Engine Assembly
TOOL REQUIREDJ 35468 Oil Seal Installer
J 33049 Camshaft Bearing Remover/Installer Set
J 34686 Rear Main Bearing Oil Seal Installer
J 8037 Piston Ring Compressor
J 36660 Torque Angle Meter
J 38612 Crankshaft Sprocket Installer
J 29113 Harmonic Balancer Installer
ASSEMBLY STEPS
1. Cylinder Block Assemble
a. Install the expansion plugs.
b. Install the camshaft position sensor.
c. Install the camshaft position sensor retaining bolt. Tighten the bolt to 10 Nm (89 inch lbs.).
d. Install the crankshaft position sensor.
e. Install the crankshaft position sensor bolt. Tighten the bolt to 11 Nm (97 inch lbs.).
f. Apply sealer GM P/N 1052080 or equivalent to the thread of the knock sensor.
g. Install the knock sensor. Tighten the knock sensor to 19 Nm (14 ft. lbs.).
h. Install the oil gallery plugs.
^ Tighten the front oil gallery plug to 19 Nm (14 ft. lbs.).
^ Tighten the rear upper oil gallery plugs to 19 Nm (14 ft. lbs.).
^ Tighten the rear lower oil gallery plugs to 33 Nm (24 ft. lbs.).
i. Install the left coolant drain plug. Tighten the coolant drain plug to 19 Nm (14 ft. lbs.).
j. Install the right side coolant drain plug. Tighten the coolant drain plug to 19 Nm (14 ft. lbs.).
k. Install the oil filter fitting. Tighten the fitting to 39 Nm (29 ft. lbs.).
l. Install the oil filter. Tighten the oil filter to 13 Nm (115 inch lbs.).
2. Camshaft Bearing Installation
CAUTION: Severe engine damage may result if the oil holes are not correctly aligned.
a. Use the following procedure in order to install the new camshaft bearings:
^ Select the camshaft bearings.
^ Select the proper expander assembly and driving washer.
^ Assemble the Camshaft Bearing Remover/Installer Set.
^ Place the intermediate camshaft bearing onto the Camshaft Bearing Remover/Installer Set.
^ Index the camshaft bearing oil hole at 4 o'clock from the front of the engine block.
^ Drive the intermediate camshaft bearings into place.
^ Place the #1 camshaft bearing onto the Camshaft Bearing Remover/Installer Set. Index the camshaft bearing oil hole at 3 o'clock from the front of the engine block.
^ Place the #4 camshaft bearing onto the Camshaft Bearing Remover/Installer Set. Index the camshaft bearing oil hole at 6 o'clock from the front of the engine block.
^ Drive the outer camshaft bearings into place.
^ Probe the bearing holes in order to ensure that the bearing holes are properly aligned. Use a piece of 3/32 inch brass rod with a 90° bend at the end.
b. Apply sealer GM P/N 12345493 to the camshaft cover.
c. Install the camshaft cover flush with the engine cylinder block.
3. Crankshaft, Bearings, and Bearing Cap Installation
CAUTION: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etch the bearing surface. Ensure that the bearing cap bolt holes and the cap mating surfaces are clean and dry.
a. Dip the bearing cap bolts in clean engine oil.
CAUTION: Upper and lower inserts may be different. Do not obstruct any oil passages.
b. Place the bearing inserts into the bearing cap and into the engine block.
NOTE: The inserts will project slightly when put into place. Ensure that they project an equal distance on both sides. Ensure that the insert tangs are engaged.
c. In the case of a thrust bearing type main bearing insert, coat the thrust surface with GM EOS P/N 1052368 or equivalent.
d. Lubricate the bearing surface with clean engine oil.
e. Install the crankshaft.
CAUTION: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not attach the bolts to pull the crankshaft bearing caps into the seats. Failure to observe this information may damage a cylinder block or a bearing cap.
f. Install the main bearing caps. Apply a small amount of sealer GM P/N 1052942 to the rear of the #4 bearing cap sealing surface.
g. Install the main bearing cap bolts. Use the Torque Angle Meter in order to tighten the main bearing cap bolts to 50 Nm (37 ft. lbs.) plus 77°.
h. Measure the crankshaft end play.
