Assemble
1. Install Crankshaft, Bearings, and Bearing Cap- Refer to component for installation procedure.
2. Install Rear Crankshaft Oil Seal
- Tools Required
- J 39084 Rear Crankshaft Oil Seal Installer, Or Equivalent
NOTE:
- Coat the crankshaft surface with engine oil.
- Lightly coat the lip of the new oil seal with engine oil or grease before installing the new oil seal.
- Do not scratch or nick the sealing edge of the oil seal.
a. Install the oil seal, with the spring cavity facing the engine, onto the crankshaft.
b. Using the rear crankshaft seal installer, drive the seal into the crankshaft until the tool bottoms against the block and the rear crankshaft bearing cap.
3. Install Oil Pump
a. Install the oil pump with the driveshaft.
b. Install the oil pump bolts.
- Tighten the oil pump bolts to 90 Nm (65 ft. lbs.).
4. Install Oil Pan
a. Apply a 2 mm (1/16 inch) bead of RTV sealant GM P/N 12345739 to the oil pan rear seal at the inside comers where the seal meets the rear main bearing cap on the block.
b. Install the oil pan rear seal to the rear main bearing cap before the sealer starts to dry.
c. Apply a 5 mm (3/16 inch) bead of RTV sealant GM P/N 12345739 to the oil pan sealing surface, inboard of the bolt holes. Install the pan before the sealer starts to dry.
d. Install the oil pan to the engine.
e. Install the oil pan bolts.
- Tighten all except the rear two bolts to 10 Nm (89 inch lbs.).
- Tighten the rear two bolts to 23 Nm (17 ft. lbs.).
5. Install Camshaft
NOTE: Replace the valve lifters when a new camshaft is installed.
a. Install the camshaft sprocket key.
b. Install the camshaft sprocket spacer, with the ID chamfer facing the camshaft.
c. Install the camshaft.
- Coat the camshaft lobes with MOLYKOTE, or the equivalent.
- Lubricate the camshaft bearing journals with engine oil.
- Carefully insert the camshaft into the block, in order to avoid damage to the camshaft bearings.
d. Install the thrust bearing.
e. Install the thrust bearing bolts.
- Tighten the bolts to 23 Nm (17 ft. lbs.).
6. Install Valve Lifter
CAUTION: Prime the new valve lifters before installation. The valve lifters may be damaged if the valve lifters are dry when the engine is started.
NOTE: Replace the lifters when you install a new camshaft. Some engines will have both standard and 0.25 mm (0.010 inch) oversize valve lifters. The oversize lifter will have the number 10 etched on the side. The block will be stamped OS on the cast pad adjacent to the lifter bore and on the top rail of the cylinder case above the lifter bore.
a. Install the valve lifters to the engine.
- Prime the new valve lifters before installation, by working the lifter plunger while submerged in clean kerosene or diesel fuel.
- Coat the lifter roller and the bearings with lubricant GM P/N 1052367, or equivalent.
- Install the lifters in their original location.
NOTE: Ensure that the straight edge of the guide plates and the clamps face away from the cylinders.
b. Install the guide plates.
c. Install the clamps.
- Tighten the clamp bolts to 25 Nm (18 ft. lbs.).
d. After installing the clamps, turn the crankshaft by hand 720° (two full turns), in order to ensure the free movement of the lifters in the guide plates.
e. If the engine will not turn over by hand, one or more of the lifters may be binding in the guide plates.
7. Install Connecting Rod and Piston
The connecting rod bearings are precision insert connecting rod bearings, and do not require shims for adjustment. Do not file the rods or the rod caps. If the engine has excessive clearances, install a new bearing. Service bearings are available in standards sizes with yellow color for identification, and 0.026 mm (0.001 inch) undersize, with green color for identification.
Selective fitting of the rod and the crankshaft is necessary in order to obtain close tolerances. For example, use one half of a 0.026 mm (0.0010 inch) undersize insert which will decrease the clearance by 0.013 mm (0.0005 inch), rather than using a full standard bearing.
