Assembly Procedure
TOOL REQUIREDJ 35468 Oil Seal Installer
J 33049 Camshaft Bearing Remover/Installer Set
J 34686 Rear Main Bearing Oil Seal Installer
J 8037 Piston Ring Compressor
J 36660 Torque Angle Meter
J 38612 Crankshaft Sprocket Installer
J 29113 Harmonic Balancer Installer
1. Crankshaft, Bearings, and Bearing Cap Installation
CAUTION: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etch the bearing surface. Clean and dry all of the bearing cap bolt holes and the mating surfaces.
a. Dip the bearing cap bolts in clean engine oil.
CAUTION: Upper and lower inserts may be different. Do not obstruct any oil passages. Check to make sure that the bearing inserts project an equal distance on both sides when placed into position. Check to make sure that the insert tangs are engaged.
b. Place the bearing inserts into the bearing cap and into the engine block.
c. Coat the thrust surface with a GM E.O.S. P/N 1052368, or equivalent.
d. Lubricate the bearing surface with clean engine oil.
e. Install the crankshaft.
f. Apply a small amount of GM P/N 1052942 sealer to the rear of the rear bearing cap sealing surface.
CAUTION: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not attach the bolts to pull the crankshaft bearing caps into the seats. Failure to observe this information may damage a cylinder block or a bearing cap.
g. Install the bearing cap. Tap the bearing cap into place with a suitable tool. Apply a small amount of sealer GM P/N 1052942, or equivalent, to the sealing surface of the rear bearing cap.
h. With the crankshaft bearing and the bearing caps installed, thrust the crankshaft rearward in order to set and align the bearing caps.
i. Thrust the crankshaft forward in order to align the rear face of the thrust main bearing.
j. Install the main bearing cap bolts. Evenly tighten the main bearing cap bolts to 50 Nm (37 ft. lbs.). Evenly turn the main bearing cap bolts an additional 75 degrees. Use the Torque Angle Meter.
k. Measure the amount of crankshaft end play.
2. Crankshaft Rear Oil Seal Installation
a. Apply engine oil to the I.D. and the O.D. of the new rear main oil seal.
b. Slide the rear main oil seal over the mandrel until the back of the seal fits squarely against the collar of the Rear Main Oil Seal Installer.
c. Install the rear main oil seal.
d. Align the dowel pin of the Rear Main Oil Seal Installer with the dowel pin in the crankshaft.
e. Attach the Rear Main Oil Seal Installer to the crankshaft. Tighten the attaching screws to 5 Nm (44 inch lbs.).
f. Turn the T handle of the Rear Main Oil Seal Installer in order to push the rear main oil seal into the bore.
g. Turn the handle until the collar seats tight against the cylinder case.
h. Loosen the handle until the handle comes to a stop.
i. Remove the attaching screws on the Rear Main Oil Seal Installer.
j. Check to ensure that the rear main oil seal is properly seated in the bore.
3. Camshaft Inter Drive Shaft Bearing Installation
a. Select the proper front, rear, and middle intermediate shaft bearings.
b. Select the proper expander assembly and the proper driving washer.
c. Assemble the Camshaft Bearing Remover/Installer.
d. Place the middle intermediate shaft bearing onto the Camshaft Bearing Remover/Installer.
e. Index the hole at the 4 o'clock position when looking at the front of the engine block.
f. Drive the intermediate shaft bearings into place.
CAUTION: Severe engine damage may result if the oil holes are not correctly aligned.
g. Use the Camshaft Bearing Remover/Installer in order to install the number 4 intermediate shaft bearing with the oil hole indexed at 4 o'clock when looking at the front of the engine.
h. Use the Camshaft Bearing Remover/Installer in order to install the number1 intermediate shaft bearing with the oil hole indexed at 4 and 7 o'clock when looking at the front of the engine block.
i. Use a piece of 3/32 inch brass rod with a 90 degrees bend at the end in order to probe the bearing oil holes and verify that the oil holes are properly aligned.
j. Install the intermediate shaft cup plug.
4. Cam Inter Drive Shaft Installation
a. Lubricate the intermediate shaft journals and the gear with engine oil. Notice: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
b. Install the intermediate shaft.
c. Install the retainer and screws. Tighten the screws to 10 Nm (89 inch lbs.).
d. Measure the intermediate shaft end play.
