Steps 1 Thru 16
This article has been updated with bulletin No: 99-06-01-016.TOOL REQUIRED
^ J 29789 Piston Ring Compressor
^ J 39946 Crankshaft Rotation Socket
^ J 38817 Rear Main Seal Installer
^ J 38820 Valve Stem Seal Installer
^ J 8062 Valve Spring Compressor
^ J 38821 Valve Spring Compressor Adapter
^ J 38819 Valve Keeper Installer
^ J 38816-1A Water Pump Remover/Installer\
^ J 38813 Front Cover Seal Installer
^ J 39344 Crankshaft Balancer Installer
^ J 38823 Water Pump Drive Pulley Installer
PROCEDURE
1. Crankshaft Bearing Installation
a. Clean the upper and lower crankcase crank bore with a lint-free cloth.
b. Clean all the oil from the backside of new bearing halves.
c. Install new upper crankshaft bearings into position. The thrust bearing belongs in the number three journal. Be sure the upper bearing insert contains the oil transfer hole and groove. Roll the bearing into position so that the lock tang engages the crank slot. The bearing must fit flush with the upper crankcase.
d. Install new lower crankcase crankshaft bearings into position in the lower crankcase. The lower crankcase crankshaft bearings are identified by No grooves or holes. The bearings must fit flush with the lower crankcase.
e. Apply a liberal amount of GM crankshaft prelude, GM P/N 1052367, or engine oil, to the upper and lower bearing surfaces.
2. Crankshaft Installation
a. Carefully lower the crankshaft into the upper crankcase.
b. Lubricate the bearing surfaces with GM crankshaft prelude, GM P/N 1052367.
c. Rotate the crankshaft to ensure smooth rotation before piston and connecting rod installation.
3. Connecting Rod Bearing Installation
a. Clean the connecting rod and the connecting rod cap bearing bore with a lint-free cloth.
b. Clean all the oil from behind the connecting rod bearing halves.
c. Install new upper connecting rod bearings into position. Roll the bearing into position so that the lock tang engages the alignment slot. The bearing must fit flush in the connecting rod.
d. Install new lower connecting rod bearings into position in the connecting rod cap. Roll the bearing into position so that the lock tang engages the alignment slot. The bearings must fit flush with the connecting rod cap.
4. Connecting Rod and Piston Installation
a. Liberally lubricate the cylinder walls, piston rings and piston skirts with engine oil.
b. Select the correctly numbered piston/connecting rod assembly for the cylinder.
c. Coat the crankshaft bearing journal and installed connecting rod bearings with GM crankshaft prelube, GM P/N 1052367.
d. Compress the piston rings using the Piston Ring Compressor or equivalent.
CAUTION: Extreme care must be exercised when installing the piston and connecting rod in order to be sure the rod does not scrape or nick the cylinder bore or the crankshaft surfaces.
e. Using both hands, slowly guide the piston and connecting rod assembly into the cylinder from the top and bottom of the cylinder. DO NOT allow the connecting rod to contact the cylinder wall.
f. When the piston ring compressor contacts the deck surface, gently tap the piston into the cylinder using the handle end of a dead-blow hammer. Guide the connecting rod onto the crankshaft bearing journal while tapping the piston into the cylinder.
g. Install the connecting rod end cap making sure the bearing lock tangs are aligned on the same side of the rod. When properly installed, the connecting rod bearing cap notches (2) should point towards each other.
h. Lubricate new connecting rod cap bolts with engine oil and install in the connecting rod. Tighten the connecting rod bolts to 25 Nm (18 ft. lbs.) + 110 degrees.
i. Repeat these procedures for the remaining piston/connecting rod assemblies using the Crankshaft Rotation Socket in order to rotate the crankshaft.
5. Lower Crankcase Installation
a. Wipe all sealing surfaces clean with a dry, lint-free cloth.
b. Work the upper-to-lower crankcase seal into its groove starting at both ends and working the seal towards the center. The seal must not be torn, nicked, or out of the groove over its entire length on both sides of the crankcase.
c. Apply a thin bead (2) of GM Gasket Maker, P/N 1052942, to the upper crankcase. The bead should run parallel to the silicone seal (1) and through the centerline of the bolt holes but not through the bolt holes. Starting from the front of the block, the bead should be about 1 mm thick until the first bolt hole. Expand to 2.5-3 mm thick from the first to the third bolt hole. After the third bolt hole the bead should be reduced to 1 mm until running off the end of the crankcase. Do not continue the bead all the way to the rear crankshaft seal.
d. Align the lower crankcase with the dowel pins in the upper crankcase.
e. Install the lower crankcase onto the upper crankcase slowly until feeling a positive stop.
f. Inspect the upper-to-lower crankcase joint in order to make sure the tower crankcase is fully seated on the upper crankcase.
g. Install the oil manifold plate.
h. Install the oil manifold plate retaining bolts. Tighten the oil manifold plate bolts to 10 Nm (89 inch lbs.).
i. Place the crankshaft oil scraper in position on the oil manifold. Align the holes with the main bearing bolt holes.
j. Install the main bearing bolts. The single stud-head bolt used for pump pick-up mounting goes in the inboard position of the third set of main bearing bolts from the front of the engine.
k. Install the upper-to-lower crankcase perimeter bolts.
