Assemble

1. Install Crankshaft, Bearings, and Bearing Cap
^ Refer to the component for installation procedure.
2. Install Crankshaft Rear Oil Seal
^ Tools Required
- J 38841 Crankshaft Rear Oil Seal Installer, Or Equivalent

a. Make sure the crankshaft rear chamfer is free of grit, loose rust, and burrs. Correct as needed.
b. Lubricate the inner and the outer diameter of the seal with engine oil.
c. Install the seal on crankshaft rear oil seal installer.
d. Position crankshaft rear oil seal installer against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.
e. Tighten the screws securely with a screwdriver in order to ensure that the seal is installed squarely over the crankshaft.
f. Turn the handle until it bottoms.
g. Remove crankshaft rear oil seal installer.
3. Install Piston, Connecting Rod, and Bearing
^ Refer to the component for installation procedure.





4. Install Camshaft
a. Install the camshaft as follows
1) Install three 5/16 18 by 4.0 inch bolts in the camshaft front bolt holes in order to handle the camshaft.
2) Use care to avoid damaging the camshaft bearings.
3) Remove the three bolts after the camshaft installation.
b. Install the camshaft retainer and the bolts.
^ Tighten the camshaft retainer bolts to 14 Nm (10 ft. lbs.).
5. Install Timing Chain and Sprockets
^ Tools Required
- J 2102 Crankshaft Sprocket Installer, Or Equivalent

a. Install the crankshaft key, if necessary.

NOTE: Ensure that the sprocket alignment mark faces away from the engine block. Ensure that the sprocket is fully seated against the crank shoulder.





b. Install the crankshaft sprocket using the crankshaft sprocket installer.





NOTE:
^ Ensure that the following conditions exist
^ The camshaft and the crankshaft timing marks are aligned
^ The camshaft dowel pin and the camshaft sprocket hole are properly aligned The gears and the chain mesh

c. Install the camshaft timing chain to the camshaft sprocket.
d. Install the camshaft sprocket and the camshaft timing chain to the front of the camshaft.

CAUTION: Do not hammer the camshaft sprocket onto the camshaft. To do so may dislodge the rear camshaft plug and damage the camshaft.

d. Install the camshaft sprocket bolts. Use the bolts to draw the camshaft sprocket onto the camshaft.
^ Tighten the camshaft sprocket bolts to 34 Nm (25 ft. lbs.).





NOTE: Replace the crankshaft position sensor reluctor ring with a new component.

e. Install the crankshaft position sensor reluctor ring onto the crankshaft until the ring is completely seated against the crankshaft sprocket using the crankshaft sprocket installer.





6. Install Engine Front Cover
a. Lubricate the sealing surface of the crankshaft front oil seal with clean engine oil.
b. Apply the RTV sealer GM P/N 12345739 or the equivalent in two places where the front cover meets the oil pan rail.





c. Install the engine front cover.
d. Install the engine front cover bolts.
^ Tighten the engine front cover bolts to 12 Nm (106 inch lbs.)





7. Install Oil Pump
a. Install the oil pump driveshaft and the retainer.
b. Install the oil pump.
c. Install the oil pump bolt.
^ Tighten the bolt to 90 Nm (65 ft. lbs.).





8. Install Oil Pan

NOTE: Install the oil pan within 10 minutes of RTV application.

a. Apply RTV sealer GM P/N 12315739 or the equivalent in four places where tine front and rear crankshaft bearing caps, meet the engine block.
b. Install the oil pan gasket to the block.
c. Install the oil pan. Ensure that the oil pan gasket stays in place.
d. Install the oil pan bolts.
^ Tighten the oil pan bolts to 25 Nm (18 ft. lbs.).
e. Install the oil pan drain plug.
^ Tighten the oil pan drain plug to 28 Nm (20 ft. lbs.).





9. Install Cylinder Head
a. Install the head gasket onto the engine block.

NOTE: Do not use sealer on any engines that use a composition gasket.

b. Align the gasket locating mark to face up.
c. Install the cylinder head onto the block. Guide the cylinder head carefully into place over the dowel pins and head gasket.
d. Coat the threads of the cylinder head bolts with sealing compound GM P/N 12346004 or equivalent.





e. Install the cylinder head bolts in the following three sequential steps:
1) The first pass to 40 Nm (30 ft. lbs.).
2) The second pass to 80 Nm (60 ft lbs).
3) The third pass to 115 Nm (85 ft. lbs.).
f. Install the spark plugs.
^ Tighten
- For a new cylinder head, tighten the spark plugs to 30 Nm (22 ft. lbs.).
- For subsequent installations, tighten the spark plugs to 20 Nm (15 ft. lbs.).





10. Install Valve Rocker Arm and Push Rod

NOTE: If a new camshaft is installed, replace all the valve lifters.

a. Coat the valve lifter rollers and inside of the valve lifter guides with prelude GM P/N 1052367 or the equivalent.
b. Install the valve lifters in the same location from which they were removed.





c. Install the valve lifter guides.

NOTE: The valve lifter guide retainer must contact all of the valve lifter guides. If the valve lifter guide retainer is bent, the valve lifter guide retainer must be replaced.

d. Install the valve lifter guide retainer
e. Install the valve lifter guide retainer bolts
^ Tighten the bolts to 26 Nm (20 ft. lbs.).