5. Connecting-Rod and Piston Installation
a. Lubricate the cylinder wall and the piston with clean engine oil.
b. Turn the crankcase to the bottom dead center.
c. Install the connecting rod thread protector.
d. Install the Universal Piston Ring Compressor.
CAUTION: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.
e. Install the piston and connecting rod assembly.
f. Remove the thread protectors.
g. Install the connecting rod bearings.
CAUTION: In order to prevent the possibility of rod bolt or bearing cap damage, the bearing caps may need to be tapped into position with a brass or leather mallet before the attaching nuts are installed. Do not use the attaching nuts to pull the bearing caps onto the rod. Failure to observe this information may result in damage to the rod bolt or the bearing cap.
h. Seat the bearing caps by pushing on by hand or by carefully taping it-lightly with a suitable tool.
i. Install the bearing cap nuts. Tighten the nuts to 20 Nm (15 ft. lbs.). Turn the nuts an additional 75 degrees with Torque Angle Meter.
j. Inspect the connecting rod for binding. Do this by prying the connecting rod back and forth with a suitable tool and check for binding. If necessary, loosen and retighten the bearing cap.
k. Measure the amount of connecting rod side clearance.
6. Camshaft Installation
CAUTION: All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings.
a. In order to reassemble, stand the camshaft carrier on end.
b. Install the camshaft. Coat the camshaft journals with engine oil, or equivalent. Coat the camshaft lobes with prelude GM P/N 1052365, or equivalent. Carefully rotate and install the camshaft into the camshaft carrier.
c. Install the camshaft thrust plate.
d. Install the camshaft thrust plate bolts. Tighten the thrust plate bolts to 10 Nm (89 inch lbs.).
e. Install the camshaft carrier rear cover and gasket.
f. Install the camshaft carrier rear cover mounting bolts. Tighten the mounting bolts to 10 Nm (89 inch lbs.).
7. Cylinder Head Installation (Left Side)
a. Install the cylinder head gasket.
b. Install the cylinder head.
c. Install the cylinder head bolts. Tighten the bolts in sequence to 60 Nm (44 ft. lbs.). Use the Torque Angle Meter in order to turn the bolts in sequence an additional 90 degrees.
d. Install the rear torque strut.
e. Install the rear torque strut bolts. Tighten the bolts to 70 Nm (50 ft. lbs.).
8. Cylinder Head Installation (Right Side)
a. Install the cylinder head gasket.
b. Install the cylinder head.
c. Install the cylinder head bolts. Tighten the bolts in sequence to 60 Nm (44 ft. lbs.). Use the Torque Angle Meter in order to turn the bolts in sequence an additional 90 degrees.
9. Valve Lifter Installation
NOTE: If lifter clatter is present upon start-up, run the engine at idle-2000 RPM for 15 minutes. This will properly charge the lifters with oil.
a. Lubricate the lifters with a GM E.O.S. P/N 1052367 (or an equivalent).
b. Install the lifters.
c. Connect the lifter hold down hoses to the camshaft carrier.
10. Camshaft Carrier Installation (Left Side)
a. Install the camshaft carrier gasket.
b. Install the camshaft carrier.
c. Install the camshaft carrier mounting bolts and nuts. Tighten the bolts and nuts to 27 Nm (20 ft. lbs.).
d. Remove the lifter hold down hoses.
11. Camshaft Carrier Installation (Right Side)
a. Install the camshaft carrier gasket.
b. Install the camshaft carrier.
c. Install the camshaft carrier mounting bolts and nuts. Tighten the bolts and nuts to 27 Nm (20 ft. lbs.).
d. Remove the lifter hold down hoses.
12. Cam Inter Drive Shaft Chain, Sprocket Installation
a. Install the tensioner to the engine block.
b. Use the upper attaching hole as the primary locator with the attaching bolt.
^ Tighten all bolts finger tight.
^ Tighten the slotted hole bolt first to 27 Nm (20 ft. lbs.).
^ Tighten the other bolts to 25 Nm (18 ft. lbs.).
c. In order to retract the tensioner, fabricate a tool using the following procedure:
^ Bend a 16 inch piece of 1/8 inch welding rod or equivalent in half, leaving a 1 inch gap between the two ends.
^ Make a bend 1 inch from the end, perpendicular to the original bend, at 60 degrees.
