back Forward -> Document ID# 208725 2000 Oldsmobile Alero Print . Remove the valve seal. 10. Remove the remaining valves. Remove any burrs that have formed at the key groove by chamfering the valve stem with an oil stone or a file. Remove the valve rotator (intake only). <. 11. using the J 36017 .

The valves may be lightly lapped to the valve seats. Burrs and minor scratches may be removed with an oil stone. Clean the valve guides. Bent or distorted valves must be replaced. 10. the valves must be replaced. The valve tip may be reconditioned by grinding. If pieces are broken off. 9. 8. 7. Ensure that the new surface is perpendicular to the valve stem. Use V blocks. and varnish. Replace the valve if chipped or worn. 2. 3. Replace the valve if the face is grooved. 6. Inspect the valve keeper groove for chipping or wear. 5. Clean the valves of carbon. Inspect the valve face for grooving. Cylinder Head and Gasket Surface Cleaning and Inspection . 1. Valve faces cannot be machined.<. Varnish can be removed by soaking the valves in Parts Immersion Solvent GM P/N United States 12345368. 11. Carbon can be removed with a wire brush. Inspect the valve stem for straightness and the valve head for bending or distortion.Back Forward -> Document ID# 208750 2000 Oldsmobile Alero Print Cylinder Head Cleaning and Inspection Valve Cleaning and Inspection Important Do not scratch the valve stem with the wire brush. Inspect the valve stem for wear. inspect the corresponding piston and cylinder head area for damage. Clean the deposits from the valve face. 4. Inspect the valve face for burning or cracking. If worn or damaged. oil. Inspect the valve stem for burrs and scratches. Follow the grinder manufacturer's instructions. GM P/N Canada 10953514 or an equivalent.

Install the self-threading screw. 2. Inspect the cylinder head gasket and mating surfaces for leaks. Chips or debris in the cylinder head bolt holes 6. Improper installation 2. Remove the spark plugs. Bolt holes in the cylinder block not drilled or tapped deep enough 7. D. Drill a hole in the plug. Other . Missing. C. B. off location or not fully seated dowel pins 4. Loose or warped cylinder head 3. Corrosion in the seal area around the coolant passages 5. E. If the gasket has failed. Use the following procedure to remove the cylinder head cup plugs: A. corrosion and blow-by.1. use the following faults to determine the cause: 1. Obtain a suitable self-threading screw. Pry out the plug and discard it.

2. Replace all suspect bolts. 10. Clean the remains of the sealer from the plug holes. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools. Important . 5.3. 4. The cylinder head may be reused if corrosion is found only outside a 4 mm (0. Inspect the cylinder head gasket surface. 6. Remove all varnish. soot and carbon to the bare metal. 9. Use a nylon bristle brush. 8. Clean the threaded holes. Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (1). Clean the cylinder head bolts.375 in) band around each combustion chamber (3). Clean the cylinder head. Important Do not use a wire brush on any gasket sealing surface. 3. 1. 7. Clean the valve guides.

sand inclusions and blow holes. <.076 mm (0. These surfaces may be reconditioned by parallel grinding. resurface the cylinder head before reusing. Inspect the cylinder head deck for corrosion. 12. The threads may be reconditioned with thread inserts.25 mm (0. If the warpage is less than 0. 2. Use the following steps to determine the amount of reconditioning needed: 1. 14.25 mm (0. If the warpage is between 0. discard the cylinder head.Do not attempt to weld the cylinder head.076 mm (0. 3. the intake. reuse the cylinder head. Inspect the cylinder head deck.Back Forward -> Document ID# 208750 2000 Oldsmobile Alero Print .003 in) and 0. and exhaust manifold mating surfaces for flatness. 13. Inspect the sealing surfaces. 16.003 in). 15. Replace the cylinder head instead. Inspect all the threaded holes for damage. Inspect the cylinder head cup plugs. 11. If the warpage is over 0. but do not resurface.010 in).010 in).

Back Forward -> Document ID# 209909 2000 Oldsmobile Alero Valve Guide Reaming/Valve and Seat Grinding Tools Required J 36019-A Valve Guide Reamer 1. Ream the valve guide bores for the oversize valves as necessary.<. Recondition the valve seat after reaming the valve guide bores. 3. Reconditioning the valve seats is very important. 4. 2. Ream the valve guides for oversize valves using the J 36019-A if the clearance exceeds the specifications. Service valves are available in the standard and 1 mm oversize. Important Print .

<. this must be done first. 3. 2. Inspect the valve seats for excessive wear and burned spots. The valves must seat perfectly for the engine to deliver optimum power and performance. Valve seats may be reconditioned by grinding.05 mm (0. it is essential that the valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the guide. The 20 degree stone will lower the seat and the 70 degree stone will raise the seat. Regardless of what type of equipment is used. 5. 4. it is essential that the valve guide is cleaned properly.Because the valve guide serves to support and center the valve grinder. 1. If grinding results in the new seat being too wide it may be narrowed by using a 20 degree or 70 degree stone. The valve seats should be concentric to within 0. If the valve guide requires reaming. Cooling the valve heads is another important factor. Good contact between each valve and its seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away. Do not attempt to reface valves from the Twin Cam engine.Back Forward -> Document ID# 209909 2000 Oldsmobile Alero Print .031 in) total indicator reading. Replace any valve that is not in serviceable condition.

<. Print .Back Forward -> Document ID# 208728 2000 Oldsmobile Alero Cylinder Head Assemble Tools Required 1. Install the new cylinder head cup plug if necessary. J 36660-A Torque Angle Meter 2. J 9666 Valve Spring Tester 1. install the spark plugs after the cylinder head has been installed on the engine. Coat the plugs with Sealer GM P/N 12345382 or an equivalent. J 8062 Valve Spring Compressor 3. Notice In order to avoid damage.

Install the valve mechanism. . The valve guides may be reamed oversize and an oversized valve may be installed. Packing of chips or carbon may result in the reamer jamming into the valve guide or broken reamer flutes. Compare the valve guide ID and the valve stem measurements. B. Notice Clean the valve guides before reaming. Refer to engine specifications for allowable clearance. Install the valve spring retainers. Use the following steps to measure the valve guide clearance: A. 5. Refer to engine specifications for the tolerances. measure the valve guide ID with a micrometer. Do not knurl the valve guides. Inspect the valve springs.2. 4. With a hole gauge. measure the valve stem. 3.

6. 10. Use the following steps to measure valve runout: A. Apply a dab of Prussian blue on the entire valve face. Apply a dab of Prussian blue on the valve seat and repeat the check. Replace as required. . 7. Install the rotator (intake valves only). Unparallel spring ends 3. The traces of Prussian blue transferred to the valve face indicates valve face concentricity. Look for the following conditions when inspecting the valve springs: 1. Recondition the valve seat or replace the valves. Seat the valve. Clean all traces of Prussian blue. Expanded height 2. The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. if required. 9. Inspect the valve spring seating surface of the valve rotators and spring seats for wear or gouging. B. but do not rotate the valve. Assemble the valves. C. D. 8. Spring tension using J 9666 .

