Assemble
1. Install Cylinder Block Pluga. Coat the threads of the oil gallery plugs with pipe sealant.
b. Install the rear and side engine block oil gallery plugs.
c. Install the front engine block oil gallery plugs.
- Tighten the oil gallery plugs to 20 Nm (15. ft. lbs.).
d. Install the engine block coolant plugs.
- Tighten the engine block coolant plugs to 20 Nm (15. ft. lbs.).
2. Install Crankshaft, Bearings, and Bearing Cap
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3. Install Crankshaft Rear Oil Seal and Housing
- Tools Required
- J 35621 Crankshaft Rear Oil Seal Installer, Or Equivalent
NOTE: Always use a new crankshaft rear oil seal and new crankshaft rear oil seal housing gasket when you install the crankshaft rear oil seal housing
a. Install the new gasket and the crankshaft rear oil housing on to the studs.
b. Install the rear oil seal housing nuts and bolts.
- Tighten the crankshaft near the oil seal housing nuts and bolts to 15 Nm (11 ft. lbs.).
c. Coat the new oil seal entirely with clean engine oil.
d. Install the seal onto the crankshaft rear oil seal installer.
e. Install the crankshaft rear oil seal installer onto the rear of the crankshaft. Tighten the screws snugly in order to ensure that the seal will be installed squarely over the crankshaft.
f. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. Tighten the wing nut on the crankshaft rear oil seal installer until the oil seal bottoms in the housing bore.
g. Remove the crankshaft rear oil seal installer from the crankshaft rear oil seal housing.
4. Install Piston, Connecting Rod, and Bearing
- Tools Required
- J 5239 Guide Set
- J 8037 Piston Ring Compressor
- J 36660 Torque Angle Meter
- Or Equivalents
a. Coat the following components with clean engine oil
- The piston
- The piston rings
- The cylinder bore
- The bearing surfaces
b. Install the piston with the stamped arrow facing forward.
c. Install the piston assembly into its matched bore. When assembled, the flanges on the connecting rod and cap should face to the front in the left bank and to the rear in the right bank.
d. Use the piston ring compressor and the guide set and lightly tap the top of the piston with a wooden hammer handle.
- Hold the piston ring compressor firmly against the engine block until all of the piston rings enter the cylinder bore.
^ Use the guide set in order to guide the connecting rod onto the crankshaft journal.
e. Remove the guide set.
f. Install the connecting rod cap and nuts.
- On the first pass, tighten the nuts evenly to 27 Nm (20 ft. lbs.).
- On the final pass, use the torque angle meter in order to tighten the nuts an additional 55°.
g. When all of the connecting rod bearings are installed, tap each connecting rod assembly lightly parallel to the crankpin in order to make sure that they have clearance.
h. Use a feeler gauge or a dial indicator in order to measure the side clearance between the connecting rod caps. The rod side clearance should be 0.16 0.35 mm (0.006.014 inch).
i. Install the engine.
5. Install Camshaft
a. Coat the following components with engine oil supplement GM P/N 1052367 or the equivalent
- The camshaft lobes
- The camshaft bearing journals
NOTE: Use care when you install the camshaft. Ail bearings are of equal diameter.
b. Install the three 5/16 18 x 4.0 inch bolts in the camshaft front bolt holes.
c. Install the camshaft.
d. Remove the three bolts from the front of the camshaft.
e. Install the camshaft retainer.
f. Install the bolts.
- Tighten the camshaft retainer bolts to 12 Nm (106 inch lbs.).
6. Install Timing Chain and Sprockets
- Tools Required
- J 5590 Crankshaft Sprocket Installer, Or Equivalent
a. Install the key into the crankshaft keyway.
b. Use the crankshaft sprocket installer in order to install the crankshaft sprocket.
NOTE: The gears must mesh in order to prevent damage to the camshaft retainer.
c. Install the camshaft sprocket and timing chain.
d. Install camshaft sprocket bolts. Be sure to align the camshaft and the crankshaft sprocket alignment marks. Do not attempt to hammer the camshaft sprocket. To do so may dislodge the rear camshaft plug and/or damage the camshaft.
