Steps 17 Thru 32
TOOL REQUIRED^ J 29789 Piston Ring Compressor
^ J 39946 Crankshaft Rotation Socket
^ J 38817 Rear Main Seal Installer
^ J 38820 Valve Stem Seal Installer
^ J 8062 Valve Spring Compressor
^ J 38821 Valve Spring Compressor Adapter
^ J 38819 Valve Keeper Installer
^ J 38816-1A Water Pump Remover/Installer
^ J 38813 Front Cover Seal Installer
^ J 39344 Crankshaft Balancer Installer
^ J 38823 Water Pump Drive Pulley Installer
PROCEDURE (Continued):
17. Secondary Camshaft Drive Chain Installation
a. Install all four secondary camshaft drive chain guides. Tighten the secondary camshaft guide bolts to 25 Nm (18 ft. lbs.).
b. Install the secondary chain guide access plugs in the front of the cylinder head. Tighten the chain guide access plugs to 4.5 Nm (39 inch lbs.).
c. Install all eight spark plugs.
d. Lock the flywheel in order to prevent crankshaft rotation.
e. Route the secondary drive chain for the left hand cylinder head over the inner row of the intermediate shaft teeth.
f. Route the secondary drive chain over the chain guide.
g. Install the intake camshaft sprocket into the chain so that the sprocket notch marked LI (left head intake) engages the cam drive pin. The cam drive pin must be perpendicular to the head face. A hex is cast into the camshafts behind the lobes for cylinder 1 (or 2, left hand) so that an open end wrench may be used in order to provide minor repositioning of the cams.
h. Install the exhaust camshaft sprocket so that the camshaft drive pin engages the sprocket notch marked LE (left head exhaust). There should be no slack in the lower section of the chain. The camshaft drive pin must be perpendicular to the cylinder head face.
i. Loosely install the intake and exhaust camshaft sprocket retaining bolts.
j. Collapse the secondary drive chain tensioners using the following procedure:
^ Rotate the ratchet release lever counterclockwise and hold.
^ Collapse the tensioner shoe and hold.
^ Release the ratchet lever. Slowly release the pressure on the shoe.
k. As the ratchet lever moves to its first click, hold the tensioner shoe inward and insert a pin through the hole in the release lever.
l. The locked ratchet mechanism should hold the shoe in a collapsed position.
m. Install the secondary drive chain tensioners.
CAUTION: Make sure the tensioner release lever faces toward you before tightening.
n. Install the secondary drive chain tensioner retaining bolts.
^ Tighten the secondary drive chain tensioner bolts to 25 Nm (18 ft. lbs.).
^ Tighten the camshaft sprocket bolts to 120 Nm (90 ft. lbs.).
o. Route the secondary drive chain for the right hand cylinder head over the outer row of the intermediate shaft teeth. Repeat steps 3 through 9 for right hand camshafts. Right hand camshaft sprockets are identified RI (right intake) and RE (right exhaust). In addition the RE sprocket must contain the camshaft position sensor pickup.
p. Install the camshaft position sensor. Tighten the camshaft position sensor retaining bolt to 10 Nm (89 inch lbs.).
18. Front Crankshaft Oil Seal Installation
a. Support the backside of the front cover around the seal opening with two blocks of wood.
b. Lubricate the seal lips with clean engine oil.
c. Install the new seal using a hammer and the Front Cover Seal Installer. Make sure the tool bottoms on the cover in order to properly position the seal.
19. Engine Front Cover Installation
a. Place a small daub of RTV sealant at the split line of the upper and lower crankcases.
b. Place the front cover gasket over the crankcase dowel pins.
c. Place the front cover in position on the crankcase.
d. Install the front cover retaining bolts. Tighten the front cover retaining bolts to 10 Nm (89 inch lbs.).
20. Crankshaft Balancer Installation
a. Position the crankshaft balancer on the nose of the crankshaft.
b. Install the balancer using the Crankshaft Balancer Installer.
c. Clean the balancer bolt threads.
d. Apply engine oil to the balancer bolt threads.
e. Install the dampener bolt. Tighten the crankshaft balancer bolt to 50 Nm (37 ft. lbs.)+ 120 degrees.
f. Use the balancer legs as a reference for the additional 120 of rotation. Make a mark on the balancer bolt flange in line with the centerline of one balancer spoke. Turn to the next spoke.