^ Repeat this process for the other end. Make sure both ends are bent in the same direction.
d. Engage under the tensioner with the tool.
e. Compress the spring with the tool.
f. Retract the tensioner.
g. Insert a cotter pin, rivet or nail into the hole. Ensure that the spring remains compressed.
h. Lightly oil or apply lithium grease to the chain contact surfaces of the nylon pad and blade.
i. Make sure the crankshaft key is installed and fully seated.
j. Slip both the sprockets and the chain over the proper shaft. Engage the slot in the key. The intermediate shaft may move against the rear cover.
k. Slide the sprocket and chain assembly on the shafts maintaining parallel alignment of the sprockets. Install the assembly in the following positions:
^ Make sure the rubber and tension blade of the tensioner does not become caught, misaligned or dislodged.
^ Install the larger chamfer and counterbore of the crankshaft sprocket toward the crankshaft. The intermediate sprocket spline sockets are installed away from the case.
^ Use the Crankshaft Sprocket Installer in order to press the crankshaft sprocket on for the final 8 mm (0.31 inches) to the seated position.
l. Pull the retaining pin from the tensioner.
13. [1][2]Engine Front Cover Installation
a. Uniformly coat both sides of the lower tabs on the [1][2]engine front cover gasket with a GM P/N 1052080 sealer, or equivalent.
b. Install the [1][2]engine front cover gasket.
c. Install the [1][2]engine front cover.
d. Install the upper [1][2]engine front cover bolts. Tighten the large bolts to 47 Nm (35 ft. lbs.). Tighten the small bolts to 27 Nm (20 ft. lbs.).
14. Oil Pump Drive Installation
a. Lubricate the oil pump drive o-ring with engine oil.
b. Install the oil pump drive o-ring.
c. Lubricate the drive gear with grease.
d. Install the oil pump drive.
e. Install the oil pump drive clamp and the mounting bolt. Tighten the oil pump drive mounting bolt to 36 Nm (27 ft. lbs.).
15. Crankshaft Oil Deflector installation
a. Install the crankshaft oil deflector.
b. Install the crankshaft oil deflector mounting nuts. Tighten the crankshaft oil deflector mounting nuts to 25 Nm (18 ft. lbs.).
16. Oil Pump Installation
a. Install the oil pump and drive rod.
b. Install the oil pump bolt. Tighten the bolt to 54 Nm (40 ft. lbs.).
17. Oil Pan Installation
a. Apply a GM P/N 12345739 sealant (or an equivalent) to where the oil pan gasket tabs seat on the rear main bearing cap groove.
b. Install the oil pan gasket.
c. Install the oil pan.
d. Install the oil pan reinforcements.
e. Install the oil pan nuts.
f. Install the oil pan bolts and studs.
^ Tighten the nuts to 11 Nm (97 inch lbs.).
^ Tighten the two rear oil pan bolts to 27 Nm (20 ft. lbs.).
^ Tighten the remaining oil pan bolts and the oil pan studs to 11 Nm (97 inch lbs.).
18. Crankshaft Balancer Installation
a. Coat the front cover seal contact area on the crankshaft balancer with engine oil.
b. Apply a GM P/N 12345739 sealant, or equivalent, to the keyway of the crankshaft balancer.
c. Install the crankshaft balancer using the Crankshaft Balancer Installer.
d. Remove the Crankshaft Balancer Installer.
19. Crankshaft Pulley Installation
a. Install the crankshaft pulley.
b. Install the crankshaft pulley bolts. Tighten the bolts to 60 Nm (44 ft. lbs.).
c. Install the crankshaft balancer bolt. Tighten the bolt to 107 Nm (79 ft. lbs.).
20. Camshaft Driven Sprocket Installation
a. Install the camshaft sprocket.
b. Install the camshaft sprocket taper wedge.
c. Install the camshaft sprocket bolt. Tighten the bolt to 130 Nm (96 ft. lbs.).
21. Camshaft Intermediate Drive Sprocket Installation
a. Lubricate the seal or the seal running surface of the intermediate shaft sprocket.
CAUTION: Do not damage the intermediate shaft oil seal during intermediate shaft belt sprocket installation.
b. Install the sprocket into position on the intermediate drive shaft through the oil seal.
c. Engage the locating tangs on the shaft sprocket into the mating sockets of the intermediate drive chain sprocket.
d. Measure the distance from the front face of the intermediate shaft sprocket to the front cover. If the measurement is more than 42 mm (1.65 inches), the tangs are not engaged.
e. Lightly lubricate the intermediate shaft belt sprocket retaining bolt and washer.
f. Install the intermediate shaft belt sprocket retaining bolt onto the intermediate drive shaft. Hold the crankshaft in order to prevent the bolt from rotating. Tighten the bolt to 130 Nm (96 ft. lbs.).
