Assemble
1. Camshaft Bearing InstallationCAUTION: The outer front and rear camshaft bearings must be installed first. These bearings serve as guides for tool pilot and help center the inner bearings during the installation process. Align the camshaft bearing oil hoses property during installation. Position the number 1 camshaft bearing oil hoses at 1 o'clock and 5 o'clock. Position the number 2-4 inner camshaft bearing oil hoses at 5 o'clock toward the left side of the engine block and even with the bottom of the cylinder bore. Position the number 5 camshaft bearing oil hole at 12 o'clock.
a. Use the Camshaft Bearing Installer in order to install the front and rear camshaft bearings.
^ Assemble the bearing tool to the driver handle.
^ Align the oil hoses.
^ Drive the front and the rear bearings inward toward the center of the engine block.
b. Use the Camshaft Bearing Installer in order to install the inner camshaft bearings. Repeat the following steps for each of the inner camshaft bearings:
^ With the nut and the thrust washer installed to the end of the putter screw threads, index the pilot in the camshaft front bearing and install the puller screw through the pilot.
^ Index the camshaft bearing in the bore. Make sure you align the oil hole.
^ Install the puffer screw through the bearing bore and bearing to be installed And assemble bearing tool to the puller screw with the shoulder toward the bearing. Make sure that enough threads are engaged.
^ Using two wrenches, hold the puller screw white you turn the nut in order to draw the bearing into the bore. When the bearing has been putted into the bore, remove the bearing tool and the putter screw and check the alignment of the bearing oil hole to the bore oil hole.
c. Install a new camshaft rear bearing hole plug.
2. Crankshaft, Bearings, and Bearing Cap Installation
a. Install the crankshaft bearing into the engine block and the crankshaft bearing caps.
b. Coat the crankshaft bearings with clean engine oil.
c. Install the crankshaft.
d. Install the crankshaft bearing caps with crankshaft bearings.
e. Be sure that the cap directional arrows point toward the front of the engine block and the cap is in its original position.
f. Instant the crankshaft bearing cap bolts and studs.
g. Thrust the crankshaft reward in order to set and align the thrust bearings and the bearing caps.
h. Thrust the crankshaft forward in order to align the rear faces of the rear crankshaft bearings. Tighten all of the bolts to 105 Nm (77 ft. lbs.).
i. Measure crankshaft end play. Use a dial indicator or feeler gauge on order to measure end play between the crankshaft bearing and the crankshaft thrust surface. If you use a feeler gauge, measure end play by inserting the gauge between the crankshaft bearing and the crankshaft thrust surfaces.
3. Crankshaft Rear Oil Seal and Housing Installation
CAUTION: 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 seat entirety with clean engine oil.
d. Install the seat 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 seat housing.
4. Piston, Connecting Rod, Bearing Installation
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 tightly tap the top of the piston with a wooden hammer handle.
^ Hold the Piston Ring Compressor firmly against the engine block unfit 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 degrees.
g. When all of the connecting rod bearings are installed, tap each connecting rod assembly tightly parapet 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 (0.006-0.014 inches).
5. Camshaft Installation
a. Install the three 5/16-18 x 4.0 inch bolts into the camshaft front bolt hoses.
NOTE: Use care when you install the camshaft. All bearings are of equal diameter.
b. Install the camshaft.
c. Remove the three bolts from the front of the camshaft.
d. Install the camshaft retainer. Tighten the camshaft retainer bolts to 12 Nm (106 inch lbs.).
e. Install the oil pump driveshaft and bolt. The bolt hole ear must be seated on the boss before you tighten the bolt. Tighten the oil pump driveshaft bolt to 18 Nm (13 ft. lbs.).
6. Timing Chain, Sprockets, and WP Driveshaft Install
a. Install the key into the crankshaft keyway.
b. Use the Crankshaft Sprocket Installer in order to install the crankshaft sprocket.
c. Use the Water Pump Driveshaft Installer in order to install the water pump driveshaft assembly.
d. Install the water pump driveshaft retainer bolts. Tighten the water pump driveshaft retainer bolts to 12 Nm (106 inch lbs.).
