Cylinder Block - Installation
INSTALLATION1. 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 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 GM P/N 12346004 or equivalent, to the threads of one of the short bolts of the rear main seal housing.
8. Rear main seal housing and new gasket to engine; secure with five housing bolts. There are two different bolt 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 timing pulley side.
10. Cylinder head; secure with ten 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 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 a crankshaft.
13. Oil pump to cylinder block using a Crankshaft Oil Seal Guide to help install the oil seal over the crankshaft. During oil pump installation, ensure that oil seal lip is not turned out.
14. Remove the Crankshaft Oil Seal Guide.
15. Apply 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 casket 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.
19. Timing belt guide and crankshaft timing sprocket. Install timing belt guide with concave side facing oil pump. Lock crankshaft with slotted screwdriver. Secure with crankshaft timing sprocket bolt. Tighten crankshaft timing sprocket bolts 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 bolts 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 the 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.
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 turning 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, tightening timing belt tensioner stud first and second tensioner bolt. Tighten
- Timing belt tensioner stud to 11 Nm (97 inch lbs.).
- Timing belt tensioner bolt to 21 Nm (20 ft. lbs.).
27. Confirm again that both sets of timing marks are aligned properly. Before installing belt cover, make sure that seal is between coolant pump and oil pump case.
28. Timing belt cover; secure with eight bolts and one nut. Tighten timing belt cover nut and bolts to 11 Nm (97 inch lbs.).
29. Crankshaft timing pulley; secure with four crankshaft timing pulley bolts. Tighten crankshaft timing pulley bolts to 11 Nm (97 inch lbs.).
30. Engine wiring harness to timing belt cover. Secure with retaining clips.
31. Generator to cylinder block. See Starting and Charging.
32. Generator cover plate; secure with two bolts. Tighten 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 bolts 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.). Adjust Valve lash.
36. Cylinder head cover to cylinder head; secure with four nuts and seals. Tighten cylinder head corer nuts to 5 Nm (44 inch lbs.).
37. Secondary (spark plug) wires to cylinders 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 the three bolts. Tighten heat shield bolts to 15 Nm (11 ft. lbs.).
40. New gasket and intake manifold with throttle body to cylinder head; secure with wire clamps, two nuts and seven bolts. Tighten intake manifold nuts and bolts to 23 Nm (17 ft. lbs.).
41. Engine assembly.