Assemble Part 1
Part 1TOOL REQUIRED
- J 41742 Connecting Rod Guide Pin
- J 8037 piston Ring Compressor
- J 42067 Rear Main Seal Installer
- J 35268-A Camshaft seal Installer
- J 42069 Timing Belt Alignment Kit
- Or Equivalent
1. Crankshaft and Bearings Installation
a. Install the crankshaft bearings to engine block.
b. Install the crankshaft sensor ring.
c. Install the crankshaft sensor bolts. Use new crankshaft sensor bolts. Tighten the sensor ring bolts to 15 Nm (11 ft. lbs.).
d. Install the crankshaft to the engine block.
e. Apply Engine Oil Supplement (EOS), GM P/N 1052368, to the bearing surfaces.
f. Install the main bearings to the main bearing caps.
g. Apply RTV sealer, GM P/N 12345739 or equivalent, to the fourth main bearing cap.
h. Install the main bearing caps to the engine block. Place the main bearing caps in numerical order.
i. Install the crankshaft bearing bridge.
j. Use new main bearing cap bolts or damage may occur when the final tightening is performed.
k. Install the main bearing cap bolts loosely.
l. Clean the old thread locking compound from the adjusting sleeves.
m. Adjust the crankshaft bearing bridge adjusting sleeves until the bushings do not contact the engine block when the bridge is fully seated. Tighten the main bearing cap bolts in three passes to 50 Nm (37 ft. lbs.) + 60° + 15°.
n. Apply thread locking compound Loctite 272, GM P/N 12345493 or equivalent, to the crankshaft bearing bridge adjusting sleeves.
o. Adjust the crankshaft bearing bridge adjusting sleeves until the bushings firmly contact the engine block.
p. Install the crankshaft bearing bridge bolts (2). Tighten the crankshaft bearing bridge bolts to 20 Nm (15 ft. lbs.).
2. Piston, Connecting Rod, and Bearing Installation
- Tools Required
- J 41742 Connecting Rod Guide Pin
- J 8037 Piston Ring Compressor
- Or Equivalents
a. Install the Connecting Rod Guide Pin onto the connecting rod hole which will allow the guide pin to clear the crankshaft bearing bridge. Only one Connecting Rod Guide Pin is required to properly align the connecting rod with crankshaft.
b. Install the upper rod bearing to the rod.
c. Coat the following components with EOS, GM P/N 1052368: Coat the piston.
^ Coat the piston rings.
^ Coat the cylinder bore.
^ Coat the bearing surfaces.
d. Perform the following steps to install the piston:
^ Position the piston with the arrow on the piston head facing toward the front of the engine.
^ Use the Piston Ring Compressor to compress the piston rings.
^ Place the piston in the cylinder.
^ Lightly tap the piston into the cylinder bore while an assistant guides the connecting rod onto the crankshaft.
e. Remove the Connecting Rod Guide Pin.
f. Perform the following steps to install the connecting rod caps with bearings to the connecting rod:
^ Install with the bumps on the connecting rod and the cap facing toward the rear of the engine.
^ Coat the bearing surface with EOS, GM P/N 1052368.
g. Use new connecting rod cap bolts.
h. Install the connecting rod cap bolts. Tighten the connecting rod bearing cap bolts to 35 Nm (26 ft. lbs.) + 45° + 15°.
i. Repeat steps for the remaining pistons.
3. Crankshaft Rear Oil Seal Installation
- Tool Required
- J 42067 Rear Main Seal Installer, Or Equivalent
a. Coat the lip of the rear main oil seal with a small amount of chassis grease, GM P/N 1052497 or equivalent.
b. Use the Rear Main Seal Installer to install the rear main oil seal.
4. Cylinder Head Installation
a. On the driver's side of the engine, install the new cylinder head gasket with OPEN/TOP imprint toward the front of the engine.
b. On the passenger side of the engine, install the new cylinder head gasket with the OPEN/TOP imprint toward the rear of the engine.
c. Install the cylinder head to the engine block ensuring adequate clearance from all wires, components, etc.
CAUTION: Use new cylinder head bolts. The required tightening method stretches the bolts, therefore the cylinder head bolts are not reusable.
d. Install the new cylinder head bolts. Tighten the cylinder head bolts in the proper tightening sequence and in stages, to 25 Nm (18 ft. lbs.) + 90° + 90° + 90° + 15°.
5. Camshaft Installation
- Tool Required
- J 35268-A Camshaft Seal Installer, Or Equivalent
a. Lubricate the camshaft bearing surfaces with GM P/N 1052367 or equivalent.
b. Install the camshafts to the cylinder heads.
Camshaft Identification
^ The intake is marked with a blue paint mark (in the approximate area shown 1) and has a code G or B cast into it near the number one bearing surface.