CAUTION: The gears must mesh in order to prevent damage to the camshaft retainer.
e. Install the camshaft sprocket and timing chain.
f. Install camshaft sprocket bolts. Be sure to align the camshaft and the crankshaft sprocket alignment marks. 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 reactor ring onto the crankshaft until the ring is completely seated against the crankshaft sprocket.
g. Install the crankshaft position sensor reluctor ring.
7. [1][2]Engine Front Cover and Oil Seal Installation
a. Use the [1][2]Engine Front Cover Aligner and Oil Seal Installer in order to install the crankshaft hub oil seal.
b. Use the [1][2]Engine Front Cover Distributor Shaft Oil Seal Installer in order to install the distributor driveshaft oil seal.
c. Use the [1][2]Engine Front Cover Water Pump Driveshaft Assembly Oil Seal Installer in order to install the water pump driveshaft oil seal.
d. Install the [1][2]engine front cover gasket.
e. Install the Water Pump Driveshaft [1][2]Engine Front Cover Oil Seal Protector onto the end of the water pump drive shaft.
f. Install the [1][2]engine front cover and bolts. Remove the Water Pump Driveshaft Engine Front Cover Oil Seal Protector. Tighten the engine front cover bolts to 12 Nm (106 inch lbs.).
CAUTION: Do not reuse the O-ring seat on the crankshaft position sensor. Install a new O-ring seat onto the sensor.
g. Lubricate the O-ring seat of the sensor with clean engine oil.
CAUTION: When you install the crankshaft position sensor, be sure that the sensor is fully seated and held stationary in the [1][2]engine front cover bore. A sensor that is not fully seated will cock in the engine front cover and may result in erratic engine operation.
h. Install the crankshaft position sensor into the [1][2]engine front cover.
i. Install the bolt into the cover. Tighten the bolt to 12 Nm (106 inch lbs.).
8. Oil Pump Installation
a. Assemble the oil pump (3), driveshaft (5), 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 oil pump 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 the oil pump bolt to 90 Nm (66 ft. lbs.).
^ Tighten the crankshaft oil deflector nuts to 40 Nm (30 ft. lbs.).
9. Oil Pan Installation
NOTE: Apply the sealer 25 mm (1.0 inches) 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 inches) wide and 20 mm (0.787 inches) long to the [1][2]engine front cover to engine block junction.
b. Apply a small amount of sealer, GM P/N 12346004 or equivalent, 25 mm (1.00 inches) 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.
^ Tighten the corner bolts or studs to 20 Nm (15 ft. lbs.).
^ Tighten the corner nuts to 20 Nm (15 ft. lbs.).
^ Tighten the remainder of the bolts to 12 Nm (106 inch lbs.).
g. Install the oil level sensor. Tighten the oil level sensor to 20 Nm (15 ft. lbs.).
h. Install the oil pan drain plug. Tighten the oil pan drain plug to 20 Nm (15 ft. lbs.).
10. Oil Filter Adapter and Valve Assembly Installation
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. Cylinder Head Installation
a. Install the new cylinder head gasket.
b. Install the gasket over the locating pins, with the yellow side of the tab on the outboard side facing up.
c. Install the cylinder head over the locating pins and the gasket.
d. Install the cylinder head bolt finger tight. Tighten the cylinder head bolts in sequence on the first pass to 30 Nm (22 ft. lbs.).
e. 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) 67 degrees.
^ Tighten the medium bolts (14, 17) 80 degrees.
.Tighten the tong bolts (1, 2, 5, 6, 9, 10, 13) 80 degrees.
f. Install the spark plugs. Tighten the spark plugs to 20 Nm (15 ft. lbs.).
g. Install the engine coolant air bleed pipe and bolts. Use a backup wrench on the pipe fittings when you install the bolts. Tighten the bleed pipe bolts to 40 Nm (30 ft. lbs.).