CAUTION: This engine uses different length intake and exhaust valve pushrods. The exhaust valve pushrods are longer than the intake valve pushrods.

f. Install the valve pushrods. Be sure that the valve pushrods seat in the valve lifter sockets.
g. Install the valve rocker arms, the balls, and the bolts.
^ Tighten the bolts to 61 Nm (45 ft. lbs.).





h. Install the splash shield.





11. Install Valve Rocker Arm Cover
a. Install the valve rocker arm cover and gasket.
b. Install the valve rocker arm cover bolts.
^ Tighten the valve rocker arm cover bolts to 8 Nm (72 inch lbs.).





12. Install Intake Manifold
a. Install seals on the cylinder block.
b. Install the gasket onto the cylinder head.
c. Install the lower intake manifold onto the engine block.
d. Coat the lower intake manifold bolts with thread locking sealant GM P/N 12345382 or equivalent.





e. Install the lower intake manifold bolts.
^ Tighten the bolts in sequence to 40 Nm (30 ft. lbs.).





f. Install the upper intake manifold gaskets.
g. Install the upper intake manifold.
h. Cover a minimum of 8 threads of the upper manifold bolts with thread locking sealant GM P/N 1234549c.





i. Install the upper intake manifold bolts.
1) In the first pass, tighten all bolts in sequence to 8 Nm (72 inch lbs.).
2) In the second pass, tighten all bolts in sequence to 14 Nm (10 ft. lbs.).
13. Install Distributor
a. Bring the engine to TDC (Top Dead Center) cylinder #1 on the compression stroke.

NOTE: Distributor cap screws are not captured in the distributor cap.

b. Remove the distributor cap screws to expose the rotor.





c. Align the pre drilled indent hole in the distributor driven gear with the white painted alignment line on the lower portion of the shaft housing.
^ Using a long screw driver, align the oil pump drive shaft in the engine with the mating drive tab at the end of the distributor shaft.





e. Guide the distributor into place.
f. Make sure the distributor is fully seated in the engine.
1) If the distributor is not fully seated, the oil pump drive shaft may not be aligned with the mating drive tab at the end of the distributor shaft.
2) Remove the distributor and align the oil pump drive shaft as stated above.





g. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base.
^ The pointer has a (8) cast into it, indicating the distributor is for an eight cylinder engine.
^ If the rotor segment does not come out within a few degrees of the pointer (8), the gear mesh between the distributor and the camshaft may be OFF by a tooth or more.
^ If this is a case repeat this procedure to achieve the proper alignment.
h. Install the distributor hold down clamp bolt to the lower intake manifold.
^ Tighten the distributor clamp bolt to 27 Nm (20 ft. lbs.).
i. Install the distributor cap.
j. Install the distributor cap screws. Do not overtighten.
^ Tighten the cap holding screws to 5 Nm (40 inch lbs.).




k. Install the ignition coil to the upper intake manifold.
l. Install the ignition coil bracket bolts to the upper intake manifold.
^ Tighten ignition coil bracket bolts to 27 Nm (20 ft. lbs.).
m. Install the ignition coil wire from the ignition coil.
n. Install the spark plug wire clips to the spark plug wire brackets.





14. Install Crankshaft Balancer
^ Tools Required
- J 23523 F Crankshaft Balancer installer, Or Equivalent

a. Inspect the crankshaft balancer Weight for signs of shifting on the hub. Replace the crankshaft balancer if the weight is shifted.
b. Inspect the crankshaft balancer hub sealing surface for grooves, nicks, or damage. Replace the crankshaft balancer if any of the above conditions exist.

NOTE:
^ The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. You must follow the installation procedures carefully, using the proper tool, or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.
^ Use a small amount of RTV sealant to seal the balancer keyway to crankshaft joint.

c. Align the key into the crankshaft keyway, if the keyway has been removed.
d. Install the crankshaft balancer hub, until the crankshaft balancer hub is completely seated against the crankshaft position censor reluctor ring using the crankshaft balancer installer tool.
e. Remove the crankshaft balancer installer tool.
f. Install the bolt and the washer into the front of the crankshaft.
^ Tighten the bolt to 149 Nm (110 ft. lbs.).





15. Install Water Pump
a. Install the gaskets.
b. Install the water pump.
c. Install the bolts.
^ Tighten the bolts to 40 Nm (30 ft. lbs.).
d. Connect the water pump bypass hose and install the clamps.





16. Install Exhaust Manifold
a. Install the exhaust manifold studs.
^ Tighten the studs to 30 Nm (22 ft. lbs.).
b. Install the gasket.
c. Install the exhaust manifold.
d. Install the nuts.
^ Tighten the nuts to 30 Nm (22 ft. lbs.).





e. Install the spark plug heat shields and nuts.
^ Tighten the nuts to 20 Nm (15 ft. lbs.).
f. Install the spark plug wire boots to the spark plugs
g. Install the EGR valve inlet pipe to the intake manifold.
h. Install the EGR valve inlet pipe to the left exhaust manifold.
17. Install Oil Level Indicator and Tube
a. Install the oil level indicator tube.
b. Install the oil level indicator tube bracket bolt to the right exhaust manifold.
^ Tighten the oil level indicator tube bracket bolt to 54 Nm (40 ft. lbs.).
c. Install the oil level indicator.





18. Install Engine Flywheel
a. Install the engine flywheel.
b. Install the engine flywheel bolts.
^ Tighten the flywheel bolts to 90 Nm (66 ft. lbs.).
19. Engine Set Up and Testing
^ Engine Set Up & Testing