^ The exhaust is marked with a green paint mark (in the approximate area shown 1) and has a code A cast into it near the number one bearing surface.
c. The bearing caps for the passenger side cylinder head is marked with an L1, L2, L3, etc. followed by a number.
d. The bearing caps for the driver side cylinder head is marked with an R1, R2, R3, etc. followed by a number.
e. Apply a small amount of Loctite or equivalent on the forward edge of the front bearing caps to ensure an adequate seal between the bearing cap and the cylinder head.
f. Install the camshaft bearing caps to their appropriate position.
g. Install the camshaft bearing cap bolts. Tighten the camshaft bearing cap bolts starting from the center cap gradually to 8 Nm (71 inch lbs.).
CAUTION: DO NOT allow the sealer to get into the oil journal of the cap.
h. Use the Camshaft Seal Installer Camshaft Seal Installer to install the camshaft seals.
6. Oil Pump Installation
First Design
a. Coat the pump side (the crosshatched area shown in the illustration) of the new oil pump gasket with a thin, even coating of anaerobic sealant GM P/N 1052942 or equivalent.
CAUTION: Do not cover and/or restrict the gasket openings with excess sealant.
b. Install the oil pump gasket. (Note the tightening sequence)
c. Install the oil pump and align with the guide pins (2).
d. Apply thread sealant GM P/N 12346004, or equivalent, to the six oil pump bolts and install the bolts. Tighten the oil pump bolts, using the sequence shown, to 8 Nm (71 inch lbs.).
e. Install the timing belt idler pulley and washer for camshafts 3 and 4. Tighten the timing belt idler pulley locking nut to 40 Nm (30 ft. lbs.).
NOTE: The timing belt and the generator are NOT reinstalled at this point, the bolts are torqued to specification to allow for proper compression of the oil pump gasket.
f. Install the generator the generator upper and lower mounting bolts. Tighten the generator lower and upper bolts to 40 Nm (30 ft. lbs.). Re-tighten the six oil pump bolts, using the sequence shown, to 9 Nm (80 inch lbs.).
g. Remove the timing belt idler pulley and washer for camshafts 3 and 4.
h. Remove the generator upper (6) and lower (3) mounting bolts.
i. Remove the generator.
j. Install the oil pump collar.
k. Install the front main oil seal. Coat the lip of the front main oil seal with a small amount of GM P/N 1052497 chassis grease or equivalent to aid in installation.
l. Use the Camshaft Seal Installer to tap the front main oil seal into place.
m. Ensure the front main oil seal if fully and evenly seated.
n. Install the crankshaft drive gear.
o. Install a new crankshaft drive gear bolt. Tighten the crankshaft drive gear bolt to 250 Nm (184 ft. lbs.) + 45° + 15°.
Second Design
NOTE: Second Design Oil Pump and Rear Timing Belt Cover Information Starting with engine unit number 08191279, a second design oil pump housing and rear timing belt cover were introduced into MY97 Catera production. The second design rear timing belt cover features an additional hole that allows access to one of the oil pump bolts located behind the cover. Since it is necessary to re-torque all of the oil pump bolts after the timing belt idler pulley installation, the access hole was added to the cover to make the re-torque procedure easier. The second design oil pump has an extended boss to shield the access hole in the rear timing belt cover from road and other debris. Both first and second design pumps use the same gaskets. Second design pumps can be installed on first design engines, however, it requires the use of the second design rear timing belt cover and a longer (M6 x 25 mm) oil pump bolt in the number six position.
a. Coat the pump side (the crosshatched area shown in the illustration) of the new oil pump gasket with a thin, even coating of anaerobic sealant GM P/N 1052942 or equivalent.
CAUTION: Do not cover and/or restrict the gasket openings with excess sealant.
b. Install the oil pump gasket (Note the tightening sequence).
c. Install the oil pump and align with the guide pins (2).
d. Apply thread sealant GM P/N 12346004, or equivalent, to the six oil pump bolts and install the bolts. Tighten the oil pump bolts, using the sequence shown, to 8 Nm (71 inch lbs.).
e. Install the oil pump collar.
f. Install the front main oil seal. Coat the lip of the front main oil seal with a small amount of GM P/N 1052497 chassis grease or equivalent to aid in installation.
g. Use the Camshaft Seal Installer to tap the front main oil seal into place.
h. Ensure the front main oil seal if fully and evenly seated.
i. Install the crankshaft drive gear.
j. Install a new crankshaft drive gear bolt. Tighten the crankshaft drive gear bolt to bolt to 250 Nm (184 ft. lbs.) + 45° + 15°.