. Install the spring valve (intake valves only).11.

Fully seat the seals on the valve guides.12. Install the spring. . Compress the valve spring. 14. 13. Install the new valve seals. Install the retainer. 15. Install the spring seat (exhaust valves only). 16. Use the J 8062 .

. 19.17. Install the valve keys. Inspect for proper valve key seating. 18. Slowly release the J 8062 from the valve/spring assembly.

20. Measure from the base of the valve spring to the top of the valve. . and other components. Measure the valve installed height using a ruler. Install the remaining valves. 21. Refer to Engine Mechanical Specifications for the correct specification. springs.

22. Notice Use the correct fastener in the correct location. <. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install the coolant outlet. Inspect the O-ring for damage. lubricants. If the O-ring is damaged. replace the O-ring. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Tighten Tighten the bolts to 26 N·m (19 lb ft). Do not use paints. These coatings affect fastener torque and joint clamping force and may damage the fastener.Back Forward -> Document ID# 208728 2000 Oldsmobile Alero Print . 23.

Remove the oil pump from the balance shaft housing.Back Forward -> Document ID# 208796 2000 Oldsmobile Alero Oil Pump Disassemble 1. Disassemble the oil pump gerotor cover from the oil pump housing. 2. Print .<.

<.Back Forward -> Document ID# 208796 2000 Oldsmobile Alero Print . Remove the roll pin with a punch. Remove varnish. 4. Clean all of the parts in cleaning solvent. Disassemble the pressure relief valve. sludge. and dirt.3.

Galling 3. 2. Damaged threads 5.<. Porous or damaged casting 4. Clean all of the oil pump parts in solvent. Inspect the gerotor for the following conditions: 1. Cracks 2. Chipping 2. Scoring 3. Excessive wear or galling 3. Excessive wear Print . 4. Replace the valve if the valve is damaged.Back Forward -> Document ID# 208801 2000 Oldsmobile Alero Oil Pump Cleaning and Inspection 1. Inspect the pressure relief valve for damage. Inspect the pump cover housing for the following conditions: 1.

The inner gerotor tip clearance 3.Back Forward -> Document ID# 208801 2000 Oldsmobile Alero Print . The gear dimensions 6. Measure the following parts: 1. <. The gerotor cavity depth 2. Replace the pump as an assembly if the housing or gears are worn beyond specifications. The outer gerotor diameter clearance 4.5.

.Back Forward -> Document ID# 208805 2000 Oldsmobile Alero Print Oil Pump Assemble 1. 2. Assemble the gerotor in the housing. This will ensure that there is oil pressure immediately on start-up and will prevent engine damage. Fill the oil pump with petroleum jelly to prime the oil pump. Notice Fill oil pump cavities with petroleum jelly prior to installation. 3. Lubricate the gerotor gears with clean engine oil.<.

Assemble the pressure relief valve. .4.

<. 6. Assemble the pump housing to the balance shaft assembly.Back Forward -> Document ID# 208805 2000 Oldsmobile Alero Print . Assemble the pump cover to the oil pump housing.5.

Inspect the front cover for any cracks.<. 3.Back Forward -> Document ID# 639593 2000 Oldsmobile Alero Print Engine Front Cover Cleaning and Inspection 1.Back Forward -> Document ID# 639593 2000 Oldsmobile Alero Print . replace it with a new gasket. Clean all sealing surfaces. <. If the gasket is damaged. Inspect the front cover gasket for any damage. 2. 4. Inspect all sealing surfaces for burrs and imperfections.

2.Back Forward -> Document ID# 206682 2000 Oldsmobile Alero Print Intake Manifold Cleaning and Inspection 1.<. <. Clean the intake manifold mating surfaces. 3. 5.Back Forward -> Document ID# 206682 2000 Oldsmobile Alero Print . Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary. Inspect the intake manifold for cracks near compression limiters. Inspect the intake manifold for damage. Replace the intake manifold as necessary. 4.

Remove the oxygen sensor prior to cleaning the manifold. Clean the exhaust manifold in solvent. Upon installation of the exhaust manifold. Caution . 2. Remove the oxygen sensor from the manifold. install a NEW gasket.<. 2. 1. Do not reuse the exhaust manifold-to-cylinder head gaskets. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.Back Forward -> Document ID# 206674 2000 Oldsmobile Alero Print Exhaust Manifold Cleaning and Inspection Important 1. do not submerge the oxygen sensor in cleaning solvent.

Wear safety glasses in order to avoid eye damage. 3.Back Forward -> Document ID# 206674 2000 Oldsmobile Alero Print . Dry the exhaust manifold with compressed air. <. 4. Use a straight edge and a feeler gauge and measure the exhaust manifold mounting face for warpage.010 in).25 mm (0. 5. Inspect for a loose or damaged heat shield. may cause an exhaust leak and may effect OBD II system performance. An exhaust manifold face with warpage in excess of 0. Exhaust manifolds not within specifications must be replaced.

<. 2. 6. Clean the oil pan mating surface.Back Forward -> Document ID# 206703 2000 Oldsmobile Alero Print . Repair or replace the oil pan as necessary. Inspect the oil pan for cracking near the pan rail and the transmission mounting points. 5. 3. Remove all the sludge and the oil deposits. Inspect the threads for the engine oil drain plug.<. Clean the oil pan. Inspect the oil pan for cracking resulting from impact or flying road debris. 4.Back Forward -> Document ID# 206703 2000 Oldsmobile Alero Print Oil Pan Cleaning and Inspection 1.

Pry the screen out with a suitable tool. Print .<. Remove the oil pump pick-up screen.Back Forward -> Document ID# 209947 2000 Oldsmobile Alero Balance Shaft Cleaning and Inspection Balance Shaft Housing Disassembly 1.

Remove the balance shaft and gear subassemblies from the housing. Loosen all of the housing bolts.2. 3. 4. . Separate the balance shaft housings.

Do not scratch or gouge the housing. Carefully remove the bearing halves from the housing.5. .

Remove the varnish. Inspect the balance shaft chain cover for the following conditions: 1. sludge.0 mm (0. sludge and dirt. Balance Shaft Chain Cover Inspection 1. 2. 2. Cracks 3. Inspect the driven sprocket for the following conditions: . 7. Inspect the balance shaft housings for the following conditions: 1. sludge and dirt. Clean all of the driven sprocket parts in cleaning solvent. Mounting hole damage 3. Broken teeth 3.6. Plastic worn off of the guide 2.080 in). and dirt. Clean all parts in cleaning solvent. Inspect the balance shaft chain guide for the following conditions: 1. Chips 4. Balance Shaft Driven Sprocket Inspection 1. Inspect the driven sprocket teeth for the following conditions: 1. 2. sludge and dirt. If the housings are damaged in any way. replace the entire assembly. Damaged threaded holes 3. Scored bearing bores 3. Clean all parts in cleaning solvent. Remove the varnish. Remove varnish. Cracks 2. Balance Shaft Housing Inspection 1. Cracks 2. Remove the thrust plate bolts. Remove the thrust plate. 2. Clean all of the balance shaft chain guide parts in cleaning solvent. Remove varnish. Broken or worn guides Balance Shaft Chain Guide Inspection 1. Ground off teeth 3. Replace the balance shaft chain guide if the guide has grooves deeper than 2. Bent teeth 2.