22. Timing Belt Idler Pulley Installation
a. Install the timing belt idler pulley.
CAUTION: A loose idler pulley bolt and spacer does not indicate a defective part. Ensure that the plastic ridge by the bolt on the idler pulley is pointing away from the engine. The part number should face outward.
b. Install the idler pulley mounting bolt. Tighten the timing belt idler pulley bolt to 50 Nm (37 ft. lbs.).
c. Inspect the timing belt idler pulley in order to ensure that the-pulley rotates freely and is tight on the timing belt front cover.
23. Timing Belt Tensioner Pulley Installation
a. Install the gasket and the mounting bracket.
b. Install the mounting bolts. Tighten the bolt to 50 Nm (37 ft. lbs.).
CAUTION: The arm bushing and the pivot tube must be clean and not lubricated.
c. Install the tensioner pulley/arm assembly and pulley bolt. Position the square lug on the camshaft timing belt pulley at 6 o'clock. Tighten the bolt to 50 Nm (37 ft. lbs.).
24. Timing Belt Tensioner Actuator installation
a. Retract the timing belt tensioner actuator.
b. Position the tensioner in a vertical position in the vise (rod tip down). Clamp the tensioner body in the vise lightly.
c. Allow the oil to drain to the boot end for at least five minutes prior to refilling.
d. Do not damage the pivot bushings when removing the tensioner assembly.
e. Straighten out a standard paper clip (0.032 in diameter, no serrations) to a minimum straight length of 47 mm (1.85 inches). Form a double loop in the remaining end of the paper clip.
f. Remove the rubber end plug from the rear of the tensioner assembly. The assembly is-filled with oil and removal of the plug may allow oil to escape. Do not remove the vent plug.
g. Push the paper clip through the center hole in the vent plug and into the pilot hole.
h. Insert a small screwdriver into the screw slot inside the tensioner, behind the rubber end plug.
i. Retract the tensioner plunger by rotating the screw in a clockwise direction, until-it is fully retracted. Push on the paper clip and slowly rotate the screw counterclockwise until the paper clip engages.
j. If the tensioner oil has been lost, fill the tensioner with SAE 5W30 Mobil 1 (or equivalent) synthetic engine oil through the end hole. Fill to the bottom of the plug hole only when the tensioner is fully retracted and the pin is installed.
k. Install the rubber end plug to the rear of the tensioner assembly. Ensure the end plug has sealed against the case.
l. Install the tensioner bushing into the side plate.
m. Ensure that the bushings and the appropriate holes are clean. Do not lubricate.
n. Install the tensioner and the side plate. Tighten bolts to 27 Nm (20 ft. lbs.).
o. Ensure that the tensioner rod ball is seated in the tensioner pulley socket.
p. Pull out paper clip and discard, allowing the tensioner to extend to its normal position.
25. Camshaft Carrier Cover Installation (Left Side)
a. Install the wrings to the camshaft carrier cover.
b. Install the gasket to the camshaft carrier cover.
c. Install the camshaft carrier cover.
d. Install the retaining bolts.
e. Fully seat the bolt isolators in the camshaft carrier cover before tightening. Tighten the bolts to 11 Nm (97 inch lbs.).
f. Install the spark plug wires.
g. Install the camshaft position sensor.
h. Install the camshaft position sensor mounting bolts.
26. Camshaft Carrier Cover Installation (Right Side)
a. Install the o-rings to the camshaft carrier cover.
b. Install the gasket to the camshaft carrier cover.
c. Install the camshaft carrier cover.
d. Install the retaining bolts.
e. Fully seat the bolt isolators into the camshaft carrier cover before tightening. Tighten the bolts to 11 Nm (97 inch lbs.).
f. Install the spark plug wires.
27. Timing Belt Installation
CAUTION: Do not bend, kink, or pry on the camshaft timing belt as damage may occur.
a. Install the camshaft timing belt by routing it around the sprockets and idlers.
b. Start at the intermediate camshaft sprocket and work counterclockwise when looking at the front of the engine.
c. Make sure to accumulate slack in the timing belt as you work the belt around the sprockets.
28. Timing Belt Cover Installation (Center)
a. Install the center timing belt cover.
b. Install the center retaining bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
c. Install the drive belt tensioner.
d. Install the drive belt tensioner bolts. Tighten the drive belt tensioner bolts to 49 Nm (33 ft. lbs.).
