Installation
^ Tool Required:- J 441040 Camshaft Sprocket Spanner Wrench
1. Apply clean engine oil to the threaded portion of all cylinder head bolts.
Cylinder Head Tightening Sequence:
2. New cylinder head gasket and cylinder head with distributor case onto cylinder block; secure with ten bolts.
^ Tighten the cylinder head bolts in three separate steps using the sequence shown, for each step.
a. 35 Nm (26 ft. lbs.).
b. 55 Nm (41 ft. lbs.).
c. 70 Nm (52 ft. lbs.).
3. Apply a liberal amount of clean engine oil to camshaft.
4. Apply GM P/N 12346240 or equivalent to the bottom of the number six camshaft carrier cap.
5. Camshaft and camshaft carrier caps onto cylinder head; secure with twelve bolts.
CAUTION: Always tighten the camshaft carrier cap bolts gradually in the order shown. If the camshaft carrier cap bolts are tightened at random, damage to the camshaft may occur.
^ Tighten the camshaft carrier cap bolts to 10 Nm (89 inch lbs.).
6. Apply engine oil to the new camshaft seal lip.
7. New camshaft seal into cylinder head until camshaft seal is flush with camshaft carrier surface.
^ Adjust the valve lash.
8. Apply GM P/N 12346240 or equivalent to the surface of the distributor case that mates with the rear of the rocker arm shaft.
9. Distributor case to cylinder head; secure with three bolts.
^ Tighten the distributor case bolts to 10 Nm (89 inch lbs.).
^ Clean the sealing surfaces on cylinder head and cylinder head cover.
NOTE: A new cylinder head cover gasket and O-rings MUST be used whenever cylinder head cover removal and installation is performed. Ensure that new gasket and O-rings are correctly positioned during cylinder head cover installation.
10. New cylinder head cover gasket and four O-rings to cylinder head cover.
11. Cylinder head cover to cylinder head; secure with six bolts.
^ Tighten the cylinder head cover bolts to 10 Nm (89 inch lbs.).
12. Distributor into distributor case.
13. A/C mounting bracket with compressor to cylinder head; secure with two bolts.
^ Tighten the A/C Mounting bracket bolts to 10 Nm (89 inch lbs.).
14. Timing belt inside cover to cylinder head; secure with two bolts.
^ Tighten the timing belt inside cover bolts to 10 Nm (89 inch lbs.).
NOTE: During camshaft timing belt gear installation, align the camshaft dwell pin with the slot in the camshaft timing belt gear designated as E.
15. Camshaft timing belt gear onto camshaft using a camshaft sprocket spanner wrench to hold the camshaft timing belt gear stationary; secure with one bolt.
^ Tighten the camshaft timing belt gear bolt to 60 Nm (44 ft. lbs.).
16. Timing belt tensioner plate and tensioner to engine; secure with timing belt tensioner stud and bolt.
NOTE: Do not tighten the timing belt tensioner stud and bolt to specification until the timing belt is properly installed. Install the timing belt tensioner stud and bolt finger tight only.
CAUTION: When installing a new or used timing belt, the directional arrows on the timing belt must be matched with the rotation of the crankshaft. If this precaution is not observed, excessive wear and timing belt failure may occur.
17. Push the timing belt tensioner plate up for timing belt installation.
18. Timing belt onto camshaft and crankshaft timing belt gears.
^ Inspect the timing marks on the cylinder head cover and camshaft timing belt gear for alignment as well as the timing marks on the oil pump casting and crankshaft timing belt gear. If these two sets of timing marks are not properly aligned, remove the timing belt and align both sets of marks as previously outlined in this procedure.
19. Timing belt tensioner spring to timing belt tensioner plate.
NOTE: Rotate the crankshaft two complete revolutions to remove any slack from the timing belt and to properly seat the timing belt. When all slack has been removed from the timing belt, inspect both sets of timing marks to ensure that they are aligned respectively.
^ Tighten
- Timing belt tensioner stud to 11 Nm (97 inch lbs.).
- Timing belt tensioner bolt to 27 Nm (20 ft. lbs.).
20. Timing belt cover to engine; secure with one nut and eight bolts.
^ Tighten the timing belt cover nut and bolts to 10 Nm (89 inch lbs.).
21. Oil pressure sending unit wire conduit to timing belt cover.
22. Crankshaft pulley to crankshaft; secure with five bolts.
^ Tighten the crankshaft pulley bolts to 16 Nm (12 ft. lbs.).
23. Radiator shroud to radiator; secure with two bolts.
^ Tighten the upper shroud bolts to 11 Nm (97 inch lbs.).
24. Carefully reposition A/C suction line and brackets to right side of radiator core support (if equipped); secure with two bolts.
^ Tighten the A/C suction line bracket bolts to 10 Nm (89 inch lbs.).
25. Raise and suitably support vehicle.
26. Two lower radiator shroud bolts.
^ Tighten the lower shroud bolts to 11 Nm (97 inch lbs.).