Burrs on the journals 3. Missing teeth 2. 2. Measure the journals for the following conditions: 1. Cracks 4. sludge and dirt. Replace the bearings any time the shafts are replaced. The taper is angled towards the counter weights. Clean all of the balance shaft and gear assembly parts in cleaning solvent. Replace both shafts even if only one needs to be replaced. Damaged bolt hole 3. Missing pieces 3. Inspect the balance shaft for the following conditions: 1. An out of round condition . Inspect the gears for the following conditions: 1. 4. 5. Scores on the journals 2. Chipped teeth Notice Do not attempt to resurface the balance shaft journals. Remove the varnish. Scored surfaces Balance Shaft and Gear Assembly Inspection 1. Burrs 2.1. The correct outside diameter 2. They have a slight taper and resurfacing the journal may remove the taper.

Hold the other shaft. Important If the shafts are not pulled in the same direction. .6. Place the gear and the shaft assemblies in the housing. Ensure that the timing marks are aligned. the gears will climb away from each other causing the reading to be incorrect. Do not rotate the gear as you will get incorrect readings. The bearings must be installed. Measure the gears for backlash using the following procedure: A. Set up the dial indicator to read off of one tooth of the balance shaft gear. B. C.

Method B does not indicate bearing or journal runout. Note the total movement and compare the movement to specifications. Method B yields the bearing clearance directly. While pulling both shafts in the same direction. Balance Shaft Bearing Inspection 1. Discoloration Balance Shaft Bearing Clearance Measurement Important Method A yields measurements from which the bearing clearance can be computed. Replace both the gear and the shaft assemblies if the backlash is out of specification. Do not mix inserts of different nominal size. Clean the bearings in cleaning solvent. Gouges 2. sludge and dirt. 9. 2. gently rock the gear in the direction of the rotation to ensure the proper measurements. Remove the varnish. 8. Scoring 3. Inspect the bearings for the following conditions: 1.7. .

Important Do not rotate the shafts after the gauging plastic has been placed on the journals. 4. The plastic will be wider on the journal end away from the counter weight. Worn or missing rollers Notice Do not attempt to remove a link from the chain. If you are replacing the inserts. 6. Place a piece of gauging plastic across the entire journal surface. Method B 1. Disassemble the housing. 2. 2. Clean all parts in cleaning solvent. This is because the journals are purposely tapered. resulting in a loss of oil pressure and engine . Average the measurements. Remove the varnish. Inspect the trust plate for the following conditions: 1. Measure the flattened plastic at the widest point with the scale on the gauging plastic package. Balance Shaft Thrust Plate Inspection 1. Gouges 2. 3. 2. Wipe all of the oil off of the balance shaft journal and the bearing surfaces. Use a micrometer in order to measure the balance shaft journal diameter in several places approximately 90 degrees apart. Damaged links 2. Remove the varnish. Compare the measurements to engine specifications. sludge and dirt. Remove all of the gauging plastic from the bearing and or journal. Inspect the balance shaft drive chain for the following conditions: 1. 5. measure using the new inserts. making the readings wrong. Burrs Balance Shaft Drive Chain Inspection 1. The chain may be weakened and may fail. If the shafts are rotated the gauging plastic will smear. sludge and dirt. 2. 4. 3. Compute the taper and runout to ensure they are within the specification limits. Refer to specifications for allowable limits. 7. Use an inside micrometer in order to measure the bearing insert ID.Method A 1. Clean the balance shaft drive chain parts in cleaning solvent. Assemble the upper and lower housings and tighten all the fasteners in sequence to specification. Subtract the bearing measurement from the journal diameter in order to get the clearance.

Scored surfaces 4. Broken teeth 3. inspect the crankshaft for burrs or nicks. If the sprocket is to be replaced. Replace the chain and sprockets if the chain tension cannot be adjusted to specification before the chain hits the housing or the guide comes to the end of its travel. and the dirt. Inspect the sprocket teeth for the following conditions: 1. 2. Balance Shaft Housing Assembly . Clean all of the drive sprocket parts in cleaning solvent. Balance Shaft Drive Sprocket Inspection 1.damage. the sludge. Ground off teeth 3. Remove the varnish. Chips 4. Inspect the sprocket for the following conditions: 1. 3. Bent teeth 2. Burrs 2.

shafts and gears with GM P/N 9985705 or an equivalent. Carefully install the bearing halves into the housing. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Replacement fasteners must be the correct part number for that application. 2. Notice Use the correct fastener in the correct location. 4. Do not use paints. Lubricate the bearings. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install the thrust plate. Tighten Tighten the thrust plate bolts to 13 N·m (115 lb in). . Install the thrust plate bolts.1. Do not scratch or gouge the housing or the bearings. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. lubricants. 3.

Ensure that the timing marks on the balance shaft gears are lined up. 7. 6. Install the balance shaft and gear assemblies into the housing.Back Forward -> Document ID# 209947 2000 Oldsmobile Alero Print . Tighten Tighten the fasteners to 5 N·m (44 lb in). 9. Install the housing fasteners. <.5. 8. Important Do not install the oil pump pick-up screen until the housing fasteners have been tightened to final specifications. Install the upper housing half to the lower housing half. Tighten the fasteners to final specifications after the housing assembly has been installed on the engine.

<. When any internal engine parts are serviced.Back Forward -> Document ID# 42592 2000 Oldsmobile Alero Print . it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. An automobile engine is a combination of many machined. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Lubricate all moving parts with engine oil or a specified assembly lubricant. honed. polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. Throughout this section.Back Forward -> Document ID# 42592 2000 Oldsmobile Alero Print Service Prior to Assembly The importance of cleanliness during assembly cannot be overstated. This will provide lubrication for initial start up. Dirt or debris will cause engine damage. care and cleanliness are important. This is considered standard shop practice even if not specifically stated. <.

Install the engine block coolant drain plug. GM P/N Canada 10953480 to the plug. 2. .<. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Notice Use the correct fastener in the correct location.Back Forward -> Document ID# 206752 2000 Oldsmobile Alero Print Engine Block Plug Installation 1. Replacement fasteners must be the correct part number for that application. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Do not use paints. These coatings affect fastener torque and joint clamping force and may damage the fastener. lubricants. Apply gasket paste GM P/N United States 12346004.