4. Crankshaft Rear Oil Seal Installation
a. Apply engine oil to the I.D. and the O.D. of the new seal.
b. Slide the new seal over the mandrel until the back of the seal bottoms squarely against the collar of the tool.
c. Install the crankshaft rear oil seal.
^ Align the dowel pin of Rear Main Bearing Oil Seal Installer with the dowel pin in the crankshaft.
^ Attach the Rear Main Bearing Oil Seal Installer to the crankshaft by hand or tighten attaching screws to 5 Nm (45 inch lbs.).
^ Turn the "T" handle of Rear Main Bearing Oil Seal Installer so that the collar pushes the seal into the bore. Turn the handle until the collar is tight against the case. Ensure that the seal is seated properly.
^ Loosen the "T" handle of V until it comes to a stop. Ensure that the collar is in the proper position to install another new seal.
^ Remove the attaching screws.
^ Check the seal. Make sure that the seal is seated squarely in the bore.
5. Piston and Connecting Rod Installation
a. Lubricate the cylinder wall and piston rings with clean engine oil.
b. Turn the crankshaft to bottom dead center.
c. Install the connecting rod stud thread protector.
d. Install the Piston Ring Compressor.
e. Install the piston and connecting rod assembly.
NOTE: Ensure that the arrow on top of the piston faces towards the front of the engine.
f. Remove the thread protectors.
g. Install the connecting rod bearings.
CAUTION: In order to prevent the possibility of rod bolt or bearing cap damage, the bearing caps may need to be tapped into position with a brass or leather mallet before the attaching nuts are installed. Do not use the attaching nuts to pull the bearing caps onto the rod. Failure to observe this information may result in damage to the rod bolt or the bearing cap.
h. Seat the bearing caps by pushing on by hand or by carefully tapping it lightly with a suitable tool.
i. Install the rod bearing cap nuts. Tighten the rod cap nuts to 20 Nm (15 ft. lbs.). Use the Torque Angle Meter in order to rotate the nuts an additional 75°.
j. Pry the connecting rod back and forth with a suitable tool and check for binding. If necessary, loosen and retighten the bearing cap.
k. Measure the connecting rod side clearance.
6. Camshaft Installation
CAUTION: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
a. Coat the camshaft journals with engine oil or its equivalent.
b. Coat the camshaft lobes with prelude. Use GM P/N 1052365.
c. Install the camshaft. Use the following procedure:
^ Install a large screwdriver into the camshaft bolt hole in order to support the camshaft.
^ Rotate the camshaft. Install camshaft into the camshaft bearings.
d. Install the camshaft thrust plate.
e. Install the camshaft thrust plate bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
f. Install the oil pump driven gear assembly.
^ Lubricate the driven gear with prelude GM P/N 1052365.
^ Lubricate the assembly with engine oil for ease of installation.
g. Install the oil pump driven gear hold down clamp and bolt. Tighten the bolts to 36 Nm (27 ft. lbs.).
7. Timing Chain and Sprockets Installation
a. Install the crankshaft sprocket using the Crankshaft Sprocket Installer.
b. Apply GM EOS P/N 1052367 or equivalent to the sprocket thrust surface.
c. Install the chain dampener to the block.
d. Align the crankshaft timing mark to the timing mark on the bottom of the chain dampener.
e. Hold the camshaft sprocket with the chain hanging down and install the chain to the crankshaft gear.
f. Align the timing mark on the camshaft gear (center line of the locator hole) with the timing mark on top of the chain dampener.
g. Remove the Crankshaft Sprocket Installer.
h. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
i. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
j. Coat the crankshaft and camshaft sprocket with engine oil. Tighten the bolt to 110 Nm (81 ft. lbs.).
8. [1][2]Engine Front Cover Installation
a. Install the front cover gasket.
b. Apply sealer to both sides of the lower tabs of the front cover gasket. Use GM RTV sealer GM P/N 12346004 or its equivalent.
c. Install the front cover.
d. Install the front cover bolts.
^ Tighten the large bolts (2) to 47 Nm (35 ft. lbs.).