29. Timing Belt Cover Installation (Left Side)
a. Install the left timing belt cover.
b. Install the left timing belt cover retaining bolts. Tighten the left timing belt cover retaining bolts to 10 Nm (89 inch lbs.).
30. Timing Belt Cover Installation (Right Side)
a. Install the right timing belt cover.
b. Install the right timing belt cover retaining bolts. Tighten the right timing belt cover bolts to 10 Nm (89 inch lbs.).
31. Exhaust Manifold Installation (Left Side)
a. If the exhaust manifold is being replaced, transfer the following parts:
^ The heated oxygen sensor. Tighten the heated oxygen sensor to 42 Nm (31 ft. lbs.).
^ The heat shield and studs.
b. Install the left exhaust manifold gasket.
c. Install the left exhaust manifold and the heat shield.
d. Install the left exhaust manifold retaining nuts. Tighten the nuts to 13 Nm (115 inch lbs.).
e. Connect the Air pipe. Tighten the pipe to 25 Nm (18 ft. lbs.).
32. Exhaust Manifold Installation (Right Side)
a. Install the right exhaust manifold gasket.
b. Install the right exhaust manifold and heat shields.
c. Install the right exhaust manifold retaining nuts. Tighten the nuts to 13 Nm (115 inch lbs.).
d. Install the AIR pipe. Tighten the pipe to 25 Nm (18 ft. lbs.).
33. Oil Distribution Cover Installation
a. Install the oil distribution cover gasket and the oil distribution cover.
b. Install the cover mounting bolts. Tighten the bolts to 27 Nm (20 ft. lbs.).
34. Lower Intake Manifold Installation
a. Install the lower intake manifold gaskets.
b. Install the lower intake manifold.
c. Install two M8 x 1.25 x 50 mm bolts with washers to the vertical holes in the intake manifold. Do this in order to align the intake bolt grommet bores with the threaded holes in the cylinder heads. Tighten the bolts to 7 Nm (62 inch lbs.).
d. Install the lower intake manifold mounting bolts.
e. Insert the rubber isolators into the manifold flange before tightening the lower intake manifold mounting bolts.
f. Draw the lower intake manifold into place. Do this by tightening the lower intake manifold mounting bolts gradually.
g. Start with the middle lower intake manifold mounting bolt and work in a circular pattern. Do not fully tighten one side or one end. Tighten the bolts to 13 Nm (116 inch lbs.). Remove the two bolts from the vertical holes of the intake manifold.
h. Install the thermostat and the gasket.
i. Install the water outlet.
j. Install the water outlet mounting bolts. Tighten the bolts to 27 Nm (20 ft. lbs.).
k. Install the coolant by-pass pipe.
l. Install the coolant by-pass pipe mounting bolt at the oil level sensor. Tighten the bolt to 10 Nm (89 inch lbs.).
m. Install the water inlet and gasket.
n. Install the water inlet mounting bolts. Tighten the bolts to 25 Nm (18 ft. lbs.).
o. Install the coolant by-pass pipe hose clamp to the water inlet.
p. Install the injector rail.
35. Upper Intake Manifold Installation
a. Install the upper intake manifold gasket.
b. Install the upper intake manifold.
c. Install the upper intake manifold bolts. Tighten the bolts to 26 Nm (19 ft. lbs.).
d. Install the vacuum hose at the upper intake manifold.
e. Install the control module mounting bracket.
f. Install the control module mounting bracket bolts. Tighten the bolts to 25 Nm (18 ft. lbs.).
g. Install the control module and the coils.
h. Install the control module and the coil mounting bolts. Tighten the bolts to 25 Nm (18 ft. lbs.).
i. Install the spark plug wires.
j. Install the evaporator emission canister purge solenoid harness and brackets. Tighten the bolts to 10 Nm (89 inch lbs.).
k. Install the fuel injector sight shield. Refer to Engine Cover Replacement
36. Oil Level Indicator and Tube Installation
a. Install the oil level indicator tube assembly.
^ Hand start the tube into the hole.
^ Use a suitable tool in order to drive the tube into the engine block.
^ Fully seat the tube into the engine block.
37. Flex Plate Installation
a. Install the flex plate.
b. Install the flex plate retainer.
c. Install the flex plate bolts. Tighten the flex plate bolts to 82 Nm (60 ft. lbs.).