21. Camshaft Cover Installation (Left)
a. Install new spark plugs if required.
b. Install a new camshaft cover seal if required.
c. Place the camshaft cover on the cylinder head using the following procedure:
^ Insert the intake camshaft end through the hole in the end of the camshaft cover.
^ Using your fingers, guide the camshaft cover up over the edge of the cylinder head. Be careful not to damage the exposed section of the camshaft cover seal on the edge of the cylinder head.
^ Work the camshaft cover into position by pivoting the cover down and to the left allowing the cover to clear the camshaft drive chain and then aligning the bolt holes.
d. Install the camshaft cover bolts. Tighten the screws to 10 Nm (89 inch lbs.).
e. Lubricate the camshaft seal lips with engine oil.
f. Push the camshaft seal into position around the intake camshaft.
g. Coat the seal retaining screws with sealant, GM P/N 1052080, or equivalent. Install the screws. Tighten the camshaft cover seal screws to 1.1 Nm (10 inch lbs.).
h. Install the water pump pulley on the intake camshaft using the Water Pump Drive Pulley Installer.
i. Feed the water pump drive belt around the water pump pulley and the water pump drive belt tensioner.
j. Compress the drive belt tensioner. Feed the drive belt around the camshaft pulley.
k. Check the drive belt for proper seating.
l. Install the water pump drive belt shield.
m. Install the water pump shield retaining nuts. Tighten the water pump shield retaining nuts to 10 Nm (89 inch lbs.).
22. Camshaft Cover Installation (Right)
a. Install new spark plugs if required.
b. Install new camshaft cover seals if required.
c. Place the right camshaft cover in position on the cylinder head by aligning the bolt holes.
d. Install the camshaft cover bolts. Tighten the camshaft cover bolts to 10 Nm (89 inch lbs.).
e. Install the canister purge solenoid.
f. Install the canister purge retaining bolt. Tighten the canister purge retaining bolt to 12 Nm (106 inch lbs.).
23. Starter Motor Installation
a. Place the starter motor in position in the engine valley.
b. Install the two starter motor retaining bolts. Tighten the starter motor retaining bolts to 30 Nm (22 ft. lbs.).
c. Install the knock sensor. Tighten the knock sensor to 20 Nm (15 ft. lbs.).
d. Connect the knock sensor wire lead.
24. Exhaust Manifold Installation (Left)
a. With the manifold still on the bench, position a new manifold gasket in place on the manifold sealing surface.
b. Install two outer manifold bolts in the manifold to retain the gasket.
c. Using two hands, position the manifold and gasket onto the cylinder head.
d. Hand tighten the two outer manifold bolts.
e. Install the remaining manifold retaining bolts. Tighten the exhaust manifold retaining bolts to 24 Nm (18 ft. lbs.).
f. Insert the end of the oil level indicator tube in the cylinder block. Align the mounting tab with the mounting bolt hole.
g. Install the oil level tube retaining bolt. Tighten the oil level tube retaining bolt to 10 Nm (89 inch lbs.).
c. Install the oil level indicator.
i. Position the exhaust crossover pipe (1) in the left exhaust manifold (3) flange.
j. Install new manifold flange bolts for maximum joint integrity. Hand tighten. Do not torque the flange bolts to specification until the engine is mounted in the vehicle.
k. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695, or equivalent.
l. Install the oxygen sensor. Tighten the oxygen sensor to 40 Nm (30 ft. lbs.).
m. Install the crossover retaining bolts at the cylinder head and lower crankcase.
^ Tighten the crossover-to-cylinder head retaining bolt to 25 Nm (18 ft. lbs.).
^ Tighten the crossover-to-lower crankcase retaining bolt to 30 Nm (22 ft. lbs.).
n. Install the EGR feed tube to the crossover pipe. Tighten the EGR feed tube-to-crossover pipe nut to 60 Nm (44 ft. lbs.).