^ Tighten the small bolts (1) to 21 Nm (15 ft. lbs.).
e. Install the drive belt tensioner.
f. Install the drive belt tensioner retaining bolt. Tighten the bolt to 50 Nm (37 ft. lbs.).
9. Oil Pump Installation
a. Install the oil pump and drive rod.
b. Install the oil pump bolt. Tighten the bolt to 41 Nm (30 ft. lbs.).
c. Install the crankshaft oil deflector.
d. Install the crankshaft oil deflector nuts. Tighten the nuts to 25 Nm (18 ft. lbs.).
10. Oil Pan Installation
a. Install a new gasket. Apply sealer GM P/N 1052942 to the joint on the oil pan rail where the main bearing cap meets the engine block (two locations).
b. Install the oil pan.
c. Install the oil pan retaining bolts. Tighten the retaining bolts to 25 Nm (18 ft. lbs.).
d. Install the oil pan side bolts. Tighten the side bolts to 50 Nm (37 ft. lbs.).
11. Cylinder Head Installation (Right Side)
a. Install the cylinder head gasket.
b. Install the cylinder head assembly.
c. Install the cylinder head bolts. Tighten the bolts in sequence to 45 Nm (33 ft. lbs.). Use the Torque Angle Meter in order to turn the bolts an additional 90°.
12. Cylinder Head Installation (Left Side)
a. .Install the left cylinder head gasket.
b. Install the left cylinder head assembly.
c. Install the left cylinder head bolts.
^ Tighten the cylinder head bolts in sequence to 45 Nm (33 ft. lbs.).
^ Turn the cylinder head bolts in sequence an additional 90° using the Torque Angle Meter.
d. Apply sealant GM P/N 12345739 to the area of the oil level indicator tube that is to be pressed into engine block.
e. Install the oil level indicator assembly.
f. Install the oil level indicator assembly retaining bolt. Tighten the oil level indicator assembly retaining bolt to 25 Nm (18 ft. lbs.).
13. Crankshaft Balancer Installation
a. Apply sealer GM P/N 12345739 to the keyway of the crankshaft balancer.
b. Place the balancer into position over the key in the crankshaft.
c. Install the Harmonic Balancer Installer onto the crankshaft.
d. Pull the balancer into position.
e. Remove the Harmonic Balancer Installer from the balancer.
f. Install the crankshaft balancer washer and bolt. Tighten the bolt to 103 Nm (76 ft. lbs.).
14. Valve Lifter Installation
a. Install the lifters in their original locations.
b. Coat the lifters with prelude GM P/N 1052365.
c. Install the valve roller lifters.
d. Install the valve lifter guide and guide bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
15. Valve Rocker Arm and Push Rod Installation
a. Install the lower intake manifold gaskets.
b. Use the following steps in order to install the pushrods.
^ Install the pushrods in their original location.
^ Coat the ends of the pushrods with prelube GM P/N 1052365 or equivalent.
^ The intake valve pushrods measure 144 mm (5.75 inches) long.
^ Exhaust valve pushrods measure 152.5 mm (6.0 inches) long.
c. Install the rocker arms in their original positions. Coat the rocker arm friction surfaces with prelude GM P/N 1052365 or equivalent.
d. Install the rocker arm bolt. Use the Torque Angle Meter in order to tighten the bolt to 10 Nm (89 inch lbs.) plus 30°.
16. Valve Rocker Arm Cover Installation (Left Side)
CAUTION: Install the valve rocker cover bolts finger tight before tightening the bolts to specification or damage to the valve rocker cover may occur.
a. Install a new gasket and new bolt grommets to the valve rocker cover. Ensure that the gasket is seated properly in the valve rocker cover groove. Ensure that the bolt grommets are fully seated in the bolt holes.
b. Apply sealer in the notch on the cover. Use GM P/N 12345739 or its equivalent.
c. Install the valve rocker cover gasket.
d. Install the valve rocker cover.
e. Install the valve rocker cover bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
f. Install the thermostat bypass pipe.
g. Install the thermostat bypass pipe retaining bolt, nut, and screw.
^ Tighten the screw to 12 Nm (106 inch lbs.).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
^ Tighten the nut to 25 Nm (18 ft. lbs.).
h. Install the thermostat bypass pipe hose clamp.
