Cylinder Block - Installation

- Tools Required, or equivalent:
J 8037 Piston Ring Compressor
J 35388 Rear Main Seal Installer
J 35403 Oil Pump Seal Installer

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing parts, apply clean oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.
- Prior to installing, apply a thin coat of oil to main bearings, main bearing caps, crankshaft and all bolt threads.
- The upper main bearings have oil grooves and oil holes; the lower main bearings do not.

1. Five upper main bearing halves to cylinder block, aligning bearing claw with the claw groove.
2. Upper thrust washers to No. 3 journal of cylinder block with oil grooves facing outward.
3. Crankshaft to cylinder block.
4. Five lower main bearings to main bearing caps, aligning bearing claw with the claw groove.
5. Lower thrust washers to No. 3 main bearing cap with oil grooves facing outward. Measure main bearing oil clearance.
6. Five main bearing caps; secure with ten main bearing cap bolts. On each bearing cap, there is an arrow and a number stamped. Install main bearing caps with arrows pointing toward crankshaft pulley side and in correct order, 1, 2, 3, 4 and 5. Tighten main bearing cap bolts to 60 Nm (44 ft. lbs.).





CAUTION: Gradual and uniform tightening is important for main bearing cap bolts. After tightening all bolts, check to be sure crankshaft rotates smoothly when turned by hand. The main bearing cap bolts must be tightened in several passes using the sequence shown.

7. Apply oil to pistons, rings, cylinder walls, connecting rod bearings and crankshaft.

CAUTION: Install a piece of hose over threads of rod bolts. This is to prevent damage to threads, crankshaft and cylinder bore. Remove hose after connecting rod is in place. When installing piston assembly into cylinder bore, point the arrow mark on piston head to crankshaft pulley side. Upper bearing half has an oil groove and oil holes; lower bearing half does not.

8. Upper connecting rod bearings to connecting rods.
9. Piston assembly into correct cylinder bore. Guide the connecting rod into place on the crankshaft. Install a piston ring compressor, ensuring it sits firmly against the cylinder block until all piston rings have entered the cylinder bore. Using a hammer handle, gently tap the piston head to install the piston into the bore.
10. Lower connecting rod bearings to connecting rod bearing caps. Measure connecting rod oil clearance.
11. Connecting rod bearing cap to connecting rod with mark facing toward crankshaft pulley side; secure with two connecting rod bearing cap nuts. Tighten connecting rod bearing cap nuts in two steps: first to 29 Nm (22 ft. lbs.), then tighten each nut an additional 90 °.
12. New rear main seal into rear main seal retainer using a rear main seal installer and hammer.
13. Apply wheel bearing lubricant GM P/N 1051344, or equivalent, to rear main seal lip.
14. Rear main seal retainer; secure with six bolts. Tighten rear main seal retainer bolts to 9.3 Nm (82 inch lbs.).
15. New oil seal to oil pump using an oil pump seal installer.
16. Coat the inside of the new oil seal with wheel bearing lubricant GM P/N 1051344, or equivalent.





CAUTION: Oil pump bolts are two lengths. Make sure two long bolts are installed in correct location, to ensure correct mounting and to prevent leaks.