NOTE:
- When using selective fit rod bearings, always use the standard bearing in the connecting rod, and use the undersize bearing in the end of the rod cap.
- Note that the color coding for selective fit rod bearings is different from the color coding for the crankshaft bearings.
- Connecting rod bearings are available in 0.026 mm (0.0010 inch) undersize for select fitting.
- These engines may have both, standard and 0.08 mm (0.0010 inch) oversize connecting rod bearings. The oversize connecting rod cap's lower end is stamped with OS.
- Tools Required
- J 8037 Universal Piston Ring Compressor, Or Equivalent
NOTE:
- Make sure that the cylinder walls are clean.
- Lightly lubricate the cylinder wall with engine oil.
- Make sure that the piston installs in the matching cylinder.
- Install new pistons in the fitted cylinders.
- Install used pistons in the cylinders from which they were removed.
a. Install the connecting rod cap.
b. Install two 1O mm (3/8 inch) hose onto the connecting rod studs.
c. Locate the piston ring end gaps with the piston viewed with the swirl indent up, in the following way:
1) The oil ring expander gap at 45° left of the swirl indent
2) The oil control ring gaps at 180° opposite of the oil expander ring
3) The second compression ring gap at the piston top and under the swirl indent
4) The first compression ring 180 degrees opposite of the second ring. Lubricate the piston and rings with engine oil.
d. Without disturbing the ring end gap location, install the universal piston ring compressor over the piston.
e. Install the piston so that the depression in the piston crown is toward the outside of the engine.
f. Tap the piston down into the bore using light blows with a hammer handle, while guiding the connecting rod to the journal from beneath the engine.
g. Hold the ring compressor against the block until all rings have entered the cylinder bore.
h. Install the hoses from the connecting rod bolts.
NOTE: Each connecting rod and bearing cap should be marked, beginning at the front of the engine. Cylinders 1, 3, 5, and 7 are the left bank and 2, 4, 6, and 8 are the right bank. The numbers on the connecting rod and bearing cap must tee on the same side when installed in the cylinder bore. If a connecting rod is transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.
i. Apply engine oil to the connecting rod bearings.
j. Install the connecting rod cap and the nuts, with the bearing.
- Tighten the connecting rod cap nuts to 65 Nm (48 ft. lbs.).
k. Measure the connecting rod side clearance.
- Use a feeler gauge between the connecting rod and the crankshaft.
- The correct clearance is 0.17.63 mm (0.007 0.025 inch).
8. Install Cylinder Head
- Tools Required
- J 39664 Manifold Cover Set, Or Equivalent
NOTE:
- Make sure that the block gasket surfaces are clean.
- The head gasket material is soft. Handle the gasket with care. Make sure the gasket surface is not creased or dented.
- Do not use a sealer on the head gasket. The head gasket manufactures with sealant on the gasket surface. Additional sealer may cause leakage or malfunction. In addition, some sealers may attack the initial sealant on the gasket.
a. Install the head gasket to the block, over the dowel pins.
b. Install the cylinder head.
- Make sure that the gasket surfaces are clean.
- Carefully guide the head into place, over the cylinder head dowel pins.
c. Install the cylinder head bolts.
- Make sure that the bolt threads are clean.
- Apply the thread sealant GM P/N 12345332, or equivalent, to the bolt threads and under the bolt heads.
1) Tighten all of the cylinder head bolts to 25 Nm (20 ft. lbs.).
2) In sequence, tighten all of the bolts to 75 Nm (55 ft. lbs.).
3) In sequence, tighten all of the bolts and additional 90-100° (1/4 plus turn).
d. Install the manifold cover set to the intake ports.
9. Install Valve Rocker Arm and Push Rod
CAUTION: Install the valve pushrods with the copper colored, painted, or marked end up in order to avoid damage or premature wear.
NOTE: Ensure that the ball ends of the valve pushrods seat in the valve rocker arms.
a. Install the valve pushrods with the copper colored, painted or marked end upwards.
b. Install the valve rocker arm shaft assembly.