17. Valve Rocker Arm Cover Installation (Right Side)
CAUTION: Install the valve rocker cover bolts finger tight before tightening the bolts to specification or damage to the valve rocker cover may occur.
a. Install a new gasket and new bolt grommets to the valve rocker cover. Ensure that the gasket is seated properly in the valve rocker cover groove. Ensure that the bolt grommets are fully seated in the bolt holes.
b. Apply sealer in the notch on the cover. Use GM P/N 12345739 or its equivalent.
c. Install the valve rocker cover gasket.
d. Install the valve rocker cover.
e. Install the valve rocker cover bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
f. Install the generator bracket assembly.
g. Install the generator bracket bolts.
18. Exhaust Manifold Installation (Left Side)
a. Install the exhaust manifold gasket.
b. Install the exhaust manifold.
c. Install the exhaust manifold nuts. Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).
d. Install the exhaust manifold heat shield.
e. Install the exhaust manifold heat shield nuts. Tighten the exhaust manifold heat shield nuts to 10 Nm (89 inch lbs.).
f. Install the generator bracket assembly.
g. Install the generator bracket bolts.
19. Exhaust Manifold Installation (Right Side)
a. Install the exhaust manifold gasket.
b. Install the exhaust manifold.
c. Install the exhaust manifold nuts. Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).
d. Install the exhaust manifold heat shield.
e. Install the exhaust manifold heat shield nuts. Tighten the exhaust manifold heat shield nuts to 10 Nm (89 inch lbs.).
20. Lower Intake Manifold Installation
a. Install the lower intake manifold. Apply sealant GM P/N 12345739 at engine block to manifold mating surface. Bead should be 2.0-3.0 mm (0.08-0.12 inches) wide and 3.0-5.0 mm (0.12-0.20 inches) thick.
CAUTION: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
b. Install the lower intake manifold retaining bolts.
^ Apply sealant GM P/N 12345382 to the threads of the bolts.
^ Tighten the vertical bolts to 13 Nm (115 inch lbs.).
^ Tighten the diagonal bolts to 13 Nm (115 inch lbs.).
c. Install the heater inlet pipe assembly.
CAUTION: Do not press on the fuel pressure regulator assembly valve when installing fuel injector rail assembly.
d. Install the fuel injector rail assembly.
^ Lightly lubricate the fuel injector O-rings using GM P/N 1051885.
^ Install the injectors of the fuel rail assembly into the bores of the manifold.
^ Carefully press on the injector rail with the palms of both hands until the injectors are fully seated.
e. Install the fuel injector rail bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
21. Upper Intake Manifold Installation
a. Install the upper intake manifold gasket.
b. Install the upper intake manifold.
c. Install the upper intake manifold bolts. Tighten the bolts to 25 Nm (18 ft. lbs.).
d. Install the coolant hoses to the throttle body.
e. Install the EGR tube assembly to the right exhaust manifold.
f. Install the EGR tube assembly nut. Tighten the EGR tube assembly nut to 25 Nm (18 ft. lbs.).
g. Install the electronic ignition control module and EVAP canister purge valve mounting bracket.
h. Install the electronic control module nuts and bolts. Tighten both the nuts and the bolts to 25 Nm (18 ft. lbs.).
i. Connect the spark plug wires to the spark plugs
j. Install the generator braces.
k. Install the generator brace nuts.
l. Install the brace bolts.
m. Install the MAP sensor.
n. Install the MAP sensor screws.
o. Install the MAP sensor electrical connector.
p. Connect the vacuum lines to the upper intake manifold.
22. Engine Flex Plate Installation
a. Install the flex plate.
b. Install the flex plate retainer.
c. Install the flex plate bolts. Tighten the bolts to 83 Nm (61 ft. lbs.).
d. Install the exhaust crossover pipe.
e. Install the exhaust crossover pipe retaining nuts. Tighten the nuts to 25 Nm (18 ft. lbs.).
f. Install the exhaust crossover pipe heat shield.
g. Install the exhaust crossover pipe heat shield screws. Tighten the screws to 10 Nm (89 inch lbs.).