17. New gasket to cylinder block and install oil pump to crankshaft, engaging spline teeth during installation; secure with seven bolts. Tighten oil pump bolts to 21 Nm (16 ft. lbs.).
18. Guide tube with oil level indicator to oil pump; secure with one bolt. Tighten guide tube bolt to 9.5 Nm (84 inch lbs.).
19. Clip crankshaft position sensor electrical connector onto tube.
20. Oil screen, with new gasket, to cylinder block; secure with two bolts and two nuts. Tighten oil screen bolts to 9.3 Nm (82 inch lbs.).
21. Apply GM P/N 12346240 or equivalent, to the oil pan mating surface in a continuous bead.
22. Oil pan to cylinder block; secure with two nuts and nineteen bolts. Tighten oil pan nuts and bolts to 4.9 Nm (43 inch lbs.).
23. Lower engine reinforcement brace to cylinder block; secure with five bolts. Tighten lower engine reinforcement brace bolts to 64 Nm (47 ft. lbs.).
24. Oil pressure switch to cylinder block, after applying GM P/N 12345493 or equivalent, to the threads. Tighten oil pressure switch to 13 Nm (115 inch lbs.). Clean oil filter mating surface of all dirt and contaminants.
25. New oil filter to cylinder block after applying clean oil to the rubber gasket. Tighten oil filter until gasket contacts seat of the mounting surface, than turn an additional 3/4 turn to seat the filter.
26. New O-ring to cylinder block.
27. Coolant pump to cylinder block; secure with three bolts. Tighten coolant pump bolts to 14 Nm (124 inch lbs.).
28. Engine mount-to-cylinder head brace; secure win three bolts. Tighten engine mount-to-cylinder head brace bolts to 51 Nm (38 ft. lbs.).
29. Generator bracket to cylinder head; secure with three bolts. Tighten generator bracket bolts to 27 Nm (20 ft. lbs.).
30. Cylinder head.
31. Camshafts.





CAUTION: Check that the camshaft and crankshaft timing gear marks are aligned as indicated.





32. Camshaft timing gear. Align camshaft key with groove on gear and slide gear on camshaft; secure with camshaft timing gear bolt. Hold camshaft at hexagonal wrench head portion to prevent rotation. Tighten camshaft timing gear bolt to 59 Nm (43 ft. lbs.). Turn the hexagonal wrench head portion of the camshaft timing gear to align the hole on the gear with the mark on the bearing cap.





33. Crankshaft timing gear. Align crankshaft key with groove on gear and slide gear on crankshaft. Temporarily install the crankshaft pulley bolt and turn the crankshaft timing gear to position the key groove of the crankshaft timing pulley upward.
34. Idler pulley; secure with idler pulley bolt. Do not tighten fully.
35. Idler pulley spring.
36. Push idler pulley to the far left and tighten the idler pulley bolt enough to hold pulley in that position.

NOTE: If installing a used timing belt, align the marks made during removal and install the belt with the arrow pointing in direction of engine rotation.

37. Timing belt to crankshaft timing gear and idler pulley. Adjust
- Loosen the idler pulley mounting bolt allowing spring to pull idler pulley to the right.
- Temporarily install the crankshaft pulley mounting bolt and turn the crankshaft two complete revolutions from TDC to TDC. Always turn the crankshaft clockwise.
- Check camshaft and crankshaft timing gears to ensure marks are still aligned.





- Measure timing belt deflection as shown. Timing belt deflection specification is 5 to 6 mm (0.20 to 0.24 inch) at 20 N (4.5 lb.).
- Tighten idler pulley mounting bolt to 37 Nm (27 ft. lbs.).
38. Timing belt guide, facing the cupped side outward.
39. Timing belt covers, starting with bottom covers; secure with nine bolts. Tighten timing belt cover bolts to 7 Nm (62 inch lbs.).
40. Crankshaft pulley.
41. Coolant pump pulley to coolant pump; secure with four bolts. Coolant pump pulley bolts to 9.3 Nm (82 inch lbs.).
42. New cylinder head cover gasket to cylinder head.
43. New seal washers to cylinder head cover.
44. Cylinder head cover to cylinder head; secure with four cap nuts. Tighten cylinder head cap nuts to 6 Nm (53 inch lbs.).
45. Two PCV hoses to cylinder head cover; secure with hose clamps.
46. Spark plugs and secondary (spark plug) wires. See Powertrain Management.
47. Engine wiring harness to cylinder head cover.
48. Engine wiring harness cover to cylinder head; secure with two bolts. Tighten engine wiring harness cover bolts to 6 Nm (53 inch lbs.).
49. A/C compressor bracket to cylinder block (if equipped). See Heating and Air Conditioning.
50. Generator/coolant pump drive belt. See cooling System.
51. Power steering pump bracket (if equipped); secure with four bolts. Tighten power steering pump bracket bolts to 43 Nm (32 ft. lbs.).
52. Engine assembly to vehicle.