CAUTION: Improper installation of the valve rocker arm shaft bolts may cause valve rocker am shaft breakage and piston to valve contact.
c. Install the bolts.
1) Rotate the crankshaft, until the mark on the crankshaft balancer is at the 2 o'clock position.
2) Rotate the crankshaft counterclockwise 88 mm (3 1/2 inch), aligning the crankshaft balancer mark with the first lower water pump bolt, at approximately the 12:30 position.
3) This procedure will position the engine so that no valves are close to a piston crown.
4) Finger tighten the bolts.
5) Alternately tighten the bolts to 5 Nm (40 ft. lbs.).
d. Rotate the crankshaft in order to make sure that there is free movement of the valve train.
10. Install Valve Rocker Arm Cover
a. Clean the sealing surfaces on the cylinder head and the valve rocker arm cover, so that the surfaces are free from oil and foreign material.
CAUTION: Do not allow the RTV sealant into the valve rocker arm cover bolt holes. This may cause a Hydraulic lock, condition, when the bolts are tightened, damaging the cylinder head casting.
b. Apply a 5 mm (3/16 inch) bead of RTV sealant GM P/N 12345739 to the valve rocker arm covers, inboard of the bolt holes. The sealer must be wet to the touch, when the bolts are tightened.
c. Install the valve rocker arm cover.
d. Install the valve rocker arm cover bolts.
- Tighten the valve rocker arm cover bolts to 22 Nm (16 ft. lbs.).
11. Install Timing Chain and Camshaft Sprocket
a. Install the keyway in the crankshaft.
NOTE:
- Do not damage the reluctor wheel square bosses.
- Align the timing marks.
b. Install the crankshaft sprocket with the reluctor wheel square bosses facing the front.
c. Install the camshaft sprocket with the timing chain with the mark on the sprocket facing the front.
d. Install the fuel injection pump camshaft gear.
e. Install the washer and the bolt.
- Tighten the bolt to 170 Nm (125 ft. lbs.).
12. Install Engine Front Cover
- Tools Required
- J 22102 Seal Installer, Or Equivalent
NOTE: Replacing either of the following will affect timing:
- The timing chain
- The timing gears
- The front cover
- The Crankshaft Position (CKP) sensor
- The crankshaft
- It will then be necessary to reprogram TDC Offset (Recovery) into the PCM.
a. Clean the front cover and the block sealing surfaces, in order to ensure that they are free from oil.
CAUTION: Perform TDC Offset Recovery procedure if the timing chain, timing gears, engine front cover, crankshaft position sensor, crankshaft or other components affecting the timing are replaced.
b. Install the front crankshaft oil seal using the seal installer with the open end of the seal facing the inside cover.
c. Coat the seal lips with grease.
d. Apply a 2 mm (3/32 inch) bead of anaerobic sealant GM P/N 1052357, or the equivalent, to the front cover sealing area.
e. Install the front cover to the engine.
f. Install the front cover bolts.
- Tighten the front cover bolts to 45 Nm (33 ft. lbs.).
g. Install the crankshaft position sensor with a new o-ring seal.
- Tighten the retaining bolt to 25 Nm (17 ft. lbs.).
13. Install Crankshaft Balancer
NOTE: Before installing the crankshaft balancer, check the oil seal contact area for grooving and roughness. Replace the crankshaft balancer if necessary.
a. Tap the crankshaft balancer into place with a mallet.
b. Make sure that the key is in place.
c. Make sure that the crankshaft balancer is completely installed on the crankshaft.
d. Install the bolt and the washer.
- Tighten the bolt to 270 Nm (200 ft. lbs.).
e. Install the crankshaft pulley and bolts.
- Tighten the crankshaft pulley bolts to 58 Nm (43 ft. lbs.).