7. Oil Pan Installation
a. Install the oil intake pipe.
b. Install the oil intake pipe bolts. Tighten the oil intake pipe bolts to 8 Nm (71 inch lbs.).
c. Apply a bead of silicone sealing compound, P/N 12346286 or equivalent, in the bottom of the oil pan housing groove. Keep the bead at least 10 mm (0.4 inch) from the bolt holes to prevent carry over onto bolt threads.
d. Install the new oil pan housing rubber seal in the groove of the housing. Apply a 3 mm (0.12 inch) bead of silicone sealant, GM P/N 12346286 or equivalent, on the OUTSIDE edge of the seal at the front of the housing and apply an identical bead on the INSIDE edge of the seal at the rear of the housing. The beads will overlap at the middle of the housing as shown in the supporting illustration.
CAUTION: Installation of the oil pan housing must be carried out within 10 minutes of applying the sealant.
e. Install the oil level sensor to the oil pan.
f. Install the oil level sensor bolts. Tighten the oil level sensor bolts until fully seated. Do not strip the oil level sensor bolts.
g. Install the oil pan gasket.
h. Replace the oil level sensor wire electrical connector O-ring.
i. Support the oil pan.
j. Install the oil level sensor wire electrical connector to the oil pan housing with the C-clip (1).
k. Install the oil pan to the oil pan housing.
l. Install the oil pan bolts. Tighten the oil pan bolts to 8 Nm (71 inch lbs.).
m. Reconnect the oil level sensor electrical connection.
8. Oil Cooler Installation
a. Install the engine oil cooler.
b. Apply a 2 mm (0.08 inch) bead of silicone sealer, GM P/N 12345997, in the groove around the engine oil cooler cover in place of the old seal.
c. Install the engine oil cooler cover.
d. Install the engine oil cooler cover bolts (2). Tighten the engine oil cooler cover bolts to 30 Nm (22 ft. lbs.).
e. Install the engine oil cooler inlet and outlet nuts (1). Tighten the engine oil cooler inlet and outlet nuts to 20 Nm (15 ft. lbs.).
f. Install the oil feed line.
g. Install the return line.
h. Install the oil feed line to the engine block. Tighten the oil feed line to 30 Nm (22 ft. lbs.).
i. Install the return line to the engine block. Tighten the return line to 30 Nm (22 ft. lbs.).
j. Install the engine oil cooler line clamp.
k. Install the crank sensor.
l. Install the crank sensor bolt. Tighten the crank sensor bolt to 8 Nm (71 inch lbs.).
m. Install the oil filter. Tighten the oil filter to 15 Nm (11 ft. lbs.).
n. Install the oil feed and install the return lines to the engine oil cooler. Use four new seals. Tighten the oil feed and tighten the return lines to 30 Nm (22 ft. lbs.).
9. Coolant Outlet Housing and Thermostat Installation
a. Install the thermostat housing with the thermostat to the engine.
b. Install the thermostat housing bolts (1). Tighten the thermostat housing bolts (1) to 20 Nm (15 ft. lbs.).
c. Use new seals when installing the thermostat housing extension.
d. Coat the new seals with engine coolant to assist in installation.
e. Push the thermostat housing extension into the thermostat housing to install the thermostat housing extension.
f. Install the thermostat housing extension bolt (2). Tighten the thermostat housing extension bolt (2) to 20 Nm (15 ft. lbs.).
10. Engine Rear Cover Installation
NOTE: Starting with engine unit number 08191279, a second design oil pump housing and rear timing belt cover were introduced into MY97 Catera production. The second design rear timing belt cover features an additional hole that allows access to one of the oil pump bolts located behind the cover. Since it is necessary to re-torque all of the oil pump bolts after the timing belt idler pulley installation, the access hole was added to the cover to make the re-torque procedure easier. The second design oil pump has an extended boss to shield the access hole in the rear timing belt cover from road and other debris. Both first and second design pumps use the same gaskets. Second design pumps can be installed on first design engines, however, it requires the use of the second design rear timing belt cover and a longer (M6 x 25 mm) oil pump bolt in the number six position.
a. Install the rear timing belt cover.
b. Coat the threaded pin with thread locking compound, GM P/N 12345382 or equivalent.
c. Install the rear timing belt cover bolts. Tighten the rear timing belt cover bolts to 8 Nm (71 inch lbs.).
d. Install the rear timing belt threaded pin. Tighten the rear timing belt threaded pin to 10 Nm (89 inch lbs.).
e. Install the timing belt idler pulley for camshafts 3 and 4.
f. Coat the timing belt idler pulley bolt with thread sealant, GM P/N 12346004 or equivalent and install the bolt. Tighten the timing belt idler pulley locking nut to 40 Nm (30 ft. lbs.).
g. If using a second design rear timing belt cover, re-tighten the six oil pump bolts. Tighten the six oil pump bolts to 9 Nm (80 inch lbs.) if applicable.
