Assemble Part 2
Part 211. Water Pump Installation
a. Install the water pump.
b. Coat the water pump seal ring with silicone grease, GM P/N 12345579 or equivalent.
c. Install the water pump seal.
d. Install the water pump bolts. Tighten the water pump bolts to 25 Nm (18 ft. lbs.).
12. Timing Belt Tensioner Pulley Installation
a. Install the timing belt tensioner bracket.
b. Install the timing belt tensioner bracket bolts. Tighten the timing belt tensioner bracket bolts to 40 Nm (30 ft. lbs.).
13. Camshaft Drive Sprocket Installation
NOTE: Install the cam gears on the camshaft alignment pins in the correct, numbered (1, 2, 3), alignment slot on the camshaft gear.
a. Install the camshaft gear.
CAUTION: Use a new camshaft gear bolt. The required tightening method will stretch the bolt, therefore the bolt is not reusable.
b. Install the camshaft gear bolt. Use the relevant Camshaft Gear Locking Tools to hold the camshaft gear and the camshaft in place while tightening the camshaft gear bolt.
c. Tighten the camshaft gear bolt to 50 Nm (37 ft. lbs.) + 60° + 15°.
14. Timing Belt Installation
- Tool Required
- J 42069 Timing Belt Alignment, Or Equivalent
CAUTION: Guide marks are printed on the timing belt to aid in installation. If these marks are not identifiable, install a new belt. Arrows are printed on the timing belt indicating the required direction of travel. When installing the timing belt, ensure the arrows are traveling in engine rotational direction (clockwise). Install the timing belt with the engine at room temperature and use care so as not to crimp the belt.
a. Start at the crankshaft drive gear and install the timing belt with the double dash (TDC) mark on the belt aligned with the marks on the oil pump and on the belt drive gear.
b. Use the Belt Holding Tool to pinch the belt to prevent the teeth from jumping.
c. Route the timing belt through the timing belt tensioner.
d. Slip the timing belt through camshaft gears 1 and 2 simultaneously, ensuring the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.
e. Route the timing belt through the idler pulley for camshafts 1 and 2.
f. Route the timing belt through the idler pulley for camshafts 3 and 4.
g. Slip the timing belt through camshaft gears 3 and 4 simultaneously, ensuring the dash marks on the timing belt align with the marks on the camshaft gears and the notches on the rear timing belt cover.
h. Measure the timing belt deflection between camshaft gear number 4 and the idler pulley for camshafts 3 and 4, the deflection must be no more than 1 cm (0.4 inch).
i. If timing belt deflection adjustment is necessary:
^ Turn the timing belt idler pulley eccentric for camshafts 3 and 4 COUNTERCLOCKWISE, with Adjustment Wrench, until the high point of the eccentric is in approximately the 12 o'clock position.
^ Tighten the idler pulley locking bolt, while holding the eccentric with Adjustment Wrench, until snug. The idler pulley bolt will be tightened to specifications after all final adjustments are made.
j. Apply additional tension to the timing belt, at the idler pulley for camshafts 1 and 2, by turning the high point of the eccentric to approximately the 9 o'clock position. Then, tighten the idler pulley locking bolt, while holding the eccentric with Adjustment Wrench, until snug. The idler pulley bolt will be tightened to specifications after all final adjustments are made.
k. Set the initial timing belt tension:
^ Turn the tensioner eccentric COUNTERCLOCKWISE to full stop, then, turn the eccentric back until the reference mark is 1 mm (0.003 inch) over the flange.
^ Tighten the timing belt tensioner locking nut until snug, the locking nut will be tightened to specifications after all final adjustments are made.
l. Inspect the alignment marks on the timing belt to ensure that they are aligned with the appropriate reference points on the camshaft gears, the rear timing belt cover and on the oil pump housing.
m. Remove the locking tools from the engine.
n. Rotate the engine, with Crank Hub Torx Socket, in the clockwise direction two revolutions stopping at 60° BTDC.
o. Install the Crankshaft Locking Tool to the crankshaft drive gear with the knurled bolt.
p. Turn the crankshaft until the lever of the Crankshaft Locking Tool firmly contacts the water pump pulley flange.
q. Secure the moveable lever of the tool to the water pump pulley flange.