- Tighten the camshaft sprocket bolts to 25 Nm (18 ft. lbs.).
NOTE: Align the keyway on the reluctor ring with the key in the crankshaft and install the reluctor ring onto the crankshaft until the ring is completely seated against the crankshaft sprocket.
e. Install the crankshaft position sensor reluctor ring.
7. Install The Engine Front Cover and Oil Seal
a. Lubricate the crankshaft front oil seal surface with clean engine oil.
NOTE: Do not attempt to reuse the composite engine front cover and gasket. You must install a new cover and gasket.
b. Install the engine front cover and gasket.
c. Install the engine front cover bolts.
- Tighten the engine front cover bolts to 12 Nm (106 inch lbs.).
8. Install The Oil Pump
a. Assemble the oil pump (3), driveshaft (53, and retainer (4).
b. Install the oil pump (3).
c. Align the slot in the end of the driveshaft (5) with the drive tang on the distributor shaft.
d. Install the bolt (1) attaching the oil pump to the rear crankshaft bearing cap.
e. Install the crankshaft oil deflector (2) and nuts (6). Tighten
- Tighten the oil pump bolt to 90 Nm (66 ft. lbs.).
- Tighten the crankshaft oil deflector nuts to 36 Nm (27 ft. lbs.).
9. Install The Oil Pan
NOTE: Apply the sealer 25 mm (1.0 inch) in either direction of the radius cavity of the junctions.
a. Apply a small amount of sealer, GM P/N 12346004 or equivalent, 10 mm (0.393 inch) wide and 20 mm (0.787 inch) long to the engine front cover to engine block junction.
b. Apply a small amount of sealer, GM P/N 12346004 or equivalent, 25 mm (1.00 inch) long to the crankshaft rear oil seal housing to engine block junction
c. Install the oil pan gasket.
d. Install the oil pan.
e. Install the oil pan reinforcements.
f. Install the Nut and the bolts to the oil pan.
1. Tighten the corner bolts or studs to 20 Nm (15 ft. lbs.).
2. Tighten the corner nuts to 20 Nm (15 ft. lbs.).
3. Tighten the remainder of the bolts to 12 Nm (106 inch lbs.).
g. Install the oil pan drain plug.
- Tighten the oil pan drain plug to 20 Nm (15 ft. lbs.).
10. Install The Oil Filter Adapter and Valve Assembly
a. Install the oil filter adapter, with new adapter oil seal and gasket.
b. Install the oil filter adapter bolts and washers.
- Tighten the oil filter adapter bolts to 25 Nm (18 ft. lbs.).
11. Install The Cylinder Head
- Tools Required
- J 36660 Torque/Angle Meter, Or Equivalent
a. Clean the gasket surfaces on the block.
b. Clean the gasket surfaces on the cylinder head.
NOTE: Do not use sealer on any engines that use a composition gasket.
c. Place the gasket in position over the cylinder head dowel pins. Align the gasket locating mark to face up.
d. Install the cylinder head to the block. Guide the cylinder head carefully into place over the dowel pins and the head gasket.
e. Coat the threads of the cylinder head bolts with sealing compound GM P/N 12346004 or equivalent.
f. Install the cylinder head bolts.
- Tighten the bolts in sequence on the first pass to 30 Nm (22 ft. lbs.).
- Use the torque/angle meter in order to tighten the cylinder head bolts on the second pass.
- Tighten the short bolts (3, 4, 7, 8, 11, 12, 15, 16) 55°.
- Tighten the medium bolts (14, 17) 65°.
- Tighten the long bolts (1, 2, 5, 6, 9, 10, 13) 75°.
12. Install The Valve Lifters
a. Coat the valve lifter rollers with prelude, GM P/N 1052367 or equivalent.
NOTE: If reusing the valve lifters, install in their original location.
b. Install the valve lifters.
c. Install the valve lifter guides.
d. Install the valve lifter guide retainer.
e. Install the valve lifter guide retainer bolts.
- Tighten the valve lifter guide retainer bolts to 25 Nm (18 ft. lbs.).