25. Exhaust Manifold Installation (Right)
a. With the manifold still on the bench, position a new manifold gasket in place on the manifold sealing surface.
b. Install two outer manifold bolts in the manifold to retain the gasket.
c. Using two hands, position the manifold and gasket onto the cylinder head.
d. Hold the manifold with one hand and draw up the bolts at the crossover pipe joint.
e. Hand tighten the two outer manifold bolts.
f. Install the remaining manifold retaining bolts. Tighten the exhaust manifold retaining bolts to 24 Nm (18 ft. lbs.).
g. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695, or equivalent.
h. Install the oxygen sensor. Tighten the oxygen sensor to 40 Nm (30 ft. lbs.).
26. Intake Manifold Installation
a. Place the intake manifold in position on the cylinder heads.
b. Install the six bolts and four studs. Tighten the intake manifold bolts and studs starting from the center and working outward in a circular pattern to 10 Nm (89 inch lbs.).
c. Install the fuel injector harness main connector.
d. Install the PCV valve and feed tubes into the camshaft covers.
e. Connect the EGR pipe to the water crossover and throttle body spacer. Tighten the EGR pipe to 28 Nm (21 ft. lbs.).
f. Connect the crankcase ventilation pipe to the throttle body spacer.
g. Connect the fuel rail bracket at the EGR valve.
h. Connect the fuel rail ground wire at the rear cylinder head.
27. Ignition Module Installation
a. Position the ignition module on the right camshaft cover.
b. Install the ignition module retaining bolts. Tighten the ignition module retaining bolts to 12 Nm (106 inch lbs.).
c. Connect all the spark plug wires to the spark plugs.
d. Secure the left bank wires in the retaining features formed into the intake manifold.
e. The right bank wires must be routed as shown to prevent possible misfires.
f. Route the left bank spark plug wires as shown to prevent wire damage.
g. Install the intake manifold sight shield with four nuts. Tighten the intake manifold sight shield nuts to 3 Nm (27 inch lbs.).
28. Oil Filter Adapter Installation
a. Position the oil filter adapter on the crankcase.
b. Install the oil filter adapter retaining bolts. Tighten the oil filter adapter retaining bolts to 16 Nm (12 ft. lbs.).
c. Install the oil filter pressure sensor. Tighten the oil pressure sensor to 16 Nm (12 ft. lbs.).
d. Fill the oil filter with oil.
e. Install the oil filter. Tighten the oil filter to 32 Nm (24 ft. lbs.).
29. Air Conditioning Compressor
a. Install the air conditioning compressor bracket.
b. Install the air conditioning compressor bracket retaining nut. Tighten the air conditioning compressor bracket nut to 30 Nm (22 ft. lbs.).
c. Position the air conditioning compressor on the cylinder block.
d. Install the front and rear retaining bolts. Tighten the air conditioning compressor retaining bolts to 50 Nm (37 ft. lbs.).
30. Generator
a. Install the rear generator mounting bracket.
b. Install the rear generator mounting bracket bolt and nut.
^ Tighten the rear generator mounting bracket bolt to 47 Nm (35 ft. lbs.).
^ Tighten the rear generator mounting bracket nut to 38 Nm (28 ft. lbs.).
c. Install the generator.
d. Install the generator retaining bolts. Tighten the generator retaining bolts to 50 Nm (37 ft. lbs.).
31. Power Steering Pump
a. Place the power steering pump in position in the engine valley. Slide the molded wedge into the retaining feature cast into the cylinder block.
b. Install the power steering pump retaining bolt. Tighten the power steering pump retaining bolt to 50 Nm (37 ft. lbs.).
32. Drive Belt Installation
a. Install the drive belt tensioner. Be sure to locate the tensioner anchor pin in the cylinder head recess.
b. Install the drive belt tensioner retaining bolt. Tighten the drive belt tensioner retaining bolt to 50 Nm (37 ft. lbs.).
c. Install the accessory belt idler pulley.
d. Install the accessory belt idler pulley retaining bolt. Tighten the accessory belt idler retaining bolt to 50 Nm (37 ft. lbs.).
e. Route the accessory drive belt around the crankshaft, the air conditioning compressor, the generator, the idler, and the drive belt tensioner pulleys.
f. Insert a 1/2 inch drive ratchet into the drive belt tensioner.
g. Rotate the tensioner counter-clockwise.
h. Route the remainder of the belt around the power steering pulley.
i. Slowly rotate the drive belt tensioner clockwise until the drive belt is tight.
j. Remove the 1/2 inch drive ratchet.
k. Check the drive belt for proper seating in all pulleys.