27. Front skid plate to undercarriage (if equipped); secure with four bolts.
^ Tighten the front skid plate bolts to 55 Nm (40 ft. lbs.).
28. Lower vehicle.
29. Coolant pump pulley and cooling fan to coolant pump; secure with four nuts.
6 Tighten the coolant fan nuts to 11 Nm (97 inch lbs.).
30. Generator/coolant pump drive belt to pulleys.
31. A/C compressor (if equipped) and/or power steering drive belt to pulleys.
^ Adjust
-G Generator/coolant pump drive belt.
- A/C compressor (if equipped) and/or power steering drive belt.
32. New exhaust manifold gasket and exhaust manifold with engine hanger to cylinder head; secure with nine nuts.
^ Tighten the exhaust manifold nuts to 23 Nm (17 ft. lbs.).
33. Raise and suitably support vehicle.
34. Front pipe/TWC assembly with new gasket to exhaust manifold; secure with three bolts.
^ Tighten the exhaust manifold-to-front pipe/TWC assembly bolts to 50 Nm (37 ft. lbs.).
35. Lower exhaust manifold heat shield to exhaust manifold; secure with two bolts.
6 Tighten the lower exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).
36. Exhaust manifold bracket to exhaust manifold and engine block; secure with one nut and two bolts.
^ Tighten
- Engine mount-to-exhaust bracket bolts to 54 Nm (40 ft. lbs.).
- Exhaust bracket-to-exhaust manifold nut to 50 Nm (37 ft. lbs.).
37. Lower vehicle.
38. Upper exhaust manifold heat shield to exhaust manifold; secure with two nuts and three bolts.
^ Tighten the upper exhaust manifold heat shield nuts and bolts to 10 Nm (89 inch lbs.).
39. Air intake pipe bracket to cylinder head; secure with three bolts.
^ Tighten the air intake pipe bracket bolts to 10 Nm (89 inch lbs.).
40. New intake manifold gasket and intake manifold with intake surge tank and throttle body to cylinder head; secure with eight nuts, three bolts.
^ Tighten the intake manifold nuts and bolts to 23 Nm (17 ft. lbs.).
41. Lower intake manifold support bracket to intake manifold; secure with two bolts.
^ Tighten the lower intake manifold support bracket bolts to 50 Nm (37 ft. lbs.).
42. Rear intake manifold reinforcement bracket to intake manifold; secure with two bolts.
^ Tighten the rear intake manifold reinforcement bracket bolts to 50 Nm (37 ft. lbs.).
43. Front intake manifold reinforcement bracket to intake manifold.
^ Tighten the front intake manifold reinforcement bracket bolts to 50 Nm (37 ft. lbs.).
44. Generator adjusting arm bracket to intake manifold; secure with one bolt and one nut.
^ Tighten the generator adjusting arm bracket nut and bolt to 50 Nm (37 ft. lbs.).
45. Coolant bypass hose to intake manifold.
46. Upper radiator hose to thermostat housing.
^ Tighten the upper radiator hose clamp at thermostat housing.
47. PCV hose to PCV valve.
48. Fuel return hose to fuel return line.
49. Fuel feed hose at fuel feed hose union.
50. Coolant hoses to the fast idle air valve below throttle body.
51. IAC air hose to the IAC valve.
52. Coolant hose to the IAC valve.
53. The following vacuum hoses:
^ EGR valve modulator.
^ EGR valve.
^ Brake booster supply hose.
^ Vacuum modulator supply hose (automatic transmission equipped vehicles).
^ EVAP SP Valve.
^ Intake manifold absolute pressure sensor hose.
54. The following electrical connectors:
^ Engine ground wire to intake surge tank.
^ Fuel injectors.
^ EGR solenoid vacuum valve.
^ EGR by-pass vacuum valve.
^ Exhaust gas recirculation (EGR) temperature sensor.
^ Evaporative emission solenoid purge (EVAP SP) valve.
^ A/C ECT switch (A/C equipped vehicles only).
^ ECT sensor sending unit.
^ Engine coolant temperature (ECT) sensor.
^ Idle Air Control (IAC) Valve.
^ Throttle Position (TP) Sensor.
55. Accelerator cable bracket to throttle body; secure with one screw, one bolt and one nut.
^ Tighten the throttle body nut and bolt to 23 Nm (17 ft. lbs.).
56. Accelerator cable and kickdown cable (automatic transmission equipped vehicles) to throttle body bellcrank.
^ Adjust
- Accelerator cable as necessary.
- Kickdown cable (automatic transmission equipped vehicles) as necessary.
57. Throttle cover from intake manifold; secure with three bolts.
^ Tighten the throttle cover bolts to 15 Nm (11 ft. lbs.).
58. Refill cooling system as necessary.
59. Air intake pipe to throttle body hose and Air cleaner intake hose.
60. Negative (-) battery cable.