^ Tighten the main bearing bolts (numbers 1 through 20) to 20 Nm (15 ft. lbs.)+65 degrees in the proper sequence.
^ Tighten the upper-to-lower crankcase perimeter bolts (numbers 21 through 28) to 30 Nm (22 ft. lbs.).
l. Lubricate the silicone seal in the oil manifold plate. With a twisting motion, install the end of the oil pump pick-up tube.
m. Install the oil pump pick-up retaining bolt and nut.
^ Tighten the oil pump pick-up tube nut to 24 Nm (18 ft. lbs.).
^ Tighten the oil pump pick-up tube bolt to 10 Nm (89 inch lbs.).
n. Install the two crankshaft position sensors. Tighten the crankshaft position sensor retaining bolts to 10 Nm (89 inch lbs.).
o. Rotate the crankshaft until the number one piston is at top dead center (TDC) and the crankshaft key way is approximately at the 7 o'clock position.
6. Rear Crankshaft Oil Seal Installation
a. Place a small amount of GM Gasket Maker, GM P/N 1052942 or equivalent, at the crankcase split line across the end of the upper/lower crankcase seal.
b. Lubricate the rear main seal sealing lips with clean engine oil.
c. Slide the seal over the arbor of the Rear Main Seal Installer. The garter spring should face the engine.
d. Thread the Rear Main Seal Installer into the crankshaft flange.
e. Install the seal by turning the handle until the tool bottoms against the crankcase.
f. When properly installed, the outer surface of the seal should be 0.5 mm below the surface of the engine block.
7. Oil Pan Installation
a. If required, install a new oil pan seal using the following procedure:
^ Clean any residual oil from the seal groove.
^ Start the seal into the pan groove and work the seal into the groove in both directions around the pan.
^ If the seal is exposed to oil, it will no longer stay in the groove. If this condition exists, replace the seal.
b. Position the oil pan onto the lower crankcase.
c. Install the oil pan retaining bolts. Tighten the oil pan retaining bolts to 10 Nm (89 inch lbs.) in the sequence shown.
d. Install the oil drain plug. Tighten the oil drain plug to 20 Nm (15 ft. lbs.).
e. Install the oil level sensor. Tighten the oil level sensor to 20 Nm (15 ft. lbs.).
f. Rotate the engine so that the engine valley is facing upward.
8. Engine Flywheel Installation
a. Apply sealant, GM P/N 12346004 or equivalent, to flywheel retaining bolts.
b. Place the flywheel in position on the crankshaft.
c. Slip one bolt into the flywheel washer.
d. Install the washer and bolt in a location at the top of its rotation allowing the flywheel to hang in position.
e. Install the remaining flywheel bolts. Tighten the flywheel retaining bolts to 15 Nm (11 ft. lbs.)+50 degrees.
9. Valve Installation
a. Lubricate the valve stem with clean engine oil.
b. Insert the valve into the valve guide until it bottoms on the valve seat.
c. Lubricate the valve seal with engine oil.
d. Using the Valve Stem Seal Installer, install the valve seal using the following procedure:
^ Place the valve lifter bore protector into the lifter bore.
^ Mount the valve seal in the Valve Stem Seal Installer.
^ Push and twist the valve seal into position on the valve guide until the seal positively locks on the guide.
e. Position the valve spring on the spring seat.
f. Compress the valve spring using the Valve Spring Compressor and the Valve Spring Compressor Adapter.
g. With the spring compressed, install the valve keepers into the Valve Keeper Installer.
h. Place the keepers into position by pushing the tool downward.
i. Release the tension on the spring compressor and remove the Valve Spring Compressor Adapter.
j. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-blow hammer. The valve keepers and the spring should remain in place.
k. Repeat this procedure for the remaining valves.
10. Cylinder Head Installation
a. Make sure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
b. Install a new cylinder head gasket using the deck face locating pins for retention.
c. Align the cylinder head with the deck face locating pins.
d. Place the cylinder head in position on the deck face.
e. Apply sealant, GM P/N 12345382 or equivalent to the M11 cylinder bolt threads.
f. Install the M11 cylinder head bolts.