5. GM P/N Canada 10953480 to the plug. Tighten Tighten the coolant jacket plug to 30 N·m (22 lb ft).3. Install the timing chain tensioner gallery oil passage plug. 4. Install the coolant jacket plug. Apply gasket paste GM P/N United States 12346004. . Tighten Tighten the oil passage plug to 20 N·m (15 lb ft).

6. 7. Tighten Tighten the oil passage plug to 10 N·m (89 lb in). Apply gasket paste GM P/N United States 12346004. . GM P/N Canada 10953480 to the plug. Install the rear oil passage plug.

Apply gasket paste GM P/N United States 12346004. GM P/N Canada 10953480 to the plug. Tighten Tighten the oil passage plug to 30 N·m (22 lb ft). Install the front oil passage plug. . 9.8.

Install the rignt side oil passage plug. GM P/N Canada 10953480 to the plug.10. . Tighten Tighten the oil passage plug to 20 N·m (15 lb ft). Apply gasket paste GM P/N United States 12346004. 11.

13.12. Install a new oil flow check valve in the oil passage for the cylinder head.Back Forward -> Document ID# 206752 2000 Oldsmobile Alero Print . Drive the check valve in until the valve is flush with the cylinder block headgasket surface. <.

Notice In order to prevent the possibility of cylinder block or crankshaft bearing cap damage. Install the main bearings and lubricate with engine oil. Install the crankshaft on the journals. the crankshaft bearing caps are tapped into the cylinder block cavity using a brass.<. or a leather mallet before the attaching bolts are installed. 2. Do not use attaching bolts to pull the .Back Forward -> Document ID# 255003 2000 Oldsmobile Alero Print Crankshaft and Bearings Installation Tools Required J 36660-A Torque Angle Meter 1. lead.

Do not use paints. Seat the crankshaft thrust bearing. Failure to use this process may damage a cylinder block or a bearing cap. lubricants. using the J 36660-A .crankshaft bearing caps into the seats. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. . Replacement fasteners must be the correct part number for that application. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Finger tighten the bolts. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Tap gently into place with a suitable tool. Install the crankshaft cap bolts. 3. Notice Use the correct fastener in the correct location. 5. Install the crankshaft caps. and rotate the bolts 90 degrees. These coatings affect fastener torque and joint clamping force and may damage the fastener. Tighten Tighten the bearing cap bolts to 20 N·m (15 lb ft). 4.

Back Forward -> Document ID# 255003 2000 Oldsmobile Alero Print .<.

Back Forward -> Document ID# 255011 2000 Oldsmobile Alero Print Crankshaft Rear Oil Seal and Housing Installation Tools Required J 36005 Rear Main Seal Installer 1. Position the new seal housing to block the gasket over the alignment dowel pins. 4. Press the new crankshaft seal into the housing. 3. Lubricate the lip of the crankshaft seal with engine oil. The gasket is reversible. 2. Install the seal housing assembly. The installer also establishes the depth of the seal in the housing.<. using the J 36005 . Notice .

or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Do not use paints. Replacement fasteners must be the correct part number for that application. Tighten Tighten the bolts to 12 N·m (106 lb in).Back Forward -> Document ID# 255011 2000 Oldsmobile Alero Print . 5. lubricants. Install the seal housing to block bolts. <. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. These coatings affect fastener torque and joint clamping force and may damage the fastener.Use the correct fastener in the correct location. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure.

Install the piston and the connecting rod to the correct bore. This protects the crankshaft journal during piston and connecting rod installation. Use the proper size bearings. Stagger each piston ring end gap equally around the piston. 2.Back Forward -> Document ID# 209970 2000 Oldsmobile Alero Print Piston. Lubricate the piston and the piston rings with engine oil.<. B. Lubricate the connecting rod bearings with engine oil. C.5 mm (0. J 36660-A Torque Angle Meter 2. B. Install the bearing inserts into the connecting rod and the connecting rod cap.375 in) fuel or vacuum hose over the connecting rod bolts. . Slide a piece of 9. Connecting Rod. A. J 8037 Piston Ring Compressor 1. and Bearing Installation Tools Required 1. Install the connecting rod bearings. A.

or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. . Important Ensure that the connecting rod cap is properly oriented on the connecting rod. Notice Use the correct fastener in the correct location. These coatings affect fastener torque and joint clamping force and may damage the fastener. F. Tighten the connecting rod bolt nuts to 25 N·m (18 lb ft). Install J 8037 over the piston. Guide the connecting rod to the connecting rod journal while tapping the piston into place. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the remaining connecting rods and piston assemblies. Remove the vacuum hose from the connecting rod bolts. Hold the J 8037 against the engine block until all the rings have entered the cylinder bore. Do not disturb the piston ring end gap location. Tap the piston into its bore with a hammer handle. Install the connecting rod cap. Place the piston in its matching bore. Do not use paints. G. I.D. H. then rotate 80 degrees using the J 36660-A . b. 4. lubricants. E. Tighten a. Replacement fasteners must be the correct part number for that application. Install the connecting rod bolt nuts. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure.

450 mm (0.5. Install the crankshaft timing sprocket with the marked side facing out and rotate the crankshaft to align the keyway with the timing mark on the engine block. 6. Measure the connecting rod side clearance with a feeler gauge.Back Forward -> Document ID# 209970 2000 Oldsmobile Alero Print .0059-0.150-0. <. The correct clearance is 0.0177 in).

J 41088 Balance Shaft Holder 2. loosely assemble the housing assembly to the block. 2. 3. If the balance shaft housing was disassembled.<. Apply GM P/N United States 12345493. .Back Forward -> Document ID# 219532 2000 Oldsmobile Alero Print Balance Shaft Housing Installation Tools Required 1. J 36660-A Torque Angle Meter 1. GM P/N Canada 10953488 or the equivalent on the housing assembly to the block bolts. Install the balance shaft assembly to the block.

lubricants. Tighten fasteners 3 and 8 to 10 N·m (89 lb in) + 40 degrees. 4. Replacement fasteners must be the correct part number for that application. Tighten the housing fasteners in sequence. 2. 6 and 7 to 15 N·m (11 lb ft) + 40 degrees. Tighten 1. . Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 5. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Tighten fasteners 1. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. 2. These coatings affect fastener torque and joint clamping force and may damage the fastener. Do not use paints. 4.Notice Use the correct fastener in the correct location.

Ensure that the balance shafts spin freely. Tighten bolts 1. 6. and 4 to 25 N·m (18 lb ft) + 70 degrees. install the oil pump pick-up screen into the housing.5. . Tighten 1. Lightly tap the oil pump pick-up screen into place with a plastic hammer. 2. Tighten the housing assembly to block bolts in sequence. 7. Tighten bolt 5 to 53 N·m (39 lb ft). 2. If the balance shaft housing was disassembled. Tighten bolt 3 to 40 N·m (30 lb in) + 60 degrees. 3.