14. Install Fuel Injection Pump
CAUTION: Never rotate the engine, with the starter, the starter location engine rotation fixture, or with the wrench from the front of the engine with the fuel injection pump removed. The loose fuel pump drive gear could become lodged in the front cover and cause gear tooth distress and shear the camshaft drive gear. Align the camshaft gear timing marks before installing the fuel injection pump drive gear.
a. Install the gasket to the front cover.
b. Install the fuel injection pump.
c. Install the electronic fuel injection pump with the ESO straight up.
d. Install the pump mount nuts.
- Tighten the nuts to 40 Nm (30 ft. lbs.).
e. Install the fuel injection pump gear. Align the, slot in the fuel injection pump gear with the locating pin on the fuel injection pump hub.
NOTE: Align the timing marks. Be certain the mark on the fuel injection pump gear is aligned with the mark on the camshaft gear. For the proper timing of the fuel injection pump, the cam gear timing mark must be in the 12 o'clock position. Rotate the crankshaft to bring the cam gear timing mark up to the 12 o'clock position.
f. Install the fuel injection pump gear retaining bolts.
- Tighten the bolts to 25 Nm (20 ft. lbs.).
g. Install the wires and hoses at the fuel injection pump.
15. Install Water Pump
a. Clean the sealing surfaces on the water pump plate and the block.
b. Install the water pump and the gasket to the water pump plate.
c. Install the bolts.
- Apply high temperature thread adhesive GM P/N 12345493, or equivalent, to the bolt threads.
- Tighten the bolts to 28 Nm (20 ft. lbs.).
d. Apply a bead of anaerobic sealer GM P/N 1052942 or the equivalent to the water pump plate.
e. Install the water pump plate to the engine.
- The sealer must be wet to the touch when installing the plate.
- Apply the sealant GM P/N 12346004, or equivalent, to the threads of the bolts and studs.
f. Install the bolts and studs.
- Tighten the water pump to the front cover bolts to 42 Nm (32 ft. lbs.).
- Tighten the water pump plate to front cover bolts to 28 Nm (20 ft. lbs.).
16. Install Oil Fill Neck
a. Install the seal.
b. Install the oil fill neck.
c. Install the holding bracket to the front cover.
d. Install the holding bracket to the thermostat housing.
- Tighten the nuts to 23 Nm (17 ft. lbs.).
17. Install Exhaust Manifold
a. Install the left exhaust manifold and the bolts.
- Tighten the bolts to 35 Nm (26 ft. lbs.).
b. Install the right exhaust manifold and the bolts.
- Tighten the bolts to 35 Nm (26 ft. lbs.).
18. Install Glow Plug
- Tools Required
- J 41515 A Glow Plug Socket, Or Equivalent
a. Install the left hand side glow plugs using the glow plug socket.
- Tighten the glow plugs to 22 Nm (16 ft. lbs.).
b. Install the right hand side glow plugs using the glow plug socket.
- Tighten the glow plugs to 22 Nm (16 ft. lbs.).
19. Install Fuel injection Nozzle
- Tools Required
- J 29873 Nozzle Socket, Or Equivalent
CAUTION: In order to remove or install an Injection nozzle, use the nozzle socket on the 30 mm portion of the nozzle. Failure to use the 30 mm hex portion will result in damage to the injection nozzle.
a. Apply a thin coating of GM P/N 14001899, or equivalent, to the threads of the injection nozzle.
b. Install the injection nozzle with the gasket, using the nozzle set.
- Tighten the nozzle to 80 Nm (59 ft. lbs.).
20. Install Fuel Inlet and Return Line
a. Install the fuel inlet line to the fuel injection pump.
b. Install the fuel return hose to the fuel injection pump.
c. Install the fuel return line brackets on the front left and the front right side rocker covers.
d. Install the fuel return hoses at the injector nozzles.
e. Install the clamps.
21. Install Fuel Injection Line
a. Install the injection line brackets.
NOTE: Install the lines in the correct position.
b. Install the injection lines to the pump.
c. Do not bend the injection lines.
d. Install the injection lines to the nozzles.
- Uncap the lines before assembly.
- Do not bend the injection lines.