The torque specification and sequence for the cylinder head bolts (1--10) using J 36660-A is:
1. First Pass 40 Nm (30 lb. ft.).
2. Second Pass 70 Degrees.
3. Third Pass 60 Degrees.
4. Fourth Pass 60 Degrees (190 Degrees total).
g. Install the M6 bolts at the front of the cylinder head. Tighten the M6 cylinder head bolts to 12 Nm (105 inch lbs.).
h. Install the coolant temperature sensor. Tighten the coolant temperature sensor to 20 Nm (15 ft. lbs.).
i. Install the oil gallery plugs at the front and rear of the cylinder head. Tighten the oil gallery plugs to 12 Nm (106 inch lbs.).
11. Water Crossover Installation
a. With the water crossover on the bench, install all eight crossover retaining bolts. The longer bolts belong in the inboard positions.
b. Slide the four crossover gaskets onto the bolts with the crossover still on the bench.
c. Place the water crossover in position and hand thread the bolts. Tighten the water crossover bolts to 25 Nm (18 ft. lbs.).
d. Install a new EGR valve gasket on the EGR valve.
e. Install the EGR valve and the retaining bolts. Tighten the EGR valve bolts to 24 Nm (18 ft. lbs.).
12. Water Pump Installation
a. Check the O-ring seal in the water crossover for tears or cuts. Replace the O-ring if necessary.
b. Place the water pump in the Water Pump Remover/lnstaller by indexing the tool into the water pump locking ears.
c. Install the water pump into the water crossover using the following procedure:
^ Index the pump locking ears with the tangs in the water crossover.
^ With the locking ears indexed, twist to lock the pump in place. Remove the tool.
d. Install the water pump housing gasket and housing.
e. Install the water pump housing bolts. Tighten the water pump housing bolts to 10 Nm (89 inch lbs.).
13. Thermostat Installation
a. Place the thermostat in the thermostat housing with the spring facing the engine.
b. Place the thermostat housing, gasket and thermostat in position on the water pump cover.
c. Install the thermostat housing bolts. Tighten thermostat housing bolts to 10 Nm (89 inch lbs.).
14. Camshaft Installation
a. Install the valve lifters with the flat surface facing up.
b. Clean the camshaft carriers with a clean, lint-free cloth.
c. Apply a liberal amount of clean engine oil to the carriers.
d. Place the camshaft in the camshaft carriers with the camshaft sprocket drive pins at the top of their rotation. The camshafts can be identified by a stamping near the rear journal. For example: L-EXH is defined as Left Bank Exhaust.
e. Install the camshaft bearing caps according to the identification marks. The arrow should point toward the front of the engine. The number indicates the position from the front of the engine and the I or E indicates intake or exhaust camshaft. Tighten the camshaft bearing cap bolts to 5 Nm (44 inch lbs.)+ 30 degrees.
f. Repeat these procedures for the remaining camshafts.
15. Primary Camshaft Drive Chain Installation
a. Install the intermediate sprocket shaft and the retaining bolts. Tighten the intermediate shaft sprockets bolts to 10 Nm (89 inch lbs.).
b. Install the crankshaft sprocket drive key. If necessary, tap the key in place with a small hammer until it bottoms on the crankshaft.
c. Align the timing marks of the intermediate and crankshaft sprockets. The marks should be aligned vertically in the installed position.
d. Install the primary timing chain on the drive sprockets.
e. Make sure that piston number one is at TDC and the crankshaft keyway is approximately at the one o'clock position.
f. Install the primary timing chain, intermediate, sprocket and crankshaft sprocket as an assembly onto their respective shafts. Use the Crankshaft Rotation Socket in order to align the crankshaft key with the drive sprocket.
g. Install the intermediate sprocket retaining bolt. Tighten the intermediate sprocket shaft bolt to 60 Nm (44 ft. lbs.).
h. Collapse the primary drive chain tensioner using the following procedure:
^ Rotate the ratchet release lever counterclockwise and hold.
^ Collapse the tensioner shoe and hold.
^ Release the ratchet lever and slowly release the pressure on the shoe.
i. As the ratchet lever moves to its first click, hold the tensioner shoe inward. Insert a pin through the hole in the release lever.
j. The locked ratchet mechanism should hold the shoe in a collapsed position.
CAUTION: Make sure the tensioner release lever faces toward you before tightening.
k. Install the primary drive chain tensioner and retaining bolts. Tighten the primary drive chain tensioner bolts to 25 Nm (18 ft. lbs.).
l. Remove the retaining pin allowing the tensioner shoe to extend.
m. Check the timing marks to make sure they are aligned vertically.
16. Oil Pump Installation
a. Install the oil pump drive spacer into the oil pump so that the drive flat engages the pump rotor.
b. Position the oil pump on the crankshaft.
c. Install the retaining bolts.
d. Apply upward pressure on the pump while tightening the three retaining bolts. Tighten the bolts in a counter clockwise pattern starting with the lower left bolt when facing the pump.
^ Tighten the oil pump mounting bolts in sequence to 10 Nm (89 inch lbs.).
^ Tighten the oil pump mounting bolts in sequence to 26 Nm (19 ft. lbs.).