This will insure that the chain continues to ride on the same surface. If a new driven sprocket will be installed. Important The surface that was marked during disassembly of the driven sprocket must show if the drive sprocket is going to be reused.Important If the balance shafts are not properly timed to the engine. Place the number one piston at TDC. Install the J 41088 on to the balance shaft assembly in order to ensure that the shafts do not rotate while the driven sprocket bolt is tightened. 8. B. Install the driven sprocket to the shaft. the engine may vibrate or make noise. either surface can be placed against the shaft. Use the following steps to time the balance shaft to the engine: A. 9. . Rotate the crankshaft 90 degrees. C.

Important The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating the bolt in a counter clockwise direction. Install the balance shaft driven sprocket bolt. . Finger tighten the bolt. 10.

If a steel gauge is used. Loosen the balance shaft chain guide bolt. 16. 15. Tighten Tighten the bolt to 13 N·m (115 lb in).11. Remove the J 41088 from the balance shaft housing assembly. . Tighten the chain tensioner bolt. Tighten the balance shaft driven sprocket bolt. 13. Important A brass feeler gauge needs to be used to ensure correct measurements are obtained. Press the chain guide tightly against the chain. Install the balance shaft chain guide. the steel gauge will not bend to conform to the guide and will cause incorrect measurements. Tighten Tighten the bolt to 40 N·m (30 lb ft) and rotate the bolt 45 degrees. 14. 12.

Tighten Tighten the bolt to 13 N·m (115 lb in). C. Install the balance shaft chain cover nut and bolt. B. Use about three pounds of force. Install the balance shaft chain cover. <.17. 18. Inserting a 1 mm (0. 19. Press the guide against the chain. Tighten Tighten the nut and bolt to 13 N·m (115 lb in). Use the following procedure to adjust the balance shaft drive chain tension: A. Tighten the chain fastener bolt.Back Forward -> Document ID# 219532 2000 Oldsmobile Alero Print .040 in) brass feeler gauge between the chain guide and the chain.

<.Back Forward -> Document ID# 255015 2000 Oldsmobile Alero Print Oil Pump Installation 1. Notice Use the correct fastener in the correct location. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. lubricants. These coatings affect fastener torque and joint clamping force and may damage the fastener. Replacement fasteners must be the correct part number for that application. 2. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Do not use paints. . Install the oil pump cover to the balance shaft housing. Install the oil pump bolts to the balance shaft housing.

C. Important A brass feeler gauge needs to be used to ensure correct measurements are obtained. Use the following procedure to adjust the balance shaft drive chain tension: A.24 lb in). Tighten Tighten the bolt to 13 N·m (115 lb in). 3. 2.040 in) brass feeler gauge between the chain guide and the chain. the steel gauge will not bend to conform to the guide and will cause incorrect measurements. Install the balance shaft chain guide. B. Press the guide against the chain. Install the balance shaft chain cover. Tighten the pump to housing long bolts to 12 N·m (2. If a steel gauge is used. Inserting a 1 mm (0. Use about three pounds of force.69 lb in).Tighten 1. 5. Tighten the pump to housing short bolts to 10 N·m (2. 4. . Tighten the chain fastener bolt.

6.Back Forward -> Document ID# 255015 2000 Oldsmobile Alero Print . Tighten Tighten the nut and bolt to 13 N·m (115 lb in). Install the balance shaft chain cover nut and bolt. <.

the engine may vibrate or make noise.<. Place the number one piston at TDC. J 36660-A Torque Angle Meter Important If the balance shafts are not properly timed to the engine. J 41088 Balance Shaft Holder 2. Install and time the balance shaft assembly to the engine using the following steps: A.Back Forward -> Document ID# 209976 2000 Oldsmobile Alero Timing Balance Shafts to Engine Tools Required 1. Print . 1.

Install the driven sprocket to the shaft. If a new driven sprocket will be installed. Important The surface that was marked during disassembly of the driven sprocket must show if the drive sprocket is going to be reused.B. 2. the balance shaft sprocket may slip allowing the balance shafts to become mistimed and cause engine vibration. Important . either surface can be placed against the shaft. If a new bolt is not used. Notice A new balance shaft driven sprocket bolt must be used any time the bolt is removed. Install the J 41088 on to the balance shaft assembly to ensure the shafts do not rotate while the driven sprocket bolt is tightened. Rotate the crankshaft clockwise 90 degrees in either direction from TDC (viewing the crankshaft from the front of the engine) C. This will insure that the chain continues to ride on the same surface.

Install the balance shaft chain guide. Do not use paints. Press the chain guide tightly against the chain. These coatings affect fastener torque and joint clamping force and may damage the fastener. 3. Tighten the chain tensioner bolt. . Notice Use the correct fastener in the correct location. 4. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. 6. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. 5. Install the driven sprocket bolt.The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating the bolt in a counter clockwise direction. Tighten Tighten the chain tensioner bolt to 13 N·m (115 lb in). Replacement fasteners must be the correct part number for that application. lubricants. Finger tighten the bolt.

<. 14. 11. 8.7. Adjust the balance shaft drive chain tension. Install the chain tensioner bolt. 9. Install the balance shaft chain cover. Install the balance shaft chain cover nut and bolt. Tighten the balance shaft driven sprocket bolt. the steel gauge will not bend to conform to the guide and will cause incorrect measurements. Press the guide against the chain using about three pounds of force. Use the J 36660-A in order to rotate the bolt an additional 45 degrees.Back Forward -> Document ID# 209976 2000 Oldsmobile Alero Print . Remove the J 41088 from the balance shaft housing assembly. Tighten Tighten the driven sprocket bolt to 40 N·m (30 lb ft). Insert a 1 mm (0. 13. Important A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. Loosen the balance shaft chain guide bolt. 10. Tighten Tighten the chain tensioner bolt to 13 N·m (115 lb in). Tighten Tighten the chain cover nut and bolt to 13 N·m (115 lb in). 12.040 in) brass feeler gauge between the chain guide and the chain. If a steel gauge is used.

Back Forward -> Cylinder Head Installation Tools Required J 36660-A Torque Angle Meter 1. Install the cylinder head gasket to the block. Document ID# 255019 2000 Oldsmobile Alero Print . Install the cylinder head. 2. Important Do not use any sealing material.<.

Notice Use the correct fastener in the correct location. Tighten bolts 1-8 to 65 N·m (40 lb ft). These coatings affect fastener torque and joint clamping force and may damage the fastener. 2. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. using the J 36660-A . Tighten 1. Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow the oil to drain before installing. 3. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install and tighten the cylinder head bolts in sequence. <. Tighten bolts 9 and 10 to 40 N·m (30 lb ft). lubricants.Back Forward -> Document ID# 255019 2000 Oldsmobile Alero Print . Replacement fasteners must be the correct part number for that application. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Do not use paints. Then turn all the bolts an additional 90 degrees in sequence.3. 4.