12. Valve Lifter Installation
a. Coat the valve lifter rollers with prelube, GM P/N 1052365 or equivalent.
b. If reusing the valve lifters, install in their original location.
c. Install the valve lifters.
d. Install the valve lifter guides.
e. Install the valve lifter guide retainer.
f. Install the valve lifter guide retainer bolts. Tighten the valve lifter guide retainer bolts to 25 Nm (18 ft. lbs.).
13. Valve Rocker Arm, Push Rod. and Stud Installation
a. Apply sealer GM P/N 12346004 or equivalent to the threads of the new valve rocker arm ball stud.
CAUTION: Be sure to keep parts in order. Parts must be put back from where they were removed.
b. Install the valve rocker arm ball stud. Tighten the valve rocker arm bail stud to 68 Nm (50 ft. lbs.).
c. Coat the valve rocker arm and valve rocker arm ball bearing surfaces with prelube GM P/N 1052365 or equivalent.
d. Install the valve pushrods. Be sure that the valve pushrods seat in the valve timer sockets.
e. Install the following parts:
^ The valve rocker arms
^ The valve rocker arm balls
^ The valve rocker arm nuts
f. Adjust the valve rocker arm nuts unfit all of the lash is gone.
^ Turn the crankshaft unfit 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).
^ 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. 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 unfit the lash is felt in the valve pushrod. Tighten the valve rocker arm nut unfit 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).
^ Turn the crankshaft 1 revolution until the hub arrow is at 12 o'clock. This is the number 6 firing position.
^ Adjust the exhaust valves 2,5,6,7 and the intake valves 3,4,6,8. Back off the valve rocker arm nut unfit 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 unfit there is no more movement. When all free play is gone, tighten the valve rocker arm nut 1 additional turn (360 degrees).
14. Valve Rocker Arm Cover Installation
a. Install the valve rocker arm cover and new gasket.
b. Install the valve rocker arm cover bolts. Tighten the valve rocker arm cover bolts to 12 Nm (106 inch lbs.).
15. Intake Manifold Installation
a. Apply a 5 mm (0.197 inches) bead of the RTV sealer, P/N 12346192 or the equivalent, to the front of the engine. Extend the bead 13 mm (0.50 inches) up each cylinder head assembly in order to retain and seal the gaskets.
b. Apply a 5 mm (0.197 inches) bead of the RTV sealer, P/N 12346192 or the equivalent, to the rear of the engine. Extend the bead 13 mm (0.50 inches) up each cylinder head assembly in order to retain and seat the gaskets.
c. Install the intake manifold with new gaskets.
d. Install the intake manifold bolts and studs.
^ On the first pass, tighten the intake manifold bolts and the studs to 10 Nm (89 inch lbs.) in sequence.
^ On the second pass, tighten the intake manifold bolts and the studs to 50 Nm (37 ft. lbs.) in sequence.
e. Install the throttle body gasket, the throttle body, and bolts. Tighten the throttle body bolts to 25 Nm (18 ft. lbs.).
f. Install the accelerator cable bracket and the bolts. Tighten the accelerator control cable bracket bolts to 12 Nm (106 inch lbs.).
g. Install the EGR valve, gasket and nuts. Tighten the EGR valve nuts to 30 Nm (22 ft. lbs.).
h. Install the crankcase vent hose.
i. Install the fuel rail with injectors and the fuel rail bolts. Tighten the fuel rail bolts to 10 Nm (89 inch lbs.).
j. Connect the fuel pressure regulator vacuum hose.
15. Crankshaft Balancer and Hub Installation
CAUTION: Failure to property align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance.
a. Use the following procedure in order to install the crankshaft balancer hub:
^ Set the number 1 piston to the top dead center.
^ White viewing from the front of the crankshaft, check the reluctor ring and verify that the keyway of the ring is properly orientated with the key of the crankshaft and that the ring is completely seated against the crankshaft sprocket.