13. Install The Valve Rocker Arm and Push Rod
NOTE: Be sure to, keep parts in order. Parts must be put back from where they were removed.
a. Coat the valve rocker arm and valve rocker arm ball bearing surfaces with prelube GM P/N 1052367 or equivalent.
NOTE: Be sure that the valve pushrods seat in the valve lifter sockets.
b. Install the valve pushrods.
c. Install the following parts
- The valve rocker arms
- The valve rocker arm balls
- The valve rocker arm nuts
d. Adjust the valve rocker arm nuts until all of the lash is gone.
1. Turn the crankshaft until the cast arrow on the crankshaft balancer hub is at 12 o'clock and the number 1 cylinder is in the firing position (top dead center).
2. Watch the number 1 cylinder valves as the crankshaft balancer hub approaches 12 o'clock. if a valve moves as the arrow moves into position, the engine is in the number 6 firing position. if this happens, turn the crankshaft one more revolution in order to reach the number 1 cylinder firing position.
3. With the engine in the number 1 firing position, adjust the exhaust valves 1,3,4,8 and the intake valves 1,2,5,7.
- Back off the valve rocker arm nut until the lash is felt in the valve pushrod.
- Tighten the valve rocker arm nut until all the lash is removed.
- Zero lash can be felt by moving the valve pushrod up and down between your thumb and forefinger until there is no more movement.
- When all free play is gone, tighten the valve rocker arm nut 1 additional turn (360 degrees).
4. Turn the crankshaft 1 revolution until the hub arrow is at 12 o'clock. This is the number 6 firing position.
5. Adjust the exhaust valves 2,5,6,7 and the intake valves 3,4,6,8.
- Back off the valve rocker arm nut until the lash is felt in the valve pushrod.
- Tighten the valve rocker arm nut until all the lash is removed.
- Zero lash can be felt by moving the valve pushrod up and down between your thumb and forefinger until there is no more movement.
- When all free play is gone, tighten the valve rocker arm nut 1 additional turn (360 degrees).
14. Install The Valve Rocker Arm Covers
NOTE: Always install cover gasket.
a. Install the new valve rocker arm cover gasket.
b. Install the valve rocker arm cover.
c. Install the valve rocker arm cover bolts.
- Tighten the bolts to 12 Nm (106 inch lbs.).
15. Install The Intake Manifold
NOTE: Do not reuse the intake manifold gaskets.
CAUTION: Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly.
a. Apply a 4.0 mm (0.15.7 inch) patch of sealant to the cylinder head side of the intake manifold gasket at each end.
b. Install the gasket onto the cylinder head.
c. Use the gasket locator pins in order to properly seat the gasket on the cylinder head.
d. Apply a 5 mm (0.197 inch) bead of sealant GM P/N 12346192 or the equivalent to the front block.
e. Apply a 5 mm (0.197 inch) bead of sealant GM P/N 12346192 or the equivalent to the rear block.
f. Extend the sealer bead 13 mm (0.499 inch) onto each gasket.
g. Apply the thread-locking sealant GM P/N 12345382 or equivalent to the threads of the lower intake mounting bolts.
h. Install the lower intake manifold onto the engine block.
i. Install the lower intake manifold bolts.
1. Tighten the bolts first pass in sequence to 3 Nm (27 inch lbs.).
2. Tighten the bolts second pass in sequence to 12 Nm (106 inch lbs.).
3. Tighten the bolts final pass in sequence to 15 Nm (11 ft. lbs.).
j. Install the oxygen sensor wire support bracket and nut.
- Tighten the wire support bracket nut to 11 Nm (97 inch lbs.).
k. Install the EGR Inlet tube.
l. Install the exhaust gas recirculation (EGR) inlet tube clamp and the bolt.