NOTE: The alignment marks on the timing belt will no longer align with the marks on the camshaft gears after one or more engine revolutions.
r. Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft drive gear and oil pump housing.
s. Use the Checking Gauge to inspect the alignment of camshaft gears 3 & 4.
t. Use the Checking Gauge to inspect the alignment of camshaft gears 1 & 2.
CAUTION: The reference marks on both sets of the camshaft gears must match exactly with the marks on the Checking Gauge.
u. If timing belt adjustment is necessary, always set the adjustment for camshafts 3 and 4 first.
v. If timing belt adjustment IS required, refer to Timing Belt Timing Procedure.
w. If timing belt adjustment IS NOT required, set the final timing belt tension:
^ Loosen the timing belt tensioner eccentric locking nut.
^ Turn the eccentric counterclockwise to full stop, then back until the reference mark is 2-4 mm (0.078-0.157 inch) ABOVE the reference mark on the flange. Tighten the timing belt tensioner eccentric locking nut 20 Nm (15 ft. lbs.).
x. Hold the timing belt idler pulley eccentrics in place for camshafts 1 & 2 and 3 & 4 with the Adjustment Wrench. Tighten both idler pulley bolts to 40 Nm (30 ft. lbs.).
y. Inspect the high points of the timing belt tensioner eccentrics. The idler pulley eccentric high point for camshafts 3 and 4 will be in approximately the 12 o'clock position. The idler pulley eccentric high point for camshafts 1 and 2 will be in approximately the 9 o'clock position.
z. Remove the Checking Gauge and the Crankshaft Locking Tool.
aa. For final inspection, rotate the engine in the clockwise direction two revolutions until reaching 60° BTDC.
bb. Install the Crankshaft Locking Tool to the crankshaft drive gear with the knurled boll.
cc. Turn the crankshaft until the lever of the J 42069-10 Crankshaft Locking Tool firmly contacts the water pump pulley flange.
dd. Secure the moveable lever of the tool to the water pump pulley flange.
ee. Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft gear and the mark on the oil pump housing.
ff. Use the Checking Gauge to inspect the alignment of camshaft gears 3 and 4.
gg. Use the Checking Gauge to inspect the alignment of camshaft gears 1 and 2.
hh. If the reference marks on the camshaft gears do not match exactly, adjust the timing belt. Refer to Timing Belt Timing Procedure.
ii. If further timing belt adjustment IS NOT necessary, continue with reassembly.
jj. Ensure all tools are removed from the engine.
15. Timing Belt Cover Installation
a. Install the front timing belt cover.
b. Install the front timing belt cover bolts. Tighten the timing belt cover bolts to 8 Nm (71 inch lbs.).
c. Install the power steering pump pulley.
d. Install the power steering pump pulley bolts. Tighten the power steering pump pulley bolts after the serpentine drive belt is installed.
e. Install the water pump pulley.
f. Install the water pump pulley bolts. Tighten the water pump pulley bolts after the serpentine drive belt is installed.
16. Camshaft Cover Installation
a. Lightly coat new seals, including the O-rings, with engine oil prior to installation to assist in holding the O-ring seals to the valve cover.
b. Install the valve cover seals.
c. Apply a thin coat of silicone sealer GM P/N 12345997 at the front and at the back of the seals.
d. Install the valve cover to the cylinder head.
e. Install the valve cover bolts. Tighten the valve cover bolts to 8 Nm (71 inch lbs.).
17. Crankshaft Balancer Installation
a. Install the harmonic balancer.
b. Install the harmonic balancer bolts. Tighten the harmonic balancer bolts to 20 Nm (15 ft. lbs.).
18. Drive Belt Tensioner Installation
a. Install the belt tensioner to the engine.
b. Install the belt tensioner bolts. Tighten the belt tensioner bolts to 40 Nm (30 ft. lbs.).
c. Install the belt to the accessory drive pulleys.
d. Use a wrench on the center bolt of the tensioner pulley (5) and rotate downward to install the belt (7) to the tensioner.
e. Tighten the water pump pulley bolts. Tighten the water pump pulley bolts to 8 Nm (71 inch lbs.).
f. Tighten the power steering pump pulley bolts. Tighten the power steering pump pulley bolts to 20 Nm (15 ft. lbs.).