1. Install the camshaft carrier dowel pins in the cylinder head. Housing and Lifter Installation Tools Required J 36660-A Torque/Angle Meter Important Ensure that the camshaft housing alignment dowel pins are in the cylinder head prior to installing the housing.<. Print .Back Forward -> Document ID# 210279 2000 Oldsmobile Alero Intake Camshaft.

Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place. Sealer is unnecessary. . The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores. If the camshaft is being replaced. the lifters actuated by the camshaft must also be replaced. Install the camshaft housing to the cylinder head with a new gasket. 6. Used lifters must be returned to the original position in the camshaft housing. Lube the camshaft lobe and journals with the camshaft and lifter prelube GM P/N United States 12345501. 3. Important 1. Install the lifters into the lifter bores. 2. 5. Notice The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up.2. GM P/N Canada 992704 or the equivalent. 4. Install the camshaft in the same position as when removed.

9. 8. Remove the loose bolt holding the housing in place. Install the new camshaft housing to the green colored camshaft housing cover seals and into the cover.7. . Sealant is unnecessary. Install the camshaft housing cover to the camshaft housing.

Do not use paints. Tighten 1. . 10. Replacement fasteners must be the correct part number for that application. 2. Rotate the bolts the amount of degrees specified in sequence. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. lubricants. install and tighten the bolts in sequence.Notice Use the correct fastener in the correct location. Tighten the camshaft housing cover to camshaft housing bolts to 22 N·m (16 lb ft) + 30 degrees. Tighten the camshaft housing to cylinder head bolts to 22 N·m (16 lb ft) + 90 degrees. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Important The top intake camshaft housing bolts are tightened to a different specification than the other camshaft housing bolts. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Using the J 36660-A .

11. GM P/N Canada 10953472 sealer or the equivalent to the joint at the end of the camshaft housing halves before the installation of the power steering pump and the pump face seal. apply a 3 mm bead of GM P/N United States 12346286.Important When reinstalling the power steering pump. <.Back Forward -> Document ID# 210279 2000 Oldsmobile Alero Print . Install the power steering pump assembly.

1. Print . Install the camshaft carrier dowel pins in the cylinder head. Housing and Lifter Installation Tools Required J 36660-A Torque/Angle Meter Important Ensure that the camshaft housing alignment dowel pins are in the cylinder head prior to installing the housing.Back Forward -> Document ID# 210281 2000 Oldsmobile Alero Exhaust Camshaft.<.

Install the lifters into the lifter bores. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores. Important 1. Install the camshaft in the same position as when removed. Lube the camshaft lobes and the journals with the Camshaft and Lifter Prelube GM P/N United States 12345501. If the camshaft is being replaced. the lifters must also be replaced. GM P/N Canada 992704 or the equivalent. 6. Used lifters must be returned to their original position in the camshaft housing. Install the camshaft housing to the cylinder head with a new gasket. 2. . Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place. 3. Sealer is unnecessary.2. 4. 5. Notice The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up.

Install the camshaft housing cover to the camshaft housing. Sealer is unnecessary. 8.7. Remove the bolt holding the housing in place. Install the new camshaft housing to the orange camshaft housing cover seals into the cover. . 9.

lubricants. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Tighten the camshaft housing cover to camshaft housing bolts to 15 N·m (11 lb ft) + 30 degrees. <. Use the J 36660-A . Rotate the bolts the amount of degrees specified in sequence. Tighten 1. Replacement fasteners must be the correct part number for that application. These coatings affect fastener torque and joint clamping force and may damage the fastener. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Tighten the camshaft housing to cylinder head bolts to 15 N·m (11 lb ft) + 90 degrees. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints.Notice Use the correct fastener in the correct location. install and tighten the bolts in sequence.Back Forward -> Document ID# 210281 2000 Oldsmobile Alero Print . 10. 2.

The alignment pins ensure proper chain housing and front cover location for correct front oil seal-to-crankshaft alignment.Back Forward -> Document ID# 255026 2000 Oldsmobile Alero Print Timing Chain Housing Installation Tool Required J 36008-A Camshaft Timing Pins Important Ensure that the alignment pins are in the cylinder block and the timing chain housing. Important .<. before installing the timing chain housing.

Install the timing chain housing to the block fasteners and hand tighten. 5. 1. These coatings affect fastener torque and joint clamping force and may damage the fastener. Install the timing chain housing. Install the chain housing to the oil pan bolts and hand tighten.Ensure that the timing chain housing to camshaft housing gaskets are properly oriented. 4. Replacement fasteners must be the correct part number for that application. 6. Install the timing chain housing to the camshaft housing bolts and hand tighten. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Install the timing chain housing gaskets. 3. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Tighten the bolts. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. 2. Tighten . No sealer is needed. If the gaskets are not properly oriented an oil leak will result. lubricants. Do not use paints. Notice Use the correct fastener in the correct location.

25 X 25) (1) to 26 N·m (19 lb ft). 3. Install the camshaft sprockets. 7. Sprockets are identical and interchangeable. Tighten the (M10 X 1. Clean the threaded hole in the camshaft with a nylon bristle brush. <.Back Forward -> Document ID# 255026 2000 Oldsmobile Alero Print .25 X 55) (2) to 50 N·m (37 lb ft). 10. Tighten the (M8 X 1. GM P/N Canada 10953488 or the equivalent on the camshaft sprocket bolts. Install the camshaft sprocket bolts and washers while holding the sprockets with J 36008-A . Clean the old sealer off of the bolt with a wire brush. Tighten Tighten the bolts to 70 N·m (52 lb ft). 8. 11. Tighten the (M8 X 1.25 X 25) (3) to 29 N·m (21 lb ft). 2.1. 9. Use Adhesive/Sealant Compound GM P/N United States 12345493.

4. 3. Add 2 coolant pellets. the pellets must be added to the radiator. Pay special attention to the tightening sequence to avoid part damage and to ensure proper sealing. Prior to installing the water pump read the entire procedure.<.Back Forward -> Document ID# 255053 2000 Oldsmobile Alero Print Water Pump Installation Important Use the following guidelines when servicing the cooling system or draining the cooling system for service procedures: 1. This film is normal. when the cooling system is serviced or drain for service procedures. On these systems. Do not place the pellets into a non-pressurized coolant recovery reservoir. Crush the pellets prior to installation. 5. 2. GM P/N 3634621 or an equivalent. The pellets must be added to the radiator or the pressurized water reservoir. . The sealant pellets may leave a film on the sides of the pressurized and non-pressurized water recovery reservoirs.