^ Install the crankshaft balancer hub with the cast arrow on the hub in the 12 o'clock position.
b. Use the Crankshaft Balancer Hub Remover and Installer in order to install the crankshaft balancer hub until the hub completely seats against the crankshaft position sensor reluctor ring.
c. Install the crankshaft balancer hub bolt and washer. Tighten the crankshaft balancer hub bolt to 100 Nm (74 ft. lbs.).
d. Install the crankshaft balancer.
^ Measure the depth of the empty balancer weight hole.
^ Record the measurement.
^ Drive the weights in the old balancer to the bottom of the hose.
^ Measure the depth of the hole.
^ Record the measurement.
^ Subtract the measurement of the hole with the weight from the measurement of the empty hole.
^ The difference between the two measurements is the length of the new balancer weight.
^ Be sure that you install the new balancer weights in the same location.
NOTE: When you replace the crankshaft balancer, be sure that you install new balancer weights of the same size. Install the new balancer in the same location as the old balancer.
d. Install the crankshaft balancer bolts. Tighten the crankshaft balancer bolts to 85 Nm (63 ft. lbs.).
16. Distributor Installation
NOTE: The distributor is driven by a camshaft pin that mates to one slot in the distributor driveshaft.
a. Align distributor driveshaft slot with distributor base timing mark.
b. Rotate the engine crankshaft until number one piston is at top dead center (the intake and exhaust valves closed). The camshaft pin will be at 9 o'clock position.
c. Install the distributor. Before you insert the distributor bolts, ensure that the distributor is fully seated to the [1][2]engine front cover. if the distributor is difficult to seat, check the alignment of the distributor driveshaft slot, the timing mark and the camshaft pin.
d. Install the distributor bolts. Tighten the distributor bolts to 12 Nm (106 inch lbs.).
e. Install the ignition coil and bracket and studs. Tighten the ignition coil studs to 40 Nm (30 ft. lbs.).
f. Connect the distributor vacuum harness.
17. Water Pump Installation
a. Install the coupling to the water pump shaft with the groove on the coupling toward the engine block. Apply a tight coat of grease to the new O-ring seals and the coupling.
b. Position the water pump and new gaskets to the engine block. Make sure that the tabs are straight up.
c. If necessary, rotate the coupling in order to align it to the water pump driveshaft splines and then seat the water pump.
d. Install the water pump bolts. Tighten the water pump bolts to 45 Nm (33 ft. lbs.).
18. Exhaust Manifold Installation (Right Side)
a. Install the exhaust manifold gasket and exhaust manifold.
b. Install the exhaust manifold studs and bolts. Tighten the exhaust manifold studs and bolts to 40 Nm (30 ft. lbs.).
c. Install the air injection pipe and check valve as an assembly. Tighten the secondary air injection pipe fitting to 55 Nm (41 ft. lbs.).
d. Install the EGR inset pipe, new gasket and the bolts and nuts.
^ Tighten the EGR inlet pipe to exhaust manifold bolt to 30 Nm (22 ft. lbs.).
^ Tighten the EGR inlet pipe to intake manifold nuts to 25 Nm (18 ft. lbs.).
19. Exhaust Manifold Installation (Left Side)
a. Install the new exhaust manifold gasket and exhaust manifold.
b. Install the exhaust manifold studs and bolts. Tighten the exhaust manifold studs and bolts to 40 Nm (30 ft. lbs.).
c. Install the secondary air injection pipe and check valve as an assembly. Tighten the secondary air injection pipe fitting to 55 Nm (41 ft. lbs.).
20. Oil Level Indicator and Tube Installation
a. Apply a sealer GM PIN 12346004 or equivalent around the oil level indicator tube 13 mm (0.5 inches) 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. Engine Flywheel Installation
a. Install the engine flywheel to crankshaft.
b. Align the locator hole to the pin.
c. Instate the engine flywheel bolts. Tighten the engine flywheel bolts to 100 Nm (74 ft. lbs.).