19. Crankcase Vent Housing Installation
a. Apply sealing compound, GM P/N 1052942 or equivalent, to the sealing surfaces.
b. Install the chamber and install the gasket to the engine block.
c. Install the chamber bolts. Tighten the chamber bolts to 8 Nm (71 inch lbs.).
d. Install the hoses to the chamber.
20. Exhaust Manifold Installation
a. Install the passenger side exhaust manifold gasket. Install the passenger side exhaust manifold.
b. Install the passenger side exhaust manifold nuts.
c. Tighten the passenger side exhaust manifold nuts to 20 Nm (15 ft. lbs.).
d. Install the AIR injection pipe (2) to the passenger side exhaust manifold.
e. Coat the AIR injection pipe bolts (1) with high temperature anti-seize compound, GM P/N 5613695 or equivalent.
f. Install the AIR injection pipe bolts. Tighten the AIR injection pipe bolts to 20 Nm (15 ft. lbs.).
g. Install the passenger side exhaust manifold heat shields.
h. Coat the exhaust manifold heat shield bolts with high temperature anti-seize compound, GM P/N 5613695 or equivalent.
i. Install the passenger side exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 8 Nm (71 inch lbs.).
j. Install the driver side exhaust manifold gasket.
k. Install the driver side exhaust manifold.
l. Install the driver side exhaust manifold nuts. Tighten the exhaust manifold nuts to 20 Nm (15 ft. lbs.).
m. Install the AIR injection pipe (2) to the driver side exhaust manifold.
n. Coat the AIR injection pipe bolts (1) with temperature anti-seize compound, GM P/N 5613695 or equivalent.
o. Install the AIR injection pipe bolts. Tighten the AIR injection pipe bolts to 20 Nm (15 ft. lbs.).
p. Install the driver side exhaust manifold heat shields.
q. Coat the exhaust manifold heat shield bolts with high temperature anti-seize compound, GM P/N 5613695 or equivalent.
r. Install the driver side exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 8 Nm (71 inch lbs.).
21. Water Crossover Installation
a. Install the coolant bridge and install the coolant bridge lower seals.
b. Install the coolant bridge upper seals and the coolant bridge bolts. Tighten the coolant bridge bolts to 30 Nm (22 ft. lbs.).
c. Install the coolant intake pipe (4) and install the coolant intake pipe seal (6).
d. Install the coolant intake pipe bolts (5). Tighten the coolant intake pipe bolts to 20 Nm (15 ft. lbs.).
e. Install the coolant intake pipe support bolt (3). Tighten the coolant intake pipe support bolt to 20 Nm (15 ft. lbs.).
22. Intake Manifold Installation
a. Install the intake manifold spacer (2) and install the intake manifold spacer seals.
b. Install the intake manifold spacer bolts (1). Tighten the intake manifold spacer bolts to 20 Nm (15 ft. lbs.).
c. Install the intake manifold (2) and install the intake manifold seals (3).
d. Install the intake manifold bolts (1). Tighten the intake manifold bolts to 20 Nm (15 ft. lbs.).
23. Intake Plenum Installation
a. Install the intake plenum and install the intake plenum seals.
b. Install the intake plenum bolts. Tighten the intake plenum bolts to 8 Nm (71 inch lbs.).
c. Install the intake plenum bolt covers.
d. Install the crankcase vent tube adapter and install the crankcase vent tube adapter seal.
e. Install the crankcase vent tube adapter bolt.
f. Tighten the crankcase vent tube adapter bolt until fully seated. DO NOT strip the bolt.
g. Install the crankcase vent tube adapter cover.
h. Install the throttle body gasket to the plenum.
i. Install the throttle body to the plenum.
j. Install the throttle body bolts. Tighten the throttle body bolts to 8 Nm (71 inch lbs.).