Use the following sequence to tighten the fasteners: A. Tighten Tighten the bolts to 14 N·m (124 lb in). <. bottom bolt first. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure.1. Install the cover to the block. Tighten Tighten the bolts to 26 N·m (19 lb ft). 4. These coatings affect fastener torque and joint clamping force and may damage the fastener. 5. lubricants.Back Forward -> Document ID# 255053 2000 Oldsmobile Alero Print . 2. Do not use paints. Install the water pump cover to the coolant pump assembly. Install the water pump bolts. Notice Use the correct fastener in the correct location. Tighten Tighten the nuts to 26 N·m (19 lb ft). or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. C. Install the pump assembly to the chain housing nuts. Install the pump cover to the pump assembly. Finger tighten the bolts. Finger tighten the nuts. B. Install the pump to chain housing nuts. Install the cover to the block bolts. 3. Replacement fasteners must be the correct part number for that application. Finger tighten the bolts. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Notice . J 36008-A Camshaft Sprocket Alignment Pins 2. 3. The sprockets are identical and interchangeable. Clean the old sealer off of the bolts with a wire brush.Back Forward -> Document ID# 361371 2000 Oldsmobile Alero Print Timing Chain. 4. Install the camshaft sprockets. Tensioner Installation Tools Required 1. Clean the threaded hole in the camshaft with a nylon bristle brush. Coat the camshaft sprocket bolts with Threadlocker GM P/N United States 12345493. GM P/N Canada 10953488 or the equivalent. Sprockets. J 39579 Camshaft Gear Holder 1. 2.<.

Use the correct fastener in the correct location. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Install the J 36008-A through the holes in the camshaft sprockets and into the holes in the timing chain housing. prior to installing the timing chain housing. Important Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing. Install the camshaft sprocket bolts and washers while holding the sprockets with J 39579 . 5. Replacement fasteners must be the correct part number for that application. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. lubricants. This will position the . Tighten Tighten the bolts to 70 N·m (52 lb ft). Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. These coatings affect fastener torque and joint clamping force and may damage the fastener. Do not use paints. 6.

If properly timed. The crankshaft must be rotated 90 degrees clockwise off of TDC to give the valves adequate clearance to open. move the chain 1 tooth forward or rearward. Notice Do not rotate the crankshaft clockwise to TDC. The length of the chain between the 2 camshaft sprockets will tighten. B. 12. the intake camshaft alignment dowel pin will slide in easily. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins: Notice Failure to follow this procedure could result in severe engine damage. A. . If the mark and the keyway are not aligned. 10. rotate the crankshaft counter-clockwise back to TDC. the camshafts are not timed correctly and the procedure must be repeated. 9. The keyway on the crankshaft and the mark on the cylinder block should be aligned with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. 7.camshaft for correct timing. Once the camshafts are in position and the dowels are installed. Leave the alignment dowel pins installed. Release the J 39579 . 13. If the dowel pin does not fully index. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 8. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. Use the J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. Remove the alignment dowel pin from the intake camshaft. 11. Important The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. Valve or piston damage could occur. Remove the slack and recheck the marks.

D. Compress the plunger until the plunger is seated flush in the tensioner. Reset the timing chain tensioner assembly. A.Important Use the following steps in order to reset the timing chain tensioner assembly to the zero position: 14. turn the complete assembly upside down on a bench or other flat surface. B. press firmly on the bottom of the tensioner housing. With the plunger face against the workbench. Insert the tensioner plunger assembly into the tensioner housing. . C. With the tensioner plunger fully extended.

07 in) maximum. The correct dimension for the plunger to extend out of the cylinder is 1.7 mm (0.15. Check the plunger to make sure that the plunger is out of the cylinder at the correct dimension. .

. Tighten the timing chain tensioner bolts. cotter pin remover. Important If the timing chain tensioner plunger is not released from the installation position. engine damage will occur when the engine is started. A. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. Using a flat blade screwdriver. Tighten Tighten the bolts to 10 N·m (89 lb in). Loosely install the tensioner assembly and bolts to the timing chain housing. or a similar tool.16. Install the timing chain tensioner shoe on the stud. Do not over tighten. 19. Release the timing chain tensioner plunger. press firmly against the face of the timing chain tensioner plunger. 17. 18. 20.

22. The plunger should press firmly against the back of the timing chain tensioner shoe.Important If the timing chain tensioner plunger cannot be depressed. C. Install the timing chain guides. Notice The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. 21. the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated. B. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of reassembly. 23. Remove the J 36008-A from the camshaft sprockets. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner. Release the tensioner plunger. The alignment dowel pins will slide in easily if the engine is timed correctly. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. Rotate the crankshaft clockwise 2 full rotations. . Align the crankshaft keyway with the mark on the cylinder block and reinstall the alignment dowel pins.

<.Back Forward -> Document ID# 361371 2000 Oldsmobile Alero Print .

Install the seal into the front cover by driving the seal in from the timing chain side using the J 36010 .Back Forward -> Document ID# 210334 2000 Oldsmobile Alero Print Crankshaft Front Cover Oil Seal Installation Tool Required J 36010 Front Crankshaft Seal Installer 1. The J 36010 will properly position the seal in the front cover.Back Forward -> Document ID# 210334 2000 Oldsmobile Alero Print . Ensure that the engine front cover is properly supported when installing the seal.<. 2. <.

Notice Use the correct fastener in the correct location. Do not . Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Install the front cover gasket. Inspect the front cover gasket for damage before reusing the gasket. Replacement fasteners must be the correct part number for that application. The gasket is reusable and does not require sealer.<. 2.Back Forward -> Document ID# 210353 2000 Oldsmobile Alero Print Engine Front Cover Installation Tools Required J 36660-A Torque Angle Meter 1.

4. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Tighten Tighten the fasteners to 12 N·m (106 lb in). Tighten Tighten the engine front cover bolts to 12 N·m (106 lb in). Install the upper front cover bolts.use paints. lubricants.Back Forward -> Document ID# 210353 2000 Oldsmobile Alero Print . These coatings affect fastener torque and joint clamping force and may damage the fastener. Lubricate the front oil seal with Chassis Grease GM P/N United States 1051344. Install the engine front cover nuts. <. GM P/N Canada 993037 or the equivalent. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. 5. 3.

Back Forward -> Document ID# 255059 2000 Oldsmobile Alero Oil Pan Installation 1. 3. Install the oil pan. Inspect the oil pan gasket for damage. 2. The oil pan gasket is reusable. Print . Install the oil pan gasket. replace as necessary.<.

Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Tighten the (4) to 26 N·m (19 lb ft). 4. 2. lubricants. Tighten the (M6 X 1. Tighten the (M8 X 1. Tighten the oil pan bolts. <.25 X 22) (2) to 24 N·m (18 lb ft). These coatings affect fastener torque and joint clamping force and may damage the fastener. Do not use paints.25 X 80) (1) to 24 N·m (18 lb ft). Replacement fasteners must be the correct part number for that application.Back Forward -> Document ID# 255059 2000 Oldsmobile Alero Print . 5. Notice Use the correct fastener in the correct location. 3. Tighten the (M8 X 1. Install the oil pan bolts and hand tighten. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Tighten 1.00 X 25) (3) to 12 N·m (106 lb in).4.