- Tighten the injection line fittings to 36 Nm (28 ft. lbs.).
e. Install the injection line clips to the brackets.
22. Install Accessory Engine Lift Brackets
a. Install the bracket assembly.
b. Install the bolts.
- Tighten the bolts to 50 Nm (37 ft. lbs.).
23. Install Coolant Crossover
a. Install the gaskets to the heads.
b. Install the coolant crossover.
c. Install the bolts and stud/nut
- Tighten the bolts and the stud/nut to 42 Nm (31 ft. lbs.).
d. Install the bypass hose and the clamps.
e. Install the engine coolant temperature (ECT) sensor.
f. Install the fuel air bleed (spreader) valve and the nut.
- Tighten the stud/nut and the nut to 41 Nm (31 ft. lbs.).
24. Install Thermostat Housing/Thermostat
a. Install the seals onto the thermostats. The seals have a split, inner edge, which install over the flange on the thermostats. The seals have a bead on the surface that faces the thermostat housing.
b. Install the thermostats to the coolant crossover.
c. Install the thermostat housing.
d. Install the bolts studs
- Tighten the bolts/studs to 42 Nm (31 ft. lbs.).
25. Install Oil Pump Drive
a. Install the new gasket to the oil pump drive.
b. Install the oil pump drive to the engine.
- Index the drive with the camshaft gear and the oil pump drive shaft. Make sure the drive seats fully.
c. Install the clamp and the bolt.
- Tighten the bolt to 42 Nm (31 ft. lbs.).
26. Install Turbocharger
a. Install the seal onto the engine block.
b. Install the turbocharger.
c. Install the turbocharger mounting bolts.
d. Install the bolts.
- Tighten the wastegate bracket mounting bolts to 65 Nm (48 ft. lbs.).
NOTE: In order to ensure heat shield clearance, locate the exhaust pipe clamps as shown.
e. Slide the exhaust clamps over the exhaust manifold and turbocharger.
f. Install the right hand side exhaust pipe.
NOTE: Tighten the clamps at the exhaust manifold end first.
g. Place the clamps in the correct position.
- Tighten the clamps to 10 Nm (90 inch lbs.).
h. Install the left hand side exhaust pipe.
NOTE: Tighten the clamps at the exhaust manifold end first.
i. Place the clamps in the correct position.
- Tighten the clamps to 10 Nm (90 inch lbs.).
27. Install POE Wiring Harness
a. Place the harness in the engine valley.
b. Plug in or connect all the wiring harness connectors to devices or attachment points.
28. Install Intake Manifold
a. Install the new gaskets onto the cylinder heads.
b. Install the intake manifolds.
NOTE: Apply teflon sealer GM P/N1236004 on the threads of the studs that are second to the end on both intake manifolds. There are a total of four studs which require the teflon sealer.
b. Apply thread-locker GM P/N 12345493 on the threads of the remaining studs.
c. Install the intake manifold studs.
- Tighten the intake manifold studs to 42 Nm (31 ft. lbs.).
d. Install the miscellaneous brackets and fuel line brackets on the intake studs.
e. Install the nuts for the brackets.
- Tighten the bracket nuts to 23 Nm (17 ft. lbs.).
f. Install the center intake manifold gaskets on the intake manifolds.
g. Install the O-ring onto the turbocharger inlet housing.
h. Lubricate the O-ring lightly with engine oil.
i. Install the center intake manifold onto the right and the left intake manifolds and on the turbocharger inlet housing.
j. Install the bolts to the center intake manifold.
- Tighten the center intake manifold bolts to 23 Nm (17 ft. lbs.).
29. Install Oil Level Indicator and Tube
a. Install a new O-ring seal to the oil level indicator tube.
b. Install the oil level indicator tube to the engine.
c. Install the oil level indicator tube bracket bolt.
- Tighten the bout to 4 Nm (35 inch lbs.).
30. Install Engine Flywheel
a. Install the flywheel.
b. Install the flywheel bolt.
- Tighten the bolts to 90 Nm (65 ft. lbs.).