Cylinder Block - Installation

CAUTION: Prior to assembling the engine, or when installing a shortblock engine assembly, make certain the oil flow check valve is properly installed (slotted end up) in the engine main oil feed passage. Failure to install this valve could result in severe engine damage.

1. Crankshaft to cylinder block.
2. Lubricate the cylinder bores and crankshaft connecting rod bearing journals with clean engine oil.
3. Connecting rod and piston assembly into each cylinder using a Piston Ring Compressor.
- Ensure that the front mark of the piston is facing forward.
- Match the connecting rod bearing caps with the correct connecting rods and piston assemblies.
4. Connecting rod bearing cap with the front mark facing forward.
5. Apply a light coat of clean engine oil to the threads and under the heads of the connecting rod bearing cap nuts.
6. Connecting rod bearing cap nuts. Tighten connecting rod bearing cap nuts to 35 Nm (26 ft. lbs.).





7. Apply Loctite sealant GM P/N 12346004, or equivalent, to the threads of one of the short bolts.
8. Rear main seal housing and new gasket to engine; secure with five housing bolts. There are two different bolts lengths. Ensure correct placement. Tighten rear main seal housing bolts to 12 Nm (106 inch lbs.).





9. Cylinder head gasket. Install new cylinder head gasket as shown with the TOP mark provided on the gasket on top side (toward cylinder head) and on crankshaft pulley side.

Cylinder Head Bolt Tightening Sequence:

10. Cylinder head; secure with eight new cylinder head bolts after applying engine oil to each bolt. Tighten cylinder head-to-engine block bolts to 73 Nm (54 ft. lbs.) following sequence. Tighten a little at a time and evenly among bolts, repeat tightening sequence three or four times before reaching specified torque.
11. Distributor to cylinder head. See Powertrain Management.





12. Apply engine oil to a Crankshaft Oil Seal Guide and fit to crankshaft.
13. Oil pump to cylinder block using a Crankshaft Oil Seal Guide to help install the oil seal over the crankshaft.

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

14. Remove the Crankshaft Oil Seal Guide.





15. Apply Loctite pipe sealant GM P/N 12346004, or equivalent, to the thread portion of the short oil pump mounting bolt indicated.
16. Oil pump mounting bolts to oil pump assembly. Tighten oil pump mounting bolts to 11 Nm (97 inch lbs.).





17. Rubber seal between oil pump and coolant pump.





18. 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.





19. Timing belt guide and crankshaft timing gear. Install timing belt guide with concave side facing oil pump. Lock crankshaft-with slotted screwdriver. Secure with crankshaft timing gear bolt. Tighten crankshaft timing gear bolt to 110 Nm (81 ft. lbs.).
20. Air conditioner compressor and bracket to cylinder block (if equipped). See Heating and Air Conditioning.





21. Tensioner plate to timing belt tensioner. Insert tensioner plate lug into the timing belt tensioner hole.





22. Timing belt tensioner and tensioner plate to cylinder block; secure with one bolt and one stud. Do not tighten fully. Check to make sure that plate movement in direction of arrow causes tensioner to move in the same direction. If it does not, remove timing belt tensioner and tensioner plate and reinsert tensioner plate lug in timing plate tensioner hole.








23. Check that timing mark on camshaft timing belt pulley is aligned with V mark on cylinder head cover. If not, align the two marks by fuming the camshaft but be careful not to turn it more than its allowable turning range.

NOTE: It is possible to have two reference marks on the camshaft timing gear. When properly installed, the camshaft pulley pin should engage with camshaft timing gear slot No.1. This will place the timing mark and reference mark A at about the eight o'clock position, and reference mark B will be aligned with the V mark on cylinder head cover.





24. Check that punch mark on crankshaft timing belt pulley is aligned with arrow mark on oil pump case. If not, align the two marks by fuming crankshaft but be careful not to turn it more than its allowable fuming range.





25. 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. When installing timing belt, match arrow mark on timing belt with rotating direction of crankshaft. In this state, the number one piston is at top dead center of the compression stroke.





26. 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. Tighten
- Timing belt tensioner stud to 11 Nm (97 inch lbs.).
- Timing belt tensioner bolt to 27 Nm (20 ft. lbs.).
27. Confirm again that both sets of timing marks are aligned properly.

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

28. Timing belt cover, secure with seven bolts and one nut.Tighten timing belt cover nut and bolts to 11 Nm (97 inch lbs.).
29. Crankshaft pulley; secure with five crankshaft pulley bolts. Tighten crankshaft pulley bolts to 16 Nm (12 ft. lbs.).
30. Engine wiring harness to timing belt cover. Secure with retaining clips.
31. Generator to cylinder block. See Starting and Charging.
32. Lower generator cover plate; secure with two bolts. Tighten lower generator cover bolts to 10 Nm (89 inch lbs.).
33. Air conditioner compressor drive belt (if equipped). Adjust air conditioner compressor drive belt to specification. See Heating and Air Conditioning.
34. Oil pump strainer; secure with oil pump strainer bolt and oil pump strainer bracket bolt. Tighten oil pump strainer bolt and oil pump strainer bracket bolt to 11 Nm (97 inch lbs.).
35. Engine oil pan; secure with fourteen bolts and two nuts. Tighten engine oil pan bolts and nuts to 11 Nm (97 inch lbs.).
36. Cylinder head cover to cylinder head; secure with four nuts and seals. Tighten cylinder head cover nuts to 5 Nm (44 inch lbs.).
37. Secondary (spark plug) wires to cylinder head cover.
38. Exhaust manifold to cylinder head; secure with engine hanger, four bolts and three nuts. Tighten exhaust manifold-to-cylinder head bolts and nuts to 23 Nm (17 ft. lbs.).
39. Exhaust manifold heat shield to exhaust manifold secure with three bolts. Tighten heat shield bolts to 15 Nm (11 ft. lbs.).
40. New gasket and intake manifold with TBI unit to cylinder head; secure with wire clamps, five nuts and two bolts. Tighten intake manifold nuts and bolts to 23 Nm (17 ft. lbs.).
41. Engine assembly.