Install the oil filter bypass valve. A.<.Back Forward -> Document ID# 206784 2000 Oldsmobile Alero Oil Filter Adapter Installation 1. B. Insert the new oil filter bypass valve in the cylinder block. Use a center punch to stake the valve in three places. Print .

Tighten Tighten the oil filter adapter to 29 N·m (21 lb ft). or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. Do not use paints. lubricants. 2. . Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Install the oil filter adapter. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.Notice Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. These coatings affect fastener torque and joint clamping force and may damage the fastener.

3. A. Install a new oil filter. Lubricate the oil filter seal with clean engine oil before installation. B. Tighten the oil filter 3/4 to one full turn after the gasket contacts the cylinder block.Back Forward -> Document ID# 206784 2000 Oldsmobile Alero Print . <.

The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.<.Back Forward -> Document ID# 361123 2000 Oldsmobile Alero Print Intake Manifold Installation Notice Never attempt to remove the intake manifold from a hot engine. Install the new gasket with the numbers stamped on the gasket faced toward the manifold surface. allow the engine to cool to ambient temperature. Install the intake manifold gasket. 2. . 1. The gasket is reusable if the gasket is undamaged.

3. Install the intake manifold.

Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not
use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque
and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence.
Tighten
Tighten the bolts and nuts to 22 N·m (16 lb ft).

5. Install the throttle body.
Tighten

Tighten the bolts and nuts to 10 N·m (89 lb in).

<- Back

Forward ->

Document ID# 361123
2000 Oldsmobile Alero

Print

<- Back

Forward ->

Document ID# 206951
2000 Oldsmobile Alero

Print

Crankshaft Balancer Installation
Tools Required
J 38122-A Harmonic Balancer Holder

1. Lubricate the front oil seal and sealing surface of the crankshaft balancer. Use Chassis Grease GM P/N United States 1051344,
GM P/N Canada 993037 or the equivalent.
2. Install the balancer onto the crankshaft indexing keyway. Tap the balancer into place using a rubber or sand filled mallet.
Notice
Do not use the J 36660 Torque Angle Meter to rotate the retaining bolt an additional 90 degrees. The torque capacity of the tool will be

Important Use the J 38122-A to prevent the crankshaft from rotating. lubricants. Install the retaining bolt and washer. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. These coatings affect fastener torque and joint clamping force and may damage the fastener. 3. Put a mark on the socket next to one of the four marks on the J 38122-A . or corrosion inhibitors on fasteners or fastener joint surfaces unless specified.Back Forward -> Document ID# 206951 2000 Oldsmobile Alero Print . Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. 3. At 90 degrees the socket indexes with the next mark on the tool. 2.exceeded and damage to the tool will result. Do not use paints. Tighten Tighten the bolt to 175 N·m (129 lb ft). 4. 1. Replacement fasteners must be the correct part number for that application. This mark will represent the zero point or 0 degrees. <. Notice Use the correct fastener in the correct location. Tighten the bolt by rotating the socket clockwise 90 degrees.

2. Print .Back Forward -> Document ID# 255074 2000 Oldsmobile Alero Exhaust Manifold Installation 1. Install the exhaust manifold gasket. Install the exhaust manifold.<.

Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not
use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque
and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
3. Install the exhaust manifold to the cylinder head retaining nuts. Follow the tightening sequence.
Tighten
Tighten the nuts to 13 N·m (115 lb in).

4. Install the exhaust manifold upper heat shield.
5. Install the exhaust manifold upper heat shield bolts.
Tighten
Tighten the bolts to 14 N·m (124 lb in).

6. Install the exhaust manifold brace to the exhaust manifold.
7. Install the exhaust manifold brace to the exhaust manifold bolt.
Tighten
Tighten the bolt to 56 N·m (41 lb ft).
8. Install the exhaust manifold brace to the oil pan.
9. Install the exhaust manifold brace to the oil pan nuts.
Tighten
Tighten the nuts to 26 N·m (19 lb ft).

<- Back

Forward ->

Document ID# 255074
2000 Oldsmobile Alero

Print

<- Back

Forward ->

Document ID# 255083
2000 Oldsmobile Alero

Print

Oil Level Indicator and Tube Installation

1. Install the tube into the block.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not
use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque
and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
2. Install the indicator tube bracket to the rear cam carrier lift bracket bolt.

Tighten Tighten the nut to 10 N·m (89 lb in). <.Back Forward -> Document ID# 255083 2000 Oldsmobile Alero Print .

<. J 36660-A Torque Angle Meter 2. Print . Install the flywheel.Back Forward -> Document ID# 255095 2000 Oldsmobile Alero Engine Flywheel Installation Tools Required 1. J 38122-A Harmonic Balancer Holder 1.

Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. The system or the components may be damaged. Notice Use the correct fastener in the correct location. These coatings affect fastener torque and joint clamping force and may damage the fastener. Do not use paints. If the correct bolt is not used. Install the retainer if the vehicle has an automatic transmission. GM P/N Canada 10953488 or the equivalent to all flywheel to crankshaft bolts that are being re-used. lubricants. Replacement fasteners must be the correct part number for that application. 3. Install the new bolts or apply Adhesive/Sealant Compound GM P/N United States 12345493. Notice This bolt is designed to permanently stretch when tightened. the parts will not be tightened correctly. or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. The correct part number fastener must be used to replace this type of fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.2. . Do not use a bolt that is stronger in this application. Carefully follow the instructions included with the thread locking compound in order to ensure proper bolt retention.

Tighten Tighten the bolts to 30 N·m (22 lb ft).4. Use the J 36660-A in order to rotate the bolts 45 degrees. Holding the crankshaft balancer with the J 38122-A . tighten the bolts evenly. <.Back Forward -> Document ID# 255095 2000 Oldsmobile Alero Print .

After the engine is at operating temperature. test the engine before installing the engine in the vehicle if possible.000 RPM until the engine is at operating temperature. Add the pellets directly to the radiator or pressurized coolant reservoir on systems that do not have caps on the radiator. Inspect the engine carefully for oil or coolant leaks. <. Fill the crankcase with oil. 4. shut the engine off. Fill the cooling system with coolant.Back Forward -> Document ID# 105949 2000 Oldsmobile Alero Print . 6. If a new camshaft and lifters have been installed.Back Forward -> Document ID# 105949 2000 Oldsmobile Alero Print Engine Set-Up and Testing After assembly. 5. 3. 2. 9. 1. 2. Listen for any abnormal engine sounds. Crank the engine several times and listen for unusual noises or any other evidence of mechanical problems. Add cooling system sealing pellets GM P/N 3634621 to the engine cooling system. 7. add engine oil supplement GM P/N 1052367 to the engine oil. use the following procedure: 1. If a test stand is not available. 10. 8. Run the engine at 1. Start the engine. Crush the pellets before installation.<.