1. Tighten the EGR inlet tube nut at the intake manifold to 23 Nm (17 ft. lbs.).
2. Tighten the EGR inlet tube nut at the exhaust manifold to 28 Nm (21 ft. lbs.).
3. Tighten the EGR inlet tube clamp bolt to 25 Nm (18 ft. lbs.).
m. Connect the canister purge system tubing.
n. Install the PCV valve.
o. Install the vacuum hose
15. Install The Distributor
a. Bring cylinder number one to Top Dead Center (TDC) of compression stroke.
b. Loosen the distributor cap screws, and remove the distributor cap.
c. Align the indent hole on the driven gear with the white paint mark on the lower distributor shaft housing.
d. Ensure that the rotor segment points to the cap hold area.
e. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary.
f. Install the distributor. The spark plug towers on the distributor cap must be aligned perpendicular to the center line of the engine.
g. Once the distributor is fully seated, align the rotor segment with the pointer cast into the distributor base. This pointer will have a 6 or an 8 cast into it, indicating the distributor is to be used in a 6 cylinder or 8 cylinder engine.
h. If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and camshaft may be off a tooth or more. Repeat the procedure again in order to achieve proper alignment.
i. Install the distributor cap.
j. Install the distributor cap mounting screws. Do not overtighten the screws as the boss may strip.
k. Install the distributor clamp and bolt.
1. Tighten the distributor the bolt to 27 Nm (20 ft. lbs.)
2. Tighten the distributor cap screws to 5 Nm (445 inch lbs.).
16. Install The Crankshaft Balancer
- Tools Required
- J 23523 F Crankshaft Balancer Remover and Installer, Or Equivalent
CAUTION: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning the crankshaft balancer.
a. Install the key into the crankshaft keyway.
b. Apply a small amount of RTV sealant onto the key in order to seal the balancer keyway and crankshaft joint.
c. Install the crankshaft balancer hub with crankshaft balancer remover until the hub is completely seated against the crankshaft position sensor reluctor ring.
d. Remove the crankshaft balancer remover.
e. Install the bolt and the washer.
- Tighten the balancer bolt to 100 Nm (74 ft. lbs.).
17. Install The Water Pump
a. Install the new gaskets.
b. Install the water pump.
c. Install the bolts.
- Tighten the bolts to 41 Nm (30 ft. lbs.).
d. Install the water pump bypass hose and the clamps.
18. Install The Exhaust Manifold (Right Side)
a. Install the new exhaust manifold gasket.
b. Install the exhaust manifold.
c. Install the spark plug heat shields.
d. Install the exhaust manifold bolts.
e. Tighten the exhaust manifold bolts.
1. Tighten the bolts on the first pass to 15 Nm (11 ft. lbs.).
2. Tighten the bolts on the final pass to 30 Nm (22 ft. lbs.).
19. Install The Exhaust Manifold (Left Side)
a. Install the new exhaust manifold gasket.
b. Install the exhaust manifold.
c. Install the spark plug heat shields.
d. Install the exhaust manifold bolts.
1. Tighten the exhaust manifold bolts on the first pass to 15 Nm (11 ft. lbs.).
2. Tighten the exhaust manifold bolts on the final pass to 30 Nm (22 ft. lbs.).
e. Install the EGR inlet pipe to the exhaust manifold.
f. Install the EGR inlet pipe clamp and bolt.
1. Tighten the EGR inlet pipe nut at the intake manifold to 23 Nm (17 ft. lbs.).
2. Tighten the EGR inlet pipe nut at the exhaust manifold to 28 Nm (21 ft. lbs.).
3. Tighten the EGR inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
20. Install The Oil Level Indicator and Tube
a. Apply a sealer GM P/N 12346004 or equivalent around the oil level indicator tube 13 mm (0.5 inch) below the bead.
b. Install the oil level indicator tube into the engine block. Rotate the tube into position.
c. Install the oil level indicator tube bolt to the engine block.
- Tighten the oil level indicator tube bolt to 12 Nm (106 inch lbs.).
d. Install the oil level indicator into the tube.
21. Install The Engine Flywheel
a. Install the engine flywheel.
b. Install the engine flywheel bolts.
- Tighten the flywheel bolts to 100 Nm (74 ft. lbs.).
Engine Set Up and Testing
After overhaul, the engine must be tested before it is installed in the vehicle. If a suitable test stand is not available, the procedure can be performed after the engine is installed in the vehicle.