Installation

CAUTION: To prevent damage to cylinder block or parts installed:
^ All parts to be installed must be perfectly clean.
^ Be sure to apply engine oil to the crankshaft journals, main bearings, thrust bearings, connecting rod bearings, pistons, piston rings, and cylinder bores.
^ Main bearings, main bearing caps, connecting rod, connecting rod bearings, connecting rod bearing caps, pistons, and piston rings are in combination sets. Do not disturb the combinations and check to ensure that each part goes back to where it came from when installing.

^ Tools Required:
- J 34853 Crankshaft Oil Seal Guide
- J 35271 Flywheel Holder
- Or Equivalents

1. Main bearings upper half to crankshaft.





2. Thrust bearings to cylinder block between No. 2 and No. 3 cylinders.- Face the engine oil groove sides to counterweights.
3. Crankshaft to cylinder block.
4. Four connecting rod caps; secure with eight cap nuts.
^ Tighten the connecting rod bearing cap nuts to 35 Nm (26 ft. lbs.).

NOTE: On each main bearing cap, the arrow mark and number are embossed. When installing each main bearing cap to the cylinder block, point the arrow mark toward the crankshaft pulley side and install each cap from crankshaft pulley end to flywheel end in order 1, 2, 3, 4 and 5.





5. Five main bearing caps and two bearing cap supports; secure with ten main bearing bolts.

NOTE:
^ Gradual and uniform tightening is important for main bearing cap bolts.
^ After tightening main bearing bolts, check to be sure that crankshaft rotates smoothly when turned by hand.

^ Tighten the main bearing cap bolts to 54 Nm (40 ft. lbs.).
6. Rear main seal housing and new gasket to engine; secure with five rear main seal housing bolts. There are two different bolt lengths. Ensure correct placement.

^ Tighten the rear main seal housing bolts to 12 Nm (106 inch lbs.).





NOTE: After the rear main seal housing bolts are tightened, the gasket may extend past the rear main seal housing. Trim the excess with a sharp knife so the gasket is flush with the cylinder block.

7. Oil pump to cylinder block, using a crankshaft oil seal guide to install the oil seal over the crankshaft.

NOTE: During oil pump installation, ensure that oil seal lip is not turned out.

8. Remove the crankshaft oil seal guide.
9. Oil pump mounting bolts to oil pump assembly.
^ Tighten the oil pump mounting bolts to 11 Nm (97 inch lbs.).
10. Rubber seals between oil pump and coolant pump.
^ Edge of oil pump gasket might bulge out: if it does, cut bulge off with sharp knife, making edge smooth and flush with end faces of pump case and cylinder block.
11. Guide tube with new O-ring to cylinder block. Apply light coat of oil to O-ring prior to installation.
12. Oil level indicator to guide tube.
13. Oil pump strainer and oil pump strainer seal to cylinder block; secure with oil pump strainer bolt first and then oil pump strainer bracket bolt.
^ Tighten the oil pump strainer bolt first and then oil pump strainer bracket bolt to 11 Nm (97 inch lbs.).





14. Apply silicone sealant GM P/N 12346240, or equivalent, to the engine oil pan mating surface in a continuous bead.
15. Engine oil pan to cylinder block; secure with fourteen bolts and two nuts starting at the center and working outward.
^ Tighten the engine oil pan bolts and nuts to 11 Nm (97 inch lbs.).
16. Remove the cylinder head cover.





17. Loosen all valve lash adjusting screws and locknuts to prevent damage to valves.





18. Timing belt guide and crankshaft timing belt gear. Install timing belt guide with concave side facing oil pump. Lock crankshaft with a crankshaft oil seal guide. Secure with crankshaft timing belt gear bolt.
^ Tighten the crankshaft timing belt gear bolt to 110 Nm (81 ft. lbs.).
19. Check that the timing mark on camshaft timing gear is aligned with V mark on cylinder head cover. If not, align the two marks by turning the camshaft.
20. Check that punch mark on crankshaft pulley is aligned with arrow mark on oil pump case. If not, align the two marks by turning crankshaft.
21. Tensioner plate to timing belt tensioner. Insert tensioner plate lug into the timing belt tensioner hole.
22. Tensioner with tensioner plate to engine; secure with tensioner retaining bolt. Do not tighten fully.





NOTE: Make sure that the tensioner plate and tensioner move in the same direction when the tensioner plate is moved counterclockwise. If there is no associated movement between the tensioner plate and the tensioner, remove the tensioner and tensioner plate and reinsert the tensioner plate lock tab into the tensioner slot, then reinstall.


23. Remove the cylinder head cover. Loosen all valve lash adjusting screws and locknuts to prevent damage to valves.





24. Rotate the camshaft timing belt gear clockwise and align the camshaft timing gear timing mark with the V timing mark on the cylinder head cover.
25. Rotate the crankshaft clockwise and align the punch mark on the crankshaft timing belt gear with the arrow timing mark on the oil pump casting. This places the number four cylinder at TDC.
26. Timing belt, tensioner spring, and spring damper. With two sets of marks aligned and tensioner plate pushed up, install timing belt on two pulleys in such a way that drive side of belt is free from any slack. Then install the tensioner spring and spring damper. Hand tighten tensioner stud only.

NOTE: When installing timing belt, match arrow mark on timing belt with rotating direction of crankshaft.

27. To take up slack in timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten timing belt tensioner stud first and tensioner bolt.
^ Adjust the timing belt tension.

^ Tighten
- Tensioner stud to 11 Nm (97 inch lbs.).
- Tensioner bolt to 27 Nm (20 ft. lbs.).

28. Confirm again that both sets of timing marks are aligned properly.

NOTE: Before installing timing belt cover, make sure that seal is between coolant pump and oil pump case.

29. Timing belt cover; secure with eight bolts and one nut.
^ Tighten the timing belt outside cover bolts and nut to 10 Nm (89 inch lbs.).
30. Crankshaft pulley; secure with five crankshaft pulley bolts.
^ Tighten the crankshaft pulley bolts to 16 Nm (12 ft. lbs.).
^ Adjust valve lash.
31. Cylinder head cover with new gasket; secure with four nuts.
^ Tighten the cylinder head cover nuts to 5 Nm (44 inch lbs.).
